Teledyne PEM-9004 Operating Instructions Manual
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Teledyne PEM-9004 Operating Instructions Manual

Portable emissions analyzer
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Portable Emissions Analyzer
OPERATING INSTRUCTIONS FOR
PEM-9004
Portable Emissions Analyzer
P/N MPEM9004
ECO: XX-XXXX
DANGER
Toxic gases may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing.
Before conducting any maintenance or servicing, consult with authorized
supervisor/manager.
Teledyne Analytical Instruments
i

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  • Page 1 Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected. Only authorized personnel should conduct maintenance and/or servicing. Before conducting any maintenance or servicing, consult with authorized supervisor/manager. Teledyne Analytical Instruments...
  • Page 2 Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.
  • Page 3 Using this instrument to analyze any other gas mixture may result in serious error. Consult the factory for additional information for gas analysis not specified at the time of purchase. Instrument Serial Number: _______________________ Teledyne Analytical Instruments...

  • Page 4: Safety Checklist

    PEM-9004 Important Notice The PEM-9004 is a gas analysis computer for measuring and computing the concentration of various gases in a combustion process. Both toxic and combustible gasses may at times be present in and around the analyzer. This instrument is designed to safely handle specific combustible gas mixtures as outlined in the product specification.
  • Page 5 NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the form Symbol of a note. CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL. Teledyne Analytical Instruments...
  • Page 6 Manuals do get lost. Additional manuals can be obtained from Teledyne at the address given in the Appendix. Some of our manuals are available in electronic form via the internet. Please visit our website at: www.teledyne-ai.com.

  • Page 7: Table Of Contents

    2.4.5 Calculating Undiluted CO Concentration 2.5 Sample System Installation ................... 13 3.1 Unpacking the Analyzer 3.2 Attaching the Probe and Thermocouples 3.3 Initial Calibration 3.4 Battery Power 3.4.1 Charging the Battery 3.4.2 Battery Replacement 3.5 Sensor Replacement Operation ..................17 Teledyne Analytical Instruments...
  • Page 8 4.4.4 Set Default 4.5 Measurement Screen 4.5.1 Flue Gas 4.5.1.1 Draft 4.5.1.2 Info 4.5.1.3 Draught Detection 4.5.1.4 Units 4.5.1.5 O Referenece 4.5.1.6 Extended Data 4.5.1.7 Graphic 4.5.1.8 Fuel 4.5.1.9 Config 4.5.1.10 Program Macros 4.5.1.11 Hold 4.5.1.12 Zoom Teledyne Analytical Instruments viii...
  • Page 9 4.8 Memory 4.9 USB-Interface 4.10 Charge Control 4.11 Battery / Line Voltage Operation 4.11.1 Charging the Battery 4.11.2 Battery Replacement Maintenance................. 57 5.1 Routine Maintenance Appendix ..................59 Specifications Recommended Spare Parts List Reference Drawings Index ..................... 65 Teledyne Analytical Instruments...

  • Page 10: List Of Figures

    PEM-9004 List of Figures Figure 2-4: Gas Conditioning System ........... 10 Figure 3-1: PEM-9004 Front Panel ..........14 Figure 4-1: PEM-9004 Front Panel ..........17 Figure 4-2: Additional Functions Available from Flue Gas Menu... 19 Figure 4-3: Data Memory Structure..........52 Figure 5-1 Water Trap and Filter ...........

  • Page 11: List Of Tables

    Portable Emissions Analyzer List of Tables Table 1-1: Measurement Capabilities of the PEM-9004 Analyzer ... 2 Table 1-2: Parameters Calculated by the PEM-9004 ...... 2 Table 4-1: Function Keys............... 18 Teledyne Analytical Instruments...
  • Page 12 Since the use of this instrument is beyond the control of Teledyne, no responsibility by Teledyne, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.

  • Page 13: Introduction

    The system is ideally suited for monitoring heaters, exhaust lines, and other flue gas installations. The PEM-9004 analyzes the gaseous products of a combustion process and provides critical information on the state of the effluent stream. Information is available on-screen and via printed reports. Data can also be output to a remote device via the USB communication port.

  • Page 14: Table 1-1: Measurement Capabilities Of The Pem-9004 Analyzer

    Introduction PEM-9004 Table 1-1: Measurement Capabilities of the PEM-9004 Analyzer Measured T.Gas Waste or flue gas °F or °C Values temperature T.Room Air or ambient °F or °C temperature Oxygen content % Volume Carbon monoxide ppm-mg/mm -mg/kWh Nitrogen monoxide ppm-mg/mm...

  • Page 15: Features

    Portable Emissions Analyzer Introduction 1.2 Features • Analysis Ranges: The PEM-9004 is available with the following analysis ranges: • 0-20.9% • 0-4000 ppm (with H compensation) • (calculated from O measurement) 0-CO max (fuel specific) And optionally: • 0-2% (0-20,000 ppm)

  • Page 16: Operator Interface

    All user controls and connections are accessible from the front panel after opening the top case. Figure 1 shows the front panel of the PEM-9004. There are 3 function buttons and 7 menu select buttons (also referred to as keys) which control all operations of the analyzer. Chapter 4 describes in detail the use of the menu select and function buttons in operating the analyzer.

  • Page 17: Operational Theory

    O and CO(H ). Depending on the options selected at the time of purchase, the PEM-9004 can also measure and display the NO, CO (high), and SO concentration of a flue gas. The analyzer, based on measurements of draft pressure, temperature, and data entered for the combustion fuel plus pertinent thermodynamic data internally stored as part of the instrument’s database, will calculate and display the...

  • Page 18: Specific Sensor Network

    The PEM-9004 incorporates a network of up to five individual sensors for analyzing oxygen, carbon monoxide, and optionally, sulphur dioxide, and nitrogen oxides. The individual sensors are arranged on a sensor block located underneath the front panel of the unit.

  • Page 19: Calculating The Waste Gas Loss

    The instrument subtracts the waste gas loss as previously calculated for a specific fuel from the total energy of the selected fuel to arrive at the overall combustion efficiency (Eta). The PEM-9004 uses the following equation: Eta = Where: Eta is the combustion efficiency expressed as a percentage.

  • Page 20: Calculating Excess Air Value (Lambda)

    As the combustion temperature increases however, increasing amounts of nitrogen oxides are formed which must be considered in the overall chemical balance. In the PEM-9004, the excess air (Lambda) value is calculated from the ratio of CO to CO as follows:...

  • Page 21: Calculating Undiluted Co Concentration

    Lambda is the excess air as calculated above. 2.5 Sample System The built-in sample system on the PEM-9004 can be though of as a fully integrated data acquisition system. In addition to sampling the gas stream and safely diverting a portion through the analyzer, it also gathers data on pressure, temperature of the gas stream, and ambient temperature.

  • Page 22: Figure 2-4: Gas Conditioning System

    After traversing the sensor block, the sample gas is passed back out through the Gas Out port on the front panel of the instrument. CAUTION: BOTH TOXIC AND FLAMMABLE GASES ARE PRESENT IN THE SAMPLE SYSTEM—INCLUDING THE FILTERS! MAKE SURE THE EXHAUST LINE IS Teledyne Analytical Instruments...
  • Page 23 USE CAUTION WHEN CHANGING FILTER ELEMENTS OR OTHERWISE OPENING ANY PORTION OF THE SAMPLE SYSTEM. ALWAYS PURGE THE SAMPLE SYSTEM TO REMOVE ANY TOXIC OR FLAMMABLE GAS FROM THE LINES BEFORE PERFORMING ANY MAINTENANCE ON THIS INSTRUMENT. Teledyne Analytical Instruments...
  • Page 24 Operational Theory PEM-9004 Teledyne Analytical Instruments...

  • Page 25: Installation

    Also covered in this section are battery issues, and information regarding battery replacement. 3.1 Unpacking the Analyzer The TAI PEM-9004 Portable Emissions Monitor is generally shipped fully functional and ready to work. Carefully unpack the analyzer and inspect it for damage. Immediately report any damage to the shipping agent.

  • Page 26: Initial Calibration

    CONNECTED TO THE ANALYZER, REMOVE THE PROBE AND FLUSH THE UNIT WITH AIR FOR FIVE MINUTES Figure 3-1: PEM-9004 Front Panel 3.3 Initial Calibration The instrument, when first powered up will go through a self- diagnostic test routine and auto calibrate. For this reason, when...

  • Page 27: Battery Power

    Gas Sensor failure. This is normal if the thermocouples are left unattached. 3.4 Battery Power The PEM-9004 has a 6V NiCad battery installed and is designed to operate only from battery power. Continuous monitoring (although not recommended) for up to 36 hours is possible from a single charge. The analyzer is equipped with a 120V 60 Hz AC battery charger for recharging the battery.

  • Page 28: Battery Replacement

    Contact factory for battery replacement 3.5 Sensor Replacement Up to 5 electrochemical cells are installed in the PEM-9004 analyzer depending on the options ordered. When new cells are ordered, they are packaged in a controlled atmosphere. The instrument is shipped with the required sensor cells installed.

  • Page 29: Operation

    Operation 4.1 User Interface Operation of the PEM-9004 is accomplished entirely from the front panel using the 7 function keys on the right plus the 3 menu select keys below the screen. The menu select keys take on additional functions depending on the menu context.

  • Page 30: Table 4-1: Function Keys

    ), then pressing F1 will select the “Save” function, F2 will select “Draught detection”, and F3 will select “CO protect”. Note that the screen display will list: “Save”, “Draught detection” and “CO protect” instead of F1, F2, and F3. Teledyne Analytical Instruments...

  • Page 31: Startup Screen

    The screen that appears includes information about the version, part-no., hours in use, etc. This initial startup screen is shortly replaced by the Main menu screen. • To hold this initial screen on the display press the ENTER button during the startup routine. Teledyne Analytical Instruments...

  • Page 32: Main Menu

    Below the status line is a list of available programs accessible from the Main menu. Each program is launched by the appropriate button indicated to the right of the program name. In most cases additional menus and additional screens will be available from within the selected program. Teledyne Analytical Instruments...

  • Page 33: Configure Menu

    This is accomplished from the Display screen. To rearrange the measurement screen: • From the Configuration menu press F1 to bring up the Display screen. The following screen appears: Teledyne Analytical Instruments...
  • Page 34 CO measurement line repositioned to the second line from the top. • Press ENTER to save the setting or CLEAR to cancel the move. Note: The same line cannot be displayed more than once. Teledyne Analytical Instruments...

  • Page 35: Fuel

    In order to create a new fuel the first three fuel-specific factors , A2 and B) have to be entered. If units than ppm or % are used 2max additional factors must be entered in order to perform the conversion to mg/m , mg/kWh or MJ/m correctly. Teledyne Analytical Instruments...

  • Page 36: Insert A New Fuel

    (Fuel 1, Fuel 2 . . . etc.). Press OK when the proper location is highlighted. the following screen appears: Press OK again to enter the editor screen. From this screen you can enter or edit the name of the fuel. Teledyne Analytical Instruments...
  • Page 37 OK. Repeat the above procedures for editing each parameter required to specify the fuel. The parameters include: 2max HW (heating value without condensation) BW (heating value with condensation) O (water content) Vatr (quantity of fuel gas, dry) Teledyne Analytical Instruments...

  • Page 38: Settings

    4.4.3.2 I NSTRUMENT OUND • Use the cycle button to highlight the Sound line on the screen. • Use the arrow keys to cycle between Yes (ON) and No (OFF). • Press OK to save the setting. Teledyne Analytical Instruments...

  • Page 39: Select Printer

    Portable Emissions Analyzer Operation 4.4.3.3 S ELECT RINTER Two printers are available in the the PEM-9004: EUROprinter (Euro-Ir) and HP84420B (HP-Ir). To select the printer to use: • Use the cycle button to move the highlight to the Printer line. •...

  • Page 40: Automatic Timer

    4.4.3.5 A UTOMATIC IMER The PEM-9004 is equipped with automatic timers that will turn off the display illumination and/or shut the instrument off to conserve battery power. Both automatic features operate independently and initiate if no key press is detected within the user-specified intervals.

  • Page 41: Set Default

    SETTINGS! THE DATA MEMORY IS NOT AFFECTED. To restore the instrument to the default settings: • Press ENTER from the Configuration Main menu. The following screen will appear: • Confirm the restoration operation by pressing ENTER or cancel the request by pressing CLEAR. Teledyne Analytical Instruments...

  • Page 42: Measurement Screen

    Backlight: Turn backlight on the display on or off. Reset CO2max-value: Enter a new value for the CO value 2max (fuel specific). To enter the Measurement screen press ENTER from the Main menu. The following screen appears: Teledyne Analytical Instruments...

  • Page 43: Flue Gas

    After the calibration the last used fuel appears on the screen as shown below. At this point, either the fuel in the framed box can be chosen or any another fuel from the database of fuels in memory. The selected fuel has to be in the framed box. Teledyne Analytical Instruments...

  • Page 44: Draft

    Use the Change Layout button to move all three functions to the same line. 4.5.1.1 D RAFT This button is used to start a draft measurement. When pressed, the following screen appears: Hold (F1): Holds the reading for the draft measurement. Set Zero (F2): Performs a zero calibration. Teledyne Analytical Instruments...

  • Page 45: Info

    O reference value. Function buttons active in this menu are: Cycle: Change values in the various fields. Change Layout: Opens the sensor status screen as shown below. CLEAR: Close the Info screen Teledyne Analytical Instruments...

  • Page 46: Draught Detection

    The function "Draught detection" displays the flue gas temperature graphically. Changes in the temperature of the flue gas are shown with a black bar. No bar appears if the temperature is constant. Press the Draught Detection button to open the Draught Detection screen. Teledyne Analytical Instruments...

  • Page 47: Units

    The PEM will automatically convert units to the specified type as determined from the Units menu. Press the units button to display the Units screen. • Use the arrow keys to select the desired units. • Press OK to confirm the selection. Teledyne Analytical Instruments...

  • Page 48: O 2 Referenece

    4.5.1.6 E XTENDED The following data can be entered and transferred to the measurement protocol: • Smoke-no. (soot content according to the Bacharach scale). • Oil derivatives. • Temperature of boiler and heat carrier. Teledyne Analytical Instruments...
  • Page 49 Use the arrow keys to select the desired digit. • Press OK to confirm the selection. • Press ENTER to save the new value selection or CLEAR to cancel the operation. Oil derivatives input m e n u Teledyne Analytical Instruments...
  • Page 50 Temperature screen. In this screen, the measured temperature can be entered through the editor. • Use the arrow keys to select the desired digit. • Press OK to confirm the selection. • Press ENTER to save the entered temperature or CLEAR to cancel the operation. Teledyne Analytical Instruments...

  • Page 51: Graphic

    ) and the calculated waste gas losses (qA) are thereby set in a relation to the excess air value (λ) and to the classical combustion diagram. Press Graphic from the Flue Gas menu to bring up the graphic display as shown below: Teledyne Analytical Instruments...

  • Page 52: Fuel

    Flue Gas menu. 4.5.1.9 C ONFIG See Section 4.4. 4.5.1.10 P ROGRAM ACROS Up to three customized measuring configurations can be created and stored as programmed macros. These macros can be started directly Teledyne Analytical Instruments...

  • Page 53: Hold

    Note: When the HOLD function is activated the alert "HOLD" appears in the top left corner of the status line replacing the name of the fuel. Teledyne Analytical Instruments...

  • Page 54: Zoom

    Note: After the device is switched off and on again, the display resets to the 10-lines layout automatically unless the 5- lines layout was a measurement configuration activated by a macro. Teledyne Analytical Instruments...

  • Page 55: Co Protect

    5-Line Layout 4.5.1.13 CO P ROTECT The PEM-9004 is equipped with a second pump (CO-flushing- pump) in order to protect the sensitive CO-sensors from CO-overload. The CO-flushing-pump switches on automatically when necessary, i.e. when the admitted CO-range is exceeded or it can be switched on manually using the CO Protect button.

  • Page 56: Print

    The printer in use can be selected from the Configuration menu. See Section 4.4.3.3. The print speed depends on the printer selected. Make sure the proper printer is activated to avoid possible failures while printing. Teledyne Analytical Instruments...

  • Page 57: Temperature

    Portable Emissions Analyzer Operation The PEM-9004 is capable of multi-tasking so the analyzer can be taking measurements, performing calculations, etc during the printing procedure. Printing takes place simultaneously in the background as other analyzer operations are being performed. To print a screen, press the Print button from the Flue Gas menu.

  • Page 58: Pressure

    The following units f o r p r e s s u r e can be s e l e c t e d : hPa, mbar, mmWC (millimeter water column) mmHg (millimeter mercury column) inWC (inches water column) inHg (inches mercury column) Psi (pounds per square inch) Teledyne Analytical Instruments...

  • Page 59: Co (O ) Measurement

    The font size of the readings can be changed with the Zoom function. See Section 4.5.1.12 Zoom . Important notice concerninq measurement of S02 and N02 ( o p t i o n ) Teledyne Analytical Instruments...

  • Page 60: Macro Start

    The Macro Start function launches configuration settings previously programmed and saved as a macro. See Section 4.5.1.10. Macros greatly facilitate the efficient operation of the PEM-9004 by loading and initiating convenient configuration settings using only a few keystrokes. Up to three customized macros can be programmed and used.

  • Page 61: Time-Date

    4.7 Time-Date The integrated clock (time and date) can be set from the Time-Date screen available from the Main menu. To set the time and date, press F2 from the Main menu. The following screen will appear: Teledyne Analytical Instruments...
  • Page 62 To set the time: • Press F1 from the Time-Date screen. The following screen will appear: • Use the arrow keys to select the desired digit. Teledyne Analytical Instruments...

  • Page 63: Memory

    Press OK to confirm the selection and move to the next digit. • Press ENTER to save the entered date or CLEAR to cancel the operation. 4.8 Memory The data memory is structured according to the menu structure shown in Figure 4.3. Teledyne Analytical Instruments...

  • Page 64: Figure 4-3: Data Memory Structure

    (or client numbers). Files could be named after the types of measurement. The PEM-9004 instrument is shipped without preset directories and files. Memory is accessed from the Memory menu available by pressing F3 from the Main menu.
  • Page 65 To create a new directory: • Press F2 to open the directory editing window. • Use the arrow keys to select the character or digit. Use the cycle button to toggle between all capital letters, lower case and numerical input. Teledyne Analytical Instruments...

  • Page 66: Usb-Interface

    The charge control has both an active phase and a passive phase. During active recharging, parameters related to the battery and the recharging process are displayed on the charge control screen. Teledyne Analytical Instruments...

  • Page 67: Battery / Line Voltage Operation

    4.11.1 Charging the Battery The PEM-9004 is equipped with an NiCd storage battery. The service life and capacity of the battery are considerably affected by the way the instrument is charged and used. In order to make the handling...

  • Page 68: Battery Replacement

    (recharging completely takes approx. 5 hours, depending on the ambient temperature). After active recharging is complete, the PEM-9004 will switch off automatically. This "reconditioning cycle" can be repeated as often as necessary.

  • Page 69: Routine Maintenance

    General Maintenance Make sure that threaded parts are straight when installed and tighten them moderately. Check O-rings for proper sealing. Check all connectors and fittings. Makes sure all connections are secure and leak tight for gas connections. Teledyne Analytical Instruments...

  • Page 70: Figure 5-1 Water Trap And Filter

    Store in a cool and dry environment at a temperature of approx. 20°C (60°F). • Damage: Warranty obligations do not apply to damage caused by improper handling, negligence and grave external influences. Figure 5-1 Water Trap and Filter Teledyne Analytical Instruments...
  • Page 71 Resolution: 1 ppm Accuracy: ± 5 ppm (up to 150 ppm) ± 5% of reading (up to 4000 ppm) Response Time (T90): <60 sec NO Measurement _____________________________ (Option) Sensor: Electrochemical, electrochemical cell Measurement Range 0-2000 ppm Resolution: 1 ppm Teledyne Analytical Instruments...
  • Page 72 Accuracy: ± 2°F, ± 1°C (0—400°C) ±0.5% of reading (up to 1000°C) Combustion Air or Ambient Air Temperature Measurement _____________________________ Sensor: K-type thermocouple (NiCr-Ni) Range: -5—212°F (-20—100°C) Resolution: 0.1°F or °C Accuracy: ± 2°F, ± 1°C (0—100°C) ± 6°F, ± 3°C (-20—0°C) Teledyne Analytical Instruments...
  • Page 73 Printer: Integral PIN printer Dimensions: Housing: 273 x 247 x 178 mm (L x W x H) 10.75 x 9.72 x 7 inches Dustproof, waterproof Weight: Approx. 8 lbs. (3.8 kg) Mechanical Connections: 7.8mm dia. Thermocouple Connectors: Omega Teledyne Analytical Instruments...

  • Page 74: Recommended Spare Parts List

    Appendix PEM-9004 Recommended Spare Parts List Teledyne Analytical Instruments...

  • Page 75: Reference Drawings

    (if available) and the model and serial number of the instrument for which the parts are intended. Orders should be sent to: TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry, CA 91749-1580 Phone (626) 934-1500, Fax (626) 961-2538 Web: www.teledyne-ai.com...
  • Page 76 Appendix PEM-9004 Teledyne Analytical Instruments...

  • Page 77: Index

    ....xii gas conditioning......... 9 combustion ........1 gas stream temperature ...... 9 combustion efficiency ....1, 3, 6, 7 graphic function ....... 39 combustion value....... 5 heat capacity ........7 condensate reservoir ......57 hold ..........41 Teledyne Analytical Instruments...

  • Page 78: Teledyne Analytical Instruments

    ........8 O2 sensor..........59 tables listing........xi oil derivates input .......38 technician symbol......v open directory ........53 Teledyne address ......63 operation...........17 temperature differential ..... 5 operator interface .......4 temperature program ....... 45 O-ring ..........57 temperature range ......3 output..........10...
  • Page 79 Portable Emissions Analyzer Index website address......... vi zoom ..........42 zero reference ........15 Teledyne Analytical Instruments...

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