sauermann SI-CA 320 User manual

Si-CA 320
USER MANUAL
FLUE GAS ANALYZER
www.sauermanngroup.com

1FOREWORD
About the Sauermann Group:
For more than 40 years, the Sauermann Group has designed, manufactured and marketed products and services for the HVACR and industrial
markets, focusing on the detection, measurement and control of indoor air quality (IAQ). We operate under three main brands:
•Sauermann, a specialist in the field of condensate pumps (with accessories and solution kits) and instrument for improving indoor air
quality,
•and Kimo Instruments and E Instruments, who specialise in instrument for measuring and controlling air parameters.
With a presence on three continents (Europe, Asia and North America), and spread over 16 sites, including four production units, the Group
employs more than 400 people.

Table of Contents
1FOREWORD............................................................................................................................... 2
2IMPORTANT INFORMATION...................................................................................................... 6
2.1 Information about this manual.................................................................................................................6
2.2 Safety information ...................................................................................................................................6
3SAFETY ..................................................................................................................................... 7
3.1 Safety verification ....................................................................................................................................7
3.2 Correct use of the product........................................................................................................................7
3.3 Non-authorised use of the product...........................................................................................................7
3.4 Precautions to be taken when using the Li-Ion battery pack......................................................................7
4WORKING PRINCIPLE................................................................................................................ 8
4.1 Working principle.....................................................................................................................................8
5PRODUCT DESCRIPTION............................................................................................................ 9
5.1 General description of the Flue gas analyzer.............................................................................................9
5.2 General characteristics of the Flue gas analyzer ........................................................................................9
5.3 Description of the components of the Flue gas analyzer..........................................................................12
5.3.1 Keyboard...........................................................................................................................................13
5.3.2 Display ..............................................................................................................................................13
5.3.3 Printer...............................................................................................................................................14
5.3.4 B-type USB connector ........................................................................................................................14
5.3.5 Serial connector (Mini Din 8-pole) ......................................................................................................14
5.3.6 Connectors for pneumatic/TC-K inputs ...............................................................................................14
6TECHNICAL FEATURES ............................................................................................................ 15
6.1 Technical Features .................................................................................................................................15
6.2 Measurement and accuracy ranges.........................................................................................................16
7USING THE FLUE GAS ANALYSER............................................................................................ 17
7.1 Preliminary operations ...........................................................................................................................17
7.2 Warning ................................................................................................................................................17
7.3 Instrument power supply........................................................................................................................18
7.3.1 Checking and replacing the batteries .................................................................................................18
7.3.2 Use with external power supply .........................................................................................................18
7.4 Generate a QR code...............................................................................................................................18
7.5 Connection diagram...............................................................................................................................19
8POWER ON - OFF .................................................................................................................... 21
8.1 Starting the device.................................................................................................................................21
9CONFIGURATION MENU ......................................................................................................... 22
9.1 Configuration →Analysis......................................................................................................................23
9.1.1 Configuration →Analysis →Fuel .....................................................................................................24
9.1.2 Configuration →Analysis →Condensation.......................................................................................25
9.1.3 Configuration →Analysis →Reference O2........................................................................................26
9.1.4 Configuration →Analysis→NOX/NO ratio ........................................................................................27
9.1.5 Configuration →Analysis →Measure units ......................................................................................28
9.1.6 Configuration →Analysis →Autozero..............................................................................................29
9.1.7 Configuration →Analysis →Measures list........................................................................................30
9.1.8 Configuration →Analysis →Air temperature....................................................................................32
9.2 Configuration→Instrument...................................................................................................................33
9.2.1 Configuration →Instrument →Bluetooth®.......................................................................................34
9.2.2 Configuration →Instrument →Time/Date ........................................................................................35
9.2.3 Configuration →Instrument →Brightness........................................................................................36
9.2.4 Configuration →Instrument →Pump...............................................................................................37

4
9.2.5 Configuration →Instrument →CO dilutor........................................................................................38
9.2.6 Configuration →Instrument →Micromanometer..............................................................................39
9.3 Configuration →Operator.....................................................................................................................40
9.4 Configuration →Alarms........................................................................................................................42
9.5 Configuration →Information.................................................................................................................43
9.5.1 Configuration →Information →Battery............................................................................................44
9.5.2 Configuration→Information→Sensors...............................................................................................45
9.5.3 Configuration→Information→Info Service.........................................................................................46
9.5.4 Configuration→Information→Reminder............................................................................................47
9.5.5 Configuration→Information→Probe..................................................................................................48
9.6 Configuration→Diagnostic ....................................................................................................................49
9.6.1 Configuration→Diagnostic→Sensors.................................................................................................50
9.6.2 Configuration→Diagnostic→Gas probe.............................................................................................51
9.6.3 Configuration→Diagnostic→Hardware .............................................................................................52
9.6.4 Configuration→Diagnostic→Pump ...................................................................................................53
9.6.5 Configuration→Diagnostic→On site cal. ...........................................................................................54
9.7 Configuration →Language ...................................................................................................................61
9.8 Configuration →Restore.......................................................................................................................62
10 MEMORY ............................................................................................................................... 63
10.1 Memory Menu...................................................................................................................................63
10.2 Memory organisations .......................................................................................................................65
10.3 Memory Menu →Save......................................................................................................................66
10.4 Memory Menu →Average ................................................................................................................68
10.5 Memory Menu →Select....................................................................................................................69
10.5.1 Memory →Recall memory ...............................................................................................................70
10.5.2 Memory: Recall the "Maintenance Certification" memory...................................................................73
10.6 Memory menu →Data logger ...........................................................................................................75
10.7 Memory →Delete.............................................................................................................................76
10.7.1 Memory →Delete →Single..............................................................................................................77
10.7.2 Memory →Delete →All...................................................................................................................78
10.8 Memory →Usage %.........................................................................................................................79
11 PRINT...................................................................................................................................... 80
11.1 Print..................................................................................................................................................80
11.2 Print →Report..................................................................................................................................81
11.3 Print →Configuration.......................................................................................................................82
11.3.1 Print →Pairing .................................................................................................................................83
11.4 Print →Printer..................................................................................................................................85
11.5 Print →Header.................................................................................................................................86
11.6 Print →Measures list........................................................................................................................88
12 FLUE GAS ANALYSIS............................................................................................................... 90
12.1 FLUE GAS ANALYSIS..........................................................................................................................90
12.1.1 Switching on the instrument and auto-calibration...............................................................................90
12.1.2 Inserting the probe inside the stack....................................................................................................90
12.1.3 Simultaneous measurement of pressure, O
2
, pollutants.......................................................................91
12.2 Flue gas analysis - preliminary operations ..........................................................................................92
12.3 Flue gas analysis - certification mode .................................................................................................94
12.4 Execution of Flue gas analysis - data logger mode..............................................................................96
12.5 Execution of flue gas analysis - manual mode.....................................................................................98
12.6 End of Analysis................................................................................................................................100
13 MEASUREMENTS .................................................................................................................. 102
13.1 MEASUREMENTS.............................................................................................................................102
13.2 Measurements →Draft ...................................................................................................................104
13.3 Measurements →Smoke ................................................................................................................105
13.4 Measurements →Ambient CO ........................................................................................................106

5
13.0 Measurements →Temperature .......................................................................................................107
13.5 Measurements →Pressure..............................................................................................................108
13.6 Measurements →Tightness test......................................................................................................109
13.6.1 Connecting the leak test kit to the instrument..................................................................................109
13.7 Measurements→Search for leak .....................................................................................................110
13.7.1 Connection of probe for gas leak .....................................................................................................110
13.7.2 Performing the test..........................................................................................................................110
13.8 Measurements →Measurements Appendices..................................................................................111
13.9 Measurements→Velocity.................................................................................................................112
13.9.1 Connection of Pitot tube to instrument.............................................................................................113
13.9.2 Test execution .................................................................................................................................114
13.10 Measurements →Power of burner ..................................................................................................115
13.10.1 Testing in manual mode ..............................................................................................................116
13.10.2 Testing in measure mode (based on Flow rate).............................................................................117
13.10.3 Testing in measure mode (based on meter) ..................................................................................118
13.11 Measurements →Ionization current ................................................................................................120
14 SENSORS .............................................................................................................................. 121
14.1 Position of sensors...........................................................................................................................121
14.1 Sensor type and relevant positioning................................................................................................122
14.2 Life of gas sensors ...........................................................................................................................123
14.3 Gas sensors life table.......................................................................................................................123
14.4 Extension to 6 sensors .....................................................................................................................124
14.5 CxHy sensor for measuring unburnt hydrocarbons ............................................................................125
14.5.1 Installing the CxHy sensor................................................................................................................125
14.6 CO2sensor for measuring carbon dioxide in combustion processes ...................................................125
14.6.1 Installing the CO2 sensor ..................................................................................................................125
15 MAINTENANCE ..................................................................................................................... 126
15.1 Ordinary maintenance......................................................................................................................126
15.2 Preventive maintenance...................................................................................................................126
15.3 Replacing the gas sensors................................................................................................................127
15.4 Replacing the battery pack...............................................................................................................131
16 TROUBLESHOOTING.............................................................................................................. 132
16.1 Troubleshooting guide.....................................................................................................................132
17 SPARE PARTS AND SERVICING ............................................................................................. 134
17.1 Spare parts......................................................................................................................................134
17.2 Service ............................................................................................................................................134
17.3 Example of a file exported as a .csv and imported into an Excel file...................................................136
18 APPENDIX A.......................................................................................................................... 141
18.1 Advice for an accurate analysis ........................................................................................................141
19 APPENDIX B.......................................................................................................................... 142
19.1 List of additional measurements.......................................................................................................142

6
ATTENTION
2IMPORTANT INFORMATION
2.1 Information about this manual
This manual describes the operation, features and maintenance of the Si-CA 320 Flue gas analyzer.
Read this instruction and maintenance manual before using the instrument. The operator must have a full understanding of the
manual and follow the instructions within.
This instruction and maintenance manual are subject to modifications as a result of technical improvements. The manufacturer
assumes no responsibility for any possible content or printing errors.
2.2 Safety information
Read the information carefully and put in place
appropriate measures to ensure safety and avoid
any danger to persons and property.
Failure to comply with these instructions may result in risks to
people, the instrument and the surroundings. The manufacturer
shall not be held responsible in the event of improper use.
On-screen information
Responsible disposal
Keyboard with preformed keys
for main controls
At the end of its life, the battery pack should be disposed of
correctly and only in the containers provided for this
purpose.
The user must ensure, at their own expense, that the device
is collected separately and properly recycled.
Magnets on the back of the Instrument
can damage credit cards, fixed discs, mechanical clocks,
pacemakers, defibrillators and other devices sensitive to magnetic fields.
Symbols Meaning Comments
15/01/14
10:00
Information
Service
Sauermann
Industrial Zone
- BP16
24700 Montpon
Tel. [phone]
Fax. [phone]
www.sauermanngroup.com
Esc
Warning

7
3SAFETY
3.1 Safety verification
• Use the product as described in the chapter "Authorised use of the product".
• When using the instrument, adhere to any safety standards in force.
• Do not use the instrument if the casing, charger, or cables are damaged.
• Do not take measurements on uninsulated components/voltage conductors.
• Ensure the instrument is kept away from solvents.
• For maintenance of the instrument, ensure that the instructions in the chapter entitled “Maintenance” are strictly adhered to.
• Any work not specified in this manual must only be carried out in Sauermann service centres. Should this not be the case, Sauermann
declines all responsibility for the normal operation of the instrument and the validity of the corresponding approvals.
3.2 Correct use of the product
This chapter describes the scope of use of the Si-CA 320.
All products in the Si-CA 320 series are portable pieces of instrument for carrying out a Flue gas analysis of the following systems:
• Boilers (oil, gas, wood, coal)
• Low temperature condensing boilers
• Gas heat generators for the industrial sector
Since the detection is done using electrochemical sensors, it is possible to use the instrument in the following applications:
• Technical support service for burner/boiler manufacturers
• Technical assistance for industrial heating systems
Other functionalities of measuring instrument:
• Calculation of chimney flue losses and efficiency
• Measurement of CO and NO in the surrounding air
• Leak test on piping systems
• Storage of the opacity category value and calculation of the average value
• Measurement of differential pressure
• Draft or pull-off measurement
• Pressure measurement of the gas supply line
3.3 Non-authorised use of the product
Use of the Si-CA 320 in areas of application other than those mentioned in the chapter 3.2"Correct use of the product" is the sole
responsibility of the operator and the manufacturer assumes no responsibility for any loss, damage or costs that may result therefrom. It is
recommended to read and pay attention to the instructions in this user and instruction manual.
The Si-CA 320 should not be used:
• as a security alarm device
• for measurements lasting more than 1hr
3.4 Precautions to be taken when using the Li-Ion battery pack
Special care is recommended when handling the instrument's internal battery pack; incorrect or improper use may result in serious
injury and/or instrument failure:
• Do not cause a short-circuit: check that the terminals are not in contact with metal or other conductive materials during transport or
storage.
• Do not reverse the polarities.
• Do not allow the batteries to come into contact with liquids.
• Do not burn the batteries or expose them to temperatures higher than 60°C.
• Do not try to disassemble the battery.
• Avoid shocks and do not perforate the batteries. Any improper usage may result in internal damage or short-circuits that may not be
visible from the outside. If the pack has fallen or has hit a hard surface, regardless of how it looks from the outside:
• Stop using it;
• Remove the battery according to the current relevant standards.
• Do not use batteries that appear to be leaking or damaged.
• Only charge the battery once it has been removed from the instrument.
• In the event of abnormal functioning, or if it looks as if overheating is occurring, immediately remove the pack from the instrument. Be
careful as the battery may be hot.

8
4WORKING PRINCIPLE
4.1 Working principle
The Si-CA 320 is a portable analyser for combustion and emissions analysis.
The device is equipped with:
• A pneumatic circuit that can contain up to 6 sensors
• An intuitive user interface allowing the device to be used without the operating instructions
• A wide (55 x 95 mm) and bright TFT colour display providing good legibility thanks to its zoom function and efficient backlighting
• A rechargeable Li-Ion battery pack
• Ticket printing via an external Bluetooth®printer (available as an option)
• Ability to generate QR codes to download the analysis/measurements displayed on the screen. The "Si-CA QRCodeApp" application,
available in the Google and Apple stores, must first be installed.
• Ability to connect to a PC via USB or Bluetooth®connection. Once the software provided with the device is in use, combustion analyses
and the configuration of the main parameters can be stored.
• Ability to connect with a smartphone via Bluetooth®. Once the "Si-CA MobileApp" application, available in Google Play, is installed, it is
possible to perform remote analyses and/or view the current analysis in real time.
Main functions:
• Flue gas analysis in manual or automatic mode. The 15 most commonly used fuels are integrated with the option to add 32 (once their
chemical composition is known).
• Pollutant monitoring
• Memory space for up to 2000 complete analyses
• Storage of acquired data and an average of it
Gas measurements:
• CO, CO2, CxHy in reference to methane
• O2
• CO (atmosphere monitoring)
• CO/H2
• CO (low, medium, high)
• NO (low, medium, high)
• NO2(low, medium, high)
• SO2(low, medium, high)
• NOx
• H2S
Measurements:
• Ambient CO (via an internal sensor)
• Drawing in the duct
• Smoke (with an external manual pump)
• Gas pressure in the pipes, pressure in the combustion chamber and verification of pressure switches using a measuring range up to
200 hPa
• Measurement of combustion air
• Auxiliary temperatures
• Tightness test
• Velocity of air or smoke leaving the duct with a Pitot tube
• Measurement of ionisation current (using external probe)
Maintenance:
• The sensors can be replaced by the user without having to send the instrument back to the after-sales service because the sensors are
delivered pre-calibrated.
• Calibration certification: the instrument is delivered with a calibration certificate. As an option, it is possible to obtain a calibration
certificate issued in accordance with the requirements of EN17025.

9
5PRODUCT DESCRIPTION
5.1 General description of the Flue gas analyzer
The Si-CA 320 portable flue gas analyzer has a sleek and ergonomic design and an extremely clear and intuitive keyboard.
Designed to satisfy both Flue gas analysis and pollutant (emission) monitoring and environmental parameter measurements, the Si-CA
320 uses two electrochemical sensors that provide oxygen and carbon monoxide values.
The environmental parameters are measured by external sensors and it is also possible to measure both the chimney draught and the
opacity category. In addition, by using the measurement scale up to 200 mbar, the system pressure and combustion chamber pressure
can be measured, and the pressure switch verified.
Designed for the eleven main fuel types such as natural gas, LPG, diesel and fuel oil, the Si-CA 320 also allows 16 other fuels of known
chemical composition to be added to the memory. Saving and averaging the acquired data, printing the results (on a plain paper roll) and
connecting to the computer for data storage via USB connection, are all features of the Si-CA 320.
The memory can store 1000 complete analyses using the appropriate software and the mini-USB communication cable. There is the
option of downloading the data to a PC.
The instrument also comes with a large (55 x 95mm) bright colour TFT display, including a zoom function and backlighting for excellent
readability.
Another feature that sets it apart from many similar products on the market is that the power supply provided with the product can
perform the dual function of both charging and supplying power to the device, thus allowing the user to perform an analysis even when
the batteries are fully discharged.
Finally, one other important function is the option to perform the reset cycle with the probe introduced into the chimney using a
sophisticated flow deflection system.
With regard to maintenance, it is useful to know that because they are pre-calibrated, the sensors can be replaced directly by the user
without having to send the instrument to a service centre; in any event, however, the instrument must be calibrated at least once a year.
In addition:
• Operator interface: so intuitive that it can be used without a need to refer to the instruction manual.
• Large, bright and colourful TFT display: great readability thanks to zoom function and efficient backlighting.
• Only one Li-Ion battery pack: rechargeable for powering the device, complete with charge indication and ability to access it from the outside.
• Pneumatic input connectors (gas and pressure/draught) not exceeding the external profile of the instrument:
For better resistance to shocks.
• Pre-calibrated sensors that can be replaced directly by the user.
5.2 General characteristics of the Flue gas analyzer
The Si-CA 320 portable analyser has been carefully designed in accordance with Client-specific standards and requirements.
The analyser contains a single electronic board with all the main circuits for its basic operation, laboratory pre-calibrated measuring
sensors, smoke extraction pump, membrane keyboard and TFT graphic display with LCD backlight. The two parts of the housing are
securely attached to each other with seven screws in the rear part of the analyser.
The pneumatic circuit and the measuring sensors with electronic modules are positioned in the rear part of the housing and are accessible
for quick maintenance or replacement by removing the magnetic cover located in the lower part of the instrument. Located on the lower
side of the analyser are the pneumatic connectors for smoke sampling and pressure/draft measurements, the T1 connector for connection
to the thermocouple plug of the gas probe, and the T2 connector for connection to the thermocouple plug of the combustion air probe.
Located on the right side are the USB port type B for connection to the external power supply or PC, and the mini DIN 8-pin port for the
serial interface or for an external probe (optional).
The user interface consists of the graphic TFT display with backlighting that is always on and the membrane keypad. The on-screen
menu and all operator notifications can be configured in the language of the user.
Using the analyser is simplified thanks to the symbol keys that provide access to the most important functions. Navigating between the
different menu programs is easy and intuitive.
Smoke extraction pump
The pump, inside the analyser, is a diaphragm pump with a direct current motor and powered directly by the instrument in order to obtain the
optimal combustion sample range for analysis; an internal range measurement sensor allows:
-keep the pump capacity constant
-check the efficiency of the pump
-check the level of filter clogging
Simultaneous measurement of pressures, O
2
and pollutants
In order to optimise the combustion parameters of the boiler, the instrument allows the simultaneous measurement of the gas valve inlet and outlet
pressure, O2level, pollutant levels and all the calculated parameters that are necessary to obtain an accurate efficiency value.
See Chapter 13.1.3.

10
Measuring sensors
The device uses pre-calibrated gas sensors from the long-life Flex-Sensor series for the measurement of oxygen (O2) and carbon monoxide
CO (hydrogen-compensated H2), nitrogen oxide (NO), nitrogen dioxide (NO2), sulphur dioxide (SO2), and hydrogen sulfide (H2S). Oxygen
(O2%) measurements are performed using an electrochemical sensor that acts as a battery; this sensor is subject to a loss of sensitivity
over time.
Measurements of toxic gases (CO, SO2, NO, NO2, H2S) are carried out using electrochemical sensors that are not subject to natural
deterioration because they are inherently devoid of oxidation processes.
The measuring sensors are electrochemical in nature and consist of an anode, a cathode, and an electrolytic solution that depends on the
type of gas to be analysed. The gas enters the sensor through a selective diffusion membrane and generates an electrical current
proportional to the absorbed gas. This current is measured, converted to a digital reading, the temperature is compensated, before being
processed by the microprocessor and shown on the display.
The gas must not be at a pressure that could damage or destroy the sensors. The maximum pressure is ± 100 mbar. The response
times of the measuring sensors used in the analyser are:
• O2= 20 secs. at 90% of the measured value
• CO(H2) = 50 secs. at 90% of the measured value
• CO = 50 secs. at 90% of the measured value
• NO = 40 secs. at 90% of the measured value
• NO2 = 50 secs. at 90% of the measured value
• SO2 = 50 secs. at 90% of the measured value
• H2S= 50 secs. at 90% of the measured value
It is recommended to wait 5 minutes (but not less than 3 minutes) to obtain reliable analytical data.
Toxic gas sensors, if exposed to concentrations greater than 50% of their measuring field for more than 10 consecutive minutes, may
exhibit a ±2% drift and an increase in the reset times.
Should this be the case, before switching off the analyser, it is advisable to wait until the measured value is less than 20 ppm by drawing
in clean air. If there is an automatic autozero solenoid valve, the unit automatically performs a purging cycle and stops when the sensor
returns to a value close to zero.
Sauermann certifies the accuracy of the measurements only under cover of a calibration certificate issued by its laboratories or by another
approved laboratory.
Dilution of CO
One of the characteristics of electrochemical sensors for CO measurement is the need to have a very long auto-calibration if they have been
in contact with a very high gas concentration (higher than the highest range) for a long time.
The CO sensor is therefore protected in the instrument by an automatic dilution system that extends the measuring range of the sensor
without overloading it.
The dilution system makes it possible to constantly maintain the effective CO sensor and ensure it is ready to operate correctly, even at very
high CO concentrations.
The dilution system also extends the measuring range of the CO sensors:
•Up to 100,000 ppm for the CO 8000 ppm full range sensor
•Up to 250,000 ppm for the CO 20,000 ppm full range sensor
This makes it possible to manage the use of the sensor and to continue measuring samples without having to interrupt the measurement.
Pressure sensor, piezoresistive sensor, temperature compensation
The analyser is equipped with a piezoresistive internal sensor and temperature compensation for measuring the draught (vacuum) of the
chimney, for leak testing of pipes, and potentially for other measurements (gas pressure in the network, pressure loss through filters, etc.).
The measuring range is from -10.00 mbar to +200.00 mbar.
Any potential drift of the sensor is zero due to the instrument's autozero system, however, this should NOT be done with the measuring
probe inserted in the chimney.
Any pressure applied to the sensor above ±300 mbar can cause permanent deformation of the membrane,
causing irreversible damage to the sensor itself.
Types of fuels
The analyser is supplied with a pre-memory that holds technical data characteristics relating to the most well-known fuel types. Using the
optional PC configuration program, it is possible to add fuels and corresponding coefficients so that up to 32 fuels can be defined in
addition to those that are already predefined. For further details, see Appendix B.
Gas extraction pump
The pump inside the instrument is a diaphragm pump, powered by the instrument, which provides an optimal flow rate of the analysed
gas sample. An internal sensor measuring the flow and thus allowing:
•the pump flow rate to be kept constant
•the efficiency of the pump to be checked
•the degree of clogging of the filters to be checked