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E Instruments 4400 Manual

Portable combustion gas analyzers
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4400
4400
Portable Combustion Gas Analyzers

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Summary of Contents for E Instruments 4400

  • Page 1 4400 4400 Portable Combustion Gas Analyzers...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION General Description of the Combustion Analyzer General features of the Flue Gas Analyzer 4400 Main configurations TECHNICAL SPECIFICATIONS Technical Specifications Overview of Flue Gas Analyzer Components Measurement and Accuracy Ranges USING THE FLUE GAS ANALYZER Preliminary operations...
  • Page 4 TABLE OF CONTENTS SENSORS Sensor Arrangement Sensor types and relevant positioning Gas sensor life Gas sensor life Expandability to 4 sensors MAINTENANCE Routine maintenance Preventive maintenance Cleaning the sample probe Maintaining the water trap / filter unit Replacing the particulate filter Replacing the gas sensors On-site recalibration 6.7.1 Flow Chart - On-site recalibration...

  • Page 5: Introduction

    “4400” is designed for seven main types of combustible substances, among which natural gas, LPG, Diesel fuel and fuel oil. Another 16 types of which the chemical composition is known can be entered in its memory. “4400” functions include storing and averaging the measurements acquired, printing the results (on ordinary rolls of paper) and connecting to the computer for filing the data, using a USB connection.

  • Page 6: 4400 Main Configurations

    1.3 4400 Main configurations 4400-N 4400-S Cod. K9401A0004 Cod. K9401A0005 SENSOR CO+H SENSOR NO SENSOR SENSOR SENSOR AUTOMATIC AUTOZERO CO DILUTION CALIBRATION CERTIFICATE INSTRUCTION MANUAL FLUE SAMPLING PROBE 300mm (12”) + 10’ Dual Hose COMBUSTION AIR TEMPERATURE PROBE CONDENSATE TRAP...

  • Page 7: Technical Specifications

    TECHNICAL SPECIFICATIONS 2.1 Technical Specifications Autozero: Automatic autozero cycle with probe inserted in the stack. Dilution: Expansion system of the CO sensor measuring range up to 50,000ppm (5.00%v/v) programmable as a simple protection of the CO sensor with triggering threshold programmable by the user. Preset triggering threshold at 1,500 ppm. Self-diagnosis: All the functions and internal functions are checked and anomalies signalled.

  • Page 8: Overview Of Flue Gas Analyzer Components

    2.2 Overview of Flue Gas Analyzer Components Fig. 2.2 LEGEND Keypad Display Cover to access the impact printer Flue Sampling probe Condensate separator and fine dust filter unit (Water Trap Assembly) Compensated male connector of the fumes exhaust temperature probe Combustion air temperature probe P- connector (negative input for measuring differential pressure) A - connector (sample probe input by means of the water trap)
  • Page 9 E Instruments does, however, certify measurement accuracy only when a calibration certificate has been issued by its own laboratory or by an authorized laboratory.
  • Page 10 The cold junction is compensated by a Pt 100 resistance thermometer which measures the temperature at the thermocouple connector. The type K thermocouple (nickel/nickel chromium) permits continuous measurements up to 800°C. If special- purpose probes are used, the instrument is able to measure temperatures as high as 999.9°C. A Pt 100 resistance thermometer located inside the instrument measures the internal temperature;...
  • Page 11 Measuring ambient CO Probe for monitoring the concentration of CO and checking safe conditions in the boiler room. An acoustic and visual warning signal is given if the thresholds are exceeded according to the OSHA levels. Internal gas leak detector sensor This sensor searches for explosive gas leaks in the pipes.

  • Page 12: Measurement And Accuracy Ranges

    2.3 Measurement Ranges and Accuracies MEASUREMENT SENSOR RANGE RESOLUTION ACCURACY Electrochemic al sensor 0 .. 25.0% vol 0.1% vol ±0.2% vol ±10 ppm 0 .. 200 ppm Electrochemic al sensor 0 .. 8000 ppm 1 ppm ±5% measured val ue 201 ..

  • Page 13: Using The Flue Gas Analyzer

    Remove the instrument from its packing and check it for damage. Make sure that the content corresponds to the items ordered. If signs of tampering or damage are noticed, notify the E Instruments service center or agent immediately and keep the original packing. A label at the rear of the analyzer bears the serial number. This serial number should always be stated when requesting technical assistance, spare parts or clarification on the product or its use.
  • Page 14 ATTENTION THE POWER SUPPLY/BATTERY CHARGER IS A SWITCHING TYPE ONE. THE APPLICABLE INPUT VOLTAGE RANGES BETWEEN 90Vac AND 264Vac. INPUT FREQUENCY: 50-60Hz. THE LOW VOLTAGE OUTPUT IS 12 VOLT WI TH AN OUTPUT CURRENT GREATER THAN 1.5A. LOW VOLTAGE SUPPLY CONNECTOR: DC PLUG 2.1x5.5x9 mm. WITH CENTRAL POSITIVE AND OUTER BARREL GROUND.

  • Page 15: Operation

    OPERATION 4.1 Working principle The gas sample is taken in through the sample probe, by a diaphragm suction pump inside the instrument. The measuring probe has a sliding cone that allows the probe to be inserted in holes with a diameter of 11 mm to 16 mm and to adjust the immersion depth: the sampling point must be roughly in the center of the flue pipe/ stack.

  • Page 16: Connecting The Combustion Air Temperature Probe

    the measurement cells. This is also the reason why it is important to periodically drain the trap, anyhow at the end of each test (see chapter 'MAINTENANCE'). A replaceable low-porosity line filter is placed after the condensate trap aimed at keeping the solid particles su spended in the gases.

  • Page 17: Keypad Overview

    4.7 Keypad overview Select / Modify On / Off Confirm Cancel / Exit Mem ory Menu Print Menu Zoom IN / OUT Configure Menu Draft Menu Measurements Menu Analysis Menu Info Menu WARNING: to turn-on / off the instrument it is necessary to press and hold the On/Off button for at least 2 seconds.

  • Page 18: Info Menu

    4.8 Info Menu This menu provides information regarding instrument status: Battery capacity: Shows the status of the internal battery. The battery charge status is shown graphically and in text as a percentage between 0 and 100%, together with the battery voltage. Configuration of sensors: It allows to check which sensors are installed on the instrument, and in which position they are installed.

  • Page 19: Flow Chart - Info Menu

    INFORMATION MEMORIES DIAGNOSTIC Battery status Memories Sensors Config. Calibration Sensors diagnostic ►Memories diagnostic Info Service INFORMATION INFO SERVICE E Instruments Battery status Tel.(215)750-1212 Sensors Config. Fax.(215)750-1399 Sensors diagnostic Memories diagnostic 4400-S ►Info Service SN:000001 Ver:1.00 PN:000000 @IST01530EEJ 01 917 5A0 19 041 1...

  • Page 20: Configure Menu

    4.9 Configure Menu This menu is used to configure the instrument’s reference parameters described below: Fuel: Lets the user select the type of fuel to be used during analysis. This datum can be changed either from this menu or during the analysis itself. Measurement units: Through this submenu the user can modify the units of measurement for all the analysis parameters, depending on how they are used.
  • Page 21 Low-level alarms are triggered when the reading drops below the defined threshold, whereas high-level alarms are triggered when the reading rises above the defined threshold. When an alarm threshold is crossed, the instrument emits an intermittent audible alarm besides activating a visible alarm wherein the background of the name of the relative reading will start flashing in the analysis screen.

  • Page 22: Flow Chart - Configure Menu

    4.9.1 Flow Chart - Configure Menu Activ ates the Configure Menu. All selected data can be modif ied by pressing cursor keys To cancel changes and return to the prev ious menu press CONFIGURATION FUEL FUEL PARAMETERS ►Fuel ►Natural gas 0.0280 Measurement units #2 Oil...
  • Page 23 FUEL FUEL PARAMETERS ▲ Wood/Pellets 8% 0.0277 Coal 0.0073 Bio-Fuel 5% 14.00 % L.P.G. 45800 kJ/kg ►Butane 49620 kJ/kg ▼ FUEL FUEL PARAMETERS ▲ Coal 0.0277 Bio-Fuel 5% 0.0073 L.P.G. 13.70 % Butane 46350 kJ/kg ►Propane 50390 kJ/kg CONFIGURATION MEASUREMENT UNITS MEASUREMENT UNITS MEASUREMENT UNITS Measurement unit can...
  • Page 24 CONFIGURATION CONTRAST CONTRAST Fuel Measurement units Reference ►Display contrast Autozero/Pump ▼ Note: The pump cannot be CONFIGURATION AUTOZERO/PUMP AUTOZERO/PUMP AUTOZERO/PUMP switched off during Fuel ►Autozero Autozero Autozero auto-calibration. Measurement units Pump Pump Pump Reference If auto-calibration has Display contrast not been performed ►Autozero/Pump ▼...
  • Page 25 CONFIGURATION CONDENSATION CONDENSATION CONDENSATION ▲ Display contrast ►Altitude Altitude Altitude Autozero/Pump R.H. air R.H. air R.H. air CO Auto-Dilution Automatic analysis ►Condensation ▼ CONDENSATION CONDENSATION CONDENSATION Altitude Altitude Altitude ►R.H. air R.H. air R.H. air CONFIGURATION TIME/DATE TIME/DATE TIME/DATE ▲ Autozero/Pump ►Time 12 12...
  • Page 26 The alarm threshold v alues can be set ALARMS ALARMS via the keys within the following Number Number range: Measure Measure maximum maximum Active Active - 99999.999 to + 99999.99 ►Limit 1500 Limit +01500.0000 Unit Unit (the value is referred to the unit of measurement set) maximum, minimum, no.
  • Page 27 REPORT HEADER TEXT EDITING Philadelphia, PA_ 1:E Instruments ►2: ▲ ◄ 9:;<=>?!“#$٪& ’)~* ► ▼ REPORT HEADER TEXT EDITING 1:E Instruments T(215)750-1212_ 2:Philadelphia, PA ►3:T(215)750-1212 ▲ ◄ 9:;<=>?!“#$٪& ’)~* ► ▼ REPORT HEADER TEXT EDITING 1:E Instruments info@info.com_ 2:Philadelphia, PA 3:T(215)750-1212 ▲...

  • Page 28: Memory Menu

    4.10 Memory Menu This menu is used to display and print individual and average values of the analysis data stored in memory. Analysis data can be ordered either by memory position or by storage date; draft and smoke values can also be recalled.

  • Page 29: Flow Chart - Memory Menu

    4.10.1 Flow Chart - Memory Menu Activ ates the Memory Menu. This menu is used to display and print the indiv idual and av erage v alues of the analysis data stored in memory. Analysis data can be ordered either by memory position or by storage date; draft, smoke and ambient CO (NO) v alues can also be recalled.
  • Page 30 RECALL MEMORY MEAS. CONDITIONS 1:19/12/10 15.30 Natural gas 2:19/12/10 16.00 Altitude 0 m 3:19/12/10 16.30 R.H. air 50% Average analysis Mario Rossi ►Meas. Conditions ▼ RECALL MEMORY RECALL DRAFT 2:19/12/10 16.00 3:19/12/10 16.30 -0.12hPa Average analysis Meas. Conditions T external: 20°C ►Draft ▼...

  • Page 31: Print Menu

    4.11 Print Menu This menu is used to access the following print and check configurations: Print analysis report: Shows the details of the selected ticket type and allows to start printing. Configure Print: Allows to set the number of printed copies and layout of the ticket. The ticket layout selection is only valid for combustion analysis and can be chosen among Complete, Partial and Total.

  • Page 32: Flow Chart - Print Menu

    4.11.1 Flow Chart - Print Menu Enables the Print Menu. Allows to print the combustion analysis data on a paper ticket which reports the measurement v alues. The printed v alues are those shown on the display when the menu is enabled. This menu can be used f or combustion analysis, ev en when recalled from the memory, for draft, smoke, ambient gas and f or tightness test results.

  • Page 33: Analysis Menu

    4.12 Analysis Menu Through this key the analysis results are displayed. Moreover the operator is allowed, once this key is further depressed, to display and possibly modify the analysis parameters before proceeding with the measurements. Measured v alues are: Oxygen percentage in the Flue. CO + H CO concentration in the Flue.

  • Page 34: Flow Chart - Analysis Menu (Zoom)

    4.12.2 Flow Chart - Analysis Menu (zoom) O O O O 4.2٪ 4.2٪ Eff 83.4٪ 2 2 2 2 O O O O 4.2٪ 2 2 2 2 9.3٪ Loss16.6٪ 9.3٪ 2 2 2 2 146p 9.3٪ Xair 1.25 Xair Xair 1.2 5 1.2 5...
  • Page 35 By pressing the Analysis key once more, and starting from any of the above screens, the user may proceed as follows: Activ ates the Analysis Menu. ANALYSIS SETUP ANALYSIS SETUP ANALYSIS SETUP ANALYSIS SETUP SELECT MEMORY ►Mem.: ►Mem.:001 Fuel.: Natural gas Date:--/--/-- Select the memory wherein to store the acquired data.

  • Page 36: Draft Menu

    4.13 Draft Menu The DRAFT menu gives access to the stack draft measurement. The user to input the external air temperature as required by the standard. Afterwards the measurement screen is reached: here the user can acquire the value displayed in order to add it to the running analysis measurements or, alternatively, print the relevant ticket through the ‘PRINT’...

  • Page 37: Readings Menu

    'HOLD' key. Tightness test: 4400 can perform the tightness test on heating plants which use combustible gases according to the standards UNI 7129 and UNI 11137-1, respectively applicable to new or renewed pipings and to existing pipings. The result of this tightness test, whose steps are described in the following, can be printed, once acquired, by starting the ' print menu ' in any of the screens of the ' Tightness Test ' menu.
  • Page 38 Somebody proposes 5000 Pa Note: 4400 allows the user to perform the tightness test even with a combustible gas different from the supply gas. Anyway the reference standard does not provide a reference pressure in this situation, so the reference pressure is taken like test gas is the same.
  • Page 39 When the 'Volume measurement' option is selected instead, the procedure, described also in the flow charts of the tightness test according to UNI 11137-1, is described in the following steps: Close both faucets in the kit assembly supplied for the test execution. •...

  • Page 40: Flow Chart - Readings Menu

    4.14.1 Flow Chart - Readings Menu Activ ates the Smoke Menu. MEASUREMENTS SMOKE PRINT In the Smoke menu the user can input the smoke v alue. The values entered with the arrow keys ►Smoke ►Measure 1: 2 ►Print report Ambient CO,NO Measure 2: - Print setup can be associated with the ongoing analysis...
  • Page 41 Tightness test flow -chart according to standards UNI 7129 and UNI 11137-1. TIGHTNESS TEST NEW PIPING ►New piping ►Start test Existing piping Stabilization NEW PIPING NEW PIPING NEW PIPING NEW PIPING Start test ►Wait time ►Wait time ► 15 min Wait time ►Stabilization NEW PIPING...
  • Page 42 VOLUME MEASURE measurement procedure is correctly terminated, Inject the syringe The 4400 shows the contents in m e a s u r e d v a l u e , the piping otherwise it requires to repeat the gas injection with the syringe.
  • Page 43 PIPING VOLUME ADD TUBE Select material with keys Vtot 25.0 dm Vtub 0.0 dm Volume measure ►Material Copper ►Add tube Diameter 20 mm Steel, Copper, PE. Subtract tube Length 0.0 m Zero volume ADD TUBE Select n ominal Vtub 0.0 dm d i am et er wi th th e...
  • Page 44 EXISTING PIPING City gas ►Natural gas L.P.G. EXISTING PIPING City gas Natural gas ►L.P.G. EXISTING PIPING EXISTING PIPING Start test ►City gas Stabilization Natural gas Piping volume L.P.G. Combustible gas ►Test gas EXISTING PIPING City gas ►Natural gas L.P.G. EXISTING PIPING City gas Natural gas ►L.P.G.
  • Page 45 EXISTING PIPING EXISTING PIPING EXISTING PIPING EXISTING PIPING ►Start test WARNING Stabilization Charge the pipe to 0.06 0.00 Piping volume the test pressure Combustible gas 100.00 hPa Test gas ZERO TEST ZERO TEST EXISTING PIPING Pressurize the piping and select TEST with the ' ' key.

  • Page 46: Flow Chart - Configure Analysis Menu

    4.15 Flow Chart - Configure Analysis Menu When depressed for at least 2 seconds, turns the instrument on. Adjusts the display contrast. 4400-S SN:00001 Ver:1.00 AUTOZERO STARTED WARNING Insert the gas probe in the chimney automatically, after 10 seconds. MEMORY...

  • Page 47: Flue Gas Analysis

    4.16 FLUE GAS ANALYSIS To perform complete flue gas analysis, follow the instructions below. ATTENTION SOME IMPORTANT WARNINGS CONSIDER DURING COMBUSTION ANALYSIS ARE LISTED BELOW: FOR A CORRECT ANALYSIS NO AIR MUS T FLOW INTO THE PIPE FROM OUTSIDE DUE TO A BAD TIGHTENING OF THE CONE OR A LEAK IN THE PIPELINE.

  • Page 48: End Of Analysis

    the following data must be configured: Memory: use this submenu to define the memory in which the test data and client details are to be stored. Fuel: the user will be asked to define the type of fuel used by the plant. Operator: this is where the name of the test operator can be entered.

  • Page 49: Flow Chart - Flue Gas Analysis

    4.16.5 Flow Chart - Flue Gas Analysis When depressed for at least 2 seconds, turns the instrument on. Adjusts the display contrast. 4400-S SN:00001 Ver:1.00 AUTOZERO STARTED WARNING Insert the gas probe in the chimney automatically, after 10 seconds. MEMORY RECALL MEMORY ►Mem.:...
  • Page 50 How to proceed in manual mode (standard sequence). MEMORY SAVE ANALYSIS 4.2٪ Eff 83.4٪ 9.3٪ Loss16.6٪ ►Save analysis Memory 001/1 146p Xair 1.25 Display average Draft SAVE test 1. Tf 190.1C Select memory Smoke 15.4C Recall memory CO,NO amb ∆T 74.7C Delete single ▼...
  • Page 51 How to proceed in manual mode (quick sequence). SAVE ANALYSIS 4.2٪ Eff 83.4٪ 9.3٪ Loss16.6٪ Memory 001/1 146p Xair 1.25 Draft Tf 190.1C Smoke 15.4C SAVE test 1. CO,NO amb ∆T 74.7C ►RefO ▼ SAVE QUIT SAVE ANALYSIS 4.2٪ Eff 83.4٪ 9.3٪...
  • Page 52 How to proceed in automatic mode. 4.2٪ Eff 83.4٪ 9.3٪ Loss16.6٪ 146p Xair 1.25 Tf 190.1C 15.4C ∆T 74.7C ►RefO ▼ 4.2٪ Eff 83.4٪ 9.3٪ Loss16.6٪ 146p Xair 1.25 Tf 190.1C 15.4C ∆T 74.7C ►RefO 001/1:120 ▼ Automatic, when the def ined time elapses. 4.2٪...

  • Page 53: Measuring The Differential Pressure (Optional Kit)

    4.17 Measuring the Differential Pressure (OPTIONAL HOSE KIT) (Part # AACKP01) The instrument is fitted with an internal temperature-compensated piezoresistive transducer to measure positive and negative pressures. This sensor, which is mounted on the instrument, is of the differential type. If the special KIT is purchased, the sensor can be used to measure the differential pressure thanks to the positive and negative pressure connectors.

  • Page 54: Sensors

    SENSORS 5.1 Sensors arrangement SENSORS ARRANGEMENT INSIDE GRAPHICAL DISPLAY THE SENSORS COMPARTMENT OF ARRANGEMENT SENSORS TYPE POSITION POSITION QUIT CONFIRM POSITION POSITION 5.2 Sensor types and relevant positioning POSITION CODE FLEX-Sensor O Cod. AAA32-240 FLEX-Sensor CO+H Cod. AACSE05 FLEX-Sensor NO Cod.

  • Page 55: Gas Sensor Life

    Sensor characteristics diminish as the reagents are consumed and when these have been used up completely the sensor must be replaced. The sensors must be recalibrated on a regular basis to assure measuring accuracy: recalibration can only be performed by a qualified E Instruments service center. Chart 5.4 illustrates the characteristics inherent to each sensor.

  • Page 56: Expandability To 4 Sensors

    5.5 Expandability to 4 sensors In the 4400 instrument range, two are the versions which can be expanded: 4400-: 2 sensors, expandable to 3 or 4 sensors. 4400-1: 3 sensors, expandable to 4 sensors. POSITION S1 POSITION S3 POSITION S1...

  • Page 57: Maintenance

    • Do not exceed sensor overload thresholds. • When the analysis is over disconnect the sample probe and let 4400 draw fresh air for a few minutes, or at • least until the displayed parameters return to their original values.

  • Page 58: Replacing The Particulate Filter

    6.5 Replacing the particulate filter If the particulate filter appears black, especially on the inner surface (see adjacent example), it has to be replaced immediately. In this way gas flow is not obstructed. Blackened particulate filter 6.6 Replacing the gas sensors The gas sensors of the instrument shall be periodically replaced (see the following table) with new or recalibrated sensors.
  • Page 59 Locate the sensor to be replaced; here is an example of a connected sensor to be replaced. Electrical connection Disconnect the sensor to be replaced; here is an example of a disconnected sensor to be replaced. @IST01530EEJ 01 917 5A0 19 041 1...
  • Page 60 The sensor is bayonet-connected to its socket; rotate it counter-clockwise to remove it. Here is an example of a rotated sensor. ATTENTION While rotating the sensor, take care not to exert any pressure onto the printed circuit abov e: apply pressure only onto the plastic body.
  • Page 61 Rotate the sensor clockwise until hearing a click (See point 4). ATTENTION While rotating the sensor, take care not to apply any pressure onto the printed circuit abov e: apply pressure onto the plastic body only. Reconnect the sensor (See point 3). Close the back door of the sensor compartment again, and tighten screws again (See point 1).

  • Page 62: On-Site Recalibration

    - Hose with Tee fitting to connect the cylinder to the flowmeter and to the instrument 6.7.1 Flow Chart - On-site recalibration When depressed for at least 2 seconds, turns the instrument on. ATTENTION Make sure autozero is executed in clean air. 4400-S SN:00001 Ver:1.00 AUTOZERO STARTED WARNING...
  • Page 63 CONFIGURATION PASSWORD PASSWORD ▲ Operator Enter the recalibration menu password Report header setup 0 0 0 0 1 1 1 1 Micromanometer 1111. Language ►Calibration CALIBRATION CO CALIBRATION The installed sensors are shown, and can be chosen for Action calibrate recalibration.
  • Page 64 Apply the gas to the instrument and regulate the cylinder output pressure so that the flow meter shows a • minimum flow (0.5 l/m) to ensure that the instrument is getting exactly the gas needed by its internal pump. The instrument measures the concentration of the applied gas; w ait at least 3 minutes for the measure to •...

  • Page 65: Replacing The Battery Pack

    6.8 Replacing the battery pack Follow these instructions to replace the battery pack: Undo the fixing screw on the battery Remove the battery pack. compartment cover, and remove it . Remove the battery pack connector, and replace the pack with a new one following the reverse procedure described above.

  • Page 66: Replacing The Printer Paper Roll

    6.9 Replacing the printer paper Follow these instructions to change the paper roll in the printer. Remove the printer cover by exerting a light Push in the plastic thin plate to remove the pressure outward, as shown by the arrow. cover of the paper compartment, as shown by the arrow, until the cover comes out.

  • Page 67: Troubleshooting

    7.0 TROUBLESHOOTING 7.1 Troubleshooting guide SYMPTOM PROBABLE CAUSES AND REMEDIES The instrument does not work at all. When the On/Off a. Keep the On/Off key depressed for at least 2 pushbutton is pressed the instrument does not come seconds. b. The battery is low; connect the battery charger to the instrument.
  • Page 68 Troubleshooting guide SYMPTOM PROBABLE CAUSES AND REMEDIES The rear lighting of the display is not on. The backlighting LED’s are faulty. Contact the nearest service center to replace the display. The batteries last less than 9 hours. a. Battery capacity is limited by low temperatures. To achieve a longer battery life it is recommended to store the instrument at higher temperatures.

  • Page 69: Spare Parts And Technical Assistance

    AAC TA03: Particulate/water filter assembly AAC TA03T: Particulate/water filter assembly with steel pipe and connector AAC UA02: Adapter cable USB-A / mini USB-B. 8.3 Service Center E Instruments International 172 Middletown Blvd. Suite B201 Langhorne, PA 19047 Tel.: (215) 750-1212 Fax.: (215) 750-1399...

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