TSI Instruments CA-CALC 6203 Series Operation manual

Model 6203 Series
CA-CALCTM
Combustion Analyzers
Operation and Service Manual
P/N 1980472 Revision –
October 2002
Combustion Analysis

October 2002
P/N 1980472 Revision -
SHIP/MAIL TO: E-Mail
TSI Incorporated [email protected]
Attn: Customer Service
500 Cardigan Road WEB SITE
Shoreview, MN 55126 www.tsi.com
USA
U.S. and CANADA INTERNATIONAL
Sales and Customer Service: Sales and Customer Service:
[phone]/[phone] (001 651) 490-2811
Fax: Fax:
[phone] (001 651) 490-3824
Model 6203 Series
CA-CALCTM
Combustion Analyzers
Operation and Service
Manual

Copyright ©
TSI Incorporated / 2002 / All rights reserved.
Part Number
1980451 / Revision -
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
[phone]
LIMITATION OF WARRANTY AND LIABILITY (effective July 2000)
Seller warrants the goods sold hereunder, under normal use and service as described in the
operator's manual, shall be free from defects in workmanship and material for twenty-four (24)
months, or the length of time specified in the operator's manual, from the date of shipment to the
customer. This warranty period is inclusive of any statutory warranty. This limited warranty is
subject to the following exclusions:
a. Batteries are warranted for 90 days from the date of shipment to the customer.
Electrochemical gas sensors are warranted for a period of twelve (12) months from the date
of shipment to the customer.
b. Parts repaired or replaced as a result of repair services are warranted to be free from defects
in workmanship and material, under normal use, for 90 days from the date of shipment.
c. Seller does not provide any warranty on finished goods manufactured by others or on any
fuses, batteries or other consumable materials. Only the original manufacturer's warranty
applies.
d. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with
respect to, and shall have no liability in connection with, goods which are incorporated into
other products or equipment, or which are modified by any person other than Seller.
The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated
herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR
PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE.
TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR
BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES,
INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED
ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL
BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE
PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE
GOODS. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE
RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS
OR CHARGES. No Action, regardless of form, may be brought against Seller more than 12
months after a cause of action has accrued. The goods returned under warranty to Seller's
factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk of loss.
Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND
LIABILITY, which contains the complete and exclusive limited warranty of Seller. This
LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its terms
waived, except by writing signed by an Officer of Seller.
Service Policy
Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our
customers, our service policy is designed to give prompt attention to any problems. If any
malfunction is discovered, please contact your nearest sales office or representative, or call TSI's
Customer Service department at [phone].

i
CONTENTS
Chapters
Introduction ........................................................................................1
Manual Purpose ............................................................................1
Using This Manual.........................................................................1
Warnings and Cautions ................................................................. 1
1 Instrument Description ............................................................... 3
CA-CALCTM 6203 Measurements and Calculations........................ 3
2 Unpacking ....................................................................................5
List of Standard Components........................................................ 5
Accessories and Replacement Parts ............................................ 5
3 Component Identification ........................................................... 7
The Gas Sensors .......................................................................... 8
The Sampling Probe......................................................................9
Flue Probe Thermocouple............................................................. 9
On-Board Temperature Measurement .......................................... 9
Diaphragm Pump ..........................................................................9
Draft Sensor .................................................................................. 9
Water Trap..................................................................................... 9
Optional Combustion Supply Air Thermocouple Probe ................9
Schematic Representation of CA-CALC....................................... 10
4 Getting Started ..........................................................................11
Supplying Power .........................................................................11
Installing Batteries .......................................................................11
Connecting the Sampling Probe .................................................11
Connecting the Optional Combustion Supply Air
Temperature Probe ..................................................................12
Connecting the Optional Portable Printer.................................... 12
Connecting to a Computer ..........................................................12
Default Instrument Settings ......................................................... 13
Factory Default Settings (U.S.).................................................... 13
Factory Defaults (Non-U.S.) ........................................................ 13
5 Basic Operation.........................................................................15
Buttons and Button Operations ...................................................15
Startup .........................................................................................16
Characters and Display Icons ..................................................... 18
Measurements and Calculations.................................................20
Data Display, Viewing Measurements and Calculations............. 22
Error Indications ..........................................................................22
Using the Sampling Probe........................................................... 22
Making a Draft Measurement......................................................24

ii
Printing to the Portable Printer and to a Computer .....................24
Handling Data..............................................................................27
6 MENU Options............................................................................29
BASE.L MENU—Option Update Sensor Baselines ....................30
FUEL MENU Option—Select Fuel ..............................................30
FP MENU Option—Fuel Parameters ..........................................31
UNITS MENU Option (changing units)........................................31
INT.SA MENU Option—Sampling Interval for Saving Data ........31
TIME MENU Option—Set Time and Date for Printout ................32
CALIB MENU Option (select sensor for calibration) ...................32
O2Gas Sensor Calibration ..........................................................33
Calibration of the CO (hydrogen compensated) Sensor .............33
Calibration Steps .........................................................................33
Draft Calibration...........................................................................34
Temperature Calibration..............................................................35
CAL.FA MENU Option—Setting the Calibration Factor for a
Replacement Gas Sensor ........................................................35
CO Sensor ...................................................................................35
NO Sensor ...................................................................................36
BAUD Rate MENU Option...........................................................37
COMM MENU Option—Set the Output Communications
Device.......................................................................................37
FP MENU Option—Fuel Parameters ..........................................37
7 Setup for Gas Calibration .........................................................41
The Calibration Setups ................................................................41
8 Maintenance and Troubleshooting..........................................45
Emptying Water Trap...................................................................45
Changing the Water Trap Filter ...................................................46
Cleaning the Sample Probe.........................................................46
Lithium Battery Replacement ......................................................46
Replacing a Gas Sensor..............................................................47
Appendixes
A Error Codes ................................................................................49
B Calculations ...............................................................................51
Undiluted Gas Concentration Calculation (COu, NOu, NOxu) ......51
Excess Air Calculation.................................................................51
Calculating Combustion Efficiency for U.S. Fuels .......................51
Siegert Formula ...........................................................................52
Determining CO2Using the O2Concentration ............................53
Emission Rate Calculations Using Emission Factors..................53
Emission Rate Factors ................................................................53

iii
A General Equation for the Combustion of a Simple
Hydrocarbon in Air ...................................................................54
Calculating CO2Max From the Carbon Content ......................... 54
Calculation of Combustion Air Requirement ...............................54
C Series CA-6203 CA-CALCTM Combustion Analyzer
Specifications ............................................................................55
D Default Settings For Different Model Letter Designations.... 57

1
Introduction
Manual Purpose
This manual describes the operation and maintenance of TSI CA-CALCTM
CA-6203 portable combustion analyzer.
Using This Manual
Before using your CA-CALC combustion analyzer, review this manual in its
entirety.
Warnings and Cautions
The manual assumes that you have a basic understanding of combustion
safety and are thoroughly familiar with the fuel burning equipment being
tested. If you are using measurements as the basis for equipment
adjustments, rely on your good judgment and experience together with the
measured data. This is especially important for safety. Remember when
adjusting equipment always follow the manufacturer’s recommendations.
WARNING
!
High temperatures and toxic gases are produced when
fossil fuels are burned. Only qualified individuals,
thoroughly familiar with operating and adjusting fuel-
burning equipment, should use gas measurements for
the purpose of making equipment adjustments.
Note
!
The CA-CALC is not intended for use as a continuous
monitor.
Notes: Best results are obtained if the CA-CALC combustion analyzer is
allowed to stabilize at the temperature of the test environment before
using.
To reduce sensor exposure to gas and to reduce build up of water
vapor in the sampling lines and water trap, turn the pump off when
not making measurements.

3
Chapter 1
Instrument Description
The CA-CALCTM combustion analyzer, Model CA-6203 is used to evaluate
the performance of burners in boilers, furnaces, and hot water tanks. The
Model CA-6203 has sensors for the direct measurement of combustion
gases; O2, CO, NO; combustion gas temperatures and draft pressure. The
CA-6203 performs a complete list of combustion and emission parameters
for a variety of system performance evaluations. Different units and different
fuel types are readily selectable.
CA-CALCTM 6203 Measurements and Calculations
Measurement Sensor
Oxygen concentration O2, electrochemical
Carbon monoxide CO, electrochemical
Nitric oxide NO, electrochemical
Flue temperature Thermocouple
Supply air temperature On-board sensor or Thermocouple probe
Draft pressure Pressure transducer, internal solid state
Calculations
CO2, Carbon Dioxide
Excess air / λ
Stack/Flue loss / qA
Combustion efficiency
Differential temperature
NOx
CO undiluted
NO undiluted
COrindex
NOxundiluted
Emission Rates CO, NO
The CA-CALC 6203 is supplied with a sampling probe having an in-line
water trap and particulate filter.
The CA-CALC 6203 operates using either an AC power supply or C-size
batteries.

Chapter 1
4
The CA-CALC 6203 stores individual data samples (up to 100), and prints
the data to a portable printer or computer. Stored data can be saved over a
user-defined interval and averaged.
The CA-CALC 6203 has a variety of standard fuels, and enables you to
modify the fuel parameters, or install your own user-defined fuel.
Loss and efficiency are calculated from standard ASME heat-loss
calculations or using the Siegert formula (refer to Appendix B).

5
Chapter 2
Unpacking
Carefully unpack your CA-CALCTM combustion analyzer and accessories
from the carrying case. Check the individual parts against the list of
components in the table below. If items are missing or damaged, notify TSI
immediately.
List of Standard Components
Qty. Item Component Part/ Model
1 Series CA-6203 CA-CALC combustion analyzer 802301
1 Sample probe with water trap, draft line and
temperature
801989
1 Power supply 7.2V
120V or
230V European, or
230V Great Britain, or
240V Australian
2613033
2613078
800169
2613106
4 C cell alkaline batteries
1 Operation and Service manual 1980472
Accessories and Replacement Parts
Item Part/Model
Combustion Supply Air thermocouple 3013003
Portable printer kit 801994
Computer cable 8940
Hard side Carrying case 1319284
CO replacement sensor 802014
O2replacement sensor 802012
NO replacement sensor 802007
Water trap filters 801947
Calibration Kit O2(N2gas) and CO 802003
Calibration Kit CO 801999
Calibration Kit NO 801937
Replacement bottled gas, CO (requires Cal. Kit) 801941
Replacement bottled gas, NO (requires Cal. Kit) 801930
Replacement bottled gas, N2(requires Cal. Kit) 801980
Bottled gas, CO with H2(requires Cal. Kit) 801942

7
Chapter 3
Component Identification
Key components of the CA-CALCTM combustion analyzer and sampling
probe are identified in Figures 1 and 2, and under section headings in the
text that follows.
1. Bottom buttons 9. Battery cover
2. LCD display 10. Battery cover tab
3. On-Off button 11. Port for flue gas thermocouple
4. Control buttons 12. Port for supply air thermocouple
5. Icon buttons 13. RS232 serial port
6. Magnets 14. Power connection
7. Vent 15. Draft sample port
8. Sensor cover 16. Gas sample port
Figure 1: CA-CALC CA- 6203

Chapter 3
8
1. Tube retaining fitting 6. Thermocouple connector
2. Probe handle 7. Flexible sample line
3. Position collar 8. Water Trap
4. Sample tube 9. Water trap filter
5. Probe tip with thermocouple
Figure 2: CA-CALC Sampling Probe Components
The Gas Sensors
The CA-CALC CA-6203 uses three gas sensors for measuring oxygen (O2),
carbon monoxide (CO) and nitric oxide (NO). CO and NO sensors are
capable of operating from two to three years. The O2sensor typically lasts
one year. Best accuracy is obtained by routine user calibration (automatic for
the O2sensor). Calibrated replacement CO and NO sensors are also available
from the factory.

Component Identification 9
The Sampling Probe
Your combustion analyzer comes equipped with a sampling probe, depicted
in Figure 2. A thermocouple extends to the end of the sampling tube for
making flue temperature measurements. Two flexible sampling lines are
used for gas sampling and draft measurement. The sampling tube is
removable for cleaning.
Flue Probe Thermocouple
The flue temperature (TS) is measured using a Type K probe, which extends
through the sampling tube to the probe tip. The thermocouple probe
measures temperatures up to 1000 degrees C (1800 degrees F).
On-Board Temperature Measurement
Your CA-CALC analyzer uses an on-board temperature detector to provide
the Combustion Supply Air (TA) temperature when no supply-air accessory
probe is present.
Diaphragm Pump
The CA-CALC analyzer samples exhaust gases from the flue and delivers
them to the electrochemical sensors using a diaphragm sampling pump.
Typical pump life is 5000 hours.
Draft Sensor
A differential pressure transducer in the CA-CALC analyzer is used to
measure draft pressure.
Water Trap
The water trap, shown in Figure 2, is used to remove moisture that collects
in the sample tubing when combustion gases are sampled. The water trap has
a two-chamber design with a particulate filter.
Optional Combustion Supply Air Thermocouple Probe
A measurement of the Combustion Supply Air (TA) temperature at the
source can be made using an optional thermocouple accessory probe (TSI
PN 3013003). This probe is connected to the supply air temperature port
shown in Figure 1.
When a Supply Air temperature probe is not used, the supply air temperature
is determined from the on-board temperature sensor.

Chapter 3
10
Schematic Representation of CA-CALC
Figure 3. Schematic Representation of CA-CALC

11
Chapter 4
Getting Started
Supplying Power
The CA-CALCTM portable combustion analyzer operates using 4 C batteries
or an AC adapter. Quality alkaline batteries enable the instrument to operate
for at least 24 hours. Use of the plug-in AC adapter conserves battery life,
and can be substituted for batteries.
Installing Batteries
Turn the combustion analyzer over and remove the
battery cover by lifting up and out on the battery
cover tab shown below. Remove the old batteries.
Note: It is not necessary to remove the
battery holder when removing or
installing batteries. Best results are
obtained if the batteries opposite the
contact springs are removed first.
Install four new C-cell batteries, noting the battery orientation depicted on
the base of the battery holder. Install spring-side batteries first.
Connecting the Sampling Probe
The sampling probe depicted in Figure 2, is connected to the instrument by
pushing the brass sample and silver draft connectors over the ports on the
instrument. Refer to the figures below showing the proper connection of the
probe tubes to the instrument sample ports. Note that the thermocouple
connector can be inserted only one way. The thermocouple connector is
oriented with the large spade to the right. Do not force the connector.

Chapter 4
12
Figure 4: Sampling Probe Connections
Connecting the Optional Combustion Supply Air Temperature
Probe
A type K thermocouple probe may be used to measure the temperature of the
air supplied to the burner.Connect the optional supply air thermocouple (see
“Accessories and Replacement Parts”) to the supply air thermocouple port
depicted in Figure 1. The thermocouple connector can be inserted only one
way—large spade to the right. Do not force the connector.
When the optional Supply Air Temperature Probe is not used, supplied
combustion air temperature is determined from the instrument temperature
using an on-board sensor.
Connecting the Optional Portable Printer
Find the printer interface cable included with the optional portable
printer. For the serial printer, connect the large 9-pin connector on the
cable to mating connector on the printer. Connect the opposite end to the
instrument’s RS232 communications and printer port. See Figure 1 for
port location.
The printer and CA-CALC combustion analyzer have both been factory
set for a baud rate of 1200. If baud rates are not matched, the printer will
print random characters, question marks or asterisks. Printer settings are
described in the printer manual, along with illustrations identifying the
correct DIP-switch configuration. To set the CA-CALC baud rate and
device settings, refer to Chapter 6, “MENU Options.”
Connecting to a Computer
Use the optional computer interface cable, Model 8940, to transfer
(download) data serially from the CA-CALC analyzer to a computer. Your
printer cable will not work for downloading to the computer. Connect the
Sample Connector
(Brass)
Draft Connector
(Silver)
Thermocouple Connector