ENERAC 500 Instruction Manual
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ENERAC 500 Instruction Manual

Micro-emissions analyzer
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INSTRUCTION MANUAL
MICRO-EMISSIONS ANALYZER
MODEL 500
ENERAC, INC.
67 BOND STREET
WESTBURY, NY 11590
(800) 695-3637
FAX (516) 997-2129
Revision 3.0

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  • Page 1 INSTRUCTION MANUAL MICRO-EMISSIONS ANALYZER MODEL 500 ENERAC, INC. 67 BOND STREET WESTBURY, NY 11590 (800) 695-3637 FAX (516) 997-2129 Revision 3.0...

  • Page 3: Table Of Contents

    C. STORAGE MENU ..................27 D. PRINTER SETUP MENU................28 E. SENSOR SETUP MENU................29 CHAPTER 6 COMMUNICATIONS ....................30 A. ENERCOM SOFTWARE ................30 B. SERIAL COMMANDS.................33 THE ENERAC 500 COMMAND SET..............34 CHAPTER 7 CALIBRATION.......................37 A. AUTOZEROING THE INSTRUMENT............37 B. SPAN CALIBRATION .................38 CHAPTER 8 MAINTENANCE ....................43 APPENDIX A MODEL 500 SPECIFICATIONS................48...

  • Page 4: List Of Abbreviations

    LIST OF ABBREVIATIONS PARAMETERS AMB T Ambient (room) temperature Carbon monoxide (a toxic gas) Carbon dioxide COMBUST Combustible gases EFFIC Combustion efficiency (for boilers and furnaces, does not apply to engines) EX AIR Excess air Nitric oxide (a toxic gas) Nitrogen dioxide (a toxic gas) Oxides of nitrogen (a toxic mixture of nitric oxide and nitrogen dioxide gases)

  • Page 5: Options

    OPTIONS The ENERAC Model 500 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. The available options on the Model 500 are as follows: a.
  • Page 6 Various cables and attachments are available for special connections to the Micro Emissions Analyzer. In addition, high resolution 0-200 PPM and extended range 0-4000 PPM versions are available on request. (For carbon monoxide only, 0-10,000 PPM and 0-20,000 PPM ranges are also available).

  • Page 7: Chapter 1 Fundamentals

    CHAPTER 1 FUNDAMENTALS The ENERAC Model 500 Micro Emissions Analyzers are hand held state of the art analyzers designed for the following tasks: • To measure the emissions of carbon monoxide, oxides of nitrogen, sulfur dioxide and oxygen from stationary and mobile combustion sources.
  • Page 8 4. One disposable fiber filter. 5. One wall-mounted AC battery charger. 6. One instruction manual. Every ENERAC sold has stored in its memory information regarding manufacturing and sensor dates, as well as product identification, serial number of unit, version and original customer.
  • Page 9 4. Do not rest the stack probe’s hose on a hot boiler surface. 5. Allow the probe tip to cool off and the instrument aspirate air before packing the probe. 6. Always be sure to use single-gas blends when calibrating the sensors. 7.

  • Page 10: The Instrument Keyboard

    CHAPTER 2 THE INSTRUMENT KEYBOARD The Model 500 can be operated by using either: • The 12 button keyboard located on the face of the analyzer, or • By the use of commands through its serial port, USB port or Bluetooth interface.
  • Page 11 software version, unit serial number, battery voltage and selected fuel. The third screen displays the ambient temperature, units of temperature, emission units, and selected oxygen reference. PRINT Sends data to the printer. The buttons of the last row are used to customize the analyzer and execute all changes in stored parameters, such as time, fuel, calibration data, etc.

  • Page 12: Basic Instrument Operation

    Please refer to the other sections of this manual for a description of the more advanced features. The Model 500 micro-emissions analyzers consist of two major components, the probe (whose function is to extract, clean, and dry the sample) and the main unit, which does the stack analysis and computations.
  • Page 13 CHAPTER 5: ANALYZER CUSTOMIZATION. It is a good idea to use the STATUS button to check the battery voltage before you begin a test. The unit will display a warning and shut down when the battery voltage drops to 4.0 volts. 4.
  • Page 14 9. If you wish to store your data into one of the 100 ENERAC 500 Serial #: 000000 storage buffers of the analyzer, press the STORE TEST RECORD button. CUSTOMER NAME Time: 10:25:00 10. When you are finished with the measurements,...

  • Page 15: The Smoke Test

    THE SMOKE TEST (ASTM METHOD D2156) The smoke test accessory, shown below, is required to perform smoke tests. If you wish to take a measurement of the smoke using the smoke spot method, press and hold the PUMP button for 3 seconds. The pump will stop and the first screen SMOKE TEST SMOKE TEST SMOKE TEST...

  • Page 16: Analyzer Description

    CHAPTER 4 ANALYZER DESCRIPTION A. POWER REQUIREMENTS The Model 500 is designed to operate from 4 AA cells supplying a voltage of 4.0 to 6.5 Volts. The flexible design allows for the use of either 4 AA alkaline primary (non rechargeable) batteries, or 4 nickel-metal-hydride rechargeable cells.

  • Page 17: Sample Flow Description

    When the battery voltage indicated drops to 4.6 Volts for alkaline or 4.2 Volts for rechargeables, you have only a few more minutes of battery life remaining. Using the printer will further reduce battery power. Always check the battery voltage with the pump turned on.

  • Page 18: Thermoelectrically Cooled Condensation Trap

    The thermoelectrically cooled condensation trap, better known as “Peltier Drier” is an optional accessory device for the model 500 emissions analyzer. Its purpose is to replace the standard condensation trap of the Model 500 for those critical applications, that demand higher accuracy for the measurement of nitrogen...
  • Page 19 The following outline drawing illustrates the drier’s operation. FIGURE 2 Mount the Peltier drier to the side of the ENERAC using the two thumbscrews. Make a tight connection so that the heatsink makes good contact with the ENERAC case.
  • Page 20 The Peltier drier requires electrical power for operation. This is available from the analyzer through the drier’s electrical connector. When operating the Peltier drier, the analyzer’s battery life is limited to 2 hours, approximately. It is therefore recommended, but not necessary, to use the battery charger for longer operation. The Peltier drier will maintain the sample at a certain temperature below ambient temperature to ensure no further condensation inside the analyzer.

  • Page 21: Sensors Description

    The sensors can be accessed by opening the bottom part of the analyzer’s back cover. All toxic gas sensors used in the Model 500 are large electrode area emission type sensors especially designed for use in the hostile exhaust gas environment.
  • Page 22 It has a range of 0 to 2000 PPM. Its life is estimated at two years. e) NITROGEN DIOXIDE SENSOR. This is an electrochemical cell similar to the nitric oxide sensor. It has a range of 0 to 500 PPM. Its life is estimated at two years.
  • Page 23 NOTE: In addition to the sensor long-life filters, the Model 500 emission analyzer uses mathematical compensation techniques to minimize any residual cross-sensitivities that its toxic sensors may have to any gases other than those they are intended to measure. For this reason, never use span gases that are blends of two or more toxic gases.

  • Page 24: Chapter 5 Analyzer Setup

    CHAPTER 5 ANALYZER SETUP The SETUP MENU allows the operator to change system parameters, perform sensor calibrations, and manage the internal storage of the ENERAC. Pressing the SHIFT key displays the SETUP MENU. The SETUP MENU contains five submenus: ** SETUP MENU ** ►System Setup...
  • Page 25 A more detailed explanation of each parameter follows: 1) TIME: To set the time of the analyzer’s internal clock (24 hour clock) you operate the SHIFT, UP, DOWN, & ENTER buttons as follows: a) Press the ENTER key to edit the TIME parameter. b) Press the UP or DOWN keys as required until the correct number corresponding to the hour (24-hour clock) appears on the display.
  • Page 26 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 extractive analyzer, whose conditioning system removes most of the water vapor before the sample reaches the sensors).

  • Page 27: Span Menu

    9) OXYGEN REF: Many environmental regulations require that the concentrations of pollutants measured, be corrected to some reference value of oxygen other than the actual concentration at the time of the measurement. Typical oxygen reference values are 0% (air free), 3%, 7% or 15%. To select the desired oxygen reference value, press the SHIFT key repeatedly until the blinking cursor is located on the OXYG REF line on the display, as described above.

  • Page 28: Storage Menu

    1. TIMED STORE: Selects the method for storing data. When timed store is OFF, the ENERAC will store one set of data into the next available buffer only when the STORE key is pressed. Any other value will turn on the periodic store function.

  • Page 29: Printer Setup Menu

    PRINT BUFFER MENU DOWN keys to move the arrow to select the desired buffer and press ENTER. If you wish to print all of the ENERAC’s stored data in sequence, move the arrow to the entry ALL BUFFERS and press ENTER.

  • Page 30: Sensor Setup Menu

    ENTER to enter edit mode, Offset: 1.234 and use the UP & DOWN keys to scroll through the SENSOR SETUP analyzer’s sensors. A list of the ENERAC 500's sensors are shown here. CO: 2000 PPM NO: 2000 PPM 2.

  • Page 31: Chapter 6 Communications

    Communication is by ASCII characters only. Use a USB cable or 9-pin serial cable to connect the analyzer’s serial port to the computer. The USB drivers must be installed first. They are located on the ENERAC CD, and the ENERAC website: www.enerac.com.
  • Page 32 BEFORE starting the Enercom software. This is because the port does not appear until the device is connected. • If your Enerac analyzer does not have an integrated USB port, you can use a USB-to-Serial adapter. • For USB connections, enter the assigned COM port number in Enercom.
  • Page 33 • Start Enercom. Click on Add Port under the Connections menu and enter the COM port number. • Your Enerac icon should appear on the screen. Click on the Enerac icon to display the analyzer menu. Monitor Opens the Monitor window. All real-time testing, data logging, graphing, and charting is done here.

  • Page 34: Serial Commands

    Start any of the available communications programs, such as PROCOMM or TERMINAL on your computer. Make sure the communications program is set to match the ENERAC’s protocol listed above. You may need to use a null modem if you have trouble communicating.

  • Page 35: The Enerac 500 Command Set

    CORF X ENERAC sets the temperature units: Fahrenheit Celsius CUST? ENERAC returns the customer name. This name appears on the display and all printouts. CUST XXXX ENERAC sets the customer name, up to 21 characters long. DATE? ENERAC returns the present date.
  • Page 36 NBUF? ENERAC returns the total number of storage buffers. PRNT XXXX Sends to the ENERAC printer the message "XXXX" up to 40 characters long. To send more characters, repeat the command. PRNT TEXT Commands the ENERAC to print on its printer all the current stack parameters including time, date, fuel and oxygen reference.
  • Page 37 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 38: Chapter 7 Calibration

    You can then press the ZERO button to start the autozero procedure. 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).

  • Page 39: Span Calibration

    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 40 (A) Span calibration using the ENERAC kit The gas calibration system supplied by ENERAC is shown in Figure 2. The kit comes with a regulator and probe adaptor. For CO, NO, NO & combustibles calibrations you must order gas cylinders containing the desired type of span gas.
  • Page 41 The NO span gas can be in the range of 10 - 2000 PPM, 2% accuracy with balance nitrogen, required. The NO span gas can be in the range of 10 - 500 PPM, 2% accuracy with balance nitrogen, preferably. The SO span gas can be in the range of 30 - 2000 PPM, 2% accuracy, with balance nitrogen, preferably.
  • Page 42 ** SPAN MENU ** ** SETUP MENU ** CO Span: 200PPM System Setup NO Span: 200PPM ►Zero/Span Setup NO2 Span: 200PPM Storage Setup SO2 Span: 200PPM Printer Setup Comb Span: 1.0% Sensor Setup Draft Span: 10 " SETUP MENU Zero Time: 60sec Span Time:120sec Calib History SPAN MENU...
  • Page 43 3:59 Feed 300ppmNO Shift to Abort 4. When the calibration is finished, press the DATA key to make sure that the display is reading correctly. (D) Stack Draft Calibration To obtain a span calibration of the draft sensor, connect a manometer to the end of the probe through a T fitting.

  • Page 44: Chapter 8 Maintenance

    CHAPTER 8 MAINTENANCE The ENERAC micro-emissions analyzers are a sophisticated piece of analytical instrumentation 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 45 For fresh alkaline batteries the voltage displayed will be approximately 6 Volts. It will gradually drop with use until at 3.9 volts a “BATTERY LOW” warning will appear. You can estimate the remaining time by observing the battery voltage. For NiMH rechargeable batteries the battery voltage will stay at approximately 4.8 volts for a long time and then drop rapidly.
  • Page 46 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 47 Locate the slot immediately beneath the printer and insert the paper end as far as it will go. Turn the Enerac on and press the “PAPER FEED” button while applying forward pressure on the paper. When the paper end appears exiting printer, replace the roll on the spindle.

  • Page 49: Model 500 Specifications

    APPENDIX A MODEL 500 SPECIFICATIONS PHYSICAL: 1. CASE 9 ¾" x 4" x 2¾" Aluminum case. Weight: 3 lbs. 2. PROBE 9"L x 3/8" OD Inconel stack probe. Probe housing connects to instrument via a 10 ft. viton hose and water trap with fiber filter. Max. continuous temperature: 2000 °F.
  • Page 50 3. OXYGEN Electrochemical cell. Life 2 years. Range: 0-25 % by volume Resolution: 0.1 % Accuracy: 0.2 % 4. NITRIC OXIDE (NO) Electrochemical cell. Life 2 years. Range: 0-2000 PPM Resolution: 1 PPM Accuracy: 4% of reading (±5 PPM when measuring less then 100 PPM) 5.
  • Page 51 Accuracy: The larger value, either 5% of reading or 0.3" WC 10. TIME/DATE Time formatted in hours, minutes, and seconds. Date in month, day, and year format COMPUTED PARAMETERS: 1. COMBUSTION EFFICIENCY Heat loss method. Range: 0-100% Resolution: 0.1% Accuracy: 1% 2.
  • Page 52 PRINTER: Internal 28 character per line, 2" thermal printer. INTERNAL STORAGE: 400 individually selectable buffers hold one complete set of measurements each in non-volatile memory. Buffer contents can be sent to printer or serial ports. Data storage performed either individually on command or on a preprogrammed periodic basis.

  • Page 53: Firmware Programming

    There are 5 miniature slide switches on a red block. See figure 4, page 46. 2. Connect the serial port of the computer to the ENERAC. Run the firmware update. The program will backup the ENERAC’s settings.

  • Page 54: Replacment Parts

    APPENDIX C REPLACMENT PARTS PART NUMBER DESCRIPTION ASSPAKTHR200 Printer Paper Roll (package of 3) ASSPAKSMKPPR Smoke Paper (package of 20) FILTER-3$$$$ Fiber Filter (package of 10) (CONDENSATION TRAP) ASSPAKFLTR1$ Line Filter (package of 3) (THERMOELECTRIC COOLER) SNSOXYCTL5FO O2 Sensor SNSCOMEMA3EX CO Sensor SNS$NOMEM3NX NO Sensor...

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