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ENERAC 700 Instruction Manual

Integrated emissions system
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INSTRUCTION MANUAL
INTEGRATED EMISSIONS
SYSTEM
MODEL 700
ENERAC, LLC
1320 LINCOLN AVE.
HOLBROOK, N.Y.
11741
(800) 695-3637
Outside USA
631-256-5903
After Hours
631-379-3502
E-mail
sales@enerac.
com
FAX (516) 997-2129
www.enerac.com

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  • Page 1 INSTRUCTION MANUAL INTEGRATED EMISSIONS SYSTEM MODEL 700 ENERAC, LLC 1320 LINCOLN AVE. HOLBROOK, N.Y. 11741 (800) 695-3637 Outside USA 631-256-5903 After Hours 631-379-3502 E-mail sales@enerac. FAX (516) 997-2129 www.enerac.com...
  • Page 2 ENERAC 700 MANUAL EDITION M700 FIRMWARE 3.0+ >= M 700 HARDWARE...

  • Page 3: Table Of Contents

    CHAPTER 5 SENSORS ........................27 CHAPTER 6 ANALYZER SETUP ....................33 CHAPTER 7 INTERNAL DATA STORAGE ................37 CHAPTER 8 INTERNAL PRINTER ....................39 CHAPTER 9 CALIBRATION.......................41 CHAPTER 10 COMMUNICATIONS ....................50 CHAPTER 11 MAINTENANCE ....................58 APPENDIX A MODEL 700 SPECIFICATIONS................64 APPENDIX B FIRMWARE PROGRAMMING................68...
  • Page 4 APPENDIXC EPA TEST METHODS ...................70...

  • Page 5: Chapter 1 Fundamentals

    The Model 700 emissions analyzer consists of the sampling system, whose function is to extract, clean, and dry the sample, and the main unit, which analyzes the sample and displays the measurements.
  • Page 6 E. Additional pump and O sensor for dual-range measurement and purging capability F. Bluetooth wireless communications The ENERAC Model 700 is the most advanced portable emissions analyzer. It uses the latest proprietary (SEM ) electrochemical sensors, and non-dispersive infrared (NDIR) technology to measure emissions.
  • Page 7 EPA Method 2, or Method 2C, Appendix A of 40CFR60. The ENERAC Model 700 can assist the operator of a combustion source with the task of optimizing its performance and saving fuel. It can be used as a management tool to assist the plant manager with keeping records and controlling costs.
  • Page 8 A. UNPACKING THE INSTRUMENT The ENERAC Model 700 Integrated Emissions System includes: • The Model 700 Emissions Analyzer with Carry case & Carry Strap • A stack-probe • A sampling-line assembly • A sample-conditioning system: either a water-trap or a thermoelectric-condenser •...
  • Page 9 B. PREPARING THE INSTRUMENT 1. Remove the instrument from its case and connect the thermoelectric condenser (or water-trap) and probe to the unit. 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.
  • Page 10 The instrument will measure correctly all sensors that do not show an error message. 6. The LOW RANGE mode is the default setting. In LOW RANGE mode, maximum concentrations are typically 2000 PPM for CO & NO, and 1000 PPM for NO &...
  • Page 11 C. IMPORTANT ADVICE Most stack gases are hot, full of moisture, corrosive and laden with soot particles. To make sure that your instrument will give you a long time of trouble-free performance, please observe the following recommendations. 1. Follow the instructions in your manual. 2.
  • Page 12 D. AUTOZERO ERRORS & BASIC TROUBLESHOOTING AUTOZERO ERRORS Channel Possible Causes Resolution Sensor has been recently Wait 10 minutes, monitor exposed to gas and has sensor voltage, and re-zero. not returned to zero. Battery was dead, sensor Charge battery, wait a few has destabilized.
  • Page 13 POWER-UP PROBLEMS Symptoms Possible Causes Resolution Battery is dead. Plug in the charger. Analyzer should turn on. Analyzer will not turn on Battery is not charging. Check charger and jack. (Screen is off). Internal initialization Reset the analyzer. problem. Internal initialization Reset the analyzer.

  • Page 15: Basic Instrument Operation

    CHAPTER 2 BASIC INSTRUMENT OPERATION THE INSTRUMENT KEYBOARD The Model 700 is operated by the 13 button keyboard located on the front of the analyzer. • The key turns the unit on and off. POWER HELP PUMP SETUP • The...
  • Page 16 To operate the instrument follow the steps outlined below. 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. Press the key and check the unit’s battery condition.
  • Page 17 The cursor PRINT (reverse color) will point to: Print Test Record Press the key to execute a printout on the ENERAC’S printer. ENTER 10. To store the data displayed, press the key. The cursor (reverse color) STORE will point to:...

  • Page 19: Chapter 3 Power Requirements

    CHAPTER 3 POWER REQUIREMENTS Power is supplied by a battery pack consisting of four D-size Ni-MH rechargeable batteries. A 120 –240 Volt AC charger having a 12 Volt DC/ 1.5 A. output is supplied with the instrument. The battery charger will charge the 9,000 mAH batteries in about six hours.

  • Page 21: Sample Extraction & Conditioning

    The sampling line connects to the probe and delivers the gas to the conditioning system. The hose may be made of Viton, Teflon, or EPDM. The integrated yellow wire is for connecting the thermocouple to the analyzer. The ENERAC Model 700 can accommodate a variety of available sample conditioning systems: WATER TRAP This is the least expensive conditioning system available.
  • Page 22 • The fiber filter should be replaced when it becomes noticeably discolored. THERMOELECTRIC CONDENSER The thermoelectrically-cooled condenser and trap, or ‘thermo-cooler’, is the standard option for the Model 700 emissions analyzer. It is recommended for most applications where condensation removal without significant loss...
  • Page 23 THE STANDARD THERMOCOOLER The following drawing shows the thermo-cooler mounted to the side of the 700. The sample, consisting of gas and partially condensed water vapor, enters the drier through the “SAMPLE INLET”. It flows through multiple narrow chilled passages, where total separation of gas and vapor occurs.
  • Page 24 The thermo-cooler requires electrical power for operation. This is available from the analyzer through the dedicated electrical connector for the device. Operation of the thermo-cooler will reduce the analyzer’s battery life. It is therefore recommended, but not necessary, to use the battery charger for longer operation. The condensation trap will fill with water after 2 to 4 hours depending on the fuel used.
  • Page 25 STACK VELOCITY (S-V) PROBE A stack velocity probe, shown here, can be used to measure the stack gas flow velocity for mass-emissions measurements of the toxic gases (pounds/hour). Pitot Tube and Hose Assembly The S-type Pitot tube consists of a pair of 3/16” diameter stainless steel tubes welded together and having their stack ends open and bent at a certain angle as required by the EPA specifications of 40CFR60 Appendix A, Method 2 for measuring stack gas velocities.
  • Page 26 OPTIONAL PROBE ACCESSORIES Sintered Hastelloy-X filter (10 microns) The purpose of the filter is to block soot particles from entering the probe housing. The filter is reusable and can be cleaned in a detergent and by blowing air from inside out. Maximum filter temperature is 1900ºF. Inconel probe extension This tube screws into the end of the sample probe to extend its reach.

  • Page 27: Chapter 5 Sensors

    CHAPTER 5 SENSORS The great versatility of the ENERAC 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 28 Sensor life is estimated at 2 years. 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 29 NO The SEM sensor of the ENERAC Model 700 is fabricated in a different manner from the typical electrochemical type sensor and is superior in accuracy, interference rejection and its design for continuous operation. This sensor also requires a constant bias voltage for proper operation. This voltage is supplied to the sensor, even when the instrument is turned off.
  • Page 30 The Model 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. It also allows purging of the sensors as required by the EPA CTM-034 method.
  • Page 31 The amount of radiation absorbed is used to calculate the concentration of the gas based on the Beer’s Law. The figure below shows an outline of the NDIR assembly. The light source is a pulsed incandescent bulb. There are four detectors: one for each gas plus a reference detector.
  • Page 32 b. Stack Temperature sensor The thermocouple is located at the tip of the probe. It measures the stack temperature minus the ambient temperature. The thermocouple junction is a shielded, ungrounded, inconel sheathed, type K thermocouple with a capability of measuring temperatures from 0 to 2000 ºF. The instrument software linearizes the thermocouple output to improve the accuracy.

  • Page 33: Chapter 6 Analyzer Setup

    CHAPTER 6 ANALYZER SETUP The SETUP MENU allows the operator to change system parameters. 1 ‘12 12:45:00 Fuel: Natural Gas Temperature Units: F Measure Units: PPM OxygenReference:TRUE Pumps:SAMPLEDuty:90% Dilute CO: 10000 PPM CO-IR Thresh:2000PPM Cooler Duty: 50% Thermal Eff:0.30 Baudrate: 9.6 kbps Velocity Units: FPS Stack Size: 5000sqin...
  • Page 34 (brake-specific fuel consumption, in BTU’s pre 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 Model...
  • Page 35 700 is an extractive analyzer, whose conditioning system removes most of the water vapor before the sample reaches the sensors). NOTE: Values of emissions in #/B and GBH are fuel and CO dependent. The fuel parameters for certain typical fuels used in the analyzer (i.e. the F- factors for anthracite, etc.) have been modified to be identical to those specified in...
  • Page 36 threshold is reached, the CO is measured with the electrochemical sensor and reported in the selected measurement units. 9) COOLER DUTY: This setting controls power to the thermoelectric cooler. See Chapter 4. 10) THERMAL EFF: Set the thermal efficiency of the engine under test. See MEASURE UNITS above.

  • Page 37: Internal Data Storage

    CHAPTER 7 INTERNAL DATA STORAGE The ENERAC Model 700 has 500 internal storage buffers. Each buffer stores one complete set of emissions data. The STORE MENU allows the operator to store data and manage the internal storage buffers. The last line of the STORE MENU shows the current buffer.
  • Page 38 4. START/STOP PERIODIC STORE: This will turn on the periodic store function. In this mode, the unit will continuously store data to consecutive buffers, at an interval specified on the next line. Once enabled, this line will read: Stop Periodic Store 5.

  • Page 39: Chapter 8 Internal Printer

    (month/day) and time (hour/minute) when the data OxygenReference:TRUE was stored appear at the bottom; empty buffers show the word “empty”. To print the contents of a specific buffer, ENERAC 700 use the keys to move the arrow to the desired UP / DOWN...
  • Page 40 keys to navigate around the keyboard, and press to select the letter / RIGHT ENTER or number. For lower-case letters, highlight and press , for symbols, ENTER shift highlight and press . The arrows in the corner will move the cursor ENTER forward or backward through the name.

  • Page 41: Chapter 9 Calibration

    Usually, the first point chosen is the zero value (called zeroing the instrument). On the Model 700, all of the sensors are zeroed together. This is known as an ‘autozero’ and includes a short countdown, typically 60 seconds.
  • Page 42 The ZERO - SPAN MENU, shown here, lets you zero all of the sensors, and span- calibrate each sensor individually. **** ZERO - SPAN **** Zero All Sensors AutoZero Errors Sensor History Amb Temp: 74 °F Zero Time: 60sec Span Time:120sec Span CO: xxxx PPM Span H...
  • Page 43 SPAN TIME: When carrying out a span calibration, you must introduce the span gas for an appropriate amount of time before the analyzer executes the span calibration. This setting, which is the same for all sensors, controls this time interval. The time is indicated in seconds, but a minimum of 2 minutes of span gas feeding is required for proper calibration.
  • Page 44 SPAN CALIBRATION (Electrochemical sensors, NDIR sensors) A full span calibration of the instrument is recommended every 2-4 months. If you cannot calibrate the analyzer yourself you should return it to the factory for a complete calibration once a year. For superior accuracy you should check the calibration of the instrument before each emissions test.
  • Page 45 OPEN OUTLET 2. An optional demand-regulator will automatically supply an adequate flow of gas to the analyzer without wasting any span gas and without venting any toxic gas to your ambient environment. This accessory, shown in the figure below, is available from the factory.

  • Page 46: Calibration Procedure

    TYPICAL SPAN GAS CALIBRATION VALUES The analyzer supports different ranges for its electrochemical sensors. Calibration values for standard-range sensors are shown here. The CO span gas can be in the range of 30 - 2000 PPM, 2% accuracy with balance nitrogen, preferably.
  • Page 47 5. Use the keys to select the appropriate SPAN menu item, UP, DOWN, & ENTER and to enter the span gas value. First set the hundreds digit, then press ENTER to advance the cursor to the tens digit, and repeat for the units digit. 6.
  • Page 48 STACK GAS VELOCITY CALIBRATION To span calibrate the velocity sensor connect a manometer directly to the velocity input on the side of the analyzer. Apply 1 inch of pressure. In the SPAN MENU, use the keys to UP / DOWN select a velocity calibration of 1.0".

  • Page 50: Chapter 10 Communications

    To install this driver: 1. Locate the FTDI USB driver on the CD or download it from the ENERAC website and save it to your desktop. 2. The downloaded file is zipped. Double-click the zipped folder and choose Extract All Files. Extract the files to a folder on the Desktop. The driver files are in the FTDI_USB folder.
  • Page 51 For Bluetooth connections, the connection process varies with different Bluetooth devices. Follow your manufacturer’s instructions for adding a device. The ENERAC’S Bluetooth modem is a Class 1 device, with a maximum range of 100m. Obstacles such as walls and equipment will reduce the effective range.
  • Page 52 B. ENERCOM SOFTWARE You can enhance the performance and versatility of the ENERAC Model 700 by using the Enercom software program. Enercom is available for most Windows operating systems. The Enercom software is a robust package that allows you to: 1.
  • Page 53 The COM port with its number should appear on the left side of the Enercom window. Enercom will look for an analyzer on this port. After a moment the ENERAC analyzer icon should appear. You are now connected to your analyzer.
  • Page 54 Note that these commands do not elicit a respond For example, to set the clock: Send: TIME 11:30:00 Response: [none] The default baud rate is 9600 bps. The analyzer can communicate at several speeds ranging from 1200 to 115,200 bps. The ENERAC 700 command set follows.

  • Page 55: Data Commands

    THE ENERAC 700 COMMAND SET DATA COMMANDS COMMAND FUNCTION ATEM? Returns the present value of ambient temperature. BATT? Returns the present battery voltage. CDOX? Returns the present value of carbon dioxide. CMNX? Returns the present value of carbon monoxide. COMB? Returns the present value of combustible gases.
  • Page 56 MODE X (Emissions option). Selects the units of emissions measurements (CO, NO, NO , NOX, SO ) as follows: PPM (volumetric) MGM (milligrams/cubic meter) #/B (pounds/million BTU) GBH (grams/brake hp-hour) OXRF? Returns the oxygen reference. OXRF XX (Emissions option). Sets the oxygen correction factor to any number as follows: XX=0-20 Percent, in 1% steps...

  • Page 57: Calibration Commands

    ZERR? Returns a list of sensors that failed autozero. MASTER COMMANDS COMMAND FUNCTION LOGO? Returns its current model name (ENERAC M700). HELP? Returns a list of all serial commands. SRAL? Returns the analyzer’s serial number. TURN OFF The analyzer powers down.

  • Page 58: Chapter 11 Maintenance

    CHAPTER 11 MAINTENANCE The ENERAC 700 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 59: Sensor Replacement

    a. Water-trap system A disposable 1-micron fiber filter is located in the bottom section of the condensation trap assembly. Its function is to prevent soot particles from reaching the analyzer pump and sensors. To replace the filter, disconnect the condensation trap from the probe. Unscrew the bottom section of the condensation trap and replace the filter with a new one.
  • Page 60 An autozero error may indicate a problem with a sensor. If you receive an error message for one of the sensors during an autozero, do not replace the sensor at first. Instead, wait a few minutes and then autozero the analyzer again. If you get an error message again, investigate and determine if moisture has entered the sensor area.
  • Page 61 NOTE: SEM four-electrode CO sensor (Hydrogen interference adjustment). There is a hydrogen cross-interference adjustment for the four-electrode carbon monoxide sensor. This calibration, intended to remove the interference of hydrogen from CO measurements, should be rarely done, typically if the sensor is being replaced.
  • Page 62 5. Battery-Pack replacement The analyzer is typically powered by a rechargeable battery-pack consisting of four, Ni-MH D-size cells. You should get up to six hours of operation from a full- charge, depending on the thermoelectric cooler power setting. You can check the condition of the batteries at any time by pressing SETUP + keys together.

  • Page 64: Model 700 Specifications

    APPENDIX A MODEL 700 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 65 SAMPLING CONDITIONING SYSTEMS 1. CONDENSATION (WATER) TRAP & FILTER SYSTEM A 12” long, 316 Stainless Steel or Inconel probe, a fiber filter, and a 34 cc polycarbonate water-trap Sampling-line: 3/8” OD x ¼” ID latex tubing; lengths available from 10’ to 50’. 2.
  • Page 66 OXYGEN 2 0 – 25% 0.1% 0.1% ABSOLUTE OR 0.2% OF READING ELECTROCHEMICAL (High Range – option) COMBUSTIBLES 0- 4% 0.01% 10% OF READING OR (Single Range option) 0.02% STACK TEMPERATURE 0 – 2000 F. (1100 C) 1 F (1 C.). 5 F.

  • Page 68: Appendix Bfirmware Programming

    The Bluetooth connection cannot be used to reprogram the analyzer’s firmware. Reprogramming the firmware will not affect the calibration settings or stored data. Firmware updates can be downloaded from the ENERAC website: www.enerac.com, or can be requested directly from Enerac, Inc.
  • Page 69 PROGRAMMING SWITCHES 9. The firmware will now be reprogrammed and verified. This will take 2-3 minutes. 10.When prompted, toggle the programming switches off and replace the back cover. 11.Turn on the analyzer. Check the firmware version on the screen. SETUP...
  • Page 70 APPENDIX C EPA TEST METHODS A SUMMARY OF THE EPA CONDITIONAL TEST METHOD CTM-030 REQUIREMENTS FOR CO, NO AND O EMISSIONS This method is applicable for the measurement of oxygen, carbon monoxide and oxides of nitrogen (NO ) emissions from sources using gaseous and liquid fuels. is the sum of NO (nitric oxide) and NO (nitrogen dioxide) concentrations.
  • Page 71 The probe must be heated until it reaches the moisture removal system. Dry transport line required from the moisture removal system to the analyzer (Fig. 7E- 1). (Here ENERAC CTM probe meets this requirement). Dual range analyzers are allowed, but they must meet the specifications listed for single range.
  • Page 72 5. The measured emissions must be between 20% and 100% of the calibration span, which is the high-level calibration span gas. It is suggested that you choose a high-level span gas that is as high as possible, up to 5 times the expected emissions concentration, but do not exceed the range of the sensor.
  • Page 73 A SUMMARY OF THE ASTM D6522 TEST METHOD FOR THE DETERMINATION OF NITROGEN OXIDES, CARBON MONOXIDE AND OXYGEN CONCENTRATIONS This test method covers the determination of nitrogen oxides (both NO and NO required), carbon monoxide (CO) and oxygen(O ) primarily from GAS FIRED sources using exclusively DIFFUSION BASED ELECTROCHEMICAL SENSORS.
  • Page 74 < 0.5% O c. Thirty minute stability test requirement: < 2% of UCG. (For a 15 minute test: < 1% of UCG) NOTE: Calibration checks are required before and after each measurement test. ENERAC 700 PARTS PRICE LIST- (3-5-2014) Part Part #...

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