TPI The Value Leader 716 User manual

TPI 716
Flue Gas Analyser
The Value LeaderTM
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Contents
Introduction........................................................1
General Overview.................................................1, 2
Instrument Overview............................................. 3 ~ 7
Front View...............................................3
Keypad...................................................4
Back View...............................................5
Side Views..............................................6
Top View................................................ 7
Basic Analyser Functions....................................... 8 ~ 10
Charging The Analyser................................8
Turning The Analyzer On ............................ 9 & 10
easurements.................................................... 11 ~ 24
Flue Gas................................................ 11 ~ 17
Temperature & Pressure.............................18 ~ 20
CO Room Test..........................................21
Tightness Test......................................... 22 & 23
Combustible Gas Leak Detection...................24
enu Navigation................................................. 25 ~ 28
emory................................................ 25
Fuel Type................................................26
Analyzer Setup.........................................27
Units of easure, Instrument Info................. 28
Turning The Analyzer Off........................................29
Specifications..................................................... 30 & 31
Calibration & Service............................................ 32
Warranty........................................................... 32
Appendix A General aintenance & Function Tests............32 ~ 35
Appendix B Error Codes and Troubleshooting....................36 & 37
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Introduction
Thank you for purchasing TPI brand products. The TPI 716 Flue Gas
Analyser is a state of the art, easy to use analyser designed not only to
display and calculate the required readings from a flue but also to cover
most of the other measurements associated with combustion. The
instrument is ruggedly constructed and comes with a 6 Year Guarantee
subject to annual servicing being carried out by TPI or one of their
approved service centres.
General Overview
The following guidelines will help prevent damage to your sensors:
Always use the mini pump filter when testing flue gases.
Periodically check and replace the mini pump filter as needed.
Always make sure the in-line filter / water trap is installed properly.
Periodically check and replace the in-line filter as needed.
Always remove water or condensation from the inside of the in-line
filter / water trap assembly prior to performing tests.
Always use the optional oil filter (p/n A773) when performing tests on oil
burning equipment unl ss you ar using th 716 with an NO
s nsor fitt d. Do not us th A773 on th 716 with NO s nsor fitt d
b caus th A773 will filt r out Nitric Oxid (NO).
Never over saturate your sensors by performing tests on equipment with
gas levels beyond the capability of you analyser.
Always keep the A796 water trap / filter assembly clean & dry and replace
the internal filter as necessary. (Replacement filter part number is A796-F.)
1
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General Overview (Continued)
This manual will guide you through the functions of the TPI 716 which will
give you many years of reliable service.
Your TPI 716 Flue Gas Analyser comes complete with the following
standard accessories:
( ) Denotes part number
• TPI 716 Analyser
• Rubber Boot (A765) 1 each installed on analyser
• Soft Carrying Case (A768) - 1 each
• Flue Sampling Probe (A770) - 1 each
• In-Line Filter / Water Trap installed on Flue probe (A796) - 1 each
• Disc water filter installed in water trap (A796W) - 1 each
• Spare In-Line Filter - 1 each (A796F is a package of 10 filters)
• Temperature Probe (GK11M) - 1 each
• Battery Charger (A766) - 1 each
• Mini Pump Protection Filter Assembly (A763) - 1 each
• xhaust Spigot Removable (A764) - 1 each
• Pressure Adaptors - Pair (A772) - 1 pair
• PC Software and cable for communication to a PC (A807).
• Instruction Manual
Your TPI 716 Flue Gas Analyzer has the following options/upgrades
available:
• Plug-In Combustible Gas Sniffer Leak Probe (716-Leak)
• Upgrade to Bluetooth connectivity (716-BT)
• Upgrade to NO sensor for Calculated NOx (716-NO)
• Upgrade to High CO Sensor-up to 10% range (716-HCO)
• Infra Red Printer (A740)
• Temperature Pipe Clamps - pair (CK21M/Pair)
• CPA1 Probe Kit (CPK3)
• Smoke Pump (A788)
• Oil (Sulfur) Filter (A773)
2
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Instrument Overview
Front View
Rubber Boot Protects the instrument from accidental damage
Display Large graphical backlit LCD Display
Keypad Selects all available functions
Rubber
Boot
LCD
Display
Keypad
3
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Keypad
4
Blue Soft Keys - The function of these keys is shown in the
lower part of the display and changes depending on what
menu the analyser is in.
In the picture center soft key controls the start function and
the left and right soft keys are disabled.
Up Arrow Key -
This key is used
to scroll up in
menus.
Down Arrow
Key - This key
is used to scroll
down in menus.
Home Key - This key is
used to return to the
Main Menu from any
other menu.
Back Key - This key is
used to go back one
menu level.
On/Off Key - This key is
used to turn the analyser
on and off.
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Back View
Calibration and Information Label: Displays calibration information and
serial number
Battery Compartment: Holds rechargeable battery
Rubber Boot Protects the instrument
5
Rubber
Boot
Information
Label
Thermocouple
Sockets
Infrared
Window
Battery
Compartment
Exhaust
Port
Calibration
Information
Gas, Pressure, USB &
Leak Probe Ports
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Side Views
Exhaust Port Port for connection of xhaust Adapter
Infrared Window Window for sending stored data to IR Printer
Rubber Boot Protects the instrument from accidental damage
6
Rubber Boot
Exhaust Port
Infrared Window
Rubber Boot
Left Hand
Side
Right
Hand Side
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Charger Socket Connection for 220V/115V charger
T1 Socket Connection for thermocouple plug on flue probe
Connection for any 'K' type thermocouple probe
T2 Socket Connection for ambient 'K' type thermocouple probe
Connection for any 'K' type thermocouple probe
Gas Sample Port Connection for Mini Pump Protection Filter and Flue Probe
P (+) Port Connections for Pressure Tubing
P (-) Port
USB Port Connection for A807 cable for communication
to a PC or connection for 716-Leak combustible gas leak
detection sniffer probe.
Top View
7
Charger
Socket
USB Port
P(+)
Port
P(-)
Port
Gas
Sample
Port
T1 Socket
T2 Socket
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BASIC ANALYSER FUNCTIONS
Charging The Analyser
Plug the charger into the charger socket on the instrument (see page 7). When the
charger is plugged in the battery level display will turn on. This display indicates
the analyser is being charged and the status of the charge.
The plug symbol confirms the
analyser is connected to the charger.
The battery symbol shows the charge
level when the analyser is on too.
The charge level is represented in
graph form as well. The charge is
displayed in percentage. (0 to 100%)
During operation the analyser will display charge status and battery condition in
the top right corner of the display.
Battery is at full capacity.
Battery is at 2/3 capacity.
Battery is at 1/3 capacity. The charger should be connected soon.
Battery is very low and needs to be recharged immediately
Indicates the analyzer is connected to the charger.
If a beeping noise is heard during charging disconnect the charger. This is an
indication the battery pack needs to be replaced.
8
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Turning The Analyser On
Always: - B for turning on pl as nsur that ONLY th in-lin pump prot ction
filt r is conn ct d to th Gas Sampl Port. This in-lin pump prot ction filt r
MUST b fitt d to th instrum nt at all tim s!!
Please DO NOT have the gas sampling probe attached at this point. The gas
sampling probe needs be fitted to the 716 only at the point where combustion
analysis begins. See page 14
Press and hold the ON/OFF key down for approximately 3 seconds. The 716 will
beep and the initial start up screen will be displayed.
After approximately 5 seconds the Main menu will be displayed & the 716 is ready
to use. However, as the Next Calibration Due Date Approaches or is Overdue one
of the following screens may appear:-
The initial start up screen displays the
following information:
Model number of the analyser
Firmware version
Firmware date
Serial number of the analyzer
Date Last Calibration was carried out
Date Next Calibration is due
9
Pump Protection Filter
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Turning The Analyser On (continued)
The main menu displays the following
information:
Battery status
Date (dd.mm.yyyy format) and time
(24hr clock)
Menu Selections
Left blue soft key activates Bluetooth
(Only models equipped with this option.)
Center blue soft key confirms selection
10
Choosing “Next” will move you onto the Main Menu Screen as displayed below.
Please Note: It is a requirement of BS7967 that an FGA is within calibration and used
in conjunction with the manufacturers instructions therefore it is NOT recommended
that “Next” be chosen by the user if the “Calibration Overdue” Screen appears. Doing
so will contravene the requirements of BS7967.
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EASURE ENTS - Flue Gas
Note: It is recommended you perform routine general maintenance on your
analyser to ensure proper function. Please refer to Appendix A for further details
The pump will start and the Zeroing screen will
display. The analyser is initializing and self
testing the sensors during this 30 second cycle.
The selected fuel type will be displayed and can be
changed as necessary (see pg 12).
The selected unit of efficiency is displayed
and can be changed as necessary (see pg 13).
If the analyser is ready for use, “Skip” will
appear above the center soft key. Pressing this
will bypass the 30 second countdown.
Turn the 716 on as outlined on page 9. After
the initial start up screen the Main Menu will
be displayed.
Using the Arrow keys select Measurements by
highlighting it.
Press the nter key (centre soft blue key) to
confirm the selection.
The Measurements menu will be displayed.
Using the Arrow keys select Flue gas by high
lighting it.
Make sure the analyser is in a clean air environment
with only the in-line pump protection filter
connected to the input.
Press the nter key (centre soft blue key) to confirm
the selection.
11
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EASURE ENTS - Flue Gas (continued)
As necessary, the fuel type can be changed to match
the fuel type of the equipment under test. The fuel
type is used in the CO2, Ratio & efficiency calculations
and therefore it is important the fuel type is correct in
order for the calculation to be accurate.
To change the fuel type use the Arrow keys to
highlight “Fuel change”.
Press the Chang key (left soft blue key) and the fuel
menu will display.
The Arrow keys are used to scroll through the
available fuel types.
The available fuels are Natural gas, Light oil, Heavy
oil, LPG, Bituminous coal, Anthracite coal, Coke,
Butane, Wood (dry), and Bagasse.
Once the desired fuel type is highlighted press the
center soft key (OK) to confirm the selection.
The analyser will return to the Zeroing display and the
countdown will continue.
12
NOTE: When selecting oil as fuel be su e to use the optional
oil filte (A773) o eadings could become e atic. See
Appendix E fo installation inst uctions.
Do NOT use the A773 with a 716 analyse with the NO
Senso Upg ade.
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After the initial purge cycle is complete or skip is
pressed the Flue gas measurement screen will
display.
This screen displays all combustion parameters
including NO & NOx (if fitted), temperature, pressure,
excess Air and Pump Speed.
If an NO sensor is fitted then the Right Hand Down
Arrow Key needs to be pressed to see Pressure &
Pump Speed as well as Temperature.
EASURE ENTS - Flue Gas (continued)
The unit of efficiency can be changed as needed
between Nett, Gross & Condensing. Nett efficiency
doesn’t take into account wet losses while Gross
efficiency does. Condensing efficiency is a common
calculation applied is some uropean Countries.
Press the right soft key (Next) to highlight “ fficiency
change” in the display.
Press the Chang key (left soft key) and the efficiency
menu will display.
Use the Arrow keys to select the desired efficiency
unit and press the center soft key (OK) to confirm the
selection.
If only CO & O2 sensors are fitted then the bottom 2
spaces on the initial front Flue Gas Measurements
Screen will display Pressure & Pump Speed. Pressing
the Right Hand Down Arrow Key will scroll through
and display the other parameters such as
Temperature etc...
13
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EASURE ENTS - Flue Gas (continued)
Connect the Gas Sampling Flue Probe Tubing complete to the In-Line Pump Protection
Filter (see below) and the 'K' Type Thermocouple Plug from the Flue Probe into
Thermocouple (T1) Socket. The GK11M ambient air temperature probe is connected to
the (T2) socket.
WARNING: - nsure the 'K' type thermocouple probes are inserted into the sockets
correctly (see page 7). The plugs are polarity marked and forcing the plug into the
socket the wrong way may result in damage to the instrument.
In-line Filter
Assembly
Ambient Air
Connection (T2)
Flue Probe
Tubing
G 11M Probe Thermocouple
Connection from
Flue Probe
Pump Protection Filter
Press the center Blue Soft Key (Start) and the pump
will start. The following screen will display:-
Press the Left Blue Soft Key to send the Displayed
Readings Directly to the Optional A740 IR Printer
Press the Right Blue Soft Key to Hold the desired
readings on the screen giving you the option to Save
or Send them to Memory, IR Printer or PC.
Press the Centre Blue Soft Key to Stop the Pump
Running. The Pump will only stop running if the CO
level is below 10ppm otherwise this option is disabled.
14
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EASURE ENTS - Flue Gas (continued)
Insert the flue probe into the sample hole of the device under test. The probe tip
should be in the middle of the flue pipe or exhaust stream.
nsure the In-Line Filter / Water Trap hangs below the analyser in the proper vertical
position when readings are being taken. Failure to comply reduces the effectiveness of
the water trap and may result in damage to the instrument. Refer to the pictures below
for correct and incorrect use.
WARNING: - Should the CO reading rise above 2,000ppm a continuous series of Alarm
Beeps will be heard. The Probe should immediately be disconnected from the
instrument and the instrument returned to a clean air environment. This Alarm alerts
the user that there is a high concentration of CO, and this procedure will protect the
sensors within the instrument. The alarm level can be changed. Please see Appendix D
Make sure to check the water trap periodically during testing to ensure it does not fill
with condensate and empty it as necessary. If the filter begins to fill during a test, open
the lid and empty out the condensate. After closing the lid, allow readings to stabilize
again.
I PORTANT: The water trap is fitted with a water block filter (p/n A796-D) in the lid to
prevent water from flowing down into the pump. If the water trap fills the water block
filter will stop the flow to the analyzer and FLO RR will display. The water trap should
be emptied immediately if this happens. The water block filter may need to be dried out
or replaced before testing can resume.
15
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EASURE ENTS - Flue Gas (continued)
Allow the readings to stabilise. Multiple parameters can be seen in the display.
16
• Carbon Monoxide (CO) reading in parts per million
(ppm)
• Carbon Dioxide (CO2) figure in percentage (%)
(calculated)
• CO/CO2 (Ratio) figure.
• Calculated fficiency ( ff.) figure in percentage
• Oxygen (O2) reading in percentage (%)
• xcess Air (X Air) in percentage
• Nitric Oxide (NO) (measured) and Nitrogen Oxide
(NOx) (calculated). If Fitt d.
• Carbon Monoxide (CO) reading in parts per million
(ppm)
• Carbon Monoxide Air Free (COAF) in parts per million
(ppm) (calculated).
• Nitric Oxide (NO) (measured). If Fitt d
• Temperature T1-ST (stack temperature)
• T2-AT (ambient temperature).
• Temperature T1 - T2 (DT)
• Pressure (Prsu)
• Pump speed in cc/min.
Pressing the Up / Down Arrow keys enables the rest of the screen to be displayed.
Once the combustion readings have stabilised they can be “Printed” directly to the
optional IR (A740) Printer by lining up the IR window on the side of the FGA (see page
6) & the IR window on the Printer. Alternatively the stabilised readings can be “H LD”
on the screen. Once the readings are held on the screen the following options are
available:- “Send” the held readings to the A740 Printer or to a Compatible PC or
“Save” the readings to a memory location of your choice. These options are explained
in further details on page 17.
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EASURE ENTS - Flue Gas (continued)
The “Held” data can be saved to a memory location
by pressing the Save key (right blue soft key) and
“Real Data Save” and “Address:” will be displayed.
Using the Up and Down Arrow keys select the
memory location to save the data.
Press the OK key (center blue soft key) to save the
data to the 716 internal memory.
Press the “Back” key at anytime to go back to
“Held” Readings
The “Held” data can also be sent to an optional
infrared printer (p/n A740) or to a PC using optional
cable and software by pressing the Send key (left
blue soft key) and “Print Out” and “PC Out” will be
displayed.
Using the Up and Down arrow keys select the type of
output you require. If sending data to a PC, connect
the USB cable to the analyzer and computer and run
the 716 PC software.
Press the OK key (center blue soft key) to print or
send data to a PC.
Press the “Back” key at anytime to go back
to “Held” Readings
Choosing the “HOLD” option will display the following screen:-
Please note the 3 new options on the Soft Blue Keys
The TPI 716 will continue to monitor live readings in
the background whilst the “Held” readings are on the
display until the “unHold” option is chosen.
You can “Save”, “Print” or “Send” out as many sets
of these readings as you require whilst the 716 is in
“Hold” mode.
Once the “unHold” button is pressed then the 716 will
return to Live readings as explained on Page 16.
17
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easurements - Temperature & Pressure
18
From the Main menu screen using the Up / Down
Arrow keys select “Measurements” in the menu.
Press “ nter” (center blue soft key) to confirm the
selection.
From the Measurements menu use the Up / Down
Arrow keys to select “Temp/Pressure” in the menu.
Press “ nter” (center soft blue key) to confirm the
selection.
The Temperature / Pressure screen will display.
This screen displays both T1 and T2 channels of
temperature as well as the difference between T1 and
T2 (DT).
If no probe is connected to the input “-----” will be
displayed indicating an open connection.
Pressure (Prsu) is also displayed in this screen.
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