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- Page 1 C o m b u s t i o n A n a l y s i s Series 6200 CA-C Combustion Analyzers Operation and Service Manual 1980431 Rev. F January 2004...
- Page 3 OTHER COUNTRIES Sales & Customer Service: Sales & Customer Service: (800) 874-2811/(651) 490-2811 (001 651) 490-2811 Fax: Fax: (651) 490-3824 (001 651) 490-3824 MAIL/SHIP TO: E-Mail TSI Incorporated answers@tsi.com ATTN: Customer Service 500 Cardigan Road WEB SITE Shoreview, MN 55126 www.tsi.com...
- Page 4 TSI Incorporated / 2001–2004 / All rights reserved. Part Number 1980431 / Revision 5 Address TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA Fax No. (651) 490-3824 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.
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Page 5: Table Of Contents
CONTENTS Introduction ..............................vii Manual Purpose ..........................vii Using This Manual..........................vii Warnings and Cautions ........................vii Chapter 1. Instrument Description ......................1 Gas Sampling Probes..........................1 Chapter 2. Unpacking ..........................3 List of Standard Components ........................3 Optional Accessories..........................3 Chapter 3. Component Identification .......................5 The Gas Sensors...........................6 Optional Combustion Supply Air Thermocouple Probe.................7 On-Board Temperature Measurement ....................7... - Page 6 Using the Sampling Probe........................19 Gas and Temperature Measurements..................19 Making a Draft Measurement ......................21 Auto Draft Meas. Feature......................21 Printing to the Portable Printer and to a Computer ................21 Printing ............................21 Printing to a Computer ......................... 21 Chapter 6.
- Page 7 Appendix A. Calculations........................49 Reference Concentration Calculation ................... 49 Excess Air Calculation........................49 Calculating Combustion Efficiency ..................... 49 Determining CO Using the O Concentration ................... 50 Emission Rate Calculations Using Emission Factors................. 50 A General Equation for the Combustion of a Simple Hydrocarbon in Air .......... 51 Calculating CO Max From the Carbon Content ................
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Page 9: Introduction
Introduction Manual Purpose This manual describes the operation and maintenance of TSI Series CA-6200 CA-C portable combustion analyzers (Models 6210, 6211, 6212, 6213, 6214, 6215 and 6216). Using This Manual Before using the CA-C combustion analyzer for the first time, review this manual in its entirety. The manual assumes that you have a basic understanding of combustion analysis and are thoroughly familiar with your fuel burning equipment. -
Page 11: Chapter 1. Instrument Description
Chapter 1. Instrument Description The CA-C combustion analyzer is a portable instrument measuring combustion gases, combustion gas and supply air temperatures and draft pressure for evaluating the performance of burners in boilers, furnaces, and hot water tanks. From the measured data, the CA-C combustion analyzer calculates a variety of combustion parameters including excess air, CO level, and combustion efficiency. -
Page 13: Chapter 2. Unpacking
Chapter 2. Unpacking Carefully unpack the CA-C 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. -
Page 15: Chapter 3. Component Identification
Chapter 3. Component Identification Key components of the CA-C combustion analyzer and sampling probe are identified in Figures 1 and 2 and under section headings in the text that follows. 1. Label buttons 10. Battery cover 2. LCD display 11. Battery cover tab 3. -
Page 16: The Gas Sensors
1. Sample tube retaining fitting 7. Tri-plex tubing 2. Probe handle 8. Water trap 3. Position collar 9. Emission Probe for NO2, SO2, with SS filter 4. SS sampling tube 10. Plastic filter 5. Sample and Draft connectors 11. Detail of standard probe tip 6. -
Page 17: Optional Combustion Supply Air Thermocouple Probe
Optional Combustion Supply Air Thermocouple Probe A measurement of the Combustion Supply air temperature is made using an optional thermocouple accessory probe (TSI PN 3013003). This probe is connected to the supply air temperature port. Combustion supply air temperature is an important value used in the determination of flue losses and efficiency. On-Board Temperature Measurement The CA-C analyzer uses an on-board resistance temperature detector (RTD) to provide the combustion supply... -
Page 18: Co Diversion Valve
CO Diversion Valve The CO diversion valve is used to divert high concentrations of carbon monoxide (>5000 ppm) away from the hydrogen compensated CO sensor. High CO concentrations cause the sensor baseline value to shift upward. Although the effect is temporary, it may take ten minutes or longer for the sensor to recover. A shift upward in the sensor baseline means the CO sensor indicates a concentration that is higher than the true concentration. -
Page 19: Chapter 4. Getting Started
Chapter 4. Getting Started Supplying Power The CA-C portable combustion analyzer operates using 4 C-cell batteries or using the AC adapter provided. Quality alkaline batteries enable the instrument to operate for 24 hours. Use of the plug-in AC adapter conserves battery life and can be substituted for batteries. -
Page 20: Setting Co Diversion Valve
Setting CO Diversion Valve Set the CO diversion in the orientation shown in the figure below. In this position, the valve is open, allowing gas to flow to the CO sensor. Only under conditions where the CO level is very high (above 5000 ppm), should the valve be closed. -
Page 21: Default Instrument Settings
You will need to do two things before you can successfully communicate with a computer. First make sure the baud analyzer matches that of the computer. Second, make sure the RS232 Device setting is set to rate of the CA-C Computer and not Printer. -
Page 22: Default Settings For Different Model Letter Designations
Default Settings For Different Model Letter Designations Instrument Model O2 ref. Excess Effc / Loss number ref. Level Draft Temp Basis Effc / Loss Fuel heat Conc. Decimals Fuel Setup CA-621X 3% " H20 ASME/heat BTU HHV periods fuel loss Efficiency composition parameters... -
Page 23: Chapter 5. Basic Operation
Chapter 5. Basic Operation Quick Start This chapter describes the steps needed to start making basic measurements. When used for the first time, the CA-C combustion analyzer parameter settings match the Defaults listed in the previous chapter. To select different instrument parameter settings refer to “Instrument Setup” in Chapter 6, “MENU Selections and Menu Items.” Steps to Quick Startup 1. -
Page 24: The Data Display Screen
The Data Display Screen Refer to the figure below to identify the key components of the main Data Display screen. Site name for data logging Device name for data logging Date and time Message area O2 reference status Battery life indication Fuel type Site: Not Selected Device: Not Selected... -
Page 25: Available Measurements
Available Measurements The CA-C analyzer automatically detects the sensors installed. Only measurements for detected sensors appear on the display. For example, if no carbon monoxide sensor is present, CO will not appear on the display. For values that are calculated, such as efficiency (Effc), sensors that provide data for the calculation must be present. If the O sensor data or stack temperature data is missing, efficiency will not be calculated and Effc will not be displayed on the Data Display. -
Page 26: Buttons And Button Operations
Buttons and Button Operations ON-OFF Control Button (red) Turns the instrument on and off. Pressing this button is accompanied by a beep. The ENTER Control Button Press the ENTER button to execute a command, such as selecting a menu item. Most instrument display screens have a message indicating the ENTER button function. -
Page 27: Icon Buttons
Icon Buttons Button Icons appear on the right side of the display and are connected to an Icon button by an indicator line. The button icons correspond to the button functions described below. You will see that some icons change when the button is pressed, indicating a change in a current status (e.g., pump on/off), or indicate that a new operation will be performed when the button is pressed again. -
Page 28: Selecting Menu Items
If no tab is present on a box, it is not linked to a button and is a message box. A good example of a message box is shown below. Message Box Selecting Menu Items Menus are lists of items or options you select to perform a needed operation. Selection of a menu item begins by moving the display cursor to the item and pressing the ENTER button. -
Page 29: Changing Units
Using the Sampling Probe Gas and Temperature Measurements Connect the sampling probe to the CA-Calc as described in Chapter 4. Place the Sampling probe through a hole in the exhaust flue, following recommendations presented below. Placement of the probe is important, and certain considerations must be given when choosing a sampling location. - Page 30 Minimum 2” (5 cm) Rotate the tube to window to ensure proper thermocouple exposure. Models CA-6210, CA-6211, CA-6212, CA-6214 1. Sampling probe 3. Exhaust flue 2. Draft regulator 4. Hot exhaust gases Figure 7: Sampling Probe Location Stack temperature measurement is extremely important to establish the heat loss from the exhaust gases and determine combustion efficiency.
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Page 31: Making A Draft Measurement
Making a Draft Measurement Before making a draft measurement, zero the draft pressure transducer by pressing the ZERO DRAFT option button in the Data Display. For zeroing, make sure the sampling probe is out of the flue, or that the draft and sample fittings are disconnected from the instrument. - Page 32 Data can be downloaded to a terminal emulator program such as the HyperTerminal, which accompanies the ® operating system program. Look for HyperTerminal in the Accessories folder. In HyperTerminal, Windows use the Capture Text option from the Transfer menu for recording instrument data. Communications Protocol Baud rate 1200 (default)
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Page 33: Chapter 6. Menu Selections And Menu Items
Chapter 6. MENU Selections and Menu Items Select from items in the main menu to perform setup operations. Access the main menu by pressing the button labeled MENU. Following is a list of the main menu items and the underlying menus. In this chapter, main menu items are described in sections in the order they appear in the menu, beginning with the Zoom Settings followed by Instrument Setup and so on. -
Page 34: Zoom Settings
Zoom Settings In the Zoom Settings screen you can select two parameters to be displayed in large characters. The large character display appears when the Zoom Display Icon button is pressed. ZOOM SETTINGS -0 PPM CO2 0.0 -0 PPM OVER = Measurement Zoomed -0 PPM Effic... - Page 35 Instrument Setup Item Description Options REF: Select between: Enable or disable the O reference calculation. The O reference applies to the CO, NO, NO and SO measurements. Refer to the next item below. REF Level: The O reference level can be adjusted between 0 and 18%.
- Page 36 Instrument Setup (continued) Item Description Options Gas Conc.: Select units for concentration display from the following: Change gas concentration units for display gas concentration using this option. The selections of parts per million units applies to all gases accept the O and CO g/MWh grams per megawatt hour...
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Page 37: Calibrate Sensors
Instrument Setup (continued) Item Description Options Effc/Loss Basis: Select from the following options: Efficiency and loss are calculated based upon heat- ASME loss (ASME) or Siegert calculations. Select between Siegert ASME or Siegert using the Effc/Loss Basis instrument setup option. In the U.S. -
Page 38: Restore Factory Cal
Restore Factory Cal In the event that a sensor calibration is performed in error, or the calibration(s) becomes corrupted, the initial sensor calibration performed at the factory can be re-installed. This is possible because factory calibration data is saved, either in the gas sensor electronics, or in the instrument. The initial data is never discarded. Calibrations are restored for individual sensors by selecting the appropriate sensor from the list in the Restore Factory Cal screen, and pressing ENTER. -
Page 39: Fuel Setup
Fuel Setup This menu selection lets you change fuel parameters for existing fuel types and add new fuel types to the fuel list. When the Fuel Setup is selected from the main MENU, the fuel list is displayed together with a table of fuel parameters. -
Page 40: Fuel Setup When Siegert Loss Calculation Used
Fuel Parameters: Name: PROPANE Carbon wt…: 81.8 % Moisture 0.0% Hydrogen wt.: 18.2 % CO2 max vol.: 13.8 % Emission Factors: Sulfur wt.: 0.00 % FSO2: 0.00145 HHV(BTU/lb): 21669 FNOx: 0.00104 LHV(BTU/lb) 19693 0.00063 move cursor <ENTER> = select <ESC> = exit SAVE &... -
Page 41: Erase Logged Data
Erase Logged Data Use the Erase Logged Data function to clear the instrument’s logging memory. When this option is selected, press YES to perform the clean-up operation. Choose NO or ESC to abort the erasing process. Caution This option permanently erases all user entered Sites, Devices and Samples from the CA-C combustion analyzer logging memory. -
Page 43: Chapter 7. Saving Data And Logging Functions
Samples can be saved under a Device name. Multiple Devices can be saved under a Site name. Refer to the schematic below. This shows the data saving organization. CA-Calc Data Management Structure Sites (35 possible) Devices (75 possible) -
Page 44: Saving Data When No Site Or Device Is Selected
Before saving a Sample, it is necessary to define a Site and Device. This is discussed in the following two sections. Saving Data When no Site or Device is Selected It is necessary to choose a Site name and Device name before saving data Samples. If a Site and Device has not been selected when the Save Data button is pressed, the following message is displayed: Store Data:... - Page 45 The data saving process is presented in the schematic in Figure 13. Information introduced in the schematic regarding creating, deleting and editing Sites and Devices is provided in the next section, “LOGGING FUNCTIONS.“ The Save Data icon button Site and Device have not been selected.
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Page 46: Logging Functions
LOGGING FUNCTIONS When using the logging routines, be sure to pay attention to all the information on the display screen, particularly in the message boxes. This will help steer you through the logging process and reduce confusion. Note: When ADDing or EDITing Site, Device or Sample names, follow the procedure described in “Entering and Changing Names”... -
Page 47: Devices
Devices From the Log Function: Sites display screen, a Site is selected using the ENTER key. This display screen which follows, shows the Devices in the Site and enables options for reviewing, selecting, adding, modifying Devices, and printing Samples. Figure 15 below, provides a schematic representation of the Devices screen, and describes the purpose of each button option. -
Page 48: Samples
Samples If there are Samples present for a Device, they are displayed when a Device is selected from the Devices screen using ENTER. This was described in the previous section. The Samples display screen enables you to view your saved data, and also provides buttons letting you delete or print saved data. Figure 16 below, provides a schematic representation of the Samples screen and describes the purpose of each button. -
Page 49: Chapter 8. Calibrations
Chapter 8. Calibrations Gas Sensors Gas sensors can be calibrated periodically to maintain the accuracy of your gas measurements. Gas sensors do drift over time, depending upon the operating environment and gas exposure history. With the exception of the O sensor, gas sensors may have a loss in signal of up to 2% per month. -
Page 50: The Calibration Setups
The Calibration Setups A TSI supplied calibration kit (Figure 17) uses a demand flow regulator to supply gas to the CA-C analyzer in response to the draw of the instrument sampling the pump. If a conventional regulator and valve are used (Figure 18), the generic setup, supplies gas to the instrument using a tee to a bleed-off extra gas. -
Page 51: Calibration Of No, No , So And Cohi (High Concentration) Sensors
Note: It is possible to do only the CO part of the calibration, bypassing calibration using the CO and H mixture. Accuracy is not impaired if there is no hydrogen in your sampled gas. WARNING Toxic Gases! Familiarize yourself with the toxic properties of the calibration gases by reading the supplied Material Safety Data Sheets (MSDS) accompanying the gas cylinders. -
Page 52: Stack And Supply Air Thermocouple Calibration
Note: For a calibration to be accepted by the CA-C combustion analyzer, the calculated calibration factor must be in the range of 14 to 17 inches of water (±) per volt. If not, an error is indicated and the calibration is not used. If this happens, it may mean there is a problem with the pressure transducer, your calibration pressure is not what you think it is, or you simply made a mistake in your calibration procedure. -
Page 53: Chapter 9. Maintenance And Troubleshooting
Chapter 9. Maintenance and Troubleshooting Emptying Water Trap Refer back to Figure 2 showing the water trap in the sample line, and to Figure 19 below. Liquid water forms in the first chamber of the water trap as gases are sampled from the flue. The water trap is designed so even when shaken, or when its orientation is changed, water does not pass to the second chamber. -
Page 54: Changing The Water Trap Filter
Changing the Water Trap Filter Identify the water trap filter (refer to Figure 19). This filter is designed to remove soot particles before they contaminate the instrument. The filter can be removed for cleaning or replacement by following these steps: 1. -
Page 55: Replacing A Sensor
Replacing a Sensor When a replacement sensor is received from TSI, the package may include a new sensor cup, fitting and tubing. These additional supplies are generally not needed for a replacement and may be put aside. To replace a sensor: 1. - Page 56 2.75" 1.4" 1. CO (hydrogen compensated) sensor position #4 6. Line on electronics board 2. O sensor position #1 7. Sensor cup 3. Sensor matting connector 8. Sensor cup fitting 4. Holes for alignment pins 9. Valve fittings and tubing connections 5.
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Page 57: Adding A New Sensor
Adding a New Sensor Sensors can be added to sensor S1 and S2 as shown in Figure 20. Positions O and CO are reserved for the Oxygen (O and hydrogen compensated carbon monoxide (CO) sensors, respectively. A third sensor should be added to S1, a fourth sensor to S2. -
Page 58: Troubleshooting Chart
Troubleshooting Chart Error message(s) after “Unrecognized sensor error” requires sensor replacement. “Ref. Voltage factor” startup. and “A/D cal factor” errors require factory service. Other errors, regarding the chemical sensors, draft measurement or thermocouples can usually be solved by re-calibrating the affected device. Pump vacuum out of range. -
Page 59: Appendix A. Calculations
Appendix A. Calculations Reference Concentration Calculation 20.9 reference × Corrected Concentrat (PPM concentrat (PPM) 20.9 measured reference is value entered as O REF level Excess Air Calculation - %CO/ × % Excess A - (%O - %CO/ λ Another expression of excess is (Greek letter Lambda) also used. -
Page 60: Determining Co Using The O Concentration
Remember either heating value, (HHV) or (LHV) can be applied in this calculation. Siegert Formula This formula is widely used in Europe to determine flue gas losses (qA) and efficiency. ⎛ ⎞ ⎜ ⎜ ⎟ ⎟ − Ta) x − ⎝... -
Page 61: A General Equation For The Combustion Of A Simple Hydrocarbon In Air
TABLE I. Factor (Ft) Nat. Gas Propane Oil #2 Oil #6 Coal Wood (dry) Bagasse Coke Methanol .00145 .00145 .00153 .00153 .00164 .00153 0.0016 0.00164 .00143 .00104 .00104 .00110 .00110 .00118 .00110 0.001 0.00118 .00103 .00063 .00063 .00067 .00067 .00072 .00067 0.00067 0.00072 .00062 Ft units: lb./MBtu PPM... -
Page 63: Appendix B. Series Ca-6200 Ca-C
Appendix B. Series CA-6200 CA-C Combustion Analyzers Detailed Specifications Oxygen (O Excess Air (%EA): 0–1000% Sensor Type Electrochemical Efficiency (E and E Range: 0–25% Range: 0–125% Accuracy: ±0.3% O Resolution: 0.1% Resolution: 0.1% O Stack Loss: 0–100% Response Time*: <30 seconds to 90% of step Supply Temperature: -22–392 F (-30-200... - Page 65 TSI Incorporated 500 Cardigan Road, Shoreview, MN 55126 U.S.A. Web: www.tsi.com...
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