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ENERAC 700 Instruction Manual

Integrated emissions system
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INSTRUCTION MANUAL
MANUAL de INSTRUCOES
INTEGRATED EMISSIONS SYSTEM
MODEL 700
MODEL 700
MODEL 700
MODEL 700
ENERAC, INC
67 BOND ST.
WESTBURY,NY. 11590
1

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  • Page 1 INSTRUCTION MANUAL MANUAL de INSTRUCOES INTEGRATED EMISSIONS SYSTEM MODEL 700 MODEL 700 MODEL 700 MODEL 700 ENERAC, INC 67 BOND ST. WESTBURY,NY. 11590...
  • Page 2 (800) 695- - - - 3637 (800) 695 3637 (800) 695 (800) 695 3637 3637 FAX (516) 997 FAX (516) 997 FAX (516) 997 FAX (516) 997- - - - 2129 2129 2129 2129...
  • Page 3 Edition 2 Hardware >= Software 2.6+...
  • Page 4 INTERNAL DATA STORAGE ....................47 CHAPTER 9 INTERNAL PRINTER ......................49 CHAPTER 10 CALIBRATION .......................... 51 CHAPTER 11 COMMUNICATIONS ....................... 57 CHAPTER 12 MAINTENANCE ........................64 APPENDIX A MODEL 700 – SEM SERIES SPECIFICATIONS ..............68 APPENDIX B FIRMWARE PROGRAMMING ....................72...

  • Page 5: List Of Abbreviations

    LIST OF ABBREVIATIONS PARAMETERS Excess air AMB TEMP Ambient (room) temperature Carbon monoxide (a toxic gas) Carbon dioxide – NDIR measurement OR calculated from O COMBUST Combustible gases DUTY Duty cycle, % of operating parameter Combustion efficiency (for boilers and furnaces, does not apply to engines) Feet per second (stack gas velocity) Hydrocarbons (NDIR) measurement- calibrated to propane...

  • Page 6: Options

    OPTIONS- OPCOES The ENERAC Model 700 is an extremely versatile emissions measurement system that meets practically all emissions requirements. It has been designed as a modular system, permitting the installation, in the field, of most of the various available options. This manual describes the complete instruments equipped with all the options.
  • Page 7 C. Inconel probe with permeation driver and Viton sample line (10-100 ft. long). ACCESSORY OPTIONS - OPCOES ACESSORIOS A. Integrated 2” fast graphic printer – Rapida Impressora B. Additional pump for dual range and purging capability – Bomba adicional para dupla medicos e capacidade de “purging” C.

  • Page 9: Chapter1 Fundamentals

    CHAPTER 1 FUNDAMENTALS The ENERAC Model 700 Integrated Emissions System is hand held state of the art analyzer designed to measure, record and transmit remotely combustion parameters used for the following tasks: O ENERAC MODELO 700 e um sistema portatil feito para medir, graver and transmit parametros de combustao usado para as seguintes tarefas: A.
  • Page 10 E. To measure the stack gas velocity and volumetric flow rate and emission rates according to the EPA Method 2, or Method 2C, Appendix A of 40CFR60. Para medir a velocidade do gas e volume de corrente e emissoes de acordo com regulamentos EPA…...
  • Page 11 The ENERAC Model 700 is the most advanced instrument of its type. It uses the latest proprietary (SEM INSIDE ) electrochemical sensor technology to measure emissions. To meet the accuracy requirements of the EPA reference methods, each SEM sensor is available with either one of two Precision Control Modules (PCMs), whose function is to select the measurement range (the ENERAC’s analytical...
  • Page 12 ENERAC has 25 years of experience in the manufacture and marketing of combustion and portable emission analyzers. The model 700 is based on this experience, together with the latest innovations in electronic and sensor technology. It also expresses our basic conviction that communications and artificial intelligence are the basic ingredients of the instrument of the future.
  • Page 13 CD-ROM and instruction manual. Um CD com programa ENERCOM e manual do instrument. B. ENERAC MODEL 700 STARTING INSTRUCTIONS 1. Remove the instrument from its case and connect the thermo-electric cooler and probe to the unit. Or, if you have a permeation type probe, connect the permeation type probe to the instrument.
  • Page 14 2. Make sure the instrument is in a clean-air, room-temperature environment and turn it on. If you have a problem with the display initializing, please RESET the unit. Verifique que o instrument esta em local de ar limpo e temperature ambiental. Ligue e caso haja problemas durante a inicializacao use o botao RESET.
  • Page 15 8. The LOW RANGE mode is the standard setting. In LOW RANGE mode, maximum concentrations are typically 2000 PPM for CO & NO, and 1000 PPM for NO & SO . If any of these parameters read OVER on the display, you must withdraw the probe from the stack immediately to prevent sensor saturation.
  • Page 16 D. IMPORTANT ADVICE IMPORTANTE CONSELHO Most stack gases are hot, full of moisture, corrosive and laden with soot particles. A maior parte dos gases sao quentes, cheios de humidade,corrosives. To make sure that your instrument will give you a long time of trouble-free performance, please observe the following recommendations.
  • Page 17 Sempre use uma mistura de gasaes, de preferencia com Nitrogenio durante calibracao de sensors. Numca use misturas com CO/NO ou CO/NO2 Every ENERAC sold has stored in its memory information regarding manufacturing and sensor dates, as well as product identification, serial...
  • Page 18 D. AUTOZERO ERROES & BASIC TROUBLESHOOTING AUTOZERO ERRORS Channel Possible Causes Resolution Sensor has been recently Wait 10 minutes, monitor (Electrochemical sensors) exposed to gas and has sensor voltage, and re-zero. not returned to zero. Battery was dead, sensor Charge battery, wait 24 has destabilized.
  • Page 19 TROUBLESHOOTING Symptoms Possible Causes Resolution Battery is dead. Plug in the charger. Analyzer will not turn Analyzer should turn on. on. (Screen is off) Battery is not charging. Check charger and jack. Check charger switch inside analyzer, next to paper roll. Internal initialization Reset the analyzer.

  • Page 21: Chapter 2 The Instrument Keyboard

    CHAPTER 2 THE INSTRUMENT KEYBOARD The Model 700 can be operated by using either: • The 13 button keyboard located on the face of the analyzer, or • By the use of commands through its serial port. A brief explanation of the instrument’s buttons follows:...
  • Page 22 HELP Context sensitive “help” key. Press this key for an explanation of observed parameters on the screen PUMP Controls Sample pump and /or dilution pump function. There are four states: A. Low range (sample pump on only), B. High range (sample and dilution pump on), C.

  • Page 23: Chapter 3 Basic Instrument Operation

    1. Remove the instrument from its case, attach the sample conditioning system supplied with your analyzer and turn the instrument on. 2. The instrument pump will immediately turn on and the ENERAC logo will appear. 3. If you are using the analyzer for the first time, press the...
  • Page 24 (reverse color) will point to: Print Test Record Press the key to execute a printout on the ENERAC’S printer. ENTER 10. When you are finished with your measurements, withdraw the probe from the stack, allow the analyzer to draw ambient air for a minute and for the...

  • Page 25: Chapter 4 Power Requirements

    CHAPTER 4 POWER REQUIREMENTS The Model 700 is supplied in either one of two power options: Standard or Heavy- Duty. A. STANDARD OPTION. Power is supplied by 4 “D” size NiMh rechargeable batteries. Also standard “alkaline” “D” batteries can be used to operate the instrument.

  • Page 27: Chapter 5 Sample Flow & Sample Conditioning System

    CHAPTER 5 SAMPLE FLOW & SAMPLE CONDITIONING SYSTEM The ENERAC Model 700 can accommodate any one of the three available sample conditioning systems. These range from the simplest water trap and latex hose conditioning system, to the recommended Teflon/Viton hose and thermoelectric condenser system, to the most sophisticated Teflon/Viton and permeation Drier system.
  • Page 28 The fiber filter should be replaced when it becomes noticeably discolored. 2. THERMOELECTRIC CONDENSER AND TEFLON/VITON HOSE This is the standard option for the Model 700. It is recommended for most applications where condensation removal without significant loss of the NO fraction of the sample is required.
  • Page 29 The following table shows the approximate relation between duty cycle and temperature differential: DUTY CYCLE SAMPLE TEMP AMBIENT TEMP (°F)* 100% *At 75°F ambient. The duty cycle of the thermoelectric cooler is set at the factory to 70% and can be adjusted as follows 1.
  • Page 30 20% (the maximum capacity of the permeation drier). 3. PERMEATION DRIER CONDITIONING SYSTEM This is a unique and proprietary conditioning system developed by ENERAC and used in its previous Model 3000E series of emissions analyzers. It has the major advantage of removing all excess water vapor from the sample without allowing any condensation to take place.
  • Page 31 A. The inconel probe The inconel probe is a five-piece assembly of metal tubing. It consists of the following parts. The gas extraction probe. This is a 3/8" diameter piece of inconel tubing that is threaded to the probe housing. The instrument thermocouple is located inside this tube.
  • Page 32 A’. The stack-velocity (S-V) probe. (OPTIONAL) If the ENERAC is equipped with (S-V) type of probe option, the section of the ENERAC’s probe that is inserted in the stack consists of three sections. You must never operate the instrument without the sintered filter.
  • Page 33 S type pitot tube Hastelloy sintered filter Inconel sampling tube Inconel sheathed thermocouple end Pitot tube orienting notch Probe retaining cap The Pitot tube is welded to the gas extraction tube. Two pieces of flexible high temperature Viton hose connect the Pitot tube to the low-pressure sensor located inside the probe case.
  • Page 34 Nitrogen dioxide and to a lesser extent sulfur dioxide react readily in water and any condensation present in the hose assembly would result in erroneous readings. The probe housing consists of the following components a. The secondary fiber filter. This is a small cylindrical 0.5 micron glass fiber filter for the removal of the finer particles from the gas stream.
  • Page 35 If the pressure in the stack exceeds +4" W.C., the "NO FILTER OR FLOW" LED will turn on. You should ignore this LED and proceed with your measurements! This is common in engine measurements, when the ENERAC probe is located in front of a catalytic converter.
  • Page 36 RED and OFF. Once the probe is inserted in the stack its status will depend on the temperature of the drier manifold. If this temperature becomes high, the LED will turn GREEN, indicating that the ENERAC heat pump has switched to cooling the manifold.

  • Page 37: Chapter 6 Sensors

    CHAPTER 6 SENSORS The great versatility of the Model 700 Emissions system is partly due to the large number of sensors available within a single analyzer. These sensors are primarily gas sensors and can be grouped into three categories based on their principle of operation: 1.
  • Page 38 EPA CTM-022 protocol requirements. The SEM NO sensor of the ENERAC Model 700 is superior to the typical electrochemical type sensor in accuracy, interference rejection, and its design for continuous operation. Its inboard disposable filter has an estimated life in excess of 100,000 PPM-hours against sulfur dioxide.
  • Page 39 The ENERAC 700 uses a second pump to draw dilution air that enables the analyzer to extend the range of the sensors by a factor of at least 4, and also...
  • Page 40 To obtain an accurate high range reading the ENERAC 700 uses an additional calibrated oxygen sensor. By combining the reading of the sample oxygen sensor and the dilution oxygen sensor an accurate calculation of the gas concentration for the high range is obtained. The figure below shows an outline of the sensor configuration.
  • Page 41 It is possible in principle to clean the gas cell, but it is a costly and time-consuming operation. NOTE: If the ENERAC is equipped with the NDIR option, the analyzer will enter an autozero countdown each time it is turned on. Consequently, you must...
  • Page 42 The NDIR bench is designed for operation primarily with measurements of engine exhausts, according to the California BAR 97 regulations. The hydrocarbons sensor is tuned to the absorption band of propane. However, it will respond to other hydrocarbons with different sensitivity. 3.

  • Page 44: Chapter 7 Analyzer Setup

    CHAPTER 7 ANALYZER SETUP The SETUP MENU allows the operator to change system parameters. ►APR 1 ‘05 12:45:00 Fuel: Natural Gas Temperature Units: F Measure Units: PPM OxygenReference:TRUE Pumps:SAMPLEDuty:90% Cooler Duty:50% Thermal Eff:0.30 Display Contrast:26 Version: 1.0 Battery: x.xx V Every parameter listed on the SYSTEM MENU screen can be changed as follows.
  • Page 45 BSFC (brake-specific fuel consumption-BTU/BHP-HR) as follows: ENGINE EFFICIENCY = 2547/BSFC NOTE: Emission units measurements in PPM, MGM, #/B and GBH are carried out on a dry basis as required by the EPA’s 40CFR75 . (The ENERAC is an...
  • Page 46 40CFR60 Appendix A method 19 of the code of federal regulations. Consult ENERAC, Inc., for details and correction factors. NOTE: NO and NO emissions in #/B or GBH are computed as NO...

  • Page 47: Chapter 8 Internal Data Storage

    Erase Buffer..._____ 00: BUFFER#02 The ENERAC Model 700 has 100 internal storage buffers. Each buffer stores one complete set of emissions data. There are two ways to store emissions data to the ENERAC’s buffer. You can either store data by selecting the option STORE...
  • Page 48 As you scroll up and down, buffers containing data show their date and time at the bottom of the display. Empty buffers show the word empty If you wish to erase all 100 of the ENERAC’s stored data, move the arrow to the entry and press...

  • Page 49: Chapter 9 Internal Printer

    UP / DOWN TEST LOG buffer and press . If you wish to print all of the ENTER 1 ‘05 12:45:00 ENERAC’s stored data in sequence, move the arrow to Fuel: Natural Gas the entry and press ALL BUFFERS ENTER XXXX XX.X XXX XX.X...
  • Page 50 keys to navigate around the keyboard, and press to select the letter or ENTER number. For lower-case letters, highlight and press , for symbols, shift ENTER highlight and press . The arrows in the corner will move the cursor ENTER forward or backward through the name.

  • Page 51: Chapter 10 Calibration

    The instrument must be started in a true "zero" environment. Otherwise it will assume as "zero" non-zero conditions and give erroneous readings. Never autozero the ENERAC, if the probe tip is still hot following a recent measurement.
  • Page 52 ZERO ALL SENSORS At the end of the autozero period the ENERAC reads the output of all sensors and sets them all to zero, with the exception of the oxygen that it sets to 20.9%. (The ambient temperature is read directly). Consequently, it is very important that at the moment of "zeroing"...
  • Page 53 You can carry out all span calibrations in sequence or just one, if you wish. You can use your own span gas, or if you need to calibrate the ENERAC in the field, you can use the convenient gas calibration kit supplied by ENERAC.
  • Page 54 Set up your calibration apparatus as shown in the figure below. You must not feed gas to the ENERAC under pressure and you must not starve the ENERAC's pump for gas. When feeding the gas to the ENERAC you must maintain a reasonably constant pressure.
  • Page 55 1. Connect the calibration apparatus and cylinder to the instrument. 2. Press the DATA key and observe the appropriate reading as you open the calibration cylinder valve. (If you are using the bypass flow meter, adjust the cylinder valve for a bypass flow rate of approximately 500 cc/min. Observe the readings of the other gas parameters for evidence of cross sensitivity and also the oxygen reading for confirmation that there is no instrument leak!
  • Page 56 Very slowly start closing the intake valve of the apparatus and observe the manometer reading climbing. Set the valve opening as soon as the manometer is reading the same pressure as that selected on the display. Press the ENTER again. The draft sensor will be calibrated to the value shown on the display.

  • Page 57: Chapter 11 Communications

    If a command doesn’t contain a question mark it will cause the ENERAC to store the data sent with the command, or take some other action, such as erasing a specific data buffer. This is the way to reprogram the instrument from a remote location.
  • Page 58 features and improvements without requiring the return of the instrument to the factory. A list of the available commands intended for general use follows.

  • Page 59: Data Commands

    ENERAC returns present value of the stack temperature TEXT? ENERAC returns a complete record of all current stack parameters. VELO? ENERAC returns present value of stack velocity or flow rate. SETUP COMMANDS COMMAND FUNCTION ATOF? ENERAC returns the ambient temperature offset in °C.
  • Page 60 MEMORY COMMANDS COMMAND FUNCTION BUFF? ENERAC returns the names of each of the 100 storage buffers. BUFF NN? ENERAC returns the name of buffer #NN (0-99). BUFF NN XX Sets the name of buffer #NN to XX. Buffer Name can be up to 11characters.

  • Page 61: Calibration Commands

    ENERAC returns a list of calibration factors for each sensor. SPAN XX NNN ENERAC span calibrates sensor XX at a span value of NNN PPM or percent. Be sure to feed the correct span gas and wait for the sensor to stabilize before the analyzer receives this command, as it will execute a span calibration immediately.
  • Page 62 B. ENERCOM SOFTWARE You can enhance the performance and versitility of the ENERAC by using one of the Enercom software programs. Enercom 2000 is available for Windows 95/98/ME/NT/XP. EnercomCE software is available for PocketPCs running WindowsCE. EnerPlam software is available for PalmOS devices. These devices connect to the ENERAC’s serial port and offer real-time monitoring of data,...

  • Page 64: Chapter 12 Maintenance

    CHAPTER 12 MAINTENANCE The ENERAC micro-emissions analyzers are sophisticated analytical instruments designed to perform accurate emissions measurements. However, because they are hand-held instruments that find uses in many environments, care must be taken to prevent physical and environmental abuse. This will help maintain trouble-free operation.
  • Page 65 It will gradually drop with use until at 4.0 volts a “BATTERY LOW” warning will appear. You can estimate the remaining time by observing the battery voltage. For NiCd or NiMH rechargeable batteries the battery voltage will stay at approximately 4.8 volts for a long time and then drop rapidly. To replace the batteries, remove all the screws that secure the analyzer’s back plate.
  • Page 66 C. Condensation removal At the end of a measurement, shake the probe vigorously to drain it of any condensation. Remove any condensation that has been trapped in the top section of the condensation trap and allow it to dry thoroughly before storing it. D.
  • Page 67 SENSOR 30 MINUTES Span calibrate the sensor as explained in CHAPTER 10: CALIBRATION. If you are installing a pre-calibrated sensor, use the following procedure: 1) While holding the key, press the key three times. The SETUP DISPLAY DATA display will show the sensor factors. 2) Press the key until you reach the appropriate sensor, then press ENTER.
  • Page 68 APPENDIX A MODEL 700 – SEM SERIES SPECIFICATIONS ANALYZER 1. PHYSICAL: Material: 0.080” thick aluminum case Dimensions (analyzer): 9.8” X 5.7” X 3.12” Weight: (analyzer) 6 lbs. (4 “D” size batteries included) Carrying case (analyzer & all accessories): 17” X 12” x 6.5”...
  • Page 69 SAMPLING & CONDITIONING SYSTEMS (SELECT OPTION ACCORDING TO THE MODEL#) 1. CONDENSATION (WATER) TRAP & FILTER SYSTEM 12” or 24” 316 SS Probe, fiber filter, and 34 cc polycarbonate water trap Sample line: 3/8” OD x ¼” ID latex braided tubing. Lengths from 10’ to 50’. 2.
  • Page 70 SENSOR RANGE RESOLUTION ACCURACY OXYGEN 1- 0 – 25% 0.1% 0.1% ABSOLUTE OR ELECTROCHEMICAL 0.2% OF READING (Concentration) OXYGEN 2 0 – 25% 0.1% 0.1% ABSOLUTE OR ELECTROCHEMICAL 0.2% OF READING (High Range – option) COMBUSTIBLES 0- 4% 0.01% 10% OF READING OR (Single Range option) 0.02% STACK TEMPERATURE...

  • Page 72: Appendix B Firmware Programming

    There are 5 miniature slide switches on a red block. Refer to the figure at the end of the manual. 2. Connect the serial port of the computer to the ENERAC. Run the firmware update. The program will backup the ENERAC’s settings.

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