TPI The Value Leader 716N User manual

716 / 716N
Flue Gas Analyzer
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 Analyzer Functions....................................... 8 ~ 10
Charging The Analyzer................................8
Turning The Analyzer On ............................ 9
Turning The Analyzer Off............................. 10
Display Backlight..................................... 10
Combustion Analysis Overview.................................11
Measurements.................................................... 12 ~ 28
Flue Gas................................................ 12 ~ 21
Typical Test Results...................................22
Temperature & Pressure.............................23 ~ 24
Tightness Test......................................... 25 ~ 26
CO Room Test..........................................27
Combustible Gas Leak Detection...................28
Menu Navigation................................................. 29 ~ 32
Memory................................................ 29
Fuel Type................................................30
Analyzer Setup.........................................31
Units of Measure, Sensor Info, Instrument Info. 32
Specifications..................................................... 33 ~ 34
Calibration & Service............................................ 35
Warranty........................................................... 35
Appendix A General Maintenance & Function Tests............36 ~ 38
Appendix B A773 Sulfur Filter Installation & Maintenance....39 ~ 40
Appendix C Error Codes and Troubleshooting....................41~ 42
Appendix D Testing for Carbon Monoxide in Ambient Air......43
Appendix E Carbon Monoxide Limits in Ambient Air Chart....44
Appendix F Carbon Monoxide Facts...............................45
Appendix G Battery Replacement..................................46
Notes:
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Notes:
Introduction
Thank you for purchasing TPI brand products. The TPI 716 Flue Gas
Analyzer is a state of the art, easy to use analyzer 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 3 Year unit
and 2 Year sensor Guarantee.
General Overview
The TPI 716 combustion analyzer uses state of the art electrochemical
sensors. This sensor technology provides the longest lasting, most
accurate and reliable means for performing combustion tests. The sen-
sors in your analyzer will need to be replaced periodically and calibra-
tion is recommended once every year.
Electrochemical sensors by nature are always active. Therefore the
time the analyzer is off and not being used must be taken into account
when determining sensor life. The sensors in your analyzer are war-
ranted for two years. This warranty does not cover sensors damaged
through misuse of the analyzer.
You should keep the battery of your 716 charged so power is constant-
ly being supplied to your sensors.
The following guidelines will help prevent damage to your sensors:
Always use the mini pump filter when testing flue gases.
Always periodically check and replace the mini pump filter as needed.
Always make sure the in-line filter / water trap is installed properly.
Always periodically check and replace the in-line filter as needed.
Always remove water or condensation from the inside of the in-line fil-
ter / water trap assembly prior to performing tests.
Always use the optional oil filter (p/n A773) when performing tests on
oil burning equipment
unless you are using the 716N. Do not use the
A773 with the 716N because the A773 will filter out Nitric
Oxide (NO).
1
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General Overview (Continued)
Never over saturate your sensors by performing tests on equipment
with gas levels beyond the capability of you analyzer.
Always keep the A795 water trap / filter assembly clean and replace the
filter as necessary. Replacement filter part number is A794F.
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 Analyzer comes complete with the following
standard accessories:
( ) Denotes part number
• TPI 716 Analyzer
• Combustible Gase Leak Probe (A806)
• Rubber Boot (A765) 1 each installed on analyzer
• Soft Carrying Case (A768) - 1 each
• Flue Sampling Probe (A770) - 1 each
• In-Line Filter / Water Trap installed on Flue probe (A795) - 1 each
• Disc water filter installed in water trap (A794W) - 1 each
• Spare In-Line Filter - 1 each (A794F is a package of 5 filters)
• Temperature Probe (GK11M) - 1 each
• Battery Charger (A766) - 1 each
• Mini Pump Protection Filter Assembly (A763) - 1 each
• Exhaust Spigot Removable (A764) - 1 each
• Pressure Tubing (A774) - 1 each 6’ piece
• Static Pressure Tips (A776) - 2 each
• 1/4” barbed to 1/8” NPT fitting (A603) - 2 each
• Gas Valve Adapter (A611) - 1 each
• Adapter Tubing (A791) - 1 each 4” piece
• Instruction Manual
Your TPI 716 Flue Gas Analyzer has the following options available:
• A807 PC Software and cable for communication to a PC.
• A740 infrared printer (Included with 716A740)
2
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Appendix G: Battery Replacement
When the battery in your analyzer will no longer charge, no longer hold a
charge, or if beeping is heard while charging this is usually an indication the
battery pack requires replacement.
For best results use a TPI replacement battery part number A007. The battery in
your analyzer is 3.6V NiMH 1600mAh rated. Never replace the battery with any
other type of battery or damage to the charge circuit will result.
The battery pack is replaced as follows:
1. Turn the analyzer over and locate the phillips head battery cover screw. See
picture below.
2. Loosen the screw. Pull out on the screw to remove the battery cover.
3. Remove the old battery pack from the battery compartment. Pull the battery
wire out of the connector.
4. Install the new battery pack by inserting the connector from the battery pack
into the connector on the analyzer. Install the battery pack into the battery com-
partment.
4. Re-install the battery cover by fitting the bottom part in first.
5. Tighten the battery cover screw.
Battery Cover
Battery Cover Screw
46
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
NOTE: When selecting oil as fuel be sure to use the optional
oil filter (A773) or readings could become erratic. See
Appendix E for installation instructions.
Do NOT use the A773 with the 716N analyzer. 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 analyzer 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 analyz-
er on and off.
Appendix F: CARBON MONOXIDE FACTS
Carbon Monoxide (CO) is invisible, odorless, and tasteless. It is the byproduct of
combustion and levels are elevated when there is incomplete combustion.
Sources of CO include:
Unvented kerosene and gas space heaters
Leaking chimneys & furnaces
Gas water heaters
Back drafting from furnaces
Wood stoves& fireplaces
Gas Stoves
Automobile exhaust
Tobacco smoke
Carbon Monoxide is picked up quickly in the body by red blood cells. At high lev-
els of CO the body replaces oxygen with carbon monoxide.
The most common symptoms of CO poisoning are headache, dizziness, weak-
ness, nausea, vomiting, chest pain, and confusion. High levels of CO inhalation
can cause loss of consciousness and death. Unless suspected, CO poisoning can
be difficult to diagnose because the symptoms mimic other illnesses.
People who are sleeping or intoxicated can die from CO poisoning before ever
experiencing symptoms.
Please see the next page for a list of exposure times and symptoms.
45
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Appendix E: Carbon Monoxide in Ambient Air Chart
This chart contains maximum exposure levels and times for carbon monoxide.
This is a general guideline only. It is recommended you check with your local
government for guidelines in your area.
44
Back View
Calibration and Information Label: Displays calibration information and
serial number
Battery Compartment: Holds rechargeable battery
Rubber Boot Protects the instrument
5
Calibration and
Information
Label
Battery
Compartment
Rubber
Boot
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Side Views
Exhaust Port Port for connection of Exhaust Adapter
Infrared Window Window for sending stored data to IR Printer
Rubber Boot Protects the instrument from accidental damage
Measurements - Temperature & Pressure
Exhaust
Port
Infrared
Window
Rubber
Boot
6
Appendix D: Testing for Carbon Monoxide in Ambient Air
The 716 can be used to test for carbon monoxide in ambient air. For example
tests can be performed in work spaces and living areas like offices and houses
to ensure safety.
1. Following the steps outlined on page 8, turn the analyzer on in a clean air
environment away from the area to be tested,
2. Select “Measurement” from the Main Menu. Select “Flue gas” from the
Measurements Menu. After a purge cycle the display below will be seen.
Ambient CO levels will be seen in the top line
of the display. (CO in ppm)
3. Connect the Pump Protection filter to the analyzer.
4. Begin testing for carbon monoxide. Move from space to space to detect any
CO that may be present. The CO reading will be seen in the top part of the dis-
play.
5. If necessary, the flue probe can be attached to test in ducts and plenums.
6. Refer to the chart on page 50 for a list of exposure times and levels of carbon
monoxide in ambient test applications and page 51 for carbon monoxide facts.
7. When testing is complete, turn the analyzer off as outlined on page 8.
43
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Problem Possible Cause Corrective Action
Efficiency reading incorrect NET efficiency selected.
Ambient temperature probe not
plugged in to T2.
Incorrect fuel selected.
Select GROSS efficiency. See page
13.
Plug ambient probe into T2. See
page 14.
Select the proper fuel for the equip-
ment being tested. See page 13.
Readings are erratic when working
on oil fired equipment. Oil filter not installed or installed incorrectly (716 only). Make sure the optional sulfur filter
(A773) is installed. See Appendix B.
One or all of the following parame-
ters; Ratio, CO air free, excess air,
and efficiency read and print dashes.
Measured values are such that the
calculated values of these parame-
ters are out of range.
Redo combustion test. Since these
are calculated values, the measure
values must be within certain levels
for these to display. If the measured
oxygen level is above 19.9% these
parameters won’t read.
These parameters might not display
or be applicable in some tests.
Pressure prints as “N/A” on my com-
bustion analysis print out. During combustion analysis if a pres-
sure measurement is not being made
this parameter will print as not being
used.
Perform the combustion test and
also connect the manometer and
monitor pressure.
Battery will not charge or hold a
charge. Defective charger or battery. Replace the charger or battery.
Send to TPI for service.
Beeping noise heard during charg-
ing. Defect in charging circuit or shorted
battery. Disconnect from the charger and
contact TPI at 800-368-5719.
Analyzer won’t turn off Oxygen and/or carbon monoxide lev-
els outside limits. Allow the analyzer to purge longer.
Appendix C: ERROR CODES & TROUBLESHOOTING (Continued)
Pressure sensor will not zero. Pressure sensor needs to be reset. Send to TPI for calibration.
42
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 optional A807 cable for communication
to a PC or connection for A806 combustible gas leak
detection probe.
Top View
7
Charger
Socket
USB Port
P(+)
Port
P(-)
Port
Gas
Sample
Port
T1 Socket
T2 Socket
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BASIC ANALYZER FUNCTIONS
Charging The Analyzer
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 dis-
play indicates the analyzer is being charged and the status of the charge.
8
The plug symbol confirms the analyz-
er is connected to the charger. The
battery symbol shows the charge
level when the analyzer is on too.
The charge level is represented in
graph form as well. The charge is dis-
played in percentage. (0 to 100%)
During operation the analyzer 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. Please see Appendix G for bat-
tery replacement instructions.
Appendix C: ERROR CODES & TROUBLESHOOTING
Code
Displayed Code Definition Possible Causes Corrective Action
Flow
Error Pump not drawing sample at
correct flow rate. Blockage / kink in flue probe hose.
Dirty or blocked filter(s).
Worn pump.
Check and rectify. See
Appendix A.
Replace filter(s). See
Appendix A.
Return to TPI for service.
InIt
O2
Err
Oxygen sensor failed to ini-
tialize Flue probe connected to 716
prior to power up.
716 did not purge completely
from last sample.
Worn or defective oxygen
sensor.
Disconnect probe and
restart.
Purge for 20 minutes and
restart.
Return to TPI for sensor
replacement.
InIt
CO
Err
Carbon monoxide sensor
failed to initialize. Flue probe connected to 716
prior to power up.
716 did not purge completely
from last sample.
Worn or defective carbon
monoxide sensor.
Disconnect probe and
restart.
Purge for 20 minutes and
restart.
Return to TPI for sensor
replacement.
Lo
bat Low battery. Battery needs to be charged. Charge battery. If the battery
won’t hold a charge, replace
the battery.
oFL Overflow indication. The
pressure being measured is
outside the maximum mea-
surement capability.
Pressure being measured is
too high or low.
Pressure sensor damaged or
defective.
Remove pressure source.
Return to TPI for service.
oFL Overflow indication. The tem-
perature being measured is
outside the maximum mea-
surement capability.
Temperature being measured
is too high or low. Remove pressure source.
oPEn Unable to read thermocouple
(temperature). Temperature probe not con-
nected to input.
Worn temperature sensor.
Connect temperature probe
to analyzer.
Replace temperature probe
or flue probe.
41
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Appendix B: A773 SULFUR FILTER INSTALLATION & MAINTENANCE
4. Beginning on the “Flue Probe” side of the A773 sulfur filter, pull the yellow
thermocouple cord out of the channel of the flue probe tube. Pull out approx-
imately the length of the water trap that was removed.
5. Being careful not to cut the yellow cord, cut out a section of the flue probe
tubing the length of the water trap on the “Flue Probe” side of the A773 sul-
fur filter. (See picture below)
6. Install the water trap in the flue probe hose where the piece was cut out. Make
sure the water trap is positioned correctly. The water trap lid should face the
“Hose End” side of the hose. (See picture below)
A773 SULFUR FILTER MAINTENANCE:
The A773 should be replaced when most of the pellets become discolored, usual-
ly white or black.
If the A773 begins to trap condensate and fill with water but the pellets are not
discolored to the point replacement is required, it should be removed and allowed
to dry. Once it is dry it can be reused.
40
Turning The Analyzer On
Always: - Before turning on please ensure nothing is connected to the Gas
Sample Port (see page 7)
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 the initial start up screen displays for approximately 5 seconds the Main
menu will be displayed.
The initial start up screen displays the
following information:
Model number of the analyzer
Firmware version
Firmware date
Serial number of the analyzer
Last calibration date of the sensors
Note: The NO sensor calibration date
will only display for 716N models.
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
9
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Turning The Analyzer Off
Always: - Before turning off return the instrument to a clean air environment
and allow the Carbon Monoxide level to return below 15ppm and the Oxygen
level to return to 20.9% (± 0.3%) Press the Power Key to turn the instrument
off:- NOTE The Instrument will not allow itself to be switched off if the CO is
above 15ppm
When the 716 is turning off the following screen is seen:
Display Backlight
The display backlight is factory set to Auto. A sensor located on the side of
the analyzer detects the amount of ambient light and automatically adjusts
the backlight intensity.
The backlight can be manually adjusted to a desired level by the user. Please
refer to Menu Navigation - Analyzer Setup on page 31.
10
The instrument has an auto shut off facto-
ry set for 10 minutes should no keys have
been pressed for this period and the CO
level is below 15ppm. The auto power off
can be set to a different time or disabled.
Please refer to Menu Navigation - Analyzer
Setup on page 31.
If the CO level is close enough to 0ppm
and the O2 level is close enough to 20.9%
the analyzer will display “Skip”. This
allows you to skip the purge by pressing
the middle soft key.
Appendix B: A773 SULFUR FILTER INSTALLATION & MAINTENANCE
USE THE A773 ONLY WITH THE 716. DO NOT USE WITH THE 716N.
When using a 716 and performing combustion tests on oil fired equipment it
is important to use the optional A773 sulfur filter. Failure to do so can result
in incorrect and readings. This filter also protects the sensors from the
affects of sulfur. The A773 does not have to be removed when working with
other types of fuels.
PROCEDURE
1. Begin with the water trap section of the flue probe oriented as shown in the
picture below.
2. Remove the water trap from the flue probe hose. (See picture below)
3. Insert the A773 sulfur filter flue probe tube where the water trap was
removed. (See picture below)
39
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Appendix A: General Maintenance (continued)
Flue Probe Integrity Check
NOTE: Perform this check after performing the Pump Operation Check outlined
on the previous page.
1. Turn the analyzer on as outlined on page 8. Do not connect anything to the
inlet. Wait until the analyzer has completed the initial purge and sensor check
and is operating normally prior to proceeding to step 2.
2. Connect the A763 mini pump protection filter and flue probe assembly to the
inlet of the analyzer and the yellow thermocouple connector to input T1.
3. Repeatedly press the Scroll/Enter key until temperature is displayed. If the
displayed temperature is approximately the ambient temperature the thermo-
couple is operating properly and you may proceed to the next step to continue
the test. If the displayed temperature is “OL” the thermocouple is open and the
probe is in need of factory service.
4. Cover the end of the flue probe with a small piece of tube and pinch the end
close. After a short period of time the analyzer should display “Flow Error” and
a rapid beeping should be heard. If this happens the flue probe his operating
properly and the integrity test is complete. If the analyzer does not display “Flow
Error” this is an indication of a possible leak somewhere in the flue probe and
you may proceed to the next step for further tests.
5. Pinch the hose below the handle of the flue probe. If the analyzer displays
“Flow Error” there is a leak in the handle assembly and the probe needs to be
factory serviced. If the analyzer does not display “Flow Error” proceed to the
next step for further tests.
6. Pinch the hose between the analyzer and the water trap. If “Flow Error” still
does not display there may be an internal leak, pump problem, or other issue
and the analyzer needs to be factory serviced. If “Flow Error” is displayed there
is a leak in the water trap assembly and the water trap assembly should be
checked as outlined on page 36 & 37.
38
COMBUSTION ANALYSIS OVERVIEW
Performing combustion analysis is very important to the overall safety and
efficiency of heating equipment. The following guidelines and descriptions are
generic and meant to provide you with a basic understanding of combustion
testing. TPI always recommends you contact the manufacturer of the device
under test, obtain information specific to the device, and follow the proce-
dures and safety guidelines for performing tests and affecting repairs.
In general, for most applications, flue gas samples should be taken prior to
the draft diverter or any other opening that allows room air to enter the sys-
tem. This prevents room air from mixing with gases in the flue and diluting
the test sample. To ensure accurate and consistent combustion tests, it is
important gas and temperature samples be taken at the same location. This is
easy with the TPI flue probe because the temperature sensor is an integral
part of the probe.
Prior to taking a sample, the device under test should be on and operating.
Putting the flue probe in the sample area prior to starting the device may
cause saturation of the sensors due to the higher initial concentration of car-
bon monoxide that may be encountered upon start up. If this happens, allow
your analyzer to purge in fresh air until the carbon monoxide level returns to
0 ppm and the oxygen level returns to 20.9%. This may take more than an
hour depending on how saturated the sensors are.
The figures on pages 16 through 18 show locations for performing tests on
commonly encountered equipment. Remember to consult with the manufac-
turer of the device under test for specific test information.
Pressing the Func Key enables access to the different functions available on
the 716. The default function is Combustion Analyzer. Other available func-
tions are: Thermometer, Manometer/Tightness Test, Combustible Gas Leak
Detector, and Date / Time display.
11
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MEASUREMENTS - Flue Gas
Note: It is recommended you perform routine general maintenance on your
analyzer to ensure proper function. Please refer to Appendix A for general
maintenance schedule and function tests.
12
The pump will start and the Zeroing screen will
display. The analyzer 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 13).
The selected unit of efficiency is displayed
and can be changed as necessary (see pg 13).
If the analyzer 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 8. After
the initial start up screen the Main Menu will
be displayed.
Using the Arrow keys select Measurements by
highlighting it.
Press the Enter key (center soft key) to con-
firm the selection.
The Measurements menu will be displayed.
Using the Arrow keys select Flue gas by high
lighting it.
Make sure the analyzer is in a clean air environ-
ment with only the pump protection filter con-
nected to the input.
Press the Enter key (center soft key) to confirm
the selection.
Appendix A: General Maintenance (continued)
Filter Check Continued
The other two filters are located in the water trap. The main filter is the A794F
particle filter. This filter stops debris and dust from traveling down to the analyz-
er. The secondary filter is the A794W water block filter. This filter stops flow in
the event the water trap fills with condensate. Refer to the picture below.
Open the water trap and look at the A794F particle filter. The filter will typically
get dirty from the inside first. If the filter is dark on the inside a replacement fil-
ter should be installed.
If the A794F is clean but saturated with water a replacement should be installed
to ensure proper flow. The saturated filter can be left to dry and reused later.
Pump Operation Check
1. Turn the analyzer on as outlined on page 8. Do not connect anything to the
inlet. Wait until the analyzer has completed the initial purge and sensor check
and is operating normally prior to proceeding to step 2.
2. Cover the analyzer inlet with your finger. The analyzer should display “FLO
ERR” and a rapid beeping should be heard.
If the analyzer does not beep and display “FLO ERR” this may be an indication
the flow sensor requires calibration, the pump is faulty, or there is an internal
leak. The analyzer should be returned for factory service.
Water trap bowl. A794
water trap pictured. A795
water trap is similar but
longer
A794F
Particle Filter
A794W
Water
Block Filter
Water trap lid. O-ring is
located in the lid recess
A794D Filter
Spacer Disc
37
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Appendix A: General Maintenance
All combustion analyzers use consumable items such filters and probes. These
items are user serviceable and can be taken care of by the operator.
The consumable items that will require operator attention are the water trap / fil-
ter assembly, flue probe, pump protection filter, and ambient temperature probe.
The recommended maintenance schedule for your analyzer is as follows:
Maintenance Performed Frequency
Water trap Check Once per week (Once per day for analyzers
Filter Check that see heavy use or are used in oil fired
applications)
Pump Operation Check Once per month (More often for analyzers
Flue Probe Integrity Check that see heavy use or are used in oil fired
Thermocouple Probe Check applications)
Water Trap Check
Visually check the water trap for:
1. Cracks in the bowl.
2. Broken ears on the bowl where the lid locks on.
3. Broken ears on the lid.
4. Worn out o-ring on the lid.
5. Loose connection to the flue probe tubing.
Filter Check
Signs of dirty or water saturated filters are a slow pump, flow error displayed
when the flue probe is connected, and measurements that take longer than nor-
mal.
TPI analyzers use three filters to protect the pump and sensors. The first filter to
check is the A763 mini pump protection filter. (see picture below)
Inspection Window
Pump Protection Filter
Look in the inspection window to check the filter. When the filter material
becomes dark, pull the black nose cone out of the tubing and replace the ball fil-
ter inside.
36
MEASUREMENTS - 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 efficiency calculation
and therefore it is important the fuel type is cor-
rect 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 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 analyzer will return to the Zeroing display
and the countdown will continue.
The unit of efficiency can be changed as needed
between Nett and Gross. Nett eficiency doesn’t
take into account wet losses while Gross efficien-
cy does. In the USA Gross efficiency is used. If
Nett is selected the efficiency will be displayed as
much higher than it is.
Press the right soft key (Next) to highlight
“Efficiency” in the display.
Press the Chang key (left soft key) and the effi-
ciency menu will display.
Use the Arrow keys to select the desired efficien-
cy unit and press the center soft key (OK) to con-
firm the selection. 13
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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 temperature and pressure.
MEASUREMENTS - Flue Gas (continued)
Connect the Pump Protection Filter assembly and Flue Probe Tubing complete
with In-Line Filter to the Gas Sample Port 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. (See below & page 7)
WARNING: - Ensure the 'K' type thermocouple probes are inserted into the sock-
ets 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
GK11M Probe Thermocouple
Connection from
Flue Probe
Pump Protection Filter
Press the center Blue Soft Key (Start) and the pump will start.
14
CALIBRATION & SERVICE
It is recommended that your analyzer be calibrated every 12 months. Please
consult Test Products International for further details or send your analyzer
to the address below for service.
TPI / Attn. Repair
9615 SW Allen Blvd. Suite 104
Beaverton, OR 97005
Please include your name, contact information, return address, and a brief
description of the service required.
The following are consumable parts for the instrument:
In-Line Filter Element (pkg of 5) User Replaceable A794F
Disc water filter User Replaceable A794W
Mini Pump Protection Filter Assem. User Replaceable A763
**Oxygen Sensor User / Factory Replaceable A761
**Carbon Monoxide Sensor User / Factory Replaceable A760
**Nitric Oxide Sensor User / Factory Replaceable A793
**Sensor replacement requires calibration gas.
These items require periodic replacement as the analyzer is used.
Please see Appendix A on page 37 for general maintenance informa-
tion.
WARRANTY
Your TPI 716 Flue Gas Analyzer is guaranteed free from defects in materials
and workmanship for 3 Years from the date of purchase. The sensors carry a
2 Year warranty. This guarantee does not affect your statuary rights. For addi-
tional information please refer to the included warranty card or contact TPI at
800-368-5719.
To obtain warranty performance or maintenance on your analyzer: - Include
with the product your name, address, phone number, written description of
the problem and proof of purchase date. Carefully package and return to:
TPI / Attn. Repair
9615 SW Allen Blvd. Suite 104
Beaverton, OR 97005
35
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SPECIFICATIONS (Continued)
Gases Range Resolution Accuracy
Oxygen 0-25% 0.1% +/- 0.3%
Carbon Monoxide 0-10,000 ppm 1 ppm +/- 5 ppm or 5%
Whichever is greater
Nitric Oxide * 0-5000ppm 1ppm +/- 5ppm (<100ppm)
+/- 5% (<1000ppm)
+/- 10% (>1000ppm)
Carbon Dioxide 0-25% 0.1% Calculated
CO/CO2 Ratio 0-0.999 0.001 Calculated
Combustion Efficiency 0-100% 0.1% Calculated
Gas Leak Sensor 100-10,000 ppm (calibrated to methane)
*716N Model Only
Pressure Measurement
Selectable Ranges mbar, psi, inH2O, mH2O, kPa, hPa,
inHg, mmHg
Range - 150 mbar to + 150 mbar
-15 kPa to + 15 kPa
-60 inH2O to 60 inH2O
Resolution 0.01 mbar, 0.001 kPa, 0.001 inH2O
Accuracy +/- 0.5% fsd
Temperature Measurement
Input Type K-Type thermocouple
Range -58°F to 1832°F (-50°C to 1000°C)*
Resolution 1°F (1°C)
Accuracy +/- (0.3% of rdg + 2°F) or
+/- (0.3% of rdg + 1°C)
* The thermocouple supplied (GK11M) has the ability to measure tempera-
tures in the -50°F to 950°F range.
34
IMPORTANT: Prior to taking a sample, the device under test should be on and
at operating temperature. Putting the flue probe in the sample area prior to
starting the device may cause saturation of the sensors due to the higher
initial concentration of carbon monoxide that may be encountered upon
start up. If this happens, allow your analyzer to purge in fresh air until the
carbon monoxide level returns to 0 ppm and the oxygen level returns to
20.9%. This may take more than an hour depending on how saturated the
sensors are.
Drill a 1/4 inch hole into the flue of the device under test. For most applica-
tions, flue gas samples should be taken prior to the draft diverter or any
other opening that allows room air to enter the system. This prevents room
air from mixing with gases in the flue and diluting the test sample.
It is important to use manufacturers recommended test locations whenever
possible.
Refer to the figure below for calculating the sample hole location.
The figures on the following pages show typical test locations on commonly
encountered equipment.
15
MEASUREMENTS - Flue Gas (continued)
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MEASUREMENTS - Flue Gas (continued)
TYPICAL TEST LOCATIONS
Atmospheric Gas Fired Fan Assist Boiler / Furnace
Typical Test Locations
Figure 1
It is important to use manufacturers recommended test locations
whenever possible.
16
SPECIFICATIONS
Instrument
Operating Temperature Range 14°F to +122°F (-10°C to +50°C)
Battery / Battery Life Rechargeable Ni-MH / > 6 Hours
Charger Input Voltage 115V or 230V : 50/60 Hz AC
Fuels Natural Gas, LPG, Light Oil, Heavy Oil,
Bituminous Coal, Anthracite Coal, Coke,
Butane, Wood, Bagasse
Pressure Ranges mbar, psi, inH2O, mH2O, kPa, hPa,
inHg, mmHg
Display Backlit Graphic LCD
Data Storage 100 sets of readings, multiple pages
Single Logging 150 sets of time stamped readings
Time & Date 24 Hour Real Time Clock
Dimensions 7.8” (200mm) x 3.5” 90mm x 2.4” (60mm)
Weight 1.1lbs (500g)
Conforms to BS7927 (and the draft BS7967)
Flue Temperature Probe
Construction Pistol Grip with Stainless Steel Shaft
Hose Length 8.2’ (2500mm)
Insertion Length 7.9” (200mm)
'K' Type Thermocouple Accuracy +/- 0.3% of fullscale, +/- 2°F (1°C)
Maximum Temperature 1472°F (800°C)
33
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Menu Navigation - Units of Measure
1. From the main menu use the Arrow keys to select “Units of Measure” and
press the “Enter” key (center blue soft key).
2. The Units of Measure menu will display. The following parameters are accessi-
ble in this menu. Use the Arrow keys and center blue soft key to select the appro-
priate parameter.
Temperature - Select between °C and °F for temperature measurements.
Pressure - Select between mbar, psi, inH2O, mmH2O, kPa, hPa, inHg, and mmHg
units of measure for pressure readings..
Efficiency - Select between Nett and Gross efficiency. Gross efficienc is used in
the USA and factors in wet losses. Using Nett efficiency in the USA will result in
abnormally high efficiencies.
Menu Navigation - Sensor Info
Allows the user to see the last and next calibration date of the sensors that are
installed in the 716.
Menu Navigation - Instrument Info
Provides the serial number, firmware version, and firmware date for reference.
Also shows the last calibration date of the unit and batter voltage / condition.
Menu Navigation - Calibration Mode
This is for factory use only.
32
Condensing Boiler / Furnace
Typical Test Locations
Figure 2
It is important to use manufacturers recommended test locations
whenever possible.
17
MEASUREMENTS - Flue Gas (continued)
TYPICAL TEST LOCATIONS
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Test all exhaust ports at the
top of the heat exchanger.
Atmospheric Forced Air Furnace
Typical Test Locations
Figure 3
It is important to use manufacturers recommended test locations
whenever possible.
18
MEASUREMENTS - Flue Gas (continued)
TYPICAL TEST LOCATIONS
Menu Navigation - Analyzer Setup
1. From the main menu use the Arrow keys to select “Analyzer Setup” and press
the “Enter” key (center blue soft key).
2. The Analyzer Setup menu will display. The following parameters are accessible
in this menu. Use the Arrow keys and center blue soft key to select the appropri-
ate parameter.
Display type - Allows the display to be switched between 8 line and 4 line.
Date / Time - Used to set the current date and time. The date is in dd:mm:yyyy
format and the time is a 24 hour clock.
Contrast - Lighten or darken the display contrast.
Backlight - Adjust the backlight level from off to full brightness or set it to auto
and the 716’s internal sensor will control the backlight brightness depending on
ambient light.
Alarm limits - Set the level at which the CO alarm sounds. The level is adjustable
from 10ppm to 3000ppm and can be turned off. Default level is 2000ppm.
Print Header - Enables the two line header on printouts to the infrared printer to
be set with your companies information. After pressing “Enter” you will be asked
for a password. Enter “7160” and press “OK”. Select Header Line 1 and then use
the Arrow keys to enter line one of the header. Press “Enter” then repeat the
process for line 2 of the header.
Auto Power - Enables the auto power off time to be set. The timer can be disabled
or set to one of the following times; 5, 10, 20, 30, or 60 minutes. If a key has not
been pressed during the time set, the analyzer will automatically begin to turn off.
Memory - Enables memory maintenance as outlined on page 29.
31
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