Wohler A 500 User manual

A
500
Combustion and Emissions Analyzer
Contents
1. Introduction
2. Getting Started
3. Operating the A 500
4. Other Operations
...................
22
5. Setup Screen Controls
........
28
6. Maintenance
.........................
32
35
40
................
42
..........................................
43
A. Appendix A - Peltier Cooler
......
44
The Measure of Technology
30.10
.2006 part nr. 21947
Contents
1. Introduction
...............................
2. Getting Started
.........................
8
3. Operating the A 500
.............
12
22
7. Sensor Replacement
.................
35
.......................
40
9. Sales/Service Centers
................
10. Warranty
..........................................
A. Appendix A - Peltier Cooler
...............................
2
.........................
8
7. Sensor Replacement
8. Parts and Service
.......................
9. Sales/Service Centers

A 500
2 Technical Service Hotline: [phone]
1. Introduction
The A 500 is a full feature residential, commercial, and light industrial grade analyzer,
that is an ideal tool for the service technician who needs to determine combustion
efficiency, carbon monoxide (CO) safety, and compliance with emissions requirements.
The A 500 utilizes an operator friendly, touch-screen display to access all its functions
and to view up to 11, easy to read, different measurements and calculations at one
time.
The A 500 measures flue gas O
2,
CO, NO, NO
2
, SO
2
, stack and ambient temperature,
pressure and draft. The A 500 also calculates and displays combustion efficiency,
stack loss, excess air, CO
2
, NO
x
, and dew point temperature. Additionally the A 500
also calculates CO, NO, NO2, NO
x
and SO
2
, to an O
2
reference selected by the user.
The A 500 comes standard with data storage for 850 complete combustion records
and, with 2 way IRDA communication capabilities, the built-in IR port can transmit test
information to a printer or PC for record keeping with just a touch of the screen. The
operator can also upload customer information from their PC to the A 500 via the IRDA
interface or can quickly and easily enter new customer information directly into the
units memory using the alphanumeric keyboard feature of the touch-screen.
Information on all models of the A 500 is contained in this manual so please disregard
information that does not relate to your model.
1.1 The A 500 Features:
1. Introduction
Figure 1: A 500

A 500
3
e-mail: [email protected] http://www.wohlerusa.com
e-mail: [email protected] http://www.wohlerusa.com
1. Introduction
• Measures and displays: O
2
and CO content in the flue-gas, combustion-air tempe-
rature, stack temperature, and pressure / draft.
• Calculates and displays: CO
2
content in the flue gas, combustion efficiency, excess
air, stack loss, and
flue gas dew point.
• Measures and displays: NO, NO
2
, SO
2
, and CO
HIGH
(depending on model)
• Displays emission measurements for NO, NO
2
, and/or SO
2
.
• Emission conversions can be displayed in parts per million (ppm), milligrams of
pollutant per cubic meter of gas (mg/m
3
), pounds of pollutant per giga BTU (#/
GBTU), or grams of pollutant per gigajoule (g/GJ).
• All combustion calculations and measurements are displayed on one screen with
emission measurements and calculations on a second.
• Real-time, on-screen, graphical display of any measured or calculated test values.
• CO sensor has a warning indicator manual bypass to protect the sensor from high
concentrations of carbon monoxide.
• Displays temperature in either °C or °F and pressure in either inches of water co-
lumn (in H
2
O), or millibars (mbar).
• When unit is turned on it automatically zeros and purges all sensing channels with
ambient air for 60 seconds .
• The water trap and filters are conveniently located at the top of the analyzer for
easy viewing, draining or changing.
• The A
500
can operate from either an AC adapter, internal rechargeable batteries,
or standard AA alcaline batteries.
• Battery utilization display.
• Time and date display.
• Built-in memory for 850 individual combustion test records.
• Records can be recalled for printing or for transmission to a PC.
• All operator and data management functions are via the Touch-screen interface.
• Customer records can include the customer name, ID, device number, and com-
ments. Information is entered using the touch screen alphanumeric display.
• Customer data appears on the printout.

A 500
4 Technical Service Hotline: [phone]
1. Introduction
1.2 Specifications
Eac
h
A
500
M
odel Measures and Displays:
O
2
: Oxygen from 0.1 to 20.9%
CO: Carbon monoxide, hydrogen compensated from 0 to 4000 ppm
T
A
TA T
: Combustion air temperature from 0 to 257 °F (–20 to 125°C)
T
S
: Stack gas temperature from 32 to 1562 °F (0 to 850°C)
P
r
: Pressure: Stack draft in the range of ±16.00 inch H
2
O (±40.00 mbar)
Optional sensors include:
CO
HIGH
: Carbon monoxide from 4001 to 32,000 ppm
NO: Nitric oxide from 0 to 2000 ppm
NO
2
: Nitrogen dioxide from 0 to 500 ppm
SO
2
: Sulfur dioxide from 0 to 4000 ppm
Eac
h
A
500
M
odel Calculates and Displays:
CO
2
: Carbon dioxide from 0 to a maximum, fuel dependent value in percent
CO
C
: Carbon monoxide from 0 to 32,000 ppm when O2 referenced (user defi-
ned)
E
ffc
: Combustion efficiency from 0 to 100%
EA: Excess air from 0 to 250%
L
oss
: Stack loss from 0 to 100%
D
pnt
: Dew point temperature in °F or °C
Depending on additional optional sensors:
NO
C
: Nitric oxide from 0 to 32,000 ppm when O2 referenced (user defined)
NO
2C
: Nitrogen dioxide from 0 to 32,000 ppm when O2 referenced (user defi-
ned)
SO
2C
: Sulfur dioxide from 0 to 32,000 ppm when O2 referenced (user defined)
NO
x
: Oxides of nitrogen (NO + NO2) from 0 to 2500 ppm
NO
xc
: Oxides of nitrogen (NO + NO2) from 0 to 32,000 ppm when O2 refe
renced (user defined)
Fuels (User Selectable):
Natural Gas Wood Oil #2 Oil #6
Propane Kerosene Coal Digester Gas
Normal Operating Environment:
Temperature +50 to +104 °F (+10 to +40 °C)
Humidity 15 to 90% Relative Humidity, non-condensing
Air Pressure Atmospheric
Power:
4 ‘AA’ rechargeable Ni-MH batteries
Warm Up Time:
60 seconds

A 500
5
e-mail: [email protected] http://www.wohlerusa.com
e-mail: [email protected] http://www.wohlerusa.com
1. Introduction
Operating Time:
Approximately 12 hours of continuous operation with fully charged batteries. No time
limit if using the AC adapter.
Accuracy:
O
2
±0.3%
CO ±5% of reading (0 and 4000ppm)
CO
HIGH
±10% of reading from 4001 and 16,000 ppm
NO ±5% of reading or ±5 ppm, whichever is greater
NO
2
±5% of reading or ±5 ppm, whichever is greater
SO
2
±5% of reading or ±10 ppm, whichever is greater
TS: Stack Temp. ±4°F from 32 to 257°F (±2°C from 0 to 125°C)
±6°F from 258 to 481°F (±3°C from 126 to 249°C)
±8°F from 482 to 751°F (±4°C from 250 to 399°C)
±16°F from 752 to 1562°F (±9°C from 400 to 850°C)
T
A
TA T
: Combustion-Air Temp. ±2°F (±1°C)
P
r
: Pressure ±3% of reading or ±0.02 inH2O (±3 Pa) whichever is
greater
Resolution:
O
2
0.1%
CO 1 ppm
CO
HIGH
2 ppm
NO 1 ppm
NO
2
1 ppm
SO
2
1 ppm
T
S
2°F (1°C)
T
A
TA T
1°F (0.1°C)
P
r
0.01 inH
2
O (1 Pa)
Display:
2
¼
“ x 4
¼
“ backlit LCD, touch screen with alphanumeric, graphic display
Dimensions:
Height: 5.8 in. (147 mm)
Width: 7.6 in. (193 mm)
Depth: 2.0 in. (51 mm)
Weight:
Approximately 3.6 lbs (1.63 kg) with batteries and probe

A 500
6 Technical Service Hotline: [phone]
1. Introduction
1.3 A 500 Components and Controls
1. Power ON/OFF switch and CO sensor bypass
2. Charging/Power Jack (side)
3. Touch Screen graphical display
4. IrDA port (top)
5. Battery compartment (back)
6. Water trap and filter
7. Water stop filter (inside)
8. Combustion air thermocouple /socket (front)
9. Connector for probe and hose assembly
10. Thermocouple
11. Probe
12. Probe assembly
13. Coarse probe filter (inside) and Plexiglas plug
14. Secondary pressure inlet
15. Combined gas and power hose
16. Ambient temperature plug
Figure 1-1: A 500
1
3
8
1. Power ON/OFF switch and CO sensor bypass
1. Power ON/OFF switch and CO sensor bypass
2. Charging/Power Jack (side)
2. Charging/Power Jack (side)
3. Touch Screen graphical display
Figure 1-1: A 500
Components
Components
11
3
7
2
3
3
4
4
1
8
6
10
9
11
1
2
1
1
4
1
5
16
5
5

A 500
7
e-mail: [email protected] http://www.wohlerusa.com
e-mail: [email protected] http://www.wohlerusa.com
1. Introduction
Figure 1-2: Display Controls in Combustion Test Run Mode
Figure 1-3: Display Controls in Combustion Test Hold Mode
System Status - Hold mode
Touch to output dis-
played test data from
IRDA port
Touch to save the
current test data to
a customer memory
location
Touch to re-enter run
mode and continue
measuring
Touch to save the
Touch to re-enter run
Touch to enter GRA-
PHIC mode to select
individual sensor to
graph
Touch to zero
pressure sensor
Touch to freeze
current displayed
values
Touch to turn pump
off for pressure
measurements
PUM2 clean out
pump running
Touch to toggle
between combus-
tion and emission
screens
Select fuel and re-
maining battery life
Touch to enter fuel
selection screen
Customer Information
Touch to enter customer
data input and management
screen
Current date (mm-dd)
and time (
a
m/
p
p
m
hour: minute)
NGAS
B 95%
04-06
p03:36
Customer Name
Pr = 0
GRAPH PUM1 DISP
H O L D
T
A
TA T
s
: 68°F
T
S
: 374°F
L
OSS
: 17.4 %
D
pnt
: 130°F
P
r
:- 0.0
2
EA
:
21%
O
2
: 4.0 %
CO
2
: 9.5 %
E
ffc
: 82.6 %
CO
: 8
PPM
CO
C
: 9
PPM
in
ch
H
2
O
NGAS
B 95%
04-06
p03:36
Customer Name
SAVE
PRINT PUM1 DISP
R U N
T
A
TA T
s
: 68°F
T
S
: 374°F
L
OSS
: 17.4 %
D
pnt
: 130°F
P
r
:- 0.0
2
EA
:
21%
O
2
: 4.0 %
CO
2
: 9.5 %
E
ffc
: 82.6 %
CO
: 8
PPM
CO
C
: 9
PPM
in
ch
H
2
O
SYSTEM IN HOLD

A 500
8 Technical Service Hotline: [phone]
2. Getting Started
Important. Please ensure the batteries are fully charged before use.
2.1 Turning on the A 500
1. Turn the analyzer ON by rotating the OFF/ON switch to its “I” position (No. 1 Figure
1-1). This starts the pump motor. The LCD should briefly display the WÖHLER A500
logo, and software version number. The screen also displays information on the to-
tal number of memory locations available, the remaining battery capacity expressed
as a percent, and the number of customer records currently stored (loaded). A
menu across the bottom of the screen allows the operator to access the functions
shown in Figure 2-2.
2. Getting Started
Lithium battery
voltage - replace
battery at 2.5 V
Number of memo-
ry locations used
Battery
life re-
maining
Touch
to enter
Setup
screen
menu
Total number of
memory locations
available
Touch
to enter
Data
screen
menu
Touch to
return to
factory
defaults
Touch
to enter
display
option
screen
Touch to
edit CO
limit (COP
starts
above
these
limit)
Touch to enter
Sensor Diagno-
sis screen
life re-
Touch to
Figure 2-1: Initial Turn-ON Screen and Menu Controls
DATASETUP DISP DIAGDEFLT CO_L
3.56
A 500
USA Version 1.
1
85
0 customers 4 loaded
B
100%

A 500
9
e-mail: [email protected] http://www.wohlerusa.com
e-mail: [email protected] http://www.wohlerusa.com
2. Getting Started
2.2 SET UP
Before using your A500 for a combustion test the following parameters or settings
must be entered or changed:
Time and Date
Measurement Units
Printer Protocol
Probe Calibration Factors
Oxygen Reference
NOTE: The
A500
r
etains its last settings until reset by the user to either the fac-
tory default settings or to new user selections.
2.3 Factory Defaults
The A 500 has been set up at the factory for the following defaults:
Time and Date Current time (EST) and date
Temperature °F
Pressure inchH2O
Emissions Unit of Measure ppm
O2 Reference 3%
Memory Formatted – no records
These settings can be changed as described below.
2.4 Setup Screen Controls
The Setup Screen is accessed by touching the SETUP key (lower left) after the A 500
is first turned ON and while its initial Turn-ON Screen (see Figure 2-1) is displayed.
(screen shows for approximately 5 seconds).
Figure 2-2: Initial Turn On Screen
DATASETUP DISP DIAGDEFLT CO_L
3.56
A 500
USA Version 1.
1
85
0 customers 4 loaded
B
100%

A 500
10
Technical Service Hotline: [phone]
Figure 2-3: Setup Screen Controls
2.5 Connecting the Probe and Hose
Plug the probe tube into the probe handle by aligning the three prongs with the appro-
priate holes in the probe handle and push together snugly, and then secure by scre-
wing on the retaining collar. Connect the hose assembly to the probe handle and to
the analyzer by first aligning red marks on each connector, inserting then twisting the
connector clockwise until locked into place.
Important: For accurate temperature measurements, the probes calibration
factor must be entered into the analyzer per Section 5.4 Calibration Factors.
The calibration factors for the probe and combustion-air probe shipped with
the A500
from the factory have already been entered. Reentry of the calibration
factor only needs to be performed if a new or different probe is used.
2.6 Connecting the Combustion-Air Probe
Plug the Combustion-Air Temperature Probe (T
A
Plug the Combustion-Air Temperature Probe (TA Plug the Combustion-Air Temperature Probe (T
) into the plug on the A500
located just
in front of the hose connector. (No. 16, Figure. 1-1). The A500 is supplied with a 1
¼
inch temperature probe. This short probe is used when the primary air source for the
burner is room air. Longer length probes are available for situations where a burner’s
combustion air is being drawn in from an outside source.
2. Getting Started
Touch to
enter Date
& Time
Set up
screen
menu
Touch to
enter Measu-
rement Unit
selection
screen
Touch to
enter printer
/IRDA selec-
tion screen
Touch to enter
thermocouple
calibration input
screen
Touch to
enter % O
2
re-
ference input
screen
To return to
initial Turn On
screen
MUNITD&T O2r ESCPRINT PROBE
3.56
A 500
USA Version 1.
1
85
0 customers 4 loaded
B
100%