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Eclipse Combustion EGA4 Instruction Manual

Eclipse combustion carbon monoxide alarm - combustible gas monitor user manual
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Instruction Manual 924-2
11/1/03
EGA4 Combustion
Analyzer

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  • Page 1 Instruction Manual 924-2 11/1/03 EGA4 Combustion Analyzer...

  • Page 2: Instruction Manual Mm850481 Ed

    AND FIRMWARE REV OR HIGHER This manual has all the information you need to install, operate and maintain the flue gas analyzers EGA4 and its accessories. Eclipse has used the best care and efforts in preparing this book and believes the information in this publication are accurate.

  • Page 3: Table Of Contents

    GENERAL DESCRIPTION ... 5 Specifications... 6 Accuracies and ranges ... 7 GENERAL ... 8 Keypad & Display... 8 Built-in printer... 8 Gas sampling probe... 8 Measuring cells ... 8 Temperature probes ... 8 Pressure sensor... 8 Fuel technical data... 8 Smoke measurement...
  • Page 4 7.10.1 CO probe operations... 29 7.11 Natural gas leak checker (option)... 30 7.12 Temperature & Humidity probe (option) ... 30 MEMORY MANAGEMENT ... 32 Store data analysis ... 32 Delete memory... 32 Recall memory ... 32 DBGas 2000 ... 33 8.4.1 Plants/Clients menu ...

  • Page 5: General Description

    GENERAL DESCRIPTION EGA4 is designed to satisfy the market needs; but they are the result of the advanced research and experience of Eclipse. EGA4 is a multigas compact palm-top multifunction instrument. The micro-processor based instrument includes a flue gas analyzer, an emissions monitor and an ambient parameters indicator. Two internal electrochemical sensors read the Oxygen (O ) and carbonic monoxide (CO) gas concentration.

  • Page 6: Specifications

    Specifications Type: 2, 3 or 4 cells palm-top flue gas analyzer. Calibration: automatic calibration procedure at instrument switching-on. Self-diagnosis: Sensors efficiency test with anomalous status announcement. Fuel types: Up to 10 totally programmable. Pump: rate of flow 0.8 lit / head –230mbar All data measured using 3 meters long probe and line filter connected.

  • Page 7: Accuracies And Ranges

    Accuracies and ranges Parameter Sensor type Electrochemical compensated up Electrochemical to 1000ppm Electrochemical Electrochemical Electrochemical Calculated Electrochemical Calculated Tair Pt100 Tgas Tc K ∆T Calculated Tflow Tc K Treturn Tc K Pressure/Draft & Piezo ∆P Excess air Calculated Efficiency Calculated Gas speed Pitot tube Smoke index...

  • Page 8: General

    Built-in printer EGA4 can be equipped with a built-in, rugged, impact type printer. It uses a low cost common roll of paper (58 mm large, 18 meters long) , more readable, long time and heat resistant better than the thermal printout on chemical paper. One key instruction is enough to obtain one, two or more copies of the analysis report with header and company reference data.

  • Page 9: Smoke Measurement

    2.16 Calibration certificate Each EGA4 portable gas analyzer, is factory calibrated and certified against Eclipse Standards, that are periodically certified by an International recognized Laboratory, and shipped with a Report of Calibration stating the nominal and actual values and the deviation errors.

  • Page 10: Physical Description

    PHYSICAL DESCRIPTION The EGA4 portable analyzer consists of a rugged and compact case, a mother board with all base function circuits, 2, 3 or 4 electrochemical cells, a gas pump, a keyboard, an LCD backlighted display, a Ni-MH rechargeable battery pack and, optionally an impact printer.

  • Page 11: Principle Of Operation

    PRINCIPLE OF OPERATION The EGA4 analyzer is based on the following functional blocks: Water trap Line filter P1 – Draft/Pressure Measurement principle The gas is sampled and aspirated through the probe with a primary pump powered at constant voltage. To position the sampling probe in the exhaust gas pathway a hole of 11mm, up to 16mm, should be drilled and the retaining cone of the sampling probe firmly screwed in it.

  • Page 12: Water Trap & Line Filter

    4.1.2 Water trap & line filter The gas flows through an external combined water trap and line filter to avoid the presence of condensation and suspended solid particles in the analysis section of the instrument. A cylinder is positioned at 15 cm from the instrument gas inlet it is divided into two parts: the water trap and the line filter.

  • Page 13: Auxiliary Measurements

    O OBTAIN AN ACCURATE MEASURE IT IS RECOMMENDED TO WAIT Toxic gas sensor can be present a ±2% drift and a long resuming time it an excessive (>150% of F.S.) gas concentration is applied. In that case it is recommended to wait for a measured value lower than 20ppm, by sucking fresh air before switch the analyzer off.

  • Page 14: Measuring Instruments (Option)

    The color of the spot on the filter is compared with a graduated (from 0 to 9) reference scale and it is called “smoke index”. You can type in the instrument up to 3 smoke index values; the analyzer calculate the average value and can print these values on the report.

  • Page 15: Recommendations

    To empty the water trap from the condensate water, remove the draining plug. DO NOT OPEN the water trap. DO NOT leave the water trap without the draining rubber plug. For the best efficiency and accuracy, we suggest to calibrate the instrument every year. EGA4 F THE IS STORED AT TEMPERATURE EXCEEDING THE OPERATIVE LIMITS...

  • Page 16: Connections

    CONNECTIONS Electro-pneumatic connections To prepare the instrument for operation connect the sampling probe to the instrument: • Plug the pneumatic connector of the probe to the GAS INLET connector. If you are using the gas sampling probe with Draft option, connect also its connector to the instrument Pressure/Draft inlet. •...
  • Page 17 Instruction Manual MM850481 ed.01 Tair probe CAUTION OR A CORRECT GAS ANALYSIS NO AIR MUST REACH THE FLUE GAS AS A RESULT OF NON TIGHT CONNECTION POINTS BETWEEN THE HEAT PRODUCER AND THE MEASUREMENT SITE PROBE HE FLUE GAS AND EXHAUST GAS PATHWAYS MUST BE CHECKED FOR GAS TIGHTNESS BEFORE CARRYING OUT A MEASUREMENT AND IF NECESSARY NON TIGHT POINTS SHOULD BE SEALED...

  • Page 18: Operations

    Display The EGA4 is designed with a large (40x56 mm) graphical display using an automatic back light system for the best reading in poor light conditions also. The instrument is able to visualize simultaneously on the display 3, 6 or 12 parameters.

  • Page 19: Display Adjustment

    The Menu and Measure area displays the analysis data, the menu and all messages for the operator. The measured and calculated parameters are displayed in different pages of 6 parameters each. Using the [ ] and [ ] keys you can change page, changing the displayed parameters. Pressing the [ ] and [ ] keys it is possible to increase or decrease the number of the displayed parameters (ZOOM function).

  • Page 20: Text Input

    The “ ” symbol below the first digit is the cursor. You can move the cursor between the digit using the [ ] and [ ] keys. You can change the selected digit using [ ] and [ ]. If “9” or “0” values are exceeded, the left digit is increased or decrease.

  • Page 21: Flue Gas Analysis

    Flue gas analysis Connect the gas probe to the analyzer as shown in chapter 7. DO NOT INSERT THE PROBE IN THE CHIMNEY. Switch the analyzer on pressing the [ON] key. The display will show the following page: EcoLine 4000 GreenLine 4000 Num.

  • Page 22: Pressure/Draught Measurement

    Pressing the [ ] and [ ] keys, it is possible to zoom-in and zoom-out increasing or decreasing the number of displayed parameters. 20.9% 0.0% GRAPHIC Ref O Pressing the [ ] and [ ] you can change page for others parameters. Pressing the [REF.

  • Page 23: Burner Pressure Measurement

    F A SINGLE TUBE GAS SAMPLING PROBE HOSE ARE CLEAN AND DRY BEFORE CONNECTION TO THE PRESSURE INPUT Special draft probe (TGD models): This special probe model has a double gas collector: one for the flue gas analysis and one for the draft measurement. When you connect the probe to the analyzer you have to insert both gas inlet and pressure inlet connectors.

  • Page 24: Input Of The Smoke Index

    Combustion air temperature (option) It is important to measure the true combustion air temperature to have a correct boiler efficiency computation. The EGA4 has a auxiliary Rtd input to measure simultaneously the air temperature. A Pt100 with a 6 meters long cable can be connected on the right side of the analyzer.

  • Page 25: Gas Speed Measurement

    Press [ESCAPE] (F1) to return to the previous page. The temperature values will be printed on the ticket report. Gas speed measurement The EGA4, is arranged for chimney speed measuring. For this measurement you need a Pitot tube to be connected to the differential pressure inputs.

  • Page 26: Analysis Data Print

    Analysis data print An internal impact printer can be installed as an option in the instrument. Read paragraph 8.10 for header report changing. To print the report (ticket) of the analysis use the following procedure: Before make all measurements you need: Smoke index, pressure and draught, T. flow, etc. After make the gas analysis measurements and wait same seconds for measurement stabilizing.

  • Page 27: Pressure Decay Procedure (Option)

    Switch the analyzer on. Keeping the [HELP] key down; press the [ ] key to bypass the autozero procedure. Press [PRINT] then press the [FEED] key for paper feed. Press the [ESCAPE] key when the paper will came out for same centimeters.
  • Page 28 Use the [ ] and [ ] keys to move the cursor symbol to the value to be changed. Press the [ENTER] key to store the new selection. Select “TEST RESULT” option for results viewing and press the [ENTER] key. Now you can connect the instrument Pressure inlet (INP) connector to the gas circuit.

  • Page 29: Ambient Co Probe (Option)

    7.10 Ambient CO probe (option) This optional external probe allows ambient CO monitoring for personnel safety. When connected to the analyzer, it monitor continuously CO concentration and it signal when the Long-term Exposure (TWA) limits are reached. An acoustic and visible signals are emitted by unit. The following page show the current exposure limits for CO gas.

  • Page 30: Natural Gas Leak Checker (Option)

    7.11 Natural gas leak checker (option) To enable natural gas monitoring press the [MENU] key from measuring page. The following page will be displayed: MENU MEASURE RECALL MEMORY FLOW/RETURN TEMP AMBIENT ANALYSIS – ESCAPE Use the [ ] and [ ] keys to move the cursor symbol to “MEASURE” option. Press the [ENTER] key to select the option.
  • Page 31 MENU MEASURE RECALL MEMORY FLOW/RETURN TEMP AMBIENT ANALYSIS – ESCAPE Use the [ ] and [ ] keys to move the cursor symbol to “MEASURE” option. Press the [ENTER] key to select the option. Press [ESCAPE] (F2) to return to the previous menu. MEASURE P DECAY LEAK TEST GAS LEAK TEST...

  • Page 32: Memory Management

    MEMORY MANAGEMENT The standard configuration include an internal memory to store up to 250 complete gas analysis divided by Tags (max. 40 tags). Each analysis includes 10 gas concentration values, data and time. Each Tag includes one or more analysis data, 16 characters ID, 3 rows for the Customer data, Draught and smoke index values, Water temperatures, etc.

  • Page 33: Dbgas 2000

    RECALL MEMORY TAG SELECTION MEMORY DATE MODE – VIS.MEM ESCAPE EFORE RECALL THE MEMORY YOU MUST SELECT THE SELECT THE READING Press [VIS.MEM] (F1) to visualize the analysis data: the selected memory data or the average values of the selected Tag.
  • Page 34 Instruction Manual MM850481 ed.01 When database is complete, you can select up to 40 boilers on the table for data transfer by selecting the “Select for data transfer” column. Pressing the “Select to Do Analysis”, you can select in automatic mode all analysis made by more than “XX”...

  • Page 35: Analysis Menu

    Instruction Manual MM850481 ed.01 8.4.2 Analysis menu This option is the main part of the program. You can transfer the analysis data from the analyzer to the PC, save and manage it using a database structure, display and export the data in Microsoft Excel compatible format.

  • Page 36: Fuels Menu

    Instruction Manual MM850481 ed.01 The operator can change the measuring units, the fuel type, etc. The program will made the conversion in real time and will display the new values. A set of 4 buttons allows you to set the printer, to print measures, export measures using an Excel compatible format, show or hide the columns.

  • Page 37: Dbgas 2000 Installation

    HE FUEL DATA TRANSFER FROM ANALYZER SHOULD BE MADE AFTER THE PROGRAM INSTALLATION OR IF THE FUEL DATA CHANGES ON THE ANALYZER O CHANGE OR ADD NEW FUELS DATA 8.4.4 DBGas 2000 Installation DBGas 2000 runs on IBM PC under WINDOWS 95/98/NT. Minimum requirements are a Pentium CPU with 16Mbyte Ram and 20 Mbyte on hard disk, a color monitor and a Microsoft mouse or a compatible one.

  • Page 38: Configuration Software

    Configuration Software GasConfig software is a PC windows compatible program for configuring the EGA4 flue gas analyzers. You can change all memory settings: displayed measurements pages, printed measurements layout, Alarms, Fuels coefficients, measuring technical units, etc. 8.5.1 How operate using GasConfig When you run GasConfig a 2 independent windows system will be displayed on the PC monitor.

  • Page 39: Gasconfig Installation

    Follow the on screen instructions making sure to provide the correct path to your Software directory when prompted. Once installed, the EGA4 Configuration Software icon will appear on your Windows screen and it will be possible to boot it by clicking on the icon as usual.

  • Page 40: Configuration

    CONFIGURATION Many parameters can be modified using the instrument keyboard. Pressing the [SETUP] key, you can change the current fuel, include or exclude the CO cell, change the technical unit, set the alarms, etc. The CONFIGURATION --- FUEL --- > LPG CO SENS.

  • Page 41: Help Key

    When you select the Alarms option, the following page will be displayed: ALARMS Alarm 1: O2 Enabled Thresh. 5.00 Type – NEXT ESCAPE Use the [ ] and [ ] keys to move the cursor symbol to the desired option. Press the [ENTER] key to change the value.

  • Page 42: Service Data

    SENSOR DIAGNOSTIC 428.46 uA 0.34 uA 1.09 uA – ESCAPE Press [ESCAPE] (F2) to return to the previous page. 9.3.3 Service Data The “SERVICE” option, allows you to read the information to contact us for service assistance and the information that we wont to know for identify your instrument configurations: instrument configuration code and serial number, firmware version, etc.

  • Page 43: Maintenance

    MAINTENANCE The EGA4 analyzer has been developed and manufactured using high quality components. A correct, systematic maintenance will prevent damage and will increase substantially the life of the instrument, giving excellent results. Anomalous conditions that require extraordinary maintenance interventions are promptly displayed, either clearly or with an information code.

  • Page 44: Clock

    Press and maintain the [SETUP] key down; press the [ON/OFF] key. The analyzer will switch on. A password input page will displayed. Insert the password code “0011” and press the [ENTER] key. The following page will displayed: SET-UP Pag.1 CLOCK SERIAL PORT ANALYSIS PAR.

  • Page 45: Analysis

    SERIAL Address Baud-rate : 9600 – ESCAPE Use the [ ] and [ ] keys to move the cursor symbol to the desired option. Press the [ENTER] key to set a new ID number or baud rate. Press [ESCAPE] (F2) to return to the previous menu. 10.2.3 Analysis Selecting this option you can change the analyzer auto-zeroing time and CH...

  • Page 46: Firmware Upgrade

    10.3 Firmware Upgrade In order to upgrade the firmware of the instrument proceed as follows: 1 - Install the ST167Flash program from the CD. 2 - Connect the infrared interface adapter to the serial port of the PC with the supplied cable (note back the serial port used: COM1 , COM2 or other).

  • Page 47: Certificates

    CERTIFICATES 11.1 Warranty terms Each instrument is shipped with a Warranty Certificate that indicates the validity conditions of the warranty itself. Eclipse warrants its products against defects in materials and workmanship. If the unit should malfunction, it must be returned during the warranty period, transportation prepaid, to Eclipse for evaluation.

  • Page 48: Appendix

    Example The following steps show how you can make a quick measurement using the EGA4 portable analyzer. Switch EGA4 on. It will begin the autozero and the autodiagnostic procedure. System error and trouble will be displayed if encountered. EcoLine 4000...
  • Page 49 Accuracies and ranges; 7 Alarms; 40 Ambient CO probe; 29 Ambient CO probe; 6; 9 Ambient T+RH probe; 6 Analysis; 45 Analysis data print; 25; 26 Analysis menu; 35 APPENDIX; 48 Auxiliary measure; 13 Barcode pen reader; 9 Basic operation; 18 Built-in printer;...
  • Page 50 Remote temperature probe; 9 Select by a list; 20 Sensor Diagnostic; 41 Serial Port; 44 Service Data; 42 Set-up menu; 43 Smoke index measurement; 13 Smoke measurement; 9; 23 Specifications; 6 status bar; 19 Store data analysis; 32 924-2 Instruction Manual 11/1/03 Instruction Manual MM850481 ed.01 T+RH% probe;...

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