Portable flue gas analysers Instruction Manual MM ed. K12

Transcription

1 GreenLine 6000 GreenLine 8000 Portable flue gas analysers Instruction Manual MM ed. K12

2 INTRODUCTORY NOTE NOTE: THIS MANUAL IS VALID FOR: INSTRUMENTS WITH SERIAL NUMBER AND FIRMWARE REV FOR RCU AND FOR MCU OR HIGHER This manual has been with all the information you need to install, operate and maintain the flue gas analyzers GreenLine 6000, GreenLine 8000 and their accessories. Eurotron has used the best care and efforts in preparing this book and believes the information in this publication are accurate. The Eurotron products are subjected to continuous improvement, in order to pursue the technological leadership; these improvements could require changes to the information of this book. Eurotron reserves the right to change such information without notice. The gas analyzer uses sophisticated analogical and digital technologies. Any maintenance operation must be carried out by qualified personnel ONLY. Eurotron supplies instructions and operative procedures for any operation on the instrument. We recommend contacting our technicians for any support requirements. The instrument is supplied by a rechargeable battery pack or by 100, 115, 230V ±10% 50/60Hz mains supply. The instrument is fully tested in conformity with the directive n 89/336/CEE Electromagnetic Compatibility. Eurotron shall not be liable in any event, technical and publishing error or omissions, for any incidental and consequential damages, in connection with, or arising out of the use of this book. The operator must not use this equipment for any other purpose than that stated. This document is the property of Eurotron and may not be copied or otherwise reproduced, communicated in anyway to third parties, not stored in any Data Processing System without the express written authority of Eurotron. All right reserved Copyright 2012 Eurotron Instruments S.r.l Via Grugnola, Sesto S. Giovanni (MI) Tel. : FAX: Mail: info@eurotron.com 2

3 TABLE OF CONTENTS 1 GENERAL DESCRIPTION Ordering code GreenLine Ordering code GreenLine Ordering code Industrial probe Specifications GENERAL Keypad & Display Bluetooth Wireless Connection Built-in printer Gas sampling probe Industrial probe & heated hose Measuring cells Flue gas temperature probes Temperature probe Pressure sensor Fuel data Smoke measurement mA auxiliary inputs T+RH% probe Leakage checking mode Burner pressure probe Gas velocity Emissions measurement (LBH) Calibration On-Site CO Dilution Calibration certificate Electromagnetic compatibility Instrument case PHYSICAL AND FUNCTIONAL DESCRIPTION Pneumatic circuits Model comparison Measurement principle Gas sampling probe Water trap & line filter CO dilution Gas treatment Gas sensors Infrared optical bench Auxiliary measurements Temperature measurements Pressure and Draft measurements Other measurements PRELIMINARY CHECK Recommendations Power supply Storage CONNECTIONS Electro-pneumatic connections Gas probe positioning Industrial probe (option) Industrial probe connection LBH probe connection (with Pitot tube) OPERATIONS Basic operation

4 6.1.1 Keyboard Display Display adjustment Numerical input Text input Selection from a list FLUE GAS ANALYSIS Basic operations Instrument power on Fuel selection Tag selection Combustion analysis Switching off Combustion air temperature measurement Smoke index measurement Measuring devices Measurement with manual pump Measurement with heated probe Pressure/Draft measurement Burner pressure measurement Analysis data print Flow/Return temperature Gas velocity measurement Pressure decay procedure Ambient CO probe (option) CO probe operations Natural gas leak checker (option) T+RH% probe (option) EMISSIONS MEASUREMENT (GREENLINE 8000 LBH) General description Probe connection SET-UP Engineering Unit Set-up Flow Meter Set-up (for GL8000 LBH only) MCU Stand-by Differential pressure sensor alignment Display Emissions Values Print Emissions Values CONFIGURATION AND PARAMETERS Configuration data transfer Configuration transfer from RCU to MCU Configuration transfer from MCU to RCU Application: use of the 1 RCU with several MCU Data transfer by means of PC Set-up menu Engineering Units Alarms O2% reference AUX1/AUX Long term analysis Peltier HELP key Header setting Sensors diagnosis Service data Instrument configuration Clock Serial Port Analysis par P decay time

5 9.4.5 Test MEMORY MANAGEMENT Memory menu Tag selection Measurement storing Display memory Delete memory Memory management by PC How to transfer Tags on MCU How to transfer the stored measures on a PC RS232/USB adapter installation Installing driver for the RS232/USB adapter: SOFTWARE PACKAGES DBGas System requirements Installing the Software Uninstalling the Software Registering the Software Compatibility Data transfer GasConfig GasConfig Installation How to operate using GasConfig Transfer configuration to PC Transfer configuration to the Analyzer MAINTENANCE Paper and Ribbon change Filter replacement Filter replacement of the industrial probe Error messages Calibration on site Zero calibration page Span calibration page Reset calibration Calibration On-Site info page CO dilution Firmware Upgrade: ST167Flash Smoke pump maintenance Scheduled maintenance CERTIFICATES Warranty terms Letter of conformity APPENDIX A1 EMC Conformity INDEX

6 1 GENERAL DESCRIPTION The new concept of split architecture applied to the GreenLine 6000 / GreenLine 8000 is a dramatic simplification of the test activity. The analyzer, equipped with aspiration pump, sampling probe heating and temperature controller, suspended particle filter, condensation drain peristaltic pump and measuring section of the analyzer can be positioned in the side of the stack sampling point. The operator can survey the overall inspection at distance, up to 20 meters, through a digital communication to the controller. The Remote Control Unit allows sending commands to the gas analysis unit, to manage stored data, to monitor in real time measured data, to printout and to transfer data to and from a Personal computer. The operator is informed, through messages, for system normal operation or if a faulty condition occurs. The analyzer has functions of draft and gas velocity measurement, report print, data acquirement. The data can be memorized and transferred to a PC, to create a database for future analysis. The printer mounted on the RCU is impact type with standard and low costs paper. Remote Control Unit (RCU) Main Control Unit (MCU) The internal memory can store 9000 analyses data. The new GreenLine 6000 and GreenLine 8000 show technical specifications and performances in line with the Protocols that have been elaborated to verify industrial emissions using portable analyzers to ensure air quality compliance. The Clean Air Act, promulgated in U.S.A. in 1970, was certainly the first law that regulates air emissions from area, stationary and mobile source. EPA (Environmental Protection Agency) and other country or state Regulatory Agency elaborate affordable and reasonable methods of achieving environmental compliance to verify stated emissions limits. These Protocols are the guidelines which prescribe the technical performances of the electrochemical sensor based analyzers to be used, as well as calibration and testing procedure which should be followed to assure valid emission data. 6

7 Features & Benefits New man-machine interface: user friendly and multi-language. New concept of split architecture and modularity: for a dramatic simplification of the test activity where the Remote control Unit can be used at up to 20 meters distance from the analyzer section (blackbox). Digital communication via a proprietary Eurotron high speed high immunity data bus: to build a fully modular measurement and analysis system High contrast graphic LCD display. Simplified display of 3, 6 or 12 parameters per page through a Zoom key and automatic backlight device. Gas conditioning system: integrated with Peltier cells, with heated probe and hose (for GreenLine 8000 only) Easy to be expanded. The modular hardware and firmware resident on flash memory allows a quick upgrade of the instrument to implement the operative mode to new application requirements. Differential pressure measurement to measure load losses, gas velocity, P, etc. Internal impact printer on common paper. Printed reports keep the original status much better than thermal printout. Internal data memory. Data storage for up to 9000 analysis (1000 for GreenLine 6000) MCU-RCU wireless communication (GL8000 only): until 100 meters in open space, for a better freedom of movement CO dilution (40:1): automatic over a programmable or manual set limit, to extend the built-in sensor range. The dilution ratio is calculated by default to guarantee the right measurement. Calibration On-Site: it allows a special alignment of a selected sensor read value directly on-site Emissions Mass measurement: with internal sensor and the Pitot tube, type "S"; for the weight measurement (Kg/h) of the emissions. (GL8000 LBH only). Bargraph display capability. It allows immediate and intuitive combustion process data interpretation. IR bench measures: it allows precision and stability and direct measure of CO 2 7

8 1.1 Ordering code GreenLine 6000 GreenLine 6000 Cat A B C D E F L M N - P Each GreenLine 6000 is equipped with a O 2 and CO sensors, pressure and draft sensor, internal 1000 memory, remote control unit with battery charger, 2.5m RS232 cable, internal impact printer, graphic display and supplied with Report of Calibration and instruction manual. GreenLine 6000 with Cooler, wireless Cat. 7846WL A B C D E F L M N - P Each GreenLine 6000 is equipped with a O 2 and CO sensors, pressure and draft sensor, internal 1000 memory, internal cooler module, remote control unit with battery charger, MCU/RCU wireless communication, 2.5m RS232 cable, internal impact printer, graphic display and supplied with Report of Calibration and instruction manual. Table A Sensor n.1 1 O 2 (0-25%) Table B Sensor n.2 2H CO ( ppm) H 2 compensated 2X CO ( ppm) 2LO CO (0-500 ppm) Table C Sensor n.3 0 none 4 NO and NOx ( ppm) 4LO NO and NOx (0-500 ppm) Table D Sensor n.4 0 none 5 NO 2 ( ppm) 5LO NO 2 (0-100 ppm) 8 CxHy (0-5% v/v) Table E Sensor n.5 0 none 6 SO 2 ( ppm) 8 CxHy (0-5% v/v) Table F Sensor n.6 0 none 7 CO% (0-10%) 8 CxHy (0-5% v/v) Table L Gas sampling probe 0 None 1 φ8mm/l300 mm gas + draft (dual hose) / max 800 C 2P φ10mm/l 750 mm gas + draft (dual hose) with removable shaft / max 800 C 3P φ10mm/l 1500 mm gas + draft (dual hose) with removable shaft / max 800 C 2SP φ10mm/l 750 mm heated gas + draft (dual hose) with removable shaft / max 800 C 3SP φ10mm/l 1500 mm heated gas + draft (dual hose) with removable shaft / max 800 C F Sintered filter mounted on the tip (max 800 C) Table M Battery charger Vac with USA plug Vac with Schuko plug Vac with UK plug Vac with European plug Vac with USA/Japan plug 8

9 Table N Options 0 None 1 GasConfig and DBGas 2004 software 2 Pitot tube L=300mm 3 Pitot tube L=750mm 4 Remote combustion air temperature probe L=2 m Table P Calibration certificate 1 Eurotron report 9

10 1.2 Ordering code GreenLine 8000 GreenLine 8000 Wireless Cat. 7848WL A B C D E F G H L M N - P Each GreenLine 8000 is equipped with a O 2 and CO sensors, pressure and draft sensor, integrated cooler, internal 9000 memory, remote control unit with battery charger, MCU/RCU wireless communication, 2.5m RS232 cable, internal impact printer, graphic display, GasConfig configuration software, DBGas2004 data manager software, and supplied with Report of Calibration and instruction manual. GreenLine 8000 Wireless, Massic Emissions Cat 7848 LBH A B C D E F G H L M N - P Each GreenLine 8000 is equipped with a O 2 and CO sensors, type "S" Pitot tube with sampling probe and temperature sensor, pressure and draft sensor, integrated cooler, internal 9000 memory, remote control unit with battery charger, MCU/RCU wireless communication, 2.5m RS232 cable, internal impact printer, graphic display, GasConfig configuration software, DBGas2004 data manager software, and supplied with Report of Calibration and instruction manual. Table A Sensor n.1 1 O 2 (0-25%) Table B Sensor n.2 2H CO ( ppm) + auto/manual sensor dilution, H 2 compensated 2X CO ( ppm) + auto/manual sensor dilution 2LO 2LO CO (0-500 ppm) + auto/manual sensor dilution Table C Sensor n.3 4 NO & NO x ( ppm) 4LO NO and NOx (0-500 ppm) Table D Sensor n.4 0 none 5 NO 2 ( ppm) 5LO NO 2 (0-100 ppm) 8 CxHy (0-5% v/v) Table E Sensor n.5 0 none 6 SO 2 ( ppm) 8 CxHy (0-5% v/v) Table F Sensor n.6 0 none 7 CO% (0-10%) 8 C xh y (0-5% v/v) 9 H 2S ( ppm) Table G Sensor n.7 0 none A CO 2 (0-15%) NDIR Table H Sensor n.8 & n.9 0 none B C xh y ( ppm) NDIR E CO (0-15%) NDIR F CO ( ppm) NDIR Table L Gas sampling probe 0 None 1 φ8mm/l300 mm gas probe + draft (dual hose) / max 800 C 10

11 2P φ10mm/l 750 mm gas probe + draft (dual hose) with removable shaft / max 800 C 3P φ10mm/l 1500 mm gas probe + draft (dual hose) with removable shaft / max 800 C 2SP φ10mm/l 750 mm heated gas probe + draft (dual hose) with removable shaft / max 800 C 3SP φ10mm/l 1500 mm heated gas probe + draft (dual hose) with removable shaft / max 800 C F Sintered filter mounted on the tip (max 800 C) Table M Battery charger Vac with USA plug Vac with Schuko plug Vac with UK plug Vac with European plug Vac with USA/Japan plug Table N Options 0 None 1 GasConfig and DBGas 2004 software 2 Pitot tube L=300mm 3 Pitot tube L=750mm 4 Remote combustion air temperature probe L=2 m Table P Calibration certificate 1 Eurotron report 11

12 1.3 Ordering code Industrial probe Code: 7852 A B C D E Table A Model 2 Heated shaft with pneumatic connection Table B Tip 2 8mm/L 750 mm max 800 C 2LBH 35mm/L 750 mm Pitot tube type "S" + gas & temperature probes / max 800 C (for GreenLine 8000 LBH only) 3 8mm/L 1500 mm max 800 C 6 8mm/L 1000 mm Inconel max 1200 C F Synthesized filter installed on the tip Table C Hose 4 2m long heated 5 3m long heated 9 special length heated hose Table D Battery charger 1 110V ±10% 50/60Hz 2 240V ±10% 50/60Hz 12

13 1.4 Specifications Main Control Unit (MCU) Type: GreenLine from 2 to 6 cells portable flue gas analyzer. GreenLine from 2 to 9 cells portable flue gas analyzer. Calibration: automatic calibration procedure at instrument switching-on. Fresh air inlet with electrovalve and separate pneumatic circuit. Self-diagnosis: Sensors efficiency test with diagnostic page. Pump: 2.6 l/min / -560mbar with electronic flow controller Flow meter: range from 1 to 3,5 l/min - accuracy 0,2 l/min. Absolute pressure (GL8000 LBH only): built-in sensor for the measurement of the barometric pressure Battery life: 6h continuous operation (without heated probe and with cooler switched off) Power supply: 110/230 Vac 50/60Hz / 3,2Ah capacity lead rechargeable battery Internal data memory: up to 9000 complete analysis data structured by Tags. Serial interface: RS422 bi-directional. RS232 with adapter. Smoke measurement: Using the heated probe or the optional external manual pump. Bacharach index memory store and printout capability as standard. Optional probes: ambient CO, explosive gas leakage sniffer, T+RH% probe. Working temperature: from 5 C to +45 C (up to 50 C for short time) Storage temperature: from 20 to +60 C Carrying case: aluminium Dimensions: 455x205x365 mm Net Weight: 10 kg Hand-held Remote Control Unit (RCU) Type: Remote Control Unit (RCU) with 2.5m connection cable Battery life: 6h continuous operation (without printer and back-light). Power supply: 1,8Ah capacity Ni-MH rechargeable battery pack / external battery charger Charging time : 8h at 90% with instrument off. Printer: Impact type 24 columns with 58 mm large and 18m long paper roll. Printer power supply: RCU itself battery pack. Print autonomy: up to 40 reports with battery full Fuel types: Up to 10 totally programmable. Service and user data: 3 programmable lines for each customer using a PC and DBGas Software. Report Header: 4 rows x 16 cher programmable from keyboard Display: Large (40x56 mm) graphic LCD display with back-light device. Bar graph and trend capability. Line filter: changeable cartridge Serial interface: RS422 bi-directional. RS232 with adapter Working temperature: from 5 C to +45 C (up to 50 C for short time) Storage temperature: from 20 to +60 C Dimensions: 115x90x330 mm Net Weight: 0.9 kg with battery and printer External optional ambient CO probe (optional) Range: from 0 to 500ppm Accuracy: ±5ppm up to 100ppm; ±5% rdg. up to 500ppm Resolution: 1ppm Response time: 30s (t90) Waiting starting time: 30s Working temperature: from 5 C to +45 C External optional natural gas leak detection probe (optional) Pre-heating time: 30s minimum Alarms indication: visual with 5 steps 5 alarms levels: 100, 200, 300, 400, 500 ppm Acoustic Alarm indication: respectively 1, 2, 3, 5 beep/s, continuous Response time: 5s (t90) Alarm levels Accuracy: ±10% at 90 days 13

14 ACCURACIES AND RANGES TABLE Parameter Sensor type Range Resolution Max response time Accuracy O 2 Electrochemical % 0.1% 20sec ±0.1% vol. CO ±10 ppm <300 ppm Compensated up Electrochemical ppm 1 ppm 50sec ±4% rdg up to 2000 ppm to 2000ppm for H 2 interferences ±10% rdg >2000 ppm CO LOW Electrochemical ppm 0.1 ppm ±2 ppm <40 ppm ±5% CO Electrochemical ppm 1 ppm 40sec ±10 ppm <300 ppm ±4% rdg up to 2000 ppm ±10% rdg >2000 ppm CO Diluted Electrochemical ppm 500 ppm CO% Electrochemical % 0.01% 50sec ±0.01% <0.2% ±5% rdg >0.2% CO NDIR ppm 1 ppm ±2% F.S. (±50ppm abs) CO NDIR % 0.01% ±0.02 abs <0.66% ±3% rdg >0.66% CO 2 Calculated 0 100% 0.1 % CO 2 NDIR % 0.01% ±0.3% abs <10% ±3% rdg >10% NO Electrochemical ppm 1 ppm 40sec ±5 ppm <100 ppm ±4% rdg. up to 3000ppm NO LOW Electrochemical ppm 0.1 ppm ±2 ppm <40 ppm ±5% NO 2 Electrochemical ppm 1 ppm 50sec ±5 ppm <100 ppm ±4% rdg up to 800 ppm NO 2 LOW Electrochemical ppm 0.1 ppm ±2 ppm <40 ppm ±5% NO x Calculated ppm 1 ppm SO 2 Electrochemical ppm 1 ppm 40sec ±5 ppm <100 ppm ±4% up to 2000 ppm C xh y Pellistor % 0.01 % 20sec ±5 F.S. C xh y NDIR ppm 1 ppm ±100ppm <2500 (methane) ±4% rdg >2500 (methane) H 2S Electrochemical ppm 1 ppm ±5 ppm <100 ppm ±4% rdg up to 500 ppm Tair Pt C 0.1 C ±(0.2% rdg+0.15 C) Tgas Tc K C 0.1 C ±(0.3% rdg+0.3 C) T Calculated C 0.1 C Tflow Pt C 0.1 C ±(0.2%rdg+0.5 C) Treturn Pt C 0.1 C ±(0.2% rdg+0.5 C) Pressure/Draft ±3Pa < 300Pa Piezo ± hpa 0.01 hpa ±1% rdg >300Pa Barometric pressure Piezo mbar 0.1 mbar ±1% F.S. Excess air Calculated infinite 0.01 Gas Velocity Pitot tube m/s 0.1m/s Efficiency Calculated % 0.1% Smoke index Internal/externa l pump 0 9 Bacharach Auxiliary Inputs 2 channels 4 20 ma 0.01 ma ±1% F.S. Relative Accuracy limits are stated as absolute or % of the reading and referred to ambient temperature range from - 5 C to 40 C. Measuring reading can be directly converted from ppm to mg/nm 3, mg/kwh; from hpa to mmh 2O, mbar, inh 2O and from C to F. The maximum response time is declared at 90% of the variation The pressure relative accuracy shown is valid only after the auto-zero procedure. The NDIR sensors are available only on GreenLine

15 2 GENERAL 2.1 Keypad & Display The tactile keyboard allows the operator entering the main operative mode and all other complementary or auxiliary modes following the menu driven instructions. The high contrast graphic LCD (40x56 mm), equipped with back-light device, displays the measured and/or calculated parameters in the preferred format (Zoom function). The above parameters can be also displayed in a graphic mode. 2.2 Bluetooth Wireless Connection The GL8000 WL model features a Bluetooth wireless communication between the MCU and the RCU. The maximum operating range for the signal transmission is 100 meters in open space. The advantage is that the operator has a better freedom of movement. The result is that operator is not more bonded directly to the instruments, an important aspect for some applications. 2.3 Built-in printer The instrument is equipped with a built-in, rugged, 24 columns, 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. Pressing just one key is enough to obtain one, two or more copies of the analysis report with header and company reference data. Because of the limited resolution of any kind of internal printer, the graphic capability is incorporated in the DBGas2004 software which can run on a PC. 2.4 Gas sampling probe Flue gas sampling probes with different length, shape and max. operating temperature are available to match requirements of different applications. The sampling probe is connected to the analyzer with 3 meters long rubber hose. The probe is stainless steel made with ABS handle and internal thermocouple K type (Ni-NiCr) for gas up to 800 C. Special heated probes are available to operate up to 1000 C. A visual and acoustic alarm indicates a low flow. The built-in water trap drain condensed moisture is periodically purged from the system by a peristaltic pump. A dual filtering system (quartz + line) cleans the gas before analysis. 2.5 Industrial probe & heated hose On GreenLine 8000 is available on request an heavy duty heated sampling probe specifically recommended to run inspection relevant with emission of NO 2 and SO 2. These gases are diluted by water and therefore the accuracy can be compromised. Only the industrial probe F7852 in combination with the internal cooler grants long term analyses at the best performance available. A heated hose allows flue gas sampling without condensation. The internal cooler, by means of Peltier cells, dries the gas and avoids the dilution of NO 2 and SO 2 into the water. A different probe or the internal cooler can be added also in a second time. 2.6 Measuring cells The analyzer uses long life EC (electrochemical) sensors. EC sensors for O 2, CO (H 2 compensated up to 2000ppm), NO, NO 2 and SO 2. These sensors do not need special maintenance but they must be replaced after the expected lifetime. For a quick replacement these cells can be supplied pre-calibrated, therefore they do not require immediate re-calibration with certified gas mixtures. Anyway, Eurotron guarantees the accuracy of the measurements only in relation to a calibration certificate issued by our labs. However a full maintenance and the certification of the instrument is recommended every year. 15

16 Up to 2 non-dispersive infrared sensors (NDIR) can be installed on GreenLine They work in order to get a longer term and more stable response sensitivity than EC sensors. The compensation of ambient temperature and pressure is automatic. An automatic device excludes the CO sensor when a CO high concentration level is revealed. 6 acoustic and visual gas concentration alarms can be set for any purpose. 2.7 Flue gas temperature probes A thermocouple type K is incorporated on the tip of the gas sampling probe to measure the flue gas temperature. This thermocouple is suitable for measurements up to 800 C (up to 1000 C with special probes). The probe is connected to the instrument with the appropriate compensated cable and connector. A Pt100 resistance thermometer is used to compensate the so-called cold joint of the thermocouple. 2.8 Temperature probe A remote Pt100 probe is available for combustion air temperature measurement (from 10 C to 100 C). This probe is strongly recommended mainly in forced air boiler to obtain an accurate calculation of its efficiency. 2.9 Pressure sensor The instrument is equipped with an internal sensor for pressure and stack Draft. A one touch procedure moves the operating mode to and from this function to the gas analysis and vice versa. The instrument also has, as a standard feature, a second pressure sensor for differential pressure measure Fuel data The instrument includes the technical data specifications for 4 of the most common fuels. Using the optional GasConfig software, it is possible to modify or add data for up to 10 different fuels Smoke measurement Smoke index measurement is carried out using a special heated probe or a manual pump (F ), supplied on demand, and through a dedicated procedure that computes the required volume of flue gas sample crossing the in line filter. The results can be evaluated by comparison with the Smoke Index Table and the memory stored to be printed on the report mA auxiliary inputs Two 4-20mA auxiliary inputs are available for other kinds of measurements such as gas or hot water delivery capacity, etc T+RH% probe An optional probe performs the simultaneous measurement of ambient temperature and relative humidity (%RH) for a comfort index computation Leakage checking mode To check gas network tightness using a pressure decay method at programmable interval times. 16

17 2.15 Burner pressure probe A 1 meter long 8x4mm in silicon rubber hose (cat. EE300088) is used to check the pressure inside the burner Gas velocity The analyzer can be connected to a Pitot tube for gas speed measurements Emissions measurement (LBH) The GL8000 LBH model only includes a built-in barometric sensor and procedure for the total mass emissions measurement (in Kg/h). The special flue gas probe also includes a Pitot tube type "S" and a temperature probe Calibration On-Site This feature allows you to calibrate the measured value for a selected sensor directly on site using a simplified procedure. It is possible to align the measured value for a small amount only CO Dilution This feature helps you to measuring high concentrations of the CO gas and to protect the CO sensor, even for highly polluted environmental. The process dilute the CO concentration that goes on the CO sensor with fresh air, breathed in by a little built-in pump Calibration certificate Each portable gas analyzer, is factory calibrated and certified on the basis of Eurotron s Standards which are periodically certified by an International recognised Laboratory, and shipped with a Report of Calibration stating the nominal and actual values and the deviation errors Electromagnetic compatibility The instrument case has been designed to fulfil the directive #89/336/CEE relevant with the Electromagnetic Compatibility. See Appendix A1 for EMC declaration of conformity. We are proud to say that Eurotron Instruments Spa has available in house a laboratory for EMC compliance and therefore can run all the tests required to build the technical carnet requested to apply the CE mark on all equipments manufactured Instrument case The instrument case is rugged to guarantee operation in severe ambient condition. The weight of the equipment (without accessories) can change upon the required configuration. The base weight is 10Kg. The case is equipped with two lateral rings to connect a carrying belt for an easy transport (supposed as a standard accessory) 17

18 3 PHYSICAL AND FUNCTIONAL DESCRIPTION The instrument consists of two functional parts: a Remote Control Unit (RCU) and a gas analysis unit (MCU). The communication between the two devices is via standard RS422, thus all data collected by the analyzer are sent to the RCU, so that they can be viewed, stored and printed. RCU consists of a rugged and compact case, a motherboard with all base function circuits, a keyboard, an LCD backlighted display, a Ni-MH rechargeable battery pack and an impact printer. The unit allows visualizing, storing and printing real time data, programming and configuring MCU, reading the MCU and RCU memory and to connect to a PC. The gas analysis unit (MCU) consists of: an aluminum case, that is able to contain the RCU and all the connection cables, a mother board, a complete gas sampling system with electrovalves for purging and protecting the EC cells, dust and coalescent filters in addition to a condensation trap and a peristaltic pump for the moisture discharge, battery and electrochemical cells. The whole pneumatic system is placed in the rear part of the analyzer, so that the maintenance is easy to do. All sampling probe connectors are placed on top of the analyzer: gas inlet, pressure and Draft input, thermocouple input, aux inputs, temperature inputs and RS422 communication port. The operator interface is the palmtop controller and it consists of: a high contrast LCD display and a 14 buttons keypad. The most used operation (analysis, Draft, printing and smoke index) can be accessed by operator pressing a single key. The unit allows gas analysis, storing data at programmed intervals, connection to a PC or to the RCU. A general system scheme is shown in the figure below: 3.1 Pneumatic circuits Here there are the schemes of the pneumatic circuits for: GreenLine 6000, GreenLine 8000 with and without NDIR bench. 18

19 19

20 3.1.1 Model comparison GL6000 GL6000 WL GL8000 WL GL8000 LBH EC Sensors max 6 max 6 Max 6 Max 6 NDIR Sensors - - Max 3 Max 3 CO dilution STD STD STD STD Cooler - STD STD STD Industrial Probe - - OPZ OPZ Wireless RCU - STD STD STD Emissions measurement STD 3.2 Measurement principle The flue gas is sucked into the analyzer through the probe by a primary pump. The power of the pump is regulated by electronics in order to keep constant the flow rate. The sample is cleaned up and dried by a dust filter and the condensation trap. The condensed water is periodically purged by a peristaltic pump. Now this gas can flow through the sensors for the analysis. The O 2 sensor is an electrochemical cell, with two electrodes and electrolyte solution, like a battery. In fact, its behavior is similar to a normal battery and therefore the sensitivity decreases along with time. The expected life does not relate to the working time and is over after about 24 months. The toxic gas measurements (CO, SO 2, NO and NO 2) use electrochemical cells too. They have an expected life of about 3 years and they are not affected by natural oxidation processes. A dedicated internal procedure avoids overflow in the CO cell from high gas concentration of NO x. An electrovalve and an auxiliary pump allow purging the sensor with fresh air. Electrochemical cells assure accurate results for time intervals of approximately 60 minutes. The zero drift is automatically corrected by GreenLine every time the instrument is switched-on and with an auto-purging procedure, that uses fresh air as reference (20.95% for O 2 cell). This operation can be made with the sampling probe inserted in the chimney by means of a switching electrovalve. The switching off of the instrument activates a procedure of purging the sensors with fresh air and draining the water from the condensation trap. The pressure/draft zero offset must be done manually before the measurement of pressure. Leave the HP and LP connectors open during this procedure. Measured and calculated parameters are indicated on a LCD graphic display (40x56 mm), equipped with a back light device for easy readings Gas sampling probe The sampling probe consists of a steel tube and a handle of thermo insulating material. A positioning cone allows placing the probe in holes with a diameter from 11 to 16 mm. The retaining screw in the cone enables the probe to be easily moved to locate the core flow, normally correspondent to the center of the section of the smoke tube. The gas temperature is acquired using a thermocouple type K with the junction placed on the tip of the probe. NOTE: THE POINT OF GAS DETECTION HAS TO BE APPROXIMATELY THE CENTRE OF THE SECTION OF THE CHIMNEY. Special probes for critical application are available on demand. 20

21 3.2.2 Water trap & line filter The gas flows through a combined water trap and line filter to avoid the presence of condensation or suspended solid particles in the analysis circuit of the instrument. Actually, we speak about so-called dry analysis. The water trap works using the expansion principle: the gas flow decreases its speed inside the cylinder, consequently, it is not able any more to carry dust or heavy particles and it will NOx/SOx filter cool. The humidity condenses and the (EE650073) solid particles fall down. At fixed intervals, that water is drained out by a peristaltic pump. Line filter for A low porosity line filter after the water autozero trap has the function to stop the procedure smallest solid particles. The filter must (EE650072) be replaced when it becomes dirty. Another line filter is placed inside the Line filter analyzer and its function is to stop (EE650072) eventual dust during the autozero procedure. A NO x/so x filter is placed before the Water trap CO cell in order to protect it. The filter purge should be replaced when the inside connector little spheres become brown.!! WARNING!! THE LINE FILTER SHOULD BE REPLACED WHEN CLEARLY DIRTY OR HUMID. NEVER MAKE ANY ANALYSIS WITHOUT LINE FILTER, AS IT CAUSES AN IRREVERSIBLE DAMAGE TO THE SENSORS. PUT THE PROBE IN ITS CASE ONLY WHEN IT IS COMPLETELY DRY CO dilution Automatic CO dilution system is a standard feature to: protect the CO sensor and to extend the measuring range up to 10%. The electrochemical sensor for the CO measurement need very long time for the autozero procedure in case of an exposure of more than its out of range concentrations for long time. To avoid this, the sensor is protected by a dilution automatic system of the gas sampling. The dilution has a 40:1 fix ratio and it can be manually activated to expand the sensor range. In this way is it possible to better manage the sensor life and continue the measurements without loosing time Gas treatment Some models (see the comparison table on par ) use a cooling system of gas sample. It is a Peltier cell system with heated probe and hose (only for the GreenLine 8000 models) (see par. 5.3) The heated probe can be supplied on demand and it has an internal thermocouple to check the gas temperature that has to be over the dew point. For that reason, inside the analyzer, there is a reference table with the appropriate values of temperature for each gas (e.g. 65 C for methane). The heated probe allows the gas reaching the cooler with its very chemical characteristics. The Peltier cells group has the function to cool the gas sampling under the dew point in a short time until 5 C. This is very important when are to be analyzed water-soluble components (e.g. SO 2). You can see in the picture the head of an industrial probe and the special heated hose. 21

22 3.2.5 Gas sensors The analyzer uses long life electrochemical cells for O 2, CO (H 2 compensated), NO, NO 2, SO 2 and CO%. These sensors do not need special maintenance, but they must be replaced after the expected lifetime. The expected life of the O 2 cell does not relate to the working time and is about 2 years. However, for the other cells the expected lifetime is about 3 years. For a quick replacement these cells can be supplied pre-calibrated and therefore do not require immediate re-calibration with certified gas mixtures, so that the replacement might be performed by the customer himself. Anyway, a full maintenance and certification of the instrument is recommended by Eurotron every year. The gas sensors are electrochemical cells composed by two electrodes (anode and cathode) and an electrolyte solution, depending on which gas has to be detected. The sampled gas goes trough a selective diffusion membrane. The oxidation process produces an electrical signal output proportional to the gas concentration. This current signal is evaluated by the electronics, converted to digital, compensated in temperature, processed by the microprocessor, sent to the Remote Control Unit (RCU) displayed, eventually printed, with a resolution depending on the sensor The flue gas must not exceed a pressure that might damage or destroy the sensor; measurements are always carried out under "no pressure" conditions (max. ±100 mbar). For this reason the pump is continuously regulated so as to ensure the same flow rate to the sensor. Each EC sensor has a different response time: O 2 = 20s to 90% of reading CO (H 2 comp.) = 50s to 90% of reading CO = 50s to 90% of reading NO = 40s to 90% of reading NO 2 = 50s to 90% of reading SO 2 = 40s to 90% of reading NOTE: IT IS RECOMMENDED TO WAIT 3-5 MINUTES TO PERFORM AN ACCURATE MEASUREMENT. Toxic gas sensors can present a ±2% drift and a long restoring time, if an excessive (>150% of F.S.) gas concentration is applied. In that case it is recommended waiting for a measured value lower than 20ppm, by sucking fresh air before switching the analyzer off. An electrovalve is installed inside the instrument to exclude/include manually or automatically the CO cell when the CO concentration is too high (e.g. when the burner is starting). CALIBRATOR OF GAS SENSORS During startup, or at interval times if programmed, all toxic gases are automatically calibrated at zero of the scale. The oxygen sensor, in parallel, will be automatically calibrated using fresh air. Toxic gases can be periodically verified and calibrated using an external gas mixture bottle. The following bottle are therefore recommended: 1000ppm NO in N ppm SO 2 in N ppm CO in N 2 The CO sensor is automatically protected by an electrovalve that switches when the measured CO concentration is over the full scale indication. In this case, the CO is kept in safe atmosphere Infrared optical bench Only on GreenLine 8000, it is possible to install gas sensors based on infrared (IR) spectroscopy. With this system, it is possible to detect CO and CO 2 (it means that it is not calculated, but really measured), and C xh y groups. Along the pneumatic circuit, before the IR bench, there is a further anti dust filter. The method is the non-dispersive IR absorption (NDIR) at 2 different wavelengths that allows precision, stability in time and high response time. Any gas absorbs light at specific wavelength, typically in IR region. A NDIR system consists of: an IR light source, a chamber containing the gas sample to analyze and a photodetector with optical filter. The light passes through the chamber and the gas sample absorbs at a specific wavelength (e.g. 4.26µm for CO 2) or at specific band range. 22

23 The filter is an optical component non dispersive and allows the photodetector identifying for sure the gas on the basis of the absorption spectrum. The more narrow is the band wavelength of the filter, the greater will be the sensitivity of the sensor. The light intensity (at a specific wavelength) that reaches the detector is inversely proportional to the gas concentration. The collected signal by the photodetector is then processed by the electronics, in order to obtain the concentration of CO, CO 2 or C xh y. In the figure you can see the general NDIR scheme: 3.3 Auxiliary measurements Temperature measurements The analyzer is equipped with temperature inputs to measure flue gas and air inlet. A thermocouple type K (nickel-nickel chromium) is included in the tip of the gas sampling probe to measure the flue gas temperature. This thermocouple is suitable for permanent measurements at temperatures up to 800 C. Temperature measurement and gas sampling from the flue gas pathway are thus always performed at the same site. The probe is connected to the apparatus with compensated cable and connector. An internal Pt100 resistance thermometer is used for the cold junction compensation. A remote Pt100 sensor (thermoresistance) can be supplied on demand with a 2 or 5 meter cable to measure the air inlet temperature in forced air boiler. This option is very important for an accurate efficiency calculation when the analyzer is quite far from the air inlet point. (BB830095) Two remote Pt100 sensors can be used to measure the flow and return temperature in a water circuit. If you have to measure the water temperature measuring the pipe temperature, we suggest using an archmodel probe with an appropriate diameter. These data can be printed on the analysis report Pressure and Draft measurements The analyzer can be equipped with a temperature compensated pressure sensor to measure the chimney Draft or a pressure. This sensor is differential, so that, using the second connector, it may perform a differential measurement of pressure; if connected to a Pitot tube, it may be used to measure gas speed or 23

24 carrying capacity. Another operative mode is the leakage pipe test to check gas network tightness using pressure decay method at programmable interval times. The pressure range is from to mmwc (± hpa) and the sensor is calibrated by the firm. NOTE: WE SUGGEST YOU TO EXECUT THE AUTOZERO PROCEDURE FOR MORE ACCURACY BEFORE PERFORMING THE PRESSURE/DRAFT MEASUREMENT. CAUTION PRESSURES EXECEEDING ±300 hpa CAN PERMANENTLY DEFORM THE MEMBRANE AND THEREFORE IRREVERSIBLY DAMAGE THE PRESSURE SENSOR Other measurements The analyzer has an auxiliary input for optional probes. Available probes are: ambient CO monitoring, temperature & relative humidity (T+RH%), natural gas monitoring probes and leakage from pipelines. Besides, the analyzer has two 4-20mA inputs, linear and opto-isolated, available for connections to external standard sensors. 24

25 4 PRELIMINARY CHECK Remove the instrument from its packing case and remove any shipping ties, clamps or packing materials. Carefully follow any instruction given on any attached tags and verify the required specifications with that ones of the new instrument. Inspect the instrument looking for possible scratches, dents, damages to case corners etc. that may have occurred during shipment. If any mechanical damage is noted, report the damage to the shipping carrier, then notify Eurotron directly or its nearest agent and save the damaged packaging for inspection. A label, on the rear of the analyzer, indicates the serial number of the instruments. Please, refer to this number for any inquiry, spare parts supply or application and for any technical support requirement. Eurotron keeps a database with all information regarding your instrument. Before using the GreenLine 8000 a full charge of the batteries is recommended. 4.1 Recommendations The instrument should be used in environments where the temperature is between -5 C and +45 C. Do not use the analyzer with clogged filters, filled with humidity nor without the filters themselves. Before store the probe in the case, be sure that the probe and the hose are clean and cold. Blow some air inside the hose in order to eliminate possible residues. WARNING IF THE INSTRUMENT IS STORED AT VERY LOW TEMPERATURES (UNDER THE OPERATION LIMITS), THE ANALYZER NEEDS SOME MINUTES TO WARM-UP TO THE ACTUAL AMBIENT TEMPERATURE BEFORE STARTING THE OPERATION. 4.2 Power supply The system can be powered as following: Gas analysis unit (MCU): it has an internal rechargeable lead battery. Anyway the mains supply should be used both for long-term analysis and for operations using the Peltier Cooler or the industrial heated probe. Remote Control Unit (RCU): it has an internal rechargeable Ni-MH battery package. An external battery charger is supplied as a standard accessory. Otherwise you can recharge the RCU directly from the connection cable RCUMCU. Both Ni-MH and lead rechargeable batteries ensure a long time operation and do not need maintenance. On RCU unit the internal battery ensures at least 6 hours of continuous operation (without printing and without display back light). NOTE: 90% BATTERY CHARGING CAN BE OBTAINED IN ABOUT 8 HOURS WITH THE INSTRUMENTS SWITCHED OFF. During operation a fully battery symbol is displayed on the bar state (right side) of the display: on the top for the analyzer and on the bottom for the controller. This symbol means that the batteries are completely full and it becomes gradually empty during the operation. When the batteries are discharged, the symbol appears and the instrument still has about 20 minutes of operation capacity to end the present analysis. Use only the proper battery charger supplied by Eurotron together to the instrument. 25

26 WARNING THE INSTRUMENT IS SHIPPED WITH AN AVERAGE LEVEL OF BATTERY CHARGE. AFTER UNPACKING IT, A FULL CHARGE OF THE BATTERY IS RECOMMENDED BY CONNECTING THE INSTRUMENT TO THE MAINS SUPPLY (OFF CONDITION) FOR HOURS. 4.3 Storage The instrument should be stored in environments where the temperature is between -20 C and +60 C. Before store the probe in the case, be sure that the probe and the hose are clean and cold. Blow some air inside the hose in order to eliminate possible residues. Before storing the instrument, perform a complete charge (12 hours) of the batteries to improve the MCU battery life. If you need to store the analyser for long time, perform a complete batteries charging every 45/60 days. 26

27 5 CONNECTIONS 5.1 Electro-pneumatic connections Connect the pneumatic connector of the probe to the GAS INLET connector on the MCU. If you are using a two hose model (suitable for Draft measurements), connect also the related hose connector to the MCU HP inlet. Connect the probe temperature sensor to the T.Gas input. Connect (if available) the remote air temperature Pt100 sensor to the T.Air input. Connect the RCU unit to the MCU unit (RS232 connector) by using the supplied specific cable (not necessary for the GL8000 WL model). Connect the supplied silicon tube to the condensation evaporation connector on the back panel. Connect (if necessary) the temperature probes of flow and return to the specific connectors T.flow-T.ret. Connect (if necessary) the proper connectors Input1 and Input2 for analog signals Connect (if necessary) the external probe to AUX PROBE connector. Gas inlet Gas Draft / Pressure Aux inputs 4/20 ma Air for autozero calibration Probe heater Air T. T. flow T. return Ext. probe RS23 ON/OFF Power supply GL8000 WL connection 27

28 Instruction Manual MM ed. K Gas probe positioning The measurement site should be at a distance of about twice the diameter of the chimney beyond the boiler. To position the sampling probe in the gas pathway, a hole of 11/16mm should be drilled and the retaining cone of the sampling probe firmly screwed in it. The retaining screw on the cone enables the probe to be easily moved in order to locate the core flow, normally corresponding to the center of the section of the stack. An easy way to find the right depth for the probe is to insert the probe until the analyzer detects the maximum temperature of the flue gas. CAUTION FOR A CORRECT GAS ANALYSIS, NO FRESH AIR MUST REACH THE FLUE GAS AS A RESULT OF NON-GAS-TIGHT CONNECTION POINTS BETWEEN THE HEAT PRODUCER AND THE MEASUREMENT SITE (PROBE). THE FLUE GAS AND PATHWAYS MUST BE CHECKED FOR GAS-TIGHTNESS BEFORE CARRYING OUT A MEASUREMENT, AND, IF NECESSARY, NON-GAS-TIGHT POINTS SHOULD BE SEALED. 5.3 Industrial probe (option) The industrial probe allows performing gas analysis at high temperatures, up to 1200 C. The probe itself and the connection hose are heated in order to suck in without condensing it. NOTE: ON GREENLINE 6000 YOU CANNOT HEAT THE HOSE. HOWEVER, IT IS POSSIBLE TO USE THE SAME SHAFTS RESISTING TO HIGH TEMPERATURES TOGETHER TO A CONVENTIONAL HOSE. The Peltier cells cooling circuit, only on GreenLine 8000, avoids dilution of NO2 and SO2 in the moisture condensed. Actually, when you have to measure NO2 or SO2 with a great precision, it is necessary to avoid dilution of these gases into the water. In order to obtain that, you have to hold the flue gas above the dew point, it means at a temperature varying in relation to the combustible (e.g. 60 C for methane). The probe consists of: A shaft (several length are available) with thermocouple for measures of the flue gas temperature, a heated handle with anti-dust filter, a heated hose (several length are available) Industrial probe connection How to connect the probe to the analyzer: Release the gas connector nut on the heated hose and insert it on the Gas Inlet connector on the Analyzer: 28

29 plug-in the hose to the connector: Screw the nut Plug-in the connector for probe heating to the Hose connector connector and the temperature probe to T.Gas connector WARNING THE HEATED HOSE WORKS BY MEANS OF MAINS SUPPLY. THEREFORE, YOU HAVE TO CONNECT THE ANALYZER TO THE MAINS SUPPLY. NOTE: the use of the probe is similar to that of the standard probe. However, to be sure that the hose is really heated, it is not enough just to handle the hose itself, as it is very well thermically insulated from the ambient. The temperature reached by the hose (depending on the combustible type) can be read from MEASURE page. Press the [HELP] key and select "SENSOR DIAGNOSIS" HELP 11: / 05/ 06 HEADER PRI NTER SENSOR DI AGNOSI S Ba t RCU 100% Ba t MCU 100% O2 CO NO NO2 SENSOR DI AGNOSI S ua ua ua ua SERVI CE Press "" (F1) to enter the next sensor diagnosis page SENSOR DI AGNOSI S SO ua MCU Ba t : V RCU Ba t : 5. 4 V Ts D 0. 7 C Press "" (F1) again to enter the next page showing the temperatures and other parameters SENSOR DI AGNOSI S T. Fl ow : C T. Ret : C Set Poi nt : l / mi n Fl ow : l / mi n Fl ow

30 press "" (F1) again to enter the next page showing other parameters (for GL8000 LBH only) SENSOR DI AGNOSI S Vgas m/ Sec Qwet m^ 3/ s QNdr y m^ 3/ s QNdr y 0. 0 Kg/ m LpAb s mba r Ap- L p mbar Vgas: stack gas velocity Q wet: Flow wet gas QN dry: Normalized flow for dry gas QN dry: Normalized volumetric mass flow for dry gas LpABS: Absolute pressure Ap-Lp: Differential pressure press "" (F1) again (for GL8000 Series and GL6000 Series with optional cooler) SENSOR DI AGNOSI S T. Ho s e 70 C Set poi nt 65 C Cool er OFF T. Pel t C Dut y Cool er The item T. Hose indicates the temperature of the heated hose and the item T. Pelt indicates the temperature of the Peltier cell (about 5 C). To enable or disable the cooler, see par

31 5.4 LBH probe connection (with Pitot tube) The GL8000 LBH need of the special smokes probe + Pitot tube type "S" to permorm the emissions measurement. Connect the LBH probe to the MCU paying attention to the following indications, then connecting it to the right LP and HP instrument inputs. NOTE: the LBH probe can be both mounted on a standard handle and on a heated industrial probe. Handle connector Port - Static meas. Port + Dynamic meas. Connect to HP Connect to LP 31

32 6 OPERATIONS 6.1 Basic operation All the procedures and programming operations on the instrument are performed using the keyboard and the display of the Remote Control Unit (RCU). NOTE: ALL NUMERIC VALUES SHOWN IN THE FIGURES OF THIS MANUAL ARE INDICATIVE AND LISTED AS AN EXAMPLE. The analyzer should be used in environments where the temperature does not exceed the specified limits (from -5 C to +45 C) and where the relative humidity is lower than 95% non-condensing Keyboard The front panel keys functions are the following: [ON/OFF] Switches the RCU on or off. [F1] and [F2] These keys are multifunction. The instrument changes the assigned function during the operations. The displayed F1 F2 pages have, on the bottom, 2 boxes each containing the assigned function (e.g. ANALYSIS ). Often, the [F2] key coincides to [] function, which permits returning to the previous page. If no word is displayed inside the box, no function is assigned to that function key. PRINT ENTER ON/OFF [], [], [ ] and [] They move the cursor symbols or increase and decrease numerical values. STORE SETUP MENU [ENTER] Accepts or saves a modified parameter or variable. [PRINT] goes to the print section (see par. 7.5) [STORE] goes to the memory section (see ch. 10) HELP LIGHT MCU [SETUP] goes to the configuration section (see ch. 9.2) [MENU] goes to the auxiliary functions. [MCU] shows the memory status of the MCU unit. [LIGHT] switches on and off the backlight. [HELP] displays the status information: battery charging level, status of the gas sensors, free memory, and changes the header of the print report. F1 F2 6.2 Display Menu&Measure area O % Ta Rj Er r CO % Dt Cal c E CO 1p Los NO 1p λ Tg Rj Er r Ef f Ef f Ts 27. 3C REF. O2 EMI SSI ON Status bar The gas analyzer is designed with a large (40x56 mm) graphic display using a back light system for best reading in poor light conditions. Three different areas can be identified on the display: Menu and Measure area, Status bar and Function boxes. Menu&Measure area The Menu and Measure area displays the analysis data, the menus and all messages for the operator. By default, the Function box 32

33 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 (3,6,12) of the displayed parameters (ZOOM function). O % CO2 0. 0% CO 63p pm O % CO % CO 3 6 pp m NO 0 pp m Tg Rj Er r o r Ef f N O % Ta Rj Er r CO % t Ca l c E CO 1 p Lo s NO 0 p l Tg Rj Er r Ef f Ef f Ts 27. 5C REF. O2 EMI SSI ON REF. O2 EMI SSI ON REF O2 EMI SSI ON Function box Two boxes are positioned on the bottom of the display. They contains the name of the function assigned to the [F1] and [F2] function keys. Status bar The status bar uses graphic symbols to describe the actual operation mode of the analyzer: / Remote Control Unit (RCU) communication with analysis unit status: =OK, =FAULT COMMUNICATION / Battery status: =charged, =discharged Max/Min/ Max, Med, Min and memorized values are displayed in memory recalling mode. Med/Mem O2 The displayed measurements are referred to oxygen Memory Card (PCMCIA) inserted. Mains supply (it appears instead of the symbol ) 6.3 Display adjustment During the autozero procedure, you can press the [ ] and [] keys to adjust the LCD contrast. During the measurements you have to press the [HELP] key and press the [ ] and [] keys to adjust the LCD contrast. 6.4 Numerical input When you have to set a numerical parameter (e.g. O 2 reference, etc.), use the following procedure: Select the parameter to be changed (e.g. O 2 reference) with the [] and [] key from the configuring menu. Press [ENTER] to enter in modify page as follows: CO Ref er ence 0. 0 The symbol below the first digit is the cursor. You can move the cursor using the [ ] and [] keys. You can change the selected digit using [] and []. If 9 or 0 values are exceeded, the digit at the left is increased or decreased. Press [ENTER] to store the value and return to the previous page. Press [] (F1) to return to the previous page without save changes. 33

34 6.5 Text input If you have to write a text (e.g. client s name, etc.) use the following procedure: Select the parameter to change (e.g. customer name) with the [] and [] key from the configuring menu. Press [ENTER] to enter in a page as following:! " #$%&' ( ) * +, -. / : ; <=>?@ABCDEFG HI J KLMNOPQRSTUVWXYZ C CONFI RM A symbol below the (blank) character in figure represents the cursor. It is used to identify the selected character; you can move it using the [ ], [], [] and [] keys. The box below the characters table shows the currently inserted text. The symbol is the end of line symbol. Press [CONFIRM] to write in the line box the selected character. The reversed character C, when selected, deletes the last inserted character. Press [ENTER] to store the text and to return to the previous page. Press [] to return to the previous page without changes. 6.6 Selection from a list If you have to select a text parameter from a list (e.g. Tag name, fuel type, etc.), use the following procedure: Select the parameter to be changed (e.g. fuel type) with the [] and [] key from the configuring menu. Press [ENTER] to enter in a page as following: - - Fue l - - Nat ur al Ga s L PG Gas oi l Combus t i bl e oi l The symbol on the left is the cursor. You can move the cursor among the items using the [] and [] keys. Press [ENTER] to store the selection and to return to the previous page. Press [] to return to the previous page without changes. 34

35 7 FLUE GAS ANALYSIS 7.1 Basic operations Instrument power on Connect the gas probe to the analyzer as shown at chapter 5 Connect the Remote Control Unit (RCU) to the analyzer by using the proper cable supplied Switch on the analyzer MCU. A green led will light on. Switch on the RCU by pressing the [ON] key. The display will show the following page: Gr eenli ne Se r i a l Nu m: Ve r s i o n : Ec oli ne Se r i a l Nu m: Ve r s i o n : Then, configuration data are automatically loaded from MCU to RCU. After a few seconds, the analyzer begins the autozero procedure: or >>>>> REMOTE Aut oz er o 121 s ec. Bat. MCU: 13. 5V Bat. RCU: 4. 8V START STOP This page displays the following information: communication status ( >>>>> means communication), time remaining to finish the autozero (180 sec by default), gas analysis unit battery voltage and RCU battery voltage. During this phase it is possible to pause the procedure by pressing the [STOP] (F2) key; the analyzer switches off the pump, and wait for a new command from the controller. The [START] (F1) key continues the autozero phase. Be sure that RCU and MCU units have the same configuration. If not, synchronize the two units (see par. 9) Fuel selection When the autozero procedure finishes, an intermittent sound advises the operator. Press the [ENTER] key to mute the unit. The following page is displayed: CONFI GURATI ON FUEL Na t ur al Gas TAG SELECTI ON ANALYSI S This page allows the operator to change the fuel type and to select a Tag. 35

36 Anyway, during the measurements you can change the fuel selection from the configuration menu (see par. 9.2) Tag selection If you select Tag Selection, it will be possible to select the plant code (Tag) where to perform the analysis, in order to store them with tidiness. Each Tag can contain more than one analysis. Select Tag selection Press [ENTER] to modify the selection. The new page shows the ID of the current Tag, the ID of the boiler, the name of the customer and the progressive number related to the Tag itself. TAG SELECTI ON PLANT 1 BOI LER 1 CUSTOMER 1 Nr 1 Use the [] and [] keys to select the desired tag already stored inside the memory Press the [ENTER] key to select a Tag. Press the [] key to return to the previous page. NOTE: the Tag can anyway be selected during the analysis, pressing the [MEMORY] key and following the procedure shown in par Combustion analysis Insert the probe in chimney. Fix it using the retaining cone and adjust the depth in order to collocate the probe in the central part of the section. Press the [ANALYSIS] (F1) key to begin the measurements. The following page will be shown: O % CO % CO 3 6 pp m NO 0 pp m Tg Rj Er r o r Ef f N REF. O2 GRAPHI C Pressing the [ ] and [] keys, it is possible to zoom-in or zoom-out, increasing or decreasing, the number of displayed parameters. Pressing [] and [] you can change page for other parameters. O % CO2 CO 0. 0% REF. O2 63ppm GRAPHI C O % Ta Rj Er r CO2 0. 0% t Cal c E CO 1p Los NO 0p l Tg Rj Er r Ef f Ef f Ts C REF O2 GRAPHI C NOTE: WHEN THE CO DILUTION IS RUNNING, THE CO VALUE ON THE ABOVE PAGES WILL BE DISPLAYED IN REVERSE COLOR. SEE PAR FOR FURTHER INFORMATION Pressing the [REF. O 2] key the measured parameters will be referred to the programmed oxygen value; please, refer to the par to program the O 2% reference. The symbol O2 will be displayed on the status bar and the box [REF. O 2] will be displayed in reverse mode. 36

37 O % CO2 CO 0. 0% REF. O2 63ppm GRAPHI C It is possible to display the measured values as bar-graph. Press the [GRAPHIC] (F2) key to change mode. This is just a qualitative visualization and we suggest referring to numerical data for more accuracy. O2 CO η Ref. O2 NUMERI C Press the [NUMERIC] (F2) key to return to the normal display mode. Using GasConfig Software, you can program the graph page: assigning up to 6 different parameter, ranges and incremental direction. NOTE: EVERY 30 MINUTES OF CONSECUTIVE ANALYSIS, THE MCU UNIT BEGINS THE AUTOMATIC CLEANING OF THE PNEUMATIC CIRCUITS. THIS PROCEDURE LASTS ABOUT 30 SECONDS TO DRAIN THE WATER TRAP AND ZEROING THE SENSORS. NOTE: FOR THE GL8000 LBH MODEL ONLY THE GRAPHIC MODE IS REPLACED WITH THE EMISSION MODE. REFER TO THE CHAPTER Switching off To switch the instrument off, use the procedure below: Disconnect the MCU from the process Switch the MCU off still leaving the RCU on. The MCU unit begins a cleaning procedure of about 2 minutes. The countdown will be displayed on RCU. When the procedure ends, the MCU pump switches off. Switch the RCU off. Clean the sampling probe and the hose from the moisture with compressed air. Put probes and hoses in the case with care. 7.2 Combustion air temperature measurement It is important to measure the combustion air temperature to have a correct boiler efficiency computation. An auxiliary Rtd (Pt100 type) input is available to measure the air temperature and simultaneously performing the analysis. Connect the optional Rtd and collocate it inside the air combustion aspiration tube and near the burner. Follow the standard procedure to make the analysis. The instrument shows the temperature on the display (T a) and the efficiency is calculated using this value. If no external Rtd is connected, the analyzer measures the instrument temperature (ambient) using an internal sensor. 37

38 7.3 Smoke index measurement This method consists of taking a gas sample from the center of the stack and crossing it through a special filter paper. The color (gray) of the spot on the filter is compared to the graduated (from 0 to 9) reference Bacharach s scale and it is called smoke index. Normative and laws about the air pollution, describe the procedure: DIN51402, 2116, 2117 and 2297 VDI directives, ASTM D T, etc. NOTE: TO PRINT THE SMOKE INDEX VALUE, IT IS NECESSARY TO EXECUTE THIS MEASUREMENT BEFORE THE COMBUSTION ANALYSIS Measuring devices The smoke index measurement can be done with a manual pump, or using a heated probe. Anyway, the comparison to the gray scale must be done by the operator. Smoke pump: it should suck 1.65 liters for each measure (normalized to 0 C, 760mmHg) through a 1cm 2 paper filter. Smoke index reference scale: it is a gray scale sheet with 10 different areas numbered from 0 to 9. The number 0 corresponds to a reflectivity of 85% ±2.5%. Every area reflects 10% less than the previous one. Paper filter: when it is clean it has a reflectivity corresponding to the 0 scale index and It has a permeability of 3 liters per cm 2 a minute (normalized to 0 C, 760mmHg) with a 200/800 mmwc resistance to the air flux Measurement with manual pump To avoid condensation inside the smoke pump, when using the manual smoke pump, we suggest heating the pump. That can be obtained sucking in some air from the chimney without using the paper filter. Introduce now the paper filter inside the pump. The gas sample should be drawn at the center of the combustion gas flow. The correct gas volume is sampled with 10 uniform pump shots. Compare the gray color of the filter with the smoke index table. The smoke index should not exceed the ones defined by the current normative. We suggest using a retaining cone during gas sampling. Press the [MENU] key to display the page below: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select SMOKE SMOKE I ns er t pr obe Pr es s [ ENTER] MEASURE 38

39 Press the [MEASURE] (F1) key to display the page below. Compare the filter with the reference scale SMOKE Meas. 1: - Meas. 2: - Meas. 3: - Oi l. Der. : NO AVG - Press []and/or [] to move the cursor to the Measure 1 input field. Press [ENTER] to input the smoke value. Press [] (F2) key and repeat again the same procedure for Measure 2 and Measure 3. The analyzer will then compute the average value. Sometimes is required the indication of the possible presence of traces of not completely burned fuel in the flue gas. This is revealed by the presence of subtle oily drops on the surface of the paper filter itself. Insert manually this information (YES NO) at the Oil.Der. row. Press [] (F1) to return to the previous page confirming the inserted data. These results will be written when the printed report will be requested Measurement with heated probe If you have the heated probe (optional) suitable for the smoke measure, follow this procedure: Pull out the gas probe from the chimney. Insert a new paper filter in the proper cleft. Insert the probe into the chimney. Press the [MENU] key to display the page below: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select SMOKE SMOKE I ns er t pr obe Pr es s [ ENTER] MEASURE If the heated probe is being used, the probe already equipped with the paper filter has to be inserted in the chimney as explained above. Press the [ENTER] SMOKE I ns er t pr obe Pr es s [ ENTER] Wai t... MESASURE 39

40 Wait about 45 sec to complete the procedure or press the [MEASURE] key to bypass the procedure. At the end, the page for inserting the value of the Measure 1 is displayed: SMOKE MEAS. 1: - MEAS. 2: - MEAS. 3: - Oi l. Der. : NO AVG - Extract from the probe the paper filter, compare it to the reference scale, as in the manual pump procedure above mentioned, and insert this value. Repeat the procedure for Measure 2 and Measure 3. Eventually, insert the information about oil derivatives. Press [] (F1) to return to the previous page confirming the inserted data. These results will be written when the printed report will be requested. 7.4 Pressure/Draft measurement The pressure/draft measurements can be performed using either the standard probe or that one with 2 hoses, suitable for draft measurement. Measurement with dual hose probe This probe is supplied with double gas collector: one for the flue gas analysis and the other one for draft measurement. When you connect the probe to the analyzer, you have to insert both GAS INLET and pressure inlet (HP) connector. If the connectors are colored, insert them according with the colors. Measurement with single hose probe Is it possible to use standard probe with single gas collector. The only difference is that the hose for gas collection has to be disconnected from the gas inlet connector and connected in the pressure inlet (HP) connector. IMPORTANT WHEN USING SINGLE GAS COLLECTOR PROBE, WE RECOMMEND CLEANING AND DRYING THE TUBE BEFORE CONNECTING TO THE PRESSURE INLET. To perform this draft measurement, proceed as following: Connect the probe as above mentioned. DO NOT INSERT THE PROBE IN THE CHIMNEY. Press [MENU] to access to main menu MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE 40

41 Select DRAUGHT. The internal pump stops and the following page is shown DRAUGHT Meas ur e 1. 0 mbar Pr es s [ ENTER] t o s av e meas ur e ZERO Before inserting the probe in the chimney, wait a few seconds and press [ZERO] to zero the offset of the sensor. Insert the probe in the chimney and fix it by the positioning cone. Wait a few instants for measurement stabilization and press [ENTER] to store the draft value (the symbol HI will appear to confirm the storage) or press [] to return to annul the operation. The stored value will be printed when the printed report will be requested Burner pressure measurement Using the burner pressure probe (cat. EE300088), it is possible to measure the pressure at the burner. Connect the probe to the instrument pressure input and connect it to the burner plug. Follow the same procedure described above in paragraph 7.4 for the measurement. 7.5 Analysis data print An internal 24 columns impact printer is installed in the Remote Control Unit (RCU). It is possible to personalize the print report programming the 4 text lines (see par ). To print the report (ticket) of the analysis use the following procedure: If it is necessary, before all measurements, perform smoke index measures, pressure, draft, T. flow, etc. in order to print all data on the same report. Perform your analysis. Press the [PRINT] key PRI NT ANALYSI S SAVED PRESS [ PRI NT] NUM. COPY 1 MODEL St andar d FEED Use the [] and [] keys to move the cursor symbol to NO. copy or Model field. Press the [ENTER] key to change the number of the reports you have to print and/or the print model for the report. Press the [PRINT] key again to print the report. You can abort the printing in progress by pressing the [] key. Press [] (F1) to abort the operation. Press [FEED] for paper advance. You can stop the paper advance by pressing the [ENTER] key. 41

42 7.6 Flow/Return temperature Connect the Pt100 probes to the proper analyzer inputs (T.flow - T.ret). Press [MENU] on the keyboard. MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select MEASURE MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBI ENT CO ENVI RON. TEMP/ HUM Press [] (F1) to display the following page: MENU GAS VELOCI TY AUX TEMPERATURE Select TEMPERATURE TEMPERATURE T. gas : C T. f l ow : C T. Ret. : C Di f f er : C T.Flow indicates the flow temperature measured by the Pt100 connected to T.Flow input T.Ret. Indicates the return temperature measured by the Pt100 connected to T.ret input. NOTE: AN ERR MESSAGE IS SHOWN IN THE CASE OF BROKEN PROBE IF IT SI NOT PROPERLY CONNECTED Furthermore in [HELP] and sensor diagnosis you can see other temperatures and parameters: Dpre indicates the duty cycle value of the inlet gas pump TsD indicates the temperature difference of the sensors after the last autozero procedure Hose indicates the temperature of the heated hose (see par. 5.3 for the industrial probe) Pelt indicates the temperature of the Peltier cells for the flue gas cooling system (see par. 5.3, 9.2.6) Dpel indicates the percentage of energy supplied by Peltier cells (0-1.00) (see par ) Set point indicates the reference value of the capacity, the unit of measure is Liters/min Flow indicates the current value of the capacity, the unit is Liters/min 42

43 7.7 Gas velocity measurement For this measurement you need a Pitot tube to be connected to the differential pressure inputs. Connect the + terminal of the tube to HP connector and the - terminal of the tube to the LP analyzer connector. ATTENTION GAS VELOCITY IS CALCULATED ASSUMING THE FLUE GAS DENSITY EQUAL TO AIR DENSITY. IT LEADS TO AN EXCES ERROR OF ABOUT 3% NOTE: FIRST OF ALL, PERFORM THE ZERO FOR THE OFFSET OF THE PRESSURE SENSOR, FOLLOWING THE PROCEDURE EXPLAINED AT PAR. 7.4 REFERRED TO PRESSURE/DRAFT MEASURES. Press [MENU] on the keyboard. MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select MEASURE MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBI ENT CO ENVI RON. TEMP/ HUM Press [] (F1) to display the following page: MENU GAS VELOCI TY AUX TEMPERATURE Select GAS VELOCITY option. GAS VELOCI TY K Vel De ns : Kg/ m 3 Ma n Au t o Insert the gas probe in the chimney Insert the Pitot tube Use the [] and [] keys to move the cursor symbol from K Vel. to "Auto" parameter. Eventually, press the [ENTER] key to select the function 43

44 There are three settable items: "Dens": press [ENTER], use the [ ] and [] keys to move from left or right of digit and [] and [] keys to change the digit selected. Den s. : "Man": press [ENTER], use the [] and [] keys to select one of this option Tf or DP ( P) and to change the values in manual way. GAS VELOCI TY Tg : 0. 0 C P : 0. 0 mbar Ve l : 0. 0 m/ s COPY Press [COPY] to copy the current temperature gas and pressure values from Pitot tube. To manually modify these values, use the [] and [] keys to select Tf or DP ( P) and press [ENTER] The analyzer calculates and shows the gas velocity. The measure can now be printed pressing [PRINT]. Press [] to get the precedent menu. NOTE: FOR THE BEST SPEED CALCULATION, DO NOT CHANGE THE BURNER RATE BETWEEN THE TEMPERATURE AND PRESSURE MEASURE. THE OPTIMUM CONDITIONS IS ACHIEVED USING 2 HOLES IN CHIMNEY IN ORDER TO GET SIMULTANEOUS MEASUREMENTS "Auto": press [ENTER], the same operation such as the Man, but the values will be input automatically. GAS VELOCI TY Tg : 0. 0 C P : 0. 0 mbar Ve l. : 0. 0 m/ s ec ZERO Press [ZERO] (F1) to zero the sensor offset 7.8 Pressure decay procedure This operation allows finding pipes leakage. It is based on pressure decay principle, it is necessary to insulate and empty the section to check. CAUTION A PRESSURE OVER ± 300 hpa CAN BUCKLE PERMANENTLY THE MEMBRANE, SO THAT THE PRESSURE SENSOR COULD BE DAMAGED IN A IRREVERSIBLE WAY Press the [MENU] key: 44

45 MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select MEASURE MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBI ENT CO ENVI RON. TEMP/ HUM Select P DECAY LEAK TEST P DECAY LEAK TEST Le ng. : max. 10 mt Ty pe : Under Tr ac k Di am. : 1/ 2 " TEST RESULT TEST Before starting the test you have to define the plant data: Leng.: Length of the pipes (max 10m - over 50m) Type : Type of plant (Under track or Visible) Diam.: Pipes diameters (from ½ to 1 ½ ) Use the [] and [] keys to move the cursor symbol to the specification to be changed. Press the [ENTER] key to modify. Press [] (F2) to return to the previous menu. 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 Connect the pressure inlet (IN P) connector to the gas circuit. CAUTION BE SURE THAT THE CIRCUIT IS EMPTY AND CLEAN: OVERPRESSURE, DUST, LIQUID AND CONDENSED MOISTURE MAY DAMAGE THE INTERNAL CIRCUITS OF THE INSTRUMENT. With depressurized circuit, press the [TEST] key. The unit displays the following page: SELECT TEST 0. 2 mmh2o Re s ul t : A START TEST ZERO Press [ZERO] (F1) to reset the reading. The instrument can memory store up to 2 different test data (A and B) Make the circuit under pressure, remembering not to overcome the limits of the instrument (±100mbar). Use air o inert gas (Nitrogen). 45

46 Select START TEST option and press the [ENTER] key to run the decay leak test. P1 : mmh2o P2 : mmh2o P3 : P4 : ~P : Re s ul t A: 300 The unit will store 4 different measurements (P1-P4) at programmed interval time (standard values are: 10, 60, 120 and 120 second). See paragraph to change these values. The instrument displays the P (P1-P4). Press [PRINT] key to print the test result. 7.9 Ambient CO probe (option) This optional external probe (see par.1.1, 1.2, 1.3 and 1.4 tab. N=8) allows ambient CO monitoring for personnel safety. When connected to the analyzer, it monitors continuously CO concentration and it signals when the Long-term Exposure (TWA) limits are reached. Acoustic and visible signal are emitted by the instrument. By default, Eurotron programs the limit at 35ppm, it means the limit of the USA rules The following table shows the current exposure limits for CO gas. This table is a guidance only, and figures must be checked before being used. Sensors used in safety applications should be fully calibrated at least every six months. Press [PRINT] key to print the test result. U.K. HSE GERMANY DFG USA OSHA TWA (8h) STEL (10 ) (30) CO probe operations Connect the probe to Aux Probe input. Press the [MENU] key: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select MEASURE MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBI ENT CO ENVI RON. TEMP/ HUM 46

47 Select AMBIENT CO If the probe is disconnected, the No probe message appears. Amb. CO: AMBI ENT CO 7 pp m ZERO NOTE: WHEN THE PROBE IS CONNECTED, YOU HAVE TO WAIT 40 SECONDS UNTIL THE MEASUREMENT. IF PROBE IS CONNECTED DURING THE AMBIENT CO PAGE, A WAITING MESSAGE IS DISPLAYED. Before inserting the probe inside the working area, expose it for some seconds in fresh and uncontaminated air. Press the [ZERO] key to reset the measure and start CO monitoring. From this moment the unit compares the monitored value with the CO limit (default OSHA limit: 35ppm). It is possible to change the CO limit using the GasConfig software for PC. Press [] (F2) to return to the previous menu. NOTE: IF THE ABOVE PROCEDURE IS EXECUTED AND THE CO PROBE REMAINS CONNECTED TO THE INSTRUMENT, THE INSTRUMENT MONITORS AMBIENT CO EVEN DURING THE OTHER OPERATIVE MODES (E.G. DURING THE FLUE GAS ANALISYS) IN ORDER TO ENSURE THE SAFETY When an alarm condition is marked, press the [ENTER] key to mute it Natural gas leak checker (option) Connect the probe to Aux Probe input. Press the [MENU] key: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select MEASURE MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBI ENT CO ENVI RON. TEMP/ HUM Select GAS LEAK TEST If the probe is disconnected, the No probe message appears. GAS LEAK TEST CH4: [ 1 box = 100ppm] Agi t a t e t h e p r ob e i n Fr es h a i r a nd p r es s [ ZERO] ZERO 47

48 NOTE: WHEN THE PROBE IS CONNECTED YOU HAVE TO WAIT 60 SECONDS UNTIL THE MEASUREMENT. IF THE PROBE IS CONNECTED DURING THE GAS LEAK TEST PAGE, A WAITING MESSAGE IS DISPLAYED. Refer to the paragraph to change the warm-up time (default: 60sec). Before inserting the probe in working area, expose it for some seconds in fresh and uncontaminated air. Press the [ZERO] key to reset the measure and start CH 4 monitoring. From this moment the unit compares the correct CH 4 reading. A graphic qualitative indication of the CH 4 concentration appears: 5 boxes. Pressing the [] key you can change the probe range from 100ppm/box to 500ppm/box. Pressing the [ ] key you can return to 100ppm/box range. Eurotron suggests using 100ppm/box for ambient gas checking and 500ppm/box for pipe gas leak testing. After zeroing, the boxes will fill proportionally with the reading and an intermittent sound advises the operator for gas concentration as shown in the following table: 1 box = 1 beep/sec 2 box = 2 beeps /sec 3 box = 3 beeps /sec 4 box = 5 beeps /sec 5 box = continuous beep Press [] (F2) to return to the previous menu T+RH% probe (option) Connect the probe to Aux Probe input. Press the [MENU] key: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select MEASURE MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBI ENT CO ENVI RON. TEMP/ HUM Select ENVIRON. TEMP/HUM ENVI RON. TEMP/ HUM Mem. di s ab l e Tamb : C Rel. Hu m. : % NOTE: WHEN THE PROBE IS CONNECTED YOU HAVE TO WAIT 60 SECONDS UNTIL THE MEASUREMENT. IF THE PROBE IS CONNECTED DURING THE ENVIRON. TEMP/HUM PAGE, A WAITING MESSAGE IS DISPLAYED. Press [] (F2) to return to the previous menu. 48

49 8 EMISSIONS MEASUREMENT (GREENLINE 8000 LBH) 8.1 General description The GreenLine 8000 LBH model features the massic emissions measurement in the stack. 8.2 Probe connection Assemble the special probe as shown in figure 1. Fig. 1 Industrial probe assembling Connect the special industrial probe as shown in figure 2. 1 Connect the hose of the industrial probe to the MCU gas input 2 Connect the heating connector of the industrial probe to the MCU heater input. 3 Connect the Pitot connectors of the industrial probe to the MCU differential Pressure inputs (pay attention to the sense of the connections). Fig. 2 connection to the GreenLine 6000/8000 MCU The emissions measurements needs the special probe tip composed by the Pitot tube type "S", the temperature sensor and the flue gas sampling tube. The MCU also has a built-in sensor for the chimney absolute pressure measurements. 49

50 8.3 SET-UP Engineering Unit Set-up Press [SETUP] to enter the set-up menu CONFI GURATI ON L OAD MCU CFG SAVE MCU CFG LOAD MCU MEAS SAVE MCU TAG Press [] two times to display the following setup page: CONFI GURATI ON PAG2 ENGENEERI NG UNI TS AL ARMS %O2 REFERENCES AZERO I NT mi n 6 0 Use the [] and [] keys to move the cursor symbol to the ENGINEERING UNITS option. Press the [ENTER] key to select the option. Press [] (F1) to return to the previous menu. MEASURI NG UNI TS > CO ppm Ot he r ppm Temp. C Pr es s. mmh2o MEASURI NG UNI TS > Leng t h m Fl ow Kg/ m The following units can be changed: CO: unit for CO measurement. The measuring units available for CO are: ppm, mg/m 3, mg/kwh, g/gj, %, g/m 3, g/kwh Other: unit for other gases measurement. The measuring units available are: ppm, mg/m 3, mg/kwh, g/gj. Temp: unit for temperature measurement. The measuring units available are: C, F. Press.: unit for pressure measurement. The measuring units available for pressure are: hpa, mbar, mmh 2O, inh 2O. Length: unit for length measurement. The measuring units available are: m, cm, ft, in. Flow: unit for flow measurement. The measuring units available are: kg/min, kg/h, gr/h, Lbs/min, Lbs/h, onc/h Flow Meter Set-up (for GL8000 LBH only) From measuring display, press [MENU] to go to the menu page: MENU MEASURE DRAFT SMOKE CAL. ON SI TE 50

51 Press [] (F1) to access the next menu page MENU? SETUP FLOW Di l ut i on ON/ OFF Di l ut i on Set Select SETUP FLOW. SETUP FLOW K v el. : CO2 [ I nput ] BWO % STACK [ c i r c. ] Di am. CO2 SETUP FLOW m 0 ppm 0 ppm FLOW SETUP Ti me s ec. 0 Thr es, mbar The following parameters can be changed: K Vel.: it is the costant of the Pitot tube. CO2 : it is possible to set the CO 2 measurement mode. Available options are: input (manual data entry); calculated from O 2 sensor; measured with the NDIR CO 2 sensor. BWO: gas humidity inside the stack. STACK: type of chimney. Available options are: circular and rectangular. Press [] (F1) to modify others parameters. The following parameters can be changed: Diam.: it is the diameter of the stack (if circular stack type is set). Width: it is the width of the stack (if rectangular stack type is set). Lenght: it is the length of the stack (if rectangular stack type is set). CO2: it is the percentile of CO 2 (if manual CO 2 is set). Press the [] key (F1) to change others parameters. The following parameters can be changed: Time sec. : This value define the temporal windows for the P averaging. Available values are from 0 to 120 seconds. If it is set to 0, no averaging is calculated. Thres. mbar : This value define the threshold level for P averaging reset. If ( P Average Actual > Threshold) then P Average value is set to Actual P. Available values are from 0.0 to mbar. Press [] to return in measuring mode MCU Stand-by From measuring page, press [MENU] to go to the menu page: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Press [] (F1) to access the next menu page MENU > STANDBY MCU Di l ut i on ON/ OFF Di l ut i on Set Select STANDBY MCU" 51

52 >>>> MCU STATUS St op anal i s y s 30 s MCU Bat : 12. 7V RCU Bat : 4. 6V I R : Di s abl e START STOP By pressing "STOP" (F2), a 30 seconds countdown for sensor cleaning starts first, and then the MCU goes in stand-by mode. By pressing "START" (F1), the sensor autocalibration starts first, and then the MCU starts the measurements. 8.4 Differential pressure sensor alignment The differential pressure sensor has to be aligned before you insert the probe into the chimney as follow: To perform this draft measurement, proceed as following: Connect the probe as above mentioned. DO NOT INSERT THE PROBE IN THE CHIMNEY. Press [MENU] to go to the measurements page: MENU MEASURE DRAUGHT SMOKE CAL. ON SI TE Select DRAUGHT. The internal pump stops and the following page is displayed DRAFT Meas ur e 1. 0 mbar Pr es s [ ENTER] t o s av e meas ur e ZERO Wait a few seconds and press [ZERO] to zero the offset of the sensor. Press [] until return in measurement mode. Now Insert the probe in the chimney. 52

53 8.4 Display Emissions Values The [EMISSION] key is displayed on the measuring page. O % CO % CO 1 ppm NO 1 ppm Tg Tj Er r or Ef f N REF. O EMI SSI ON Press the [EMISSION] key (F2) to run the massic Emission calculations. O % CO % CO NO Tg Tj Er r or Ef f N REF. O2 EMI SSI ON E A symbol E is shown on the right side of the display to indicate the Emission measurements. All Emission measure are converted with the engineering unit set. By pressing the [] key you can enter the following display page: Ta C t C L os N % λ 1. 8 Ts C Ts D C REF. O2 EMI SSI ON E By pressing the [] key again you can enter the last display page: NO2 SO2 NO NOx CO% REF. O Lbs / h L bs / h L bs / h L bs / h L bs / h E EMI SSI ON The last page will show the data depending on the sensor type installed into the instrument 53

54 8.5 Print Emissions Values An internal 24 columns impact printer is installed in the Remote Control Unit (RCU). To print the emission report (ticket) of the analysis use the following procedure: Perform your gas analysis. Press the [PRINT] key PRI NT ANALYSI S SAVED PRESS [ PRI NT] NO. COPY 1 MODEL St andar d FEED Use the [] and [] keys to move the cursor symbol to NO. copy field. Press the [ENTER] key to change the number of the reports you have to print. Use the [] and [] keys to move the cursor symbol to Model field. Press the [ENTER] key to change the print model for your report. If you choose the Emissions model, the system will print the analysis data and the emissions for your stack. Press the [PRINT] key again to print the report. You can abort the printing in progress by pressing the [] key. Press [] (F1) to abort the operation. Press [FEED] for paper advance. You can stop the paper advance by pressing the [ENTER] key. Printed values are: Bwo: Proportion of water vapor in the gas stream by volume K pitot: pitot tube velocity constant QNdry: Normalized flow for the dry gas QMdry: Normalized volumetric mass flow for the dry gas Vgas: stack gas velocity PAtm: absolute stack pressure (measured with the on board pressure transducer) P: is measure by the Pitot type S and the on board differential pressure transducer. Figure 3: Example for Emissions model 54

55 9 Configuration and parameters 9.1 Configuration data transfer The following procedures describe data transfer from MCU to RCU and vice versa. Moreover, we discuss about data transfer from instrument to PC. ATTENTION CONFIGURATION DATA AND PARAMETERS ARE AUTOMATICALLY TRANSFERRED FROM RCU TO MCU WITH THE EXCEPTION OF THE PARAMETERS ABOUT ALARM S SIGNALS (9.2.2) HOWEVER, RCU AND MCU CAN HAVE DIFFERENT CONFIGURATIONS AS THEY HAVE INDEPENDENT MEMORIES. TO CHECK THE MCU CONFIGURATION, CONNECT THE INSTRUMENT TO PC (9.1.4) OR READ DATA FROM RCU (9.1.2) Configuration transfer from RCU to MCU Even if the parameters changes of MCU occur automatically, you can transfer data manually from RCU to MCU. Anyway, the manual data writing is necessary for alarms configuration (see par.9.2.2). Follow the procedure: Go to the setup page ([SETUP] key) Select WRITE MCU CFG Press [ENTER] and wait a few seconds, until the message Done Press [] to return back to the previous pages Configuration transfer from MCU to RCU Data transfer from MCU to RCU should be done every time that the configuration of MCU is modified by PC. Press [SETUP] and select READ CFG MCU Press [ENTER] and wait a few seconds until the message Done Press [] to return back to the previous pages Application: use of the 1 RCU with several MCU One of the advantages of the separated unit RCU is the possibility to use more MCU with just one RCU. 2 conditions can occur: Use of RCU to transfer configuration to a MCU: With RCU disconnected, make your changes and transfer them on the proper MCU. Follow the procedure of the par Use of RCU to collect data from a MCU: Connect the RCU to the proper MCU Perform the analysis Store the analysis from the memory management menu ([STORE] key). See chapter Data transfer by means of PC To connect the instrument with a PC, see chapter 11. The transfer of the configuration parameters is shown in par

56 9.2 Set-up menu Using the RCU you can change most of the parameters. Press [SETUP] to enter the set-up menu CONFI GURATI ON LOAD MCU CFG SAVE MCU CFG LOAD MCU MEAS SAVE MCU TAG Press [] one or more times to visualize these pages of options: CONFI GURATI ON PAG FUEL > L PG FUEL PARAMETERS CONFI GURATI ON PAG2 ENGENEERI NG UNI TS AL ARMS %O2 REFERENCES AZERO I NT mi n 6 0 CONFI GURATI ON PAG3 AUX1 AUX2 CONF. MCU MEM. COOL ER OFF Use the [] and [] keys to move the cursor symbol to the desired option. Press the [ENTER] key to select the option. Press [] (F1) to return to the previous menu. Fuel Select among the stored fuels. Fuel Parameters It is possible to visualize the coefficients used by the analyzer for the selected fuel. To change the values you have to use the configuration software. Engineering Unit It is possible to change the technical units for gas, temperature and pressure measurements. Alarms Set the alarm levels, Min/Max operation and enable/disable all the 6 possible acoustic and visible alarms. %O2 references You can set the %O 2 reference for CO measurements and for other gases. AZERO Int. Set the interval time (minutes) between 2 purging phases. Note: this parameter can be stored on MCU only with the procedure shown in par COOLER It is possible to activate/deactivate the conditioning unit. It activates the internal cooling unit and the heated hose (if connected). When this function is active, connect the MCU to mains supply Engineering Units When you select the engineering units option, the following page is displayed: ENGI NEER UNI TS > CO ppm Ot he r ppm Temp. C Pr es s. Pa ENGI NEER UNI TS > Leng t h m Fl ow Kg/ m Press [] (F1) to view the second page CO: unit for CO measures Other: unit for other gases The measuring units available for CO are: ppm, mg/m 3, mg/kwh, g/gj, %, g/m 3, g/kwh The measuring units available for other gases are: ppm, mg/m 3, mg/kwh, g/gj. The measuring units available for temperature are: C, F. 56

57 The measuring units available for pressure are: hpa, mbar, mmh 2O, inh 2O. Length: unit for length measurement. The measuring units available are: m, cm, ft, in. Flow: unit for flow measurement. The measuring units available are: kg/min, kg/h, gr/h, Lbs/min, Lbs/h, onc/h Alarms When you select the Alarms option, the following page is displayed: ALARMS Al a r m 1: O2 Enabl ed : Yes Thr es h. : Ty pe : Mi n Press [] (F1) to display next alarm pages. Up to 6 alarms can be set for different gas type and levels. How to modify settings related to a selected alarm: Enabled: yes/no Threshold: sets the limit Type: min/max (sets the threshold type) When the measured value overcomes the threshold, an intermittent sound (beep) informs you about this condition. Simultaneously, the parameter is displayed in the measuring page in reverse mode. You could mute the alarms pressing the [ENTER] key, so that the beep will stop, but the reverse mode still remains until the measured value goes under threshold. WARNING WHEN THE CONFIGURATION CHANGES, SYNCHRONIZE MCU WITH RCU AS SHOWN IN PAR O2% reference Sets a reference for the percentage of oxygen for CO measures and for other gases not diluted. This parameter influences the analysis pressing the [Ref.O2] key. See par %O 2 - CO: sets the O 2% reference for CO %O 2 - other: sets the O 2% reference for other gases NOTE: MEASURES REFERRED TO THE O 2 PERCENTAGE ARE DILUTED MEASURES, WHICH INDICATE JUST THE COMBUSTION S QUALITY. INSTEAD, THE MEASURE OF POLLUTING GASES REFERRED TO A SPECIFIC O 2% INDICATES THE POLLUTING POTENTIAL FOR THE PLANT UNDER TEST AUX1/AUX2 When you select the AUX1 or AUX2 option, you can program auxiliary inputs 4-20mA. Usually: gas indication, pressure, velocity or temperature. AUX1 CO ppm ZERO 0. 0 FULL SCALE

58 The measuring units available for other gases are: ppm, mg/m 3, mg/kwh, g/gj, %, g/m 3, g/kwh The measuring units available for temperature are: C, F. The measuring units available for pressure are: hpa, mbar, mmh 2O, inh 2O. The measuring units available for velocity is: m/sec Zero: sets the 0 value (offset) Full scale: sets the value for the full scale Long term analysis This feature is to perform a long-term analysis. Data are stored in the MCU memory and related to the selected Tag. If necessary, change the Tag Select CONF MCU MEM. CONF. 17: / 06/ 06 St ar t hour mem 0 St ar t mi n mem 0 Le ngt h [ mi n] 0 I n t. [ s ec ] 0 DATE Start hour mem input acquisition start hour (0-23) Start min mem input acquisition start minute Length input acquisition minutes length Int. input seconds interval time between two acquisitions Press [DATE] (F1) CONF. 18: / 11/ 06 Year 2006 Mont h 11 Day 28 HOUR START Input the acquisition starting date NOTE: BE SURE THAT DATE AND HOUR OF MCU AND RCU ARE THE SAME (SEE PAR ) Press [START] (F2) to store the configuration. The analyzer waits for the right date and time to start acquisition. If parameters are incomplete, an error message is shown. The analyzer works in order to save sensors, pumps and energy. When the interval time between two analyses is more than 30 minutes, the analyzer enters the stand-by mode. It takes 30 seconds for purging phase and switching off the pumps. 5 minutes before the next acquisition, the analyzer wakes up and it performs the autozero procedure (max 3 min.). Then there are 2 min. to stabilize the measure. After that, your GreenLine performs the analysis, stores it and returns back in stand-by mode for next measure. 58

59 Measure Interval time >= 30' Measure Pump off Pump on Stand by time Autozero time 2 minutes The analysis can be visualized and printed by RCU or transferred on PC. During the automatic analyses, it is possible to check them or turn off the RCU. The status of memorization can be visualized pressing [MCU]: ON/OFF Peltier It enables or disables the cooling circuit by means of Peltier cell (only on GreenLine 8000, see par ) The percentage of energy supplied to the cell and its temperature are visible on the temperature page (see par. 7.6). 9.3 HELP key Help menu informs about the GreenLine status (electrochemical cells status and battery level), allows you to change the 4 rows header printer text, etc. When you select this option, the following page is displayed: HELP HEADER PRI NTER SENSOR DI AGNOSI S Ba t t. 100% AC POWER MCU SERVI CE If the instrument is charging, there is not the battery level, but the AC POWER message (see par. 6.2) Header setting The HEADER PRINTER option, allows you to set 4 rows of 16 characters each for report header printing. R1 R2 R3 R4 HEADER PRI NTER Select the R1, R2, R3, and R4 rows and press [ENTER] key to insert or change the text (see par. 6.5) Sensors diagnosis The SENSOR DIAGNOSTIC option, allows you to read the actual status of the inserted cells. Use the [] and [] keys to move the cursor symbol to the desired option. Press the [ENTER] key to show the cells status, it means a µa indication of the generated current. 59

60 O2 CO NO NO2 SENSOR DI AGNOSI S ua ua ua ua NOTE: The high of the O 2 cell, out of the analysis, is due to the usual presence of the oxygen in the ambient. Those current values increase (absolute value) along with the gas quantity revealed. Press [] (F1) to enter the second page on the sensor diagnostic feature: SENSOR DI AGNOSI S SO ua MCU Ba t : V RCU Ba t : 5. 2 V Ts D 0. 8 C Press [] (F1) again to enter the third page on the sensor diagnostic feature: SENSOR DI AGNOSI S T. Fl o w Er r T. Ret Er r Se t Poi nt l / mi n Fl ow l / mi n Fl ow press "" (F1) again to enter the next page showing other parameters (for GL8000 LBH only) SENSOR DI AGNOSI S Vgas m/ Sec Qwet m^ 3/ s QNdr y m^ 3/ s QNdr y 0. 0 Kg/ m LpAb s mba r Ap- L p mbar Vgas: stack gas velocity Q wet: Flow wet gas QN dry: Normalized flow for dry gas QN dry: Normalized volumetric mass flow for dry gas LpABS: Absolute pressure Ap-Lp: Differential pressure Press [] (F1) again to enter the fourth page on the sensor diagnostic feature (for GL8000 Series or G6000 Series with optional cooler only): SENSOR DI AGNOSI S T. Ho s e Er r Set Po i nt 65 C Cool e r OFF T. Pe l t C Dut y Cool er

61 9.3.3 Service data The SERVICE option, allows you to read the information about instrument configurations, serial number, firmware version, etc. Press the [SERVICE] (F1) to display a page like that:: Eur ot r on SpA Tel Fax Mod Ec oli ne 6000 Cod F x - 0- Press [], to open the second shielded where the user can see all information about to serial number of RCU and MCU, of the firmware s versions and the date with the hours of building of the firmware I NFO MCU SN: V: I NFO RCU SN: V: Bu i l d Oc t / 1 4: 5 7: 3 6 The Cod item is referred to the type of sensors installed 9.4 Instrument configuration Configuration menu is protected by a password. This procedure menu allows the operator to change some internal parameters: date and time, communication baud rate, auto zero time and leak test timing. Follow this procedure to enter the configuration menu: Switch the MCU off Pressing [SETUP] key down, press the [ON/OFF] key. The analyzer switches on. A password input page is displayed. Insert the password code 0011 and press the [ENTER] key. The following page will displayed: SET- UP Pag. 1 Cl oc k Ser i al po r t Anal y s i s p ar. P dec a y t i me SET- UP Pag. 2 PRI NTER TEST CLOCK TEST TEST OUTPUT TEST KEYBOARD TX CFG Press [] (F1) to view the second page Clock Select this option for date and time settings. Verify that the current values are corrects because the analyzer use these data for analysis storing. 61

62 CLOCK Hou r : 10 Mi n ut es : 22 DATE Use the [] and [] keys to move the cursor symbol to the desired option. Press [ENTER] to enter in the option setting page. Press [] to return to the previous menu. Press [DATE] to change the date. DATE Da y : 10 Mo nt h : 06 Ye ar : 2006 Ty pe : EURO HOUR Use the [] and [] keys to move the cursor symbol to the desired option. Press the [ENTER] key to set a new date or date format (European or USA). Press [] to return to the previous menu. Press [HOUR] to change time Serial Port Selecting this option, you can set the parameters required to the instrument s communication. The parameters you can modify are: the ID number (address) of the instrument and the communication s velocity (baud rate). SERI AL Add r es s : 0 Bau d- r at e : Analysis par. Selecting this option you can change the analyzer auto-zero time, the CH 4 & Natural gas heating probe time, the time of a purging phase and the interval time between two peristaltic pump activations. We suggest maintaining the default values. Anal y s i s p ar. Au t oz. Ti me 180 CH4 He at. T. 60 Ze r o Ti me 180 Pe r i s t. I nt. 300 Anal y s i s p ar. P. ATM Press [] (F1) to view the second page NOTE "ZERO TIME" IS THE AUTOZERO OF IR BENCH (INFRARED). TO AVOID THE DAMAGING OF THE INSTRUMENTS THE MINIMAL VALUE OF SET CAN NEVER BE LESS THEN 130. THEREFORE THE INSTRUMENT, IN THIS CASE, WILL NEVER ALLOW TO GO UNDER THIS MINIMAL VALUE. 62

63 9.4.4 P decay time Selecting this option, you can change the timing for leak test using the decay method. The test takes a total period of 310 seconds and the programmable times represent the intervals between 2 measurements. P DECAY TI ME P1 Ti me 10 P2 Ti me 60 P3 Ti me 120 P4 Ti me Test Go to the second SET-UP page and select the option you want to test SET- UP Pag. 2 PRI NTER TEST CLOCK TEST TEST OUTPUT TEST KEYBOARD PRINTER TEST: the printer will print a test report in order to verify its properly working CLOCK TEST: it shows current date and time TEST OUPUT: it checks the functioning of visual and acoustic signals TEST KEYBOARD: it checks the properly keyboard working 63

64 10 MEMORY MANAGEMENT The standard configuration includes an internal memory able to store a lot of complete analysis. Each one includes values of gas concentration, temperatures, measure s date and time 9000 memories for GreenLine8000 (1000 for GreenLine6000) can be split up in groups of measures called Tag. The system is able to manage up to 40 Tag. Typically, each Tag represents a combustion plant. Each Tag contains the following information that can be stored by a PC: 16 characters for generator s name (tag), two 16 characters rows to identify a specific boiler and the client s name. Analysis data are stored on MCU manually or periodically (see par ). Using RCU it is possible to show and print them. The use, generally, is to select a Tag (corresponding to a plant under test), perform the auxiliary measures, the analysis and finally store them (see par ). If necessary, perform and store other analysis. It is always possible to select a Tag, show measures related to it and print them. If you have a PC connection, it is possible to transfer data and store them in order to have an archive of all the analysis realized. For that purpose you have to use the PC software DBGas2004. Both MCU and RCU have internal memory to guarantee a great flexibility. So that, you can use RCU as intermediate removable unit for data transfer (measures or configurations) from and on a PC. This allows transferring data on PC without moving the MCU Memory menu By means of this menu, it is possible to get all functions for memory management of RCU and MCU: Select a Tag Store the analysis into the selected Tag (only on MCU) Visualization (and printing) on the stored analysis Erasing the memory NOTE: MEMORIZATION OF AN ANALYSIS IS ALWAYS DONE ON THE MCU MEMORY. IF MCU AND RCU ARE CONNECT, IT IS POSSIBLE TO ARCHIVE AND SEEK THE SELECTED ANALYSIS INSIDE THE MCU MEMORY (REMEMBER THAT MORE THAN A MEASURE CAN BE REFERRED TO ONE TAG; SEE PAR ) IF YOU WANT TO HAVE AT YOUR DISPOSAL ALL MEMORIES OF MCU ALSO ON RCU, TYPICALLY WHEN THE UNITS ARE DISCONNECTED, IT IS NECESSARY TO COPY THE WHOLE MCU S MEMORY ON RCU, THROUGH CONFIGURATION MENU (SEE PAR ) Press the [STORE] key. The MCU memory page will be displayed: MCU Memor y STORE TAG SELECTI ON RECALL MEMORY DELETE MEMORY Press the [] (F1) key. The MCU memory page is shown: RCU Memor y TAG SELECTI ON RECALL MEMORY DELETE MEMORY If you press again the [] (F1), you come back to the page of the MCU memory. Press [] (F2) to come back to the configuration menu. 64

65 Tag selection Select a Tag on the analyzer. It means to select the generator (plant) where you want to operate on. After selecting a Tag, all the operations performed are referred to this specific generator (memorization and visualization of the measurers). Select Tag selection : TAG SELECTI ON PLANT 1 BOI LER 1 CUSTOMER 1 Nr 1 Use the [] and [] keys to move the cursor to the desired Tag (1-40) Press the [ENTER] key to select a tag Press the [] to come back to the previous page NOTE: PLANT, BOILER, CUSTOMER DATA ARE SPECIFIABLE THROUGH THE SOFTWARE FOR MEMORY MANAGEMENT DBGAS 2004 (SEE PAR. 11.1) Measurement storing This function allows storing analysis data on MCU Select STORE Press the [ENTER] key to confirm Press [] to come back to the previous page STORE!! PLEASE WAI T!! s t or i ng i n pr ogr es s NOTE: DATA REFERRED TO AN ANALYSIS ARE STORED AND PERMANENTLY RELATED TO THE SELECTED TAG (UNTIL ERASING MCU MEMORY) Display memory Select RECALL MEMORY option and press the [ENTER] key. RECAL L MEMORY TAG SEL ECTI ON SELECT MEMORY MODE VI EW MEM Select TAG SELECTION and choose a tag (1-40) 65

66 Press the [ENTER] key to confirm Press the [] to come back to the previous page To specify the mode of the visualization, do as follow: Select MODE Select single, average or average3 mode. The average mode shows the average values of all stored measurements related to a selected Tag Press [VIEW MEM] to display data stored If you select a Tag with no measures, an error message is shown. Measurement s data are displayed in the analysis page format and in the right column of the display a MEM appears. NOTE: IN THIS CASE, THE F2 KEY HAS THE FUNCTION INSTEAD OF GRAPHIC Press [PRINT] to print a report Delete memory Select DELETE MEMORY!! ATTENTION!! ALL DATA STORED WILL BE DELETED IF YOU PRESS [DELETE] Pressing [DELETE], you confirm data erasing (wait a few instants) Pressing [] the delete operation is cancelled Memory management by PC If you use a PC, the operator joins analysis to a Tag that can be selected among those specified by PC with DBGas2004 software. DBGas 2004 allows managing an archive on PC, with all information about a plant, customer and installed boilers (see par. 11.1) How to transfer Tags on MCU First of all, you have to create the IDs of the generators (also called TAGs) by means of PC software DBGas The created Tags must be transferred to MCU. Two ways to perform this operation are available: from PC directly to MCU, or from PC to RCU first, and then to MCU. To transfer the TAGs directly from PC to MCU: connect the serial cable to the PC and to the MCU; select the desired TAGs from the DBGas 2004 software, and then send them to the MCU. To transfer TAGs from PC to RCU, then from RCU to MCU: connect the serial cable to the PC and to the RCU; select the desired TAGs from the DBGas 2004 software, and then send them to the RCU. Disconnect the serial cable from the RCU and connect the terminal to the MCU, now. Enter the CONFIGURATION menu by pressing the SETUP key, and select the WRITE REMOTE TAG option to send the TAGs of the RCU on the MCU. 66

67 CONFI GURATI ON LOAD REMOTE CFG WRI TE REMOTE CFG LOAD REMOTE MI S WRI TE REMOTE TAG NOTE: BE SURE THAT BOTH THE RCU AND MCU ARE SWITCHED ON AND CONNECTED. YOU CAN ALSO USE THE SERIAL CABLE CONNECTION WITH THE MODELS THAT FEATURE THE BLUETOOTH COMMUNICATION INTERFACE, IF THE WIRELESS COMMUNICATION IS NOT POSSIBLE FOR ANY REASON. WARNING: THIS OPERATION WILL DELETE ALL PREVIOUS MEASUREMENTS AND TAGS STORED ON MCU How to transfer the stored measures on a PC Stored measures are always stored on the MCU. All measures can be also displayed and printed by using the RCU. When you need to transfer measures on PC by using RCU, you have to transfer measures from MCU to RCU first, then connect RCU to PC in order to transfer data in the archive of the DBGas 2004 software. To transfer the stored measures directly from to MCU to PC: connect the serial cable to the PC and to the MCU; select the desired TAGs from the DBGas 2004 software, and then download them on the PC. To transfer the stored measures on RCU first, then from RCU to PC: connect the serial cable to the RCU and to the MCU, or use the wireless Bluetooth communication with models that support this feature. Enter the CONFIGURATION menu by pressing the SETUP key, and select the LOAD REMOTE TAG option to send the TAGs from the MCU to the RCU. CONFI GURATI ON LOAD REMOTE CFG WRI TE REMOTE CFG LOAD REMOTE MI S WRI TE REMOTE TAG Disconnect the serial cable from the MCU and connect it to the PC (or connect the serial cable to the RCU and to the PC if you have previously used the wireless communication); select the desired TAGs from the DBGas 2004 software, and download them to the PC. NOTE: BE SURE THAT BOTH THE RCU AND MCU ARE SWITCHED ON AND CONNECTED. YOU CAN ALSO USE THE SERIAL CABLE CONNECTION WITH THE MODELS THAT FEATURE THE BLUETOOTH COMMUNICATION INTERFACE, IF THE WIRELESS COMMUNICATION IS NOT POSSIBLE FOR ANY REASON RS232/USB adapter installation The RS232/USB adapter can be used to directly connect the instrument to a computer without the RS232 serial port, but with the USB port only. The adaptor can be used with PCs under the operating systems Windows XP and Windows 95/98. Depending on the configuration of the computer, the adaptor could be automatically identified or not. If the adaptor isn t properly identified you ll need to manually install its driver, that you can find on the instrument s software CD. You need to follow the driver installation below only at first connection of the adaptor. Then, every time you connect the adaptor to your USB port, it will be automatically identified and it will be ready to operate. 67

68 If you have previously installed a similar adaptor on your pc and the drivers that are about to install are different from those already installed, please uninstall the already installed drivers FIRST. Please refer to the Driver s Uninstall procedure of your Operating System Installing driver for the RS232/USB adapter: Close all the active windows and/or applications. If you computer runs in Windows XP or Windows XP SP1, temporally disconnect the PC from the web. To do this, temporally remove the network cable from your pc, if connected, or by disabling your network card going to the Control Panel \ Network and Dial-Up Connections, right-clicking on the appropriate connection and selecting Disable from the menu. The connection can be re-enabled after the correct driver installation. This it s not necessary if your computer runs Window XP SP2 if configured to ask before connecting to Windows Update. Windows XP SP2 can have this parameter already setted, and to verify this open the Control Panel, select System, select the Hardware tab and click Windows Update. Please verify that this option is DISABLED. Connect the adaptor to a USB port of your computer. This will automatically launch the Windows Found New Hardware Wizard, if the adaptor is not automatically identified and installed on your system. The following page will be displayed: select No, not this time to avoid the driver search in internet, then click Next to proceed with the installation 68

69 Select the second option: Install from a list or a specific location (Advanced), then click Next Select the option referring to the following page, flagging Search for the best driver in these locations. Press Browse to select the file path. Select the folder where the driver is present on the CD: D:\\EE26032-SW-DRIVER USB-Seriale FTDI, then select the folder referred to your operative system and click OK. The driver will be automatically installed on your system. NOTE: IF WINDOWS XP IS CONFIGURED TO WARN WHEN UNSIGNED (NON-WHQL CERTIFIED) DRIVERS ARE ABOUT TO BE INSTALLED, YOUR COMPUTER WILL BE DISPLAY THE HARDWARE INSTALLATION WARNING PAGE. CLICK ON CONTINUE ANYWAY TO CONTINUE WITH THE INSTALLATION. IF WINDOWS XP IS CONFIGURED TO IGNORE FILE SIGNATURE WARNINGS, NO MESSAGE WILL APPEAR. At the end Windows will show a message indicating that the installation was successful. Click Finish to complete the installation. 69

70 WARNING THE ADAPTOR WILL BE CONFIGURED ON YOUR SYSTEM AS A COMMUNICATION COM USB SERIAL PORT, NOT AS A CLASSIC USB PORT. INTO THE DEVICE MANAGER OF YOUR PC THE PORT WILL APPEAR IN THE COM AND LPT PORT CATEGORY. NOTE: PLEASE ALSO REMEMBER TO SET BOTH THE CORRECT COM PORT NUMBER AND THE PORT SPEED IN BAUD ON THE SOFTWARE SETTINGS THAT YOU ARE RUNNING, OTHERWISE YOU WILL HAVE ANY COMMUNICATION BETWEEN THE INSTRUMENT AND THE COMPUTER. 70

71 11 SOFTWARE PACKAGES The software package consists of a CD-ROM that contains the programs DBGas2004, GasConfig and ST167flash. DBGas2004 is the software for managing analysis data, GasConfig is for managing configuration s parameters and ST167flash is for eventually updates the firmware DBGas 2004 DBGas 2004 is a PC Windows compatible software to manage all checks and measures activities on boilers and to transfer data from and to Eurotron Gas analyzers. The software is designed for a complete and efficient managing and recording of the boilers analysis data of your clients. DBGas 2004 allows you to have a no limits database on your PC with all customer and boiler s information, to select up to 40 boilers (each one is associated to a Tag) to be checked, to assign an operator name and transfer the data to the analyzer. The operator can store the analysis data and print the report; after the analysis he can transfer the data to the PC. The software will assign the analysis to the correct boiler in the database. Operator can view and print the data. Therefore, it is possible to maintain an historical archive for several years. IMPORTANT IF YOU ARE TRANSFER DATA FROM PC TO THE RCU AND VICEVERSA, YOU HAVE TO SWITCH THE RCU ON BY PRESSING THE [ON/OFF] KEY BY KEEPING THE [MCU] KEY DOWN. Plants/Boilers Database The fundamental plant (or Customer) and Boiler data can be manually input from the PC. It is possible to select one or more boiler for downloading to the flue gas analyser. The database can be imported or exported from (to) a CSV format. 71

72 Analysis database Optionally (DBGas 2004 Standard version) you can add the analysis database module. You can upload the data from the flue gas analyser and menage them (store, read, print, graph) easily with your PC. Graphic The DBGas 2004 Standard version includes the graphic module. This software module allows you to display the analysis data as a graphic trend. It is useful when you perform long term analysis with the GreenLine 6000 and GreenLine 8000 analysers. 24,40 112,0 Tfumi [ C] Ta [ C] 24,20 24,00 110,0 23,80 23,60 108,0 23,40 23,20 106,0 23,00 22,80 104,0 22,60 22,40 102, LogMan The DBGas 2004 LogMan version includes the real time data acquisition module. It is useful when you perform long term analysis with the GreenLine 6000 and GreenLine 8000 analysers System requirements The following hardware and software are required to use DBGas 2004: Operative system Windows TM 98/2000/XP; Processor, such as an Intel Pentium II or Advanced Micro Devices (AMD) processor; RAM 256Mbyte; 150 Mbyte free hard-disk space, CD-ROM drive, and dual RS232 serial port Installing the Software Before starting installation, close all the programs active. To install the software: 72

73 Insert the DBGas 2004 CD-ROM in your drive; Follow the instructions on the screen to install the software. If the DBGas 2004 setup program does not start automatically, follow these steps: Click the Start button Point to RUN Write D:SETUP.EXE (if D is the drive letter for your CD player). Click OK. Follow the instructions on the screen to install the software. The software is installed. You can run the DBGas 2004 from the program menu Uninstalling the Software To remove DBGas 2004 program : Click the Start button Point to Programs Point to DBGas 2004 Click Uninstall Click OK button The software is removed, including all related entries in your system registry Registering the Software When installed the DBGas 2004 will run in Demo Mode. You should insert the registration key code included in your DBGas 2004 package. This code should be entered to activate the program and to run in the different edition. To register the software: Run DBGas 2004 Click Help Click Info Click the Enter Registration Code button and write the registration code. Demo Mode: DBGas 2004 includes all options but the database is limited to max 5 Plants. Lite edition: DBGas 2004 do not allows the data download from the Flue gas analyser. Standard edition: DBGas 2004 includes all options without database limits Compatibility DBGas 2004 can run with most of the Eurotron flue gas analysers. The following list show the compatible instruments for this software revision. 73

74 Compatible Flue Gas Analysers UniGas 1000 GreenLine 2000 GreenLine 2000 UniGas GreenLine 4000 GreenLine 4000 UniGas GreenLine 6000 GreenLine 6000 GreenLine Data transfer There are 2 different ways to transfer Tag s data from PC to analyzer: PC MCU and PC RCU MCU NOTE: SHOULD ARISE COMMUNICATION S PROBLEMS, COMMUNICATION INTERRUPTED OR INEXISTENT: FOLLOW THE ERROR S MESSAGES AND, IN ANY CASE, BE SURE THAT THE SETTINGS OF THE SERIAL PORT ARE CORRECT (SEE PAR ). TO AVOID ANY PROBLEM, WE SUGGEST QUITTING THE PROGRAM, RUN IT NEWLY AND TRANSFER DATA AS FIRST OPERATION. PC MCU TRANSFER Connect the serial cable by means of the proper adapter, between MCU and the serial port on PC. Press Send to transfer data to MCU A window like that showed below appears; wait for completing the bar progress. Now the system will be immediately ready for storing analysis data after a normal connection to RCU. Be sure that the stored analysis is associated to the proper Tag. PC RCU MCU TRANSFER If the data transfer is realized on RCU. Follow these operations: connect the Remote Control Unit (RCU) to PC by means of the adapter, switch the RCU on by pressing the [ON/OFF] key keeping [MCU] key down. Press then the Send button on the DBGas2004 to send the data to the analyzer (as above mentioned). Disconnect RCU from PC and connect it to MCU. Switch on both unities and wait for autozero procedure. Press the [SETUP] key to view the following page: CONFI GURATI ON LOAD REMOTE CFG WRI TE REMOTE CFG LOAD REMOTE MI S WRI TE REMOTE TAG Select Write remote Tag to transfer data from RCU to MCU READING THE MEMORY OF RCU OR MCU, EACH TAG WILL BE ASSOCIATED RIGHT NOW TO THE ID SET BY PC, IT MEANS THE ID OF THE BOILER, THE INSTRUMENT REFERRED TO IT END THE CLIENT (SEE PAR. 10) EXAMPLE: Suppose to have 2 plants referred to 1 or 2 different clients, but the first has got 2 boilers and the second 3 boilers. After transferring data to the instrument, 2+3 Tag will be stored with related data. 74

75 11.2 GasConfig GasConfig software is a PC windows compatible program for configuring the Eurotron flue gas analyzers. You can change all memory settings: displayed measurements pages, printed measurements layout, alarms, fuels coefficients, technical units, etc GasConfig Installation GasConfig has been designed to work with operating systems Windows 9x/ME/XP/NT. Minimum requirements are: Pentium CPU with 16Mbyte Ram 20 Mbytes free space on hard disk Color monitor 800x600 CD-ROM drive Microsoft mouse or a compatible one In order to install GasConfig for Windows, follow the procedure below: Place the GasConfig disk in a CD-ROM drive; From the Windows Start Menu, select <RUN>; Enter the filename D:SETUP.EXE (eventually, substitute the letter D for the disk drive that contains GasConfig disk) Follow the on screen instructions making sure to provide the correct path to your GasConfig directory when prompted. Once installed, the program s icon will appear on your Windows program list and it will be possible to boot it by clicking on the icon as usual. 75

76 How to operate using GasConfig When you run GasConfig a 2 independent windows will be displayed: The window on the left is an icon list. This list shows all possible parameters that are possible to visualize on the analyzer (O 2, CO, T gas, Draft, etc.). NOTE: THE PROGRAM CAN BE USED WITH DIFFERENT TYPE OF ANALYZERS, SO THE LIST CAN CONTAIN PARAMETERS NOT AVAILABLE IN YOUR INSTRUMENT. A main menu bar allows you loading and saving configuration data on PC, in order to have different configurations for different applications, changing data rate setting, transferring data from and to the analyzer. Serial sets the communication port RS232: you should exactly know which port you are connected to, choosing among 4 available ones. Usually, on the back of PC, COM1 and COM2 are visible. After selecting which port to operate on, set the data transfer rate (expressed in baud) and the right address. ATTENTION SET THE SAME DATA TRANSFER RATE AND THE SAME ADDRESS BOTH ON PC AND ON THE INSTRUMENT, OTHERWISE NO DATA TRANSFER WILL HAPPEN (SEE PAR ) NOTE: SHOULD ARISE COMMUNICATION S PROBLEMS, COMMUNICATION INTERRUPTED OR INEXISTENT: FOLLOW THE ERROR S MESSAGES AND, IN ANY CASE, BE SURE THAT THE SETTINGS OF THE SERIAL PORT ARE CORRECT (SEE PAR ). TO AVOID ANY PROBLEM, WE SUGGEST QUITTING THE PROGRAM, RUN IT NEWLY AND TRANSFER DATA AS FIRST OPERATION. Language set the language used by the program Set instrument clock allows setting the internal clock of the instrument by PC (see par ) The window in the right side is the main owner s interface. It is organized in several folders, which contain all those parameters that are possible to modify. You have just to select, with the mouse, the right folder in order to show and modify the related parameters. 76

77 WARNING BEFORE CONFIGURATION DATA TRANSFERRING FROM AND TO YOUR PC, BE SURE TO HAVE SELECTED THE RIGHT INSTRUMENT MODEL USING THE INSTRUMENT OPTION ON THE MAIN MENU BAR. NOTE: MANY PARAMETERS ARE ALSO CONFIGURABLE FROM THE INSTRUMENT ITSELF, WITHOUT PC (SEE CHAPTER 9) The available function folders are: General This page allows you setting the general parameters like: engineering units, O 2% reference values, etc. Pages You can set up to 6 different pages on your instrument to display up to 36 different measured and calculated values. To select a parameter, it is enough to drag&drop the icon related to the proper parameter from the parameter s window to the desired page. Printer You can program the complete layout for report printing: header, measured parameters, etc. Alarms Aux Inputs Analog Output Timer Fuels Bar graphs Service You can enable, disable, and program up to 6 different acoustic and visible alarms for critical measurements. It allows managing the auxiliary inputs available on the instrument, usually 4-20mA It allows managing analogic output available on the instrument You can change the autozero time, leak decay time and other programmable time for the operation of the instrument Up to 10 different fuels coefficient tables can be programmed and it is possible to select the calculation formula on the basis of the desired law. You can set up to 6 different bar graphs, when there is the graphic option. 3 services information lines can be programmed for factory co-ordinates. (We suggest having Eurotron phone and fax numbers). 77

78 Transfer configuration to PC Before any configuration changes we suggest transferring the gas analyzer configuration to the PC. You have two different ways to transfer these data: RCU PC TRANSFER Connect RCU to PC through the adapter. Switch on RCU by pressing the [ON/OFF] key keeping [MCU] key down. Select from the menu Profile the option Receive to read the data from the RCU MCU PC TRANSFER Switch on MCU and connect it to PC Select from the menu Profile the option Receive to read the data from the unit Transfer configuration to the Analyzer You have two different ways to transfer configuration data from PC to the gas analyzer: PC RCU MCU TRANSFER When the data transfer occurs from PC to RCU, you have to follow these operations: Connect RCU to PC through the adapter. Switch on RCU by pressing the [ON/OFF] key keeping [MCU] key down. Select from the menu Profile the option Send to write data to the RCU. Disconnect the RCU from the PC. Switch on MCU. Switch on RCU by pressing the [ON/OFF] key keeping [MCU] key down. Press the [SETUP] key to view the following page: CONFI GURATI ON LOAD REMOTE CFG WRI TE REMOTE CFG LOAD REMOTE MI S WRI TE REMOTE TAG Select the WRITE REMOTE CFG option and wait for data transfer from RCU to MCU. PC MCU TRANSFER When the data transfer occurs from PC to MCU, you have to connect PC to MCU and Select from the menu Profile the option Send to write data to the MCU The system will be immediately ready for storing data after a connection to RCU. 78

79 12 MAINTENANCE The gas analyzer has been designed and manufactured using high quality components. A correct, systematic maintenance will prevent from 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 Paper and Ribbon change Open the cover pressing as shown in figure: Extract the exhausted paper roll. You can use standard paper roll but you have to check before for its dimensions (max. 57mm ±1mm large and 48mm ±1mm roll diameter). If necessary substitute the ribbon cartridge (cod. EE490002). Approach the end of the new paper roll (cod. EE340005) to the slot under the printer. Switch the analyzer on. Keeping the [HELP] key down; press the [] key to bypass the autozero procedure. Press [PRINT], and then press the [FEED] key for paper feeding. Press the [] key when the paper will come out for several centimeters. Close the cover inserting the end of paper in its slot. 79

80 12.2 Filter replacement In order to protect the pneumatic circuit and the sensors, inside the instrument there are some protection filters. The smoke filtering system consists of a dust inline filter (placed after the water trap) and an anti-interference NO x/so x filter (placed before the CO sensor). Inside the analyzer there is another dust filter that is to prevent ambient dust to enter the pump during purging and autozeroing procedure. We suggest: Replacing line filters when they become dirty Replacing So x/no x filter when some its inside particles turn to brown. Note: all filters have a proper connection way, we recommend connecting them rightly. NOx/SOx filter (EE650073) Line filter for autozero procedure (EE650072) Line filter (EE650072) Water trap purge connector 12.3 Filter replacement of the industrial probe Periodically check or replace, when necessary, the anti-dust filter (EE650056) on the tip of the probe: EE WARNING TO PREVENT DAMAGING, DO NOT WRAP THE HOT HOSE. AFTER USE, WAIT ABOUT 15/20 MINUTES BEFORE STORAGE. 80

81 12.4 Error messages The gas analyzer performs the auto-diagnostic procedure when switched on. During the measures, it checks also for anomalous conditions. If the analyzer founds trouble, it displays a message on LCD and triggers an acoustic signal to warm the operator for the possible presence of a faulty communication. Sometimes, these messages correspond to an unrecoverable problem and it is necessary to return the instrument to Eurotron for maintenance. Frequently these messages are referred to recoverable troubles and you can solve them. The following table shows the possible error messages: Error message Problem Solutions Calc Err Probe Er Parameter calculation error. The external Rtd probe is unconnected or damaged. RJ Err Internal temperature reference damaged. Connect or replace the external temperature probe. Return the instrument to Eurotron for maintenance Over Over range condition The problem is solved automatically when measure return inside the range Under Under range condition The problem is solved automatically when measure return inside the range No calculus available The instrument cannot perform the calculus. Check and solve the others error conditions. (e.g. O 2>18%). Excluded CO sensor excluded by electro-valve Automatic CO sensor protection is active. Perform one or more autozero cycle in fresh air. Tc Error The thermocouple is unconnected or damaged. Connect or replace the temperature probe. Tsens E Cell compensation error Return the instrument to Eurotron for maintenance. Zero Err The autozero procedure has failed Perform one or more autozero cycle in fresh air. If the problem remains, Return the instrument to Eurotron for maintenance. Sens. Er Cell out of order Return the instrument to Eurotron for maintenance. No meas. No sens. Empty Memory The cell is non installed No probe No external probes connected Connect the right probe Fault Communication No communication between the unities Check for the connection between the unities and be sure that MCU is turned on 12.5 Calibration on site This feature allows you to correct the measured value for a selected sensor directly on site. It is possible to align the measured value for a small amount only. The information related to the selected sensor can be read on the calibration on site info page. See par for further details. The two available alignments are: The "ZERO" value, for the selected sensor The "SPAN" value, for the selected sensor This procedure is available for the following gases: CO, CO% (or H 2S depending on the onboard installed sensor), NO, NO 2, SO 2 and CxHy-5%. 81

82 NOTE: IF THE SELECTED SENSOR DATA ARE NOT BEEN UPLOADED IN THE CONFIGURATION OF YOUR INSTRUMENT, WHEN YOU RUN THE CALIBRATION ON SITE PROCEDURE AN ERROR MESSAGE WILL APPEAR NOTE: A NEW CALIBRATION ON SITE PROCEDURE WILL START AFTER A PREVIOUS PROCEDURE RESET ONLY. SEE PAR FOR FURTHER DETAILS To run the procedure: Press the [MENU] key to enter the menu page MENU MEASURE DRAUGHT SMOKE CAL. ON- SI TE Select CAL. ON SITE and press the [ENTER] key CAL. ON- SI TE > Sens : Res et Cal. On- Si t e Cal. On- Si t e I nf o Cal OS The cursor will be located on the first row: choose the sensor you want to align first, by pressing the [ENTER] key Scroll up and down the list by pressing the [] and [] keys Sen s : > CO CO% NO Sen s : > NO2 SO2 Cx Hy - 5% H2S Press the [ENTER] key to select the desired sensor The display will return to the calibration on site main page, that now will show the selected sensor on the first row CAL. ON- SI TE > Sens : CO Res et Cal. On- Si t e Cal. On- Si t e I nf o Cal OS Press the [CALOS] (F1) key to run the Calibration ON SITE procedure 82

83 CAL. ON- SI TE > PPM c al St ar t Cal On- Si t e A desired concentration value is required. This value will be used to perform the procedure. Press the [ENTER] key to input the desired "SPAN" value PPM c al. : To increase or decrease the value use the [] and [] keys; to change the digit use the [ ] and [] keys Press [ENTER] to confirm the input value The display will now show the set value ( ppm for example) CAL. ON- SI TE > PPM c al St a r t Cal On- Si t e Select "Start Cal On-Site" and press [ENTER] key to enter the calibration on site dedicated pages You now enter two consecutive pages called "ZERO CAL. GAS" and "SPAN CAL. GAS" (identified by these titles on the top of each one) Zero calibration page Zer o CAL. GAS Ap pl y 0 ppm Pr es s [ ENTER] Rd g: This page displays the concentration of the selected gas. This concentration is displayed in "ppm" (or in percentage if you select the CO% sensor) and the last field called "RDG" displays the read value. WAIT FOR THE FLOW GAS STABILIZATION By pressing now the [ENTER] key the instrument will acquire the gas value. 83

84 The maximum acceptable ranges for the zero value are as follows: CO 50 ppm NO 50 ppm NO 2 20 ppm SO 2 20 ppm H 2S 20 ppm CxHy ppm CO% 0.05% Two cases can happen: 1. If the read value (displayed by the "RDG" field) is in the range, the instrument automatically goes on the subsequent "SPAN CAL. GAS" page (see par ) 2. If the read value (displayed by the "RDG" field) is out of range, an ERROR page will appear and the message "OUT OF RANGE" will be displayed. From now on the procedure is terminated. Press the [] (F2) key to escape Span calibration page Span CAL. GAS Ap pl y ppm Pr es s [ ENTER] Rd g: This page displays the concentration of the selected gas. This concentration is displayed in "ppm" (or in percentage if you select the CO% sensor) and the last field called "RDG" display the read value. WAIT FOR THE FLOW GAS STABILIZATION By pressing now the [ENTER] key the instrument will acquire the read gas value. The acceptable ranges for the span value are as follows: CO set value ±30 % NO set value ±30 % NO 2 set value ±30 % SO 2 set value ±30 % H 2S set value ±30 % CxHy set value ±30 % CO% set value ±30 % Two cases can happen: 1. If the read value (displayed by the "RDG" field) is in the range the following confirmation page will be displayed: 84

85 CAL. ON- SI TE CAL ON- SI TE DONE The calibration on site parameters will be now stored. The complete information about the aligned selected senor are now available on the "CAL ON-SITE INFO" page. (see par ). Press the [] (F2) key to return to the main menu page MENU MEASURE DRAUGHT SMOKE CAL. ON- SI TE Press the [] (F2) key to return to the measuring page. 2. If the read value (displayed by the "RDG" field) is out of range, an ERROR page will appear and the message "OUT OF RANGE" will be displayed. From now on the procedure is terminated Reset calibration This function allows you to reset a previous calibration for the selected sensor NOTE: A NEW CALIBRATION ON SITE PROCEDURE WILL START AFTER A PREVIOUS PROCEDURE RESET ONLY. IT'S NOT POSSIBLE TO RUN A NEW PROCEDURE AND AN ERROR MESSAGGE WILL INVITE YOU TO FIRST RESET THE PREVIOUS ONE. CAL. ON- SI TE PAY ATTENTI ON! Res et pr ev i ous Cal On Si t e NOTE: THE CALIBRATION RESET WILL BE PERFORMED FOR THE SELECTED SENSOR ONLY To run the calibration reset: Press the [MENU] key to enter the menu page MENU MEASURE DRAUGHT SMOKE CAL. ON- SI TE 85

86 Select CAL. ON SITE and press the [ENTER] key CAL. ON- SI TE > Sens : Res et Cal. On- Si t e Cal. On- Si t e I nf o Cal OS Select Reset Cal. On-Site and press the [ENTER] key Res et Cal. On- Si t e > Ar e y ou s ur e? CONFI RM Press the [CONFIRM] (F1) key to confirm or the [] (F2) key to return The display will return to the main menu page Calibration On-Site info page This page is useful to verify if a selected sensor has been aligned or not. Press the [MENU] key to enter the menu page MENU MEASURE DRAUGHT SMOKE CAL. ON- SI TE Select CAL. ON SITE and press the [ENTER] key CAL. ON- SI TE > Sens : Res e t Cal. On- Si t e Cal. On- Si t e I nf o Cal OS If no sensor type is displayed, or you want select another sensor, select "Sens:" and press the [ENTER] key 86

87 Scroll up and down the list by pressing the [] and [] keys Sen s : > CO CO% NO Sen s : > NO2 SO2 Cx Hy - 5% H2S Press the [ENTER] key to select the desired sensor The display will return to the calibration on site main page, that now will show the set sensor on the first row CAL. ON- SI TE > Sens : CO Res et Cal. On- Si t e Cal. On- Si t e I nf o Cal OS Select Cal. On-Site Info and press the [ENTER] key Ca l. On- Si t e I nf o Gas : CO Zer o: Gai n: The displayed data are referred to: GAS: the selected sensor Zero and Gain: calibration on site parameters NOTE: IF THE SELECTED SENSOR HAS NOT BEEN ALIGNED, THE ZERO VALUE DISPLAYED IS AND THE GAIN VALUE DISPLAYED IS CO dilution This feature helps you to measuring high concentrations of the CO gas, even for highly polluted environmental. The process dilute the CO concentration that goes on the CO sensor with fresh air, breathed in by a little built-in pump. The CO dilution procedure can operate in 3 different ways: OFF, ALWAYS and AUTO. NOTE: WHEN THE CO DILUTION IS RUNNING, THE CO VALUE ON THE MAIN MEASURING PAGE WILL BE DISPLAYED IN REVERSE COLOR. NOTE: THE CO DILUTION RESULTS IN BOTH LESS CO RESOLUTION AND A DIFFERENT ENGINEERING UNIT OF THE READ VALUE. THE CO DILUTED RESOLUTION IS 500 PPM (0.05%) AND HIS ENGINEERING UNIT DISPLAYED IS "%" 87

88 Press the [MENU] key to enter the menu page MENU MEASURE DRAUGHT SMOKE CAL. ON- SI TE Press the [] (F1) key to enter the next menu page MENU STANDBY MCU DI LUTI ON: OFF DI LUTI ON SET WARNING DO NOT ENTER THE "DILUTION SET": THIS FUNCTION IS STRICTLY RESERVED TO THE AUTHORIZED CERTIFICATION CENTER ONLY! Select "DILUTION: OFF" and press the [ENTER] key DI LUTI ON: >OFF ALWAYS AUTO Select "OFF" and press the [ENTER] key to disable the dilution function Select "ALWAYS" and press the [ENTER] key to always enable the dilution function and always run the built-in air pump Select "AUTO" and press the [ENTER] key to enable the automatic dilution function NOTE: IN AUTO MODE, THE DILUTION WILL START WHEN THE CO CONCENTRATION IS HIGHER THEN THE SET VALUE IN THE CO ALARM PAGE. WHEN THE CO CONCENTRATION DECREASE AT LEAST THE 50% OF THE SET VALUE IN THE CO ALARM PAGE, THE BUILT-IN AIR PUMP SWITCH OFF. NOTE: EVERY TIME YOU CHANGE THE CO ALARM SETTINGS IN THE CO ALARM PAGE REMEMBER TO TRANSFER THE NEW CONFIGURATION TO THE MCU Press the [] key to return to the main menu page When the CO dilution function is running, the report will also print the message "DILUTION ENABLE" for you reference Firmware Upgrade: ST167Flash The instrument has embedded in its memory a software (firmware) which is loaded at every turning on and which allows operating. This firmware can be changed and substituted; this guarantees a continuous upgrade of the instrument and the exploitation of its possibilities. To upgrade the firmware, you need the ST167Flash program and a file with extension HFW, which represents the firmware itself that has to be transferred to the instrument. 88

89 This software is compatible with all versions of Windows. The program needs the following minimum requirements of the Personal Computer: Pentium CPU with at least 16MB of RAM 20MB free space on hard-disc Monitor with resolution 800x600 Microsoft mouse or compatible To install the program, follow the procedure: Insert the CD-ROM From Start menu, select Run Insert the filename D:Setup.exe (eventually, substitute the letter D with the proper ID of your CD-ROM drive) Follow the instructions showed on the screen by the installation program After installing the program, run it from Programs menu: Connect the instrument to PC through the serial communication cable With the instrument switched off, press the [F1] key together with the [ON/OFF] key in order to set the instrument in firmware upgrade status. When upgrading the MCU, switch the instrument on keeping the microswitch below the Alarm led down. Select the right COM port (Serial port) Select the same communication velocity (expressed in Baud) either on PC (Baud rate) and on the instrument ATTENTION SET THE SAME BAUD RATE EITHER ON PC AND THE INSTRUMENT, OTHERWISE NO COMMUNICATION HAPPENS. IN CASE OF COMMUNICATION PROBLEMS, TRY TO DECREASE THE BAUD RATE. Insert in the field Filename the position where the file with HFW extension is, it means the firmware that has to be transferred to the instrument. Press Program and wait the complete data transfer Press END to quit the program NOTE: EVENTUALLY, PRESS READ ME TO READ AN HELP ONLINE. 89