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yellow jacket CA502 User And Maintenance Manual

Combustion analyzer
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Summary of Contents for yellow jacket CA502

  • Page 2: Table Of Contents

    TABLE OF CONTENTS IMPORTANT INFORMATION Information about this manual Danger levels and other symbols SAFETY Safety check Intended purpose Improper use of the product Precautions for the usage of the Li-Ion battery package WORKING PRINCIPLE General overview of the analyzer DESCRIPTION OF THE PRODUCT Working principle Measurement cells...
  • Page 3 TABLE OF CONTENTS INSTRUMENT PARAMETER Setting Menu 10.0 MEASUREMENTS 10.1 Menu→Measurements 10.2 Menu→Measurements→Comb. analysis 10.3 Menu→Measurements→Draft 10.4 Menu→Measurements→CO air 10.5 Menu→Measurements→Pressure 11.0 MEMORY 11.1 Menu→Memory 12.0 CONFIGURATION 12.1 Menu→Configuration 12.2 Menu→Configurationan→Analysis 12.2.1 Menu→Configuration→Analysis→Fuel 12.2.2 Menu→Configuration→Analysis→Condensation 12.2.3 Menu→Configuration→Analysis→O2 Reference 12.2.4 Menu→Configuration→Analysis→Measure units 12.2.5 Menu→Configuration→Analysis→Autozero 12.2.6...
  • Page 4 Total or partial reproduction of this document by any means (including photocopying or storage on any electronic medium) and transmittal of same to third parties in any manner, even electronically, is strictly prohibited unless explicitly authorized in writing ® by YELLOW JACKET...

  • Page 5: Important Information

    1.1 Information about this manual ® ➢ This manual describes the operation and the characteristics and the maintenance of the YELLOW JACKET Combustion Analyzer model CA502. ➢ Read this operation and maintenance manual before using the device. The operator must be familiar with the manual and follow the instructions carefully.

  • Page 6: Safety

    This chapter describes the areas of application for which the CA502 is intended. Using the CA502 in other application areas transfers the risk to the operator and the manufacturer assumes no responsibility and liability for loss, damage or costs which could be a result. It is mandatory to read and pay attention to the Use And Maintenance manual.

  • Page 7: Working Principle

    WORKING PRINCIPLE 3.1 General overview of the Analyzer CA502 is a portable industrial analyzer for flue gas and emissions monitoring. The instrument is equipped with: Pneumatic line able to manage up to 2 sensors. − Easy and immediate user interface so it could be used without the manual support.

  • Page 8: Description Of The Product

    In this case, before turning off the analyzer, it is advisable to wait for the measured value to be lower than − 20ppm by intaking clean air. The CA502 is intended to have a cleaning cycle of the pneumatic circuit. The duration of the cycle depends on − what has been set in the menu Configuration→Analysis→Autozero.

  • Page 9: Bluetooth Connection

    4.10 Software and available applications YJ Combustion App This APP, allows the user the ability to scan the QR code generated by the CA502 to download the data of the performed analyses and/or measures and store, email, or print the report.

  • Page 10: Components Description

    5.0 COMPONENTS DESCRIPTION 5.1 Instrument interface DESCRIPTION: Keyboard with key functions: KEYS FUNCTION Activates the context keys shown on the display. - Turns on and off the instrument. accesses the instrument menu. - If pressed for at least 2 seconds, turns off the instrument. Exits the current screen.
  • Page 11 Display LCD backlit Display, White/Black 128 x 128 pixel with white LEDs. CAUTION: If the instrument is exposed to extremely high or extremely low temperatures, the quality of the display may be temporarily impaired. Display appearance may be improved by pressing on the contrast key. Date, time and battery status.

  • Page 12: Technical Specifications

    TECHNICAL SPECIFICATIONS 6.1 Technical specifications Power: Li-Ion battery pack with internal protection circuit. Average life of the battery package: 500 empty / full charge cycles. Battery charger: External 5Vdc 2A battery charger with female A-type USB connector + connection to the device with the serial communication cable supplied. Charging time: 5 hours to charge from 0% to 90% (6 hours for 100%).

  • Page 13: Measurement And Accuracy Ranges

    6.2 Measurement and Accuracy Ranges RESPONSE MEASUREMENT SENSOR RANGE RESOLUTION ACCURACY TIME T90 Electrochemical 0 .. 21.0% vol 0.1% vol ±0.2% vol <20 sec. sensor Electrochemical ±20 ppm 0 .. 400 ppm high H2 immunity 0 .. 4000 ppm 1 ppm <30 sec.

  • Page 14: Using The Flue Gas Analyzer

    • Do not exceed sensor overload thresholds. • When it has finished being used, before turning the CA502 off remove the probe and let it circulate ambient clean air for at least 30 seconds to purge all traces of gas.

  • Page 15: Use With External Power Pack

    According to the charging level of the battery, the CA502 can be left in storage for a time correlated to the battery level itself. Below, a table that explains the correlation between battery charging level and storage time. BATTERY CHARGE...

  • Page 16: Connection Diagram

    7.5 Connection diagram P/N 68613 P/N 68617 P/N 68622 P/N 68622 P/N 68620...

  • Page 17: Flue Gas Analysis

    THE PATH. THE CONNECTORS OF THE GAS SAMPLING PROBE AND OF THE CONDENSATION FILTER MUST BE WELL CONNECTED TO THE CA502. KEEP THE CONDENSATION TRAP IN A VERTICAL POSITION DURING THE ANALYSIS. INCORRECT POSITIONING MAY CAUSE CONDENSATE TO GO IN THE CA502 AND DAMAGE THE SENSORS.

  • Page 18: Preliminary Operations

    Keep When the autozero phase is complete, press the key “ “, to proceed with the combustion analysis press “ “, to repeat the autozero phase. Repeat 8.1.2 Preliminary Operations The following parameters need to be set prior to performing the combustion analysis: 11/12/17 10:00 11/12/17...
  • Page 19 8.1.6 End of the Analysis 11/12/17 10:00 11/12/17 10:00 11/12/17 10:00 SET ANALYSIS ANALYSIS [1/3] PRINT ►Mode Manual Curr. analysis 190.1 C Fuel 15.4 C ►Copy number Natural gas 4.2 % Printer Start Print Memory QR Code 23 ppm Status Free 2.9 % Pairing BT...

  • Page 20: Performing The Combustion Analysis - Auto Mode

    8.1.5 Performing the combustion analysis - Auto Mode 11/12/17 10:00 11/12/17 10:00 AN. SETTINGS ANALYSIS [1/3] ►Mode Auto 190.1 C Automatically Fuel 15.4 C stores the first Natural gas 4.2 % sample when the Start interval time is over. Interval 23 ppm Memory 2.9 %...
  • Page 21 Additional Information INTERACTIVE OPERATION DESCRIPTION By pushing the button related to this function, the CA502 stops the current Pause analysis when the set time interval is over. This condition is shown with the symbol “ “. When the “Paused” phase is over, the interactive function “Keep” is shown. By...

  • Page 22: End Of The Analysis

    “Configuration→Analysis→Autozero→Purging”. During the purge, the pump sucks clean air until it reduces the concentration of CO. The CA502 automatically turns off within a maximum of 10 minutes. Note: It is always advisable to purge the instrument with clean air for at least 5 - 10 minutes before turning it off.
  • Page 23 Cleaning hose Fig. b remove the water trap, just rotate the cover and unhook the filter holder body; remove the internal cup and then replace the filter (see figure below). Clean all of the filter parts using only water, then dry the components and reassemble the filter. Replacing the particulate filter Filter part number: 68612 If the particulate filter appears black, especially on the inner surface (see adjacent example), it needs to be...

  • Page 24: Instrument Parameter

    INSTRUMENT PARAMETER 9.1 Menu 15/06/18 10:00 FUNCTION MENU Returns to the previous screen. ► Measurements Memory Configuration Selects the available parameters. Diagnostic Info service Enters in the selected parameter setting. SUB-MENU FUNCTION This menu is used to collect the draft, ambient CO and pressure Measurements. Measurements SEE CHAPTER 10.0 This parameter sets the number of the memory records on which the combustion...

  • Page 25: Measurements

    It is necessary to perform the autozero in the clean air. This will ensure the ambient CO measurement is correct. It is advisable to turn on the CA502 and wait for the autozero completion outside the area where the test is being performed.

  • Page 26: Menu→Measurements→Comb. Analysis

    10.2 Menu→Measurements→Comb. analysis 11/12/17 10:00 FUNCTION SET ANALYSIS Activate the context keys shown on the ►Mode Auto display. Fuel Natural gas Returns to the previous screen. Interval Memory Status Free Selects the available parameters. Start Enters the selected parameter and con- firms the choice made.

  • Page 27: Menu→Measurements→Draft

    10.3 Menu→Measurements→Draft 15/06/18 10:00 FUNCTION DRAFT Activate the keys shown on the bottom Inlet lines of the display. Draft 0.00 h ►Zero sensor Returns to the previous screen. Starts the pressure sensor autozero. Save Print INTERACTIVE OPERATION FUNCTION Save The measure will be printed on the ticket of the current combustion analysis Allows the option to print or generate the QR code for reading on the YJ Com- Print bustion APP.

  • Page 28: Menu→Measurements→Co Air

    It is necessary to perform the autozero in the clean air, so the ambient CO measurement is correct. It is recommended to turn on the CA502 and wait for the autozero completion outside the area where the test is being performed.

  • Page 29: Menu→Measurements→Pressure

    10.5 Menu→Measurements→Pressure 15/06/18 10:00 FUNCTION PRESSURE Activate the keys shown on the bottom Press. 0.00 h line of the display. ►Zero Sensor. Returns to the previous screen. Perform the Zero Sensor of the pres- sure sensor. Save Print INTERACTIVE OPERATION FUNCTION Save The measure will be printed on the ticket of the current combustion analysis Allows the option to print or generate the QR code for reading on the YJ Com-...

  • Page 30: Memory

    11.0 MEMORY 11.1 Menu→Memory FUNCTION 11/12/17 10:00 MEMORY Activate the keys shown on the bottom ► Memory line of the display. Status full Modifies the memory number and then Time 09:50 confirms the changed setting. Date 11/12/17 When selecting the analysis, shows the detail of the evidenced analysis.
  • Page 31 2. Visual review of the memory content 11/12/17 10:00 11/12/17 10:00 11/12/17 10:00 AVERAGE [1/2] MEMORY MEMORY ► Average analysis 190.1 C ► Memory Analysis 1 15.4 C Status full Analysis 2 4.2 % Time 09:50 Select Analysis 3 23 ppm Date 11/12/17 Draft...
  • Page 32 5. Detail of QR code generation to download the data and the additional measures. 11/12/17 10:00 11/12/17 10:00 PRINT MEMORY ► Average analysis Memory Analysis 1 ►Copy number Analysis 2 Printer Print Print Analysis 3 QR Code Draft Pairing BT Pressure Print Delete...

  • Page 33: Configuration

    Restore Returns to the previous screen. SUB MENU FUNCTION This menu is used to set the reference parameters of the CA502 in order to Analysis perform the combustion analysis and/or additional measures. SEE CHAPTER 12.2 This menu is used to set the different reference parameters of the CA502.

  • Page 34: Menu→Configurationan→Analysis

    Condensation assumed as atmospheric pressure at sea level. The air relative humidity input is calculated at the combustion air temperature as measured from the CA502. If the relative humidity value is unknown the operator is recommended to enter 50% for the value.

  • Page 35: Menu→Configuration→Analysis→Fuel

    12.2.1 Menu→Configuration→Analysis→Fuel 15/06/18 10:00 15/06/18 10:00 FUEL [1/2] FUEL [2/2] ► Natural gas Coal Propane ► Bio-fuel 5% #2 Oil Bagasse #4 Oil Butane #6 Oil Diesel Wood/Pel. 8% FUNCTION Returns to the previous screen. Scrolls through the pages. Confirms the choice of fuel to be used during the analysis. Example: 11/12/17 10:00...

  • Page 36: Menu→Configuration→Analysis→Condensation

    12.2.2 Menu→Configuration→Analysis→Condensation 15/06/18 10:00 CONDENSATION ► Altitude Altitude above sea level R.H. air Relative humidity of air FUNCTION When pressed in modify mode cancels the selection made, otherwise returns to the previous screen. The arrows select each line displayed. In edit mode, it scrolls through the suggested values.

  • Page 37: Menu→Configuration→Analysis→O2 Reference

    12.2.3 Menu→Configuration→Analysis→O2 Reference 15/06/18 10:00 02 REFERENCE Percentage of Oxygen in CO measurement ► CO 0.0 % FUNCTION When pressed in modify mode cancels the selection made, otherwise returns to the previous screen. The arrows select each line displayed. In edit mode, it scrolls through the suggested values.

  • Page 38: Menu→Configuration→Analysis→Measure Units

    12.2.4 Menu→Configuration→Analysis→Measure units 15/06/18 10:00 MEASURE UNITS ► CO Measurement unit can be set as: ppm - mg/m - mg/kWh - g/GJ - g/m ng/J - g/kWh - % Pressure Measurement unit can be set as: inH2O - psi - hPa - Pa - mbar - mmH2O - mmHg Draft mmH2O Measurement unit can be set as: inH2O - psi - hPa - Pa - mbar - mmH...

  • Page 39: Menu→Configuration→Analysis→Autozero

    12.2.5 Menu→Configuration→Analysis→Autozero 15/06/22 10:00 AUTOZERO ► Autozero 30 s Duration of autozero, expressed in seconds. Purging Duration of the cleaning cycle, expressed in seconds. FUNCTION When pressed in modify mode cancels the selection made, otherwise returns to the previous screen. >...

  • Page 40: Menu→Configuration→Analysis→Air Temp

    12.2.6 Menu→Configuration→Analysis→Air temp 15/06/22 10:00 AIR TEMP. T probe --- F ►T air 32.0 F T probe FUNCTION Enters edit mode of the selected element and then confirms the change. > When in modify mode, sets the desired value. When pressed in modify mode cancels the selection made, otherwise returns to the previous screen.

  • Page 41: Menu→Configurationan→Instrument

    12.3 Menu→Configuration→Instrument 15/06/18 10:00 FUNCTION INSTRUMENT Returns to the previous screen. ► Display On site calib. Clock Selects the available parameters. Bluetooth Enters in the selected parameter. SUB MENU FUNCTION With the arrow keys it is possible to increase or decrease the brightness and the Display contrast of the display.

  • Page 42: Menu→Configuration→Instrument→Display

    12.3.1 Menu→Configuration→Instrument→Display 15/06/18 10:00 DISPLAY ► Brightness Contrast FUNCTION When pressed in modify mode cancels the selection made, otherwise returns to the previous screen. The arrows select each line displayed. In edit mode, it scrolls through the suggested values. Enters the modify mode for the selected parameter, then confirms the modification.

  • Page 43: Menu→Configuration→Instrument→Clock

    12.3.2 Menu-Configuration-Instrument-On Site Calibration ® This menu is for calibration at YELLOW JACKET certified calibration center only. 12.3.3 Menu→Configuration→Instrument→Clock 15/06/22 10:00 CLOCK Time 10:00PM Time, in the chosen format Date 06/15/22 Date, in the chosen format Mode Date format: USA (America) or EU (Europe)

  • Page 44: Menu→Configuration→Instrument→Bluetooth

    ® 12.3.4 Menu→Configuration→Instrument→Bluetooth (if available) 15/06/22 10:00 BLUETOOTH Status ® Bluetooth status: On or Off Device ID 008025CE0E6E Device MAC address FUNCTION Activate the keys shown on the bottom line of the display. Goes back to the previous screen. INTERACTIVE OPERATIONS DESCRIPTION ®...

  • Page 45: Menu→Configuration→Alarm

    9.4.3 Menu→Configuration→Alarm 12.4 Menu→Configuration→Alarm 11/12/22 10:00 ALARM ► Measure Observed parameter: CO - O2 Mode Kind of set alarm: Max / Min / Off Limit 18.0 % Concentration threshold of the observed gas. FUNCTION Enters the modify mode for the selected parameter, then confirms the modification.

  • Page 46: Menu→Configuration→Print

    12.5 Menu→Configuration→Print FUNCTION 15/06/22 10:00 PRINT Enters the modification mode of the ►Copy number selected data and then confirms it. Printer Mode fast Selects the available parameters. modification mode, scrolls QR code available values. Pairing BT When pressed in modify mode cancels the selection made, otherwise returns to the previous screen.

  • Page 47: Menu→Configuration→Print→Pairing

    12.5.1 Menu→Configuration→Print→Pairing ® 1. When the Bluetooth printer is set, proceed with the following procedure: 15/06/18 10:00 15/06/18 10:00 15/06/18 10:00 PAIRING BT PAIRING BT PRINT Printer Turn on the Copy number printer and detection in Printer progress ... start searching Start QR code ►...

  • Page 48: Menu→Configuration→Language

    12.6 Menu→Configuration→Language 15/06/18 10:00 LANGUAGE [1/2] ► Español √ English Français FUNCTION Returns to the previous screen. Scrolls through the available languages. Sets the selected language. Example: 15/06/18 10:00 15/06/18 10:00 LANGUAGE [1/2] LANGUAGE [1/2] ► Español √ Español √ English ►...

  • Page 49: Menu→Configuration→Reset

    12.7 Menu→Configuration→Restore 15/06/18 10:00 15/06/18 10:00 RESTORE RESTORE Deleting and Clear memory data resetting data and restore factory setting? Push OK to continue FUNCTION Exits the current screen without resetting. Starts the factory data reset phase.

  • Page 50: Diagnostic

    13.0 DIAGNOSTIC 13.1 Menu→Diagnostic FUNCTION 15/06/18 10:00 DIAGNOSTIC Returns to the previous screen. ► Sensors Gas probe Hardware Selects the available parameters. Enters in the selected parameter. SUB MENU DESCRIPTION Displays the information on the state and calibration of the electrochemical sensors and provides the ID data of the sensor: Code Sensors...

  • Page 51: Menu→Diagnostic→Sensors

    13.1.1 Menu→Diagnostic→Sensors Messages on the state and calibration of the electrochemical sensors: 15/06/22 10:00 SENSORS No problem detected absent The sensor was not detected ►S1: O2 err data Memory data error of the sensor S2: CO unknown It is necessary to update the firmware of the device err pos The sensor has been installed in the wrong position S3:---...

  • Page 52: Menu→Diagnostic→Gas Probe

    13.1.2 Menu→Diagnostic→Gas probe 15/06/22 10:00 Connect flue sampling probe filter unit assembly to the instrument; GAS PROBE Fully insert the black rubber cap (68624) on the gas probe tip, as shown in the following picture: Close the flue gas probe Push OK to Provided black rubber cap continue...

  • Page 53: Menu→Diagnostic→Hardware

    13.1.3 Menu→Diagnostic→Hardware FUNCTION 15/06/22 10:00 HARDWARE Returns to the previous screen. Memory Calibration ►Voltages Selects the available parameters. ADC channels Enters in the selected parameter. INTERACTIVE OPERATIONS DESCRIPTION Shows the values in mV. Shows the values in Bit. Note: the memory and calibration parameters are not accessible if their condition is OK. Visualization example: 11/12/22 10:00...

  • Page 54: Infoservice

    14.0 INFOSERVICE 09/05/22 10:00 INFO SERV [1/2] YELLOW JACKET® Email:custserv@ yellowjacket.com 4266 E. Street rd. Trevose, PA 19053 09/05/22 10:00 INFO SERV [2/2] Model CA502 S.N. 9999 FW rev. 9.99 FW P.N. HW rev. Boot rev. 1.00 Rev. 1379M FUNCTION Returns to the previous screen.

  • Page 55: Sensors

    The sensors must be recalibrated on a regular basis to assure measuring accuracy: ® recalibration can only be performed by a qualified YELLOW JACKET service center. Table 15.4 illustrates the characteristics inherent to each sensor.

  • Page 56: Maintenance

    Do not clean the instrument with abrasive cleaners, thinners or other similar detergents. 16.2 Preventive maintenance At least once a year send the instrument to the Yellow Jacket service center for a complete overhaul and thorough internal cleaning. ®...

  • Page 57: Maintenance→Gas Sensors Replacing

    16.3 Gas sensors replacing Unscrew the four screws of the instrument base; Locate the position of the sensor to be replaced; be- then slide apart the base of the instrument to access low is an example of a sensor to be replaced. the internal parts.
  • Page 58 Insert the new sensor paying attention to match the sensor connectors with the relevant supports on the circuit board. Place back the tubes (See point 4). Close back the base of the instrument and screw back the four screws (See point 2). Turn on the instrument to check the new sensor works correctly through the menu "Sensor Troubleshooting".

  • Page 59: Maintenance→Replacing The Battery Pack

    16.4 Replacing the battery pack Follow these instructions to replace the battery pack: Remove the base of the instrument Extract the battery pack. Remove the battery pack connector, and replace the pack with a new one following the reverse procedure described above.

  • Page 60: Firmware Update

    17.0 FIRMWARE UPDATE The manufacturer periodically releases firmware updates of the instrument in order to correct unavoidable mistakes or improve the instrument performance or add new functions. This update can be performed by the user by following the simple instructions below. Instructions to update the combustion analyzer with a new firmware: 1.

  • Page 61: Troubleshooting

    That battery pack is old. Aging can cause the batteries to reduce their capacity. If the performance has become unacceptable change the internal The instrument battery performance is lower than what battery with an original part Yellow Jacket.(68623) stated in the “Technical features” chapter. d. Verify measured...
  • Page 62 Troubleshooting guide Troubleshooting guide SYMPTOM PROBABLE CAUSES AND REMEDIES The following symbol "----" appears on the analysis The instrument is not able to calculate a numerical screen. value based on the flue gas analysis conducted. The "----" are replaced by numbers when the analyzer detects valid combustion data.

  • Page 63: Spare Parts And Servicing

    68614 Adapter cable USB-A / USB-B ® 68611 Wireless Bluetooth printer 68618 O-ring replacement for water trap 68620 Manometer hose 68621 POSG cone for probe 19.3 Service Centers ® YELLOW JACKET 4266 E. Street Rd. Trevose, PA 19053 Email:custserv@yellowjacket.com WWW.YELLOWJACKET.COM...

  • Page 64: Annex A - Analysis Report Examples

    190.1 C 15.4 C 91.4 % Save Print ® SCAN THE QR CODE USING THE YELLOW JACKET APP, TO DOWNLOAD THE ACQUIRED DATA. THE ACQUIRED DATA ARE SAVED IN THE INSTRUMENT MEMORY. APP settings. Insert a customer email address. Select subject matter line and fill out yellowjacket@yellowjacket.com...

  • Page 65: Annex B - Optional Measurements List

    ANNEX B Optional measures list: MEASURE DEFINITION λ, n (l,n) Air index (defined as λ, sometimes also indicated as n). Air excess. Expressed as a percentage according to the formula in the appendix D, is e (Exc. Air) the ratio between the volume of air actually entering the combustion chamber and the one theoretically needed.

  • Page 66: Measurement Units Matching → Abbreviations

    Measurement units matching → abbreviations mg/m mg/Kwh g/GJ ng/J g/Kwh mbar mmHg °C °F...

  • Page 67: Annex C - Coefficients Of The Fuels And Formulas

    ANNEX C Coefficients of the Fuels and Formulas The following chart, lists the coefficients of the memorised fuels, used for calculating losses and efficiencies. Details of the coefficients of the fuels: Coefficients for calculating combustion efficiency Fuel A1 USA CO2t M air V dry gas (KJ/Kg)

  • Page 68: Warranty Certificate

    WARRANTY CERTIFICATE WARRANTY The CA502 flue gas analyzer is guaranteed for 12 months from purchasing document date including the electronic parts, the internal electro-chemical sensors. ® YELLOW JACKET undertakes to repair or replace, free of charge, those parts that, in its opinion, are found to be faulty during the warranty period.

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