Series 6300 CA-CALC TM Compliance Protocol Emissions Analyzers

Combustion Analysis Series 6300 CA-CALC TM Compliance Protocol Emissions Analyzers Operation and Service Manual 1980505, Revision A September 2004

Series CA-6300 CA-CALC TM Compliance Protocol Emissions Analyzers Operation and Service Manual 1980505, Revision A September 2004 U.S. AND CANADA OTHER COUNTRIES Customer Service: Customer Service: (800) 861-7897/(651) 490-2707 (001 651) 490-2707 Fax: Fax: (651) 490-3824 (001 651) 490-3824 MAIL/SHIP TO: E-Mail TSI Incorporated answers@tsi.com ATTN: Customer Service 500 Cardigan Road WEB SITE Shoreview, MN 55126 www.tsi.com USA

Copyright TSI Incorporated / 2004 / All rights reserved. Part Number 1980505 Address TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA Fax No. (651) 490-3824 LIMITATION OF WARRANTY AND LIABILITY (effective July 2000) Seller warrants the goods sold hereunder, under normal use and service as described in the operator's manual, shall be free from defects in workmanship and material for twenty-four (24) months, or the length of time specified in the operator's manual, from the date of shipment to the customer. This warranty period is inclusive of any statutory warranty. This limited warranty is subject to the following exclusions: a. Batteries are warranted for 90 days from the date of shipment to the customer. Electrochemical gas sensors are warranted for a period of twelve (12) months from the date of shipment to the customer. b. Parts repaired or replaced as a result of repair services are warranted to be free from defects in workmanship and material, under normal use, for 90 days from the date of shipment. c. Seller does not provide any warranty on finished goods manufactured by others or on any fuses, batteries or other consumable materials. Only the original manufacturer's warranty applies. d. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with respect to, and shall have no liability in connection with, goods which are incorporated into other products or equipment, or which are modified by any person other than Seller. The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE. TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES, INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE GOODS. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS OR CHARGES. No Action, regardless of form, may be brought against Seller more than 12 months after a cause of action has accrued. The goods returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk of loss. Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY, which contains the complete and exclusive limited warranty of Seller. This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its terms waived, except by writing signed by an Officer of Seller. Service Policy Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers, our service policy is designed to give prompt attention to any problems. If any malfunction is discovered, please contact your nearest sales office or representative, or call TSI's Customer Service department at (651) 490-2707 or (800) 861-7897. ii

CONTENTS Introduction...vii Manual Purpose... vii Using This Manual... vii Warnings and Cautions... vii Chapter 1. Instrument Description...1 Chapter 2. Unpacking...3 Chapter 3. Component Identification...5 Case and Operation Platform...6 Probe for Gas Sampling...6 Permeation Dryer...6 Combustion Analyzer...6 Sample Ports and Thermocouple Inputs...6 Purge/Sample Valve...6 Serial Port and Printer/Computer Switch...7 Combustion Analyzer...7 The Gas Sensors...7 Optional Combustion Supply Air Thermocouple Probe...7 On-Board Temperature Measurement...7 Diaphragm Pump...7 Draft Sensor...7 Water Trap...7 Stack Probe Thermocouple...8 CO Diversion Valve...9 Instrument Mounting...9 Schematic Representation of CA-Calc Combustion Analyzer...9 Gas Sampling Probes...9 Drying Probe D... 10 Standard Emission Probe E... 11 Calibration Adapter Supplies... 11 Chapter 4. Getting Started... 13 Supplying Power... 13 Installing Batteries... 13 Connecting the Gas Sampling Drying or Emission Probe... 13 Setting the CO Diversion Valve... 14 Connecting the Optional Combustion Supply Air Temperature Probe... 14 Printer... 14 Connecting to a Computer... 14 Default Instrument Settings... 15 Factory Defaults (U.S.)... 15 Factory Defaults (Non-U.S.)... 15 Default Settings For Different Model Letter Designations... 16 Chapter 5. Basic Operation... 17 Quick Start... 17 Steps to Quick Startup... 17 Baseline Calibration... 18 The Main Data Display Screen... 19 Available Measurements... 19 Buttons and Button Operations... 21 ON-OFF Control Button (red)... 21 The ENTER Control Button... 21 The ESC Control Button... 21 iii

Arrow Control Buttons... 21 Icon Buttons... 22 Labeled Buttons... 22 Selecting Menu Items... 23 Changing a Number Value... 23 Changing Units... 24 Entering and Changing Names... 24 Using the Sampling Probe... 24 Gas and Temperature Measurements... 24 Dryer Installation... 26 Making a Draft Measurement... 27 Auto Draft Meas. Feature... 27 Printing to the Portable Printer and to a Computer... 27 Printing... 27 Printing to a Computer... 27 The Test Protocol Option... 29 Logging Data Continuously... 29 Reviewing the Saved Data... 29 Chapter 6. MENU Selections and Menu Items... 31 Instrument Setup... 32 Calibrate Sensors... 35 Restore Factory Cal... 35 Set Contrast... 35 Set Time and Date... 36 Fuel Setup... 36 Fuel Setup When Siegert Loss Calculation Used... 37 Restore Fuel Settings... 37 Chapter 7. Using the Built-in CTM 034 Test Protocol... 39 Overview... 39 A CTM 034 Gas Measurement Test... 39 Step 1. Instrument Calibration (recommended)... 39 Performing a Gas Measurement Test using CTM 034 Test Protocol... 40 What You Will Need... 40 Step 1. Calibration... 40 Step 2. Pre-test Verification... 40 Data Display During Verification... 41 Step 3. Performing the Source Test... 41 Step 4. Post-test Verification... 42 Viewing Pre-Test and Post-Test Verification Data... 42 Viewing the Source Test Data... 42 Printouts of Pre-Test Verification Tests and Post-Test Verification Tests... 43 Printouts of Source Tests... 44 Repeatability Testing... 45 Test Results for CTM 034 Test... 45 Explanation of Test Results... 45 Sensor Measurement Correction using Pre-Test and Post-Test Verifications... 45 Basic Rules Applied for Source Test Correction using Pre-Test and Post-Test Verifications... 46 Notes on CTM 34 Emission Calculations Performed By Your Compliance Protocol Emissions Analyzer... 46 Chapter 8. Calibrations and Verifications... 49 Gas Sensors... 49 TSI Calibration Gases... 50 Calibrating the O 2 Sensor... 50 Calibration Steps... 50 iv Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Calibration of the CO (Hydrogen Compensated) Sensor... 50 Calibration Steps... 50 Calibration of NO, NO 2, SO 2 Sensors... 51 Calibration Steps... 51 Draft Sensor Calibration... 51 Calibration Procedure... 51 Stack and Supply Air Thermocouple Calibration... 52 Calibration Procedure... 52 Chapter 9. Maintenance and Troubleshooting... 53 Emptying Water Trap... 53 Changing the Water Trap Filter... 54 Sample Probe Maintenance... 54 High Concentration Overload... 54 Adding or Replacing a Gas Sensor... 54 Sensor Positions... 55 Replacing a Sensor... 55 Adding a New Sensor... 57 Troubleshooting Chart... 58 Appendix A. Calculations... 61 O 2 Reference Concentration Calculation... 61 Excess Air Calculation... 61 Calculating Combustion Efficiency... 61 Determining CO 2 Using the O 2 Concentration... 62 Emission Rate Units Calculations Using Emission Factors... 62 A General Equation for the Combustion of a Simple Hydrocarbon in Air... 63 Calculating CO 2 Max From the Carbon Content... 63 Calculation of Combustion Air... 63 Appendix B. Series CA-6300 CA-CALC Combustion Analyzers Detailed Specifications... 65 Contents v

Introduction Manual Purpose This manual describes the operation and maintenance of TSI Series CA-6300 CA-CALC TM Portable Compliance Protocol Emissions Analyzers (Models CA-6315 and CA-6316). Using This Manual Before using the CA-CALC TM Combustion Analyzer for the first time, review this manual in its entirety. The manual assumes that you have a basic understanding of combustion analysis and are thoroughly familiar with your fuel burning equipment. When performing equipment adjustments, rely on good judgment and experience along with the measured data. This is especially important where safety issues are of concern. Equipment adjustments must always coincide with the fuel burning equipment manufacturer s recommendations. Warnings and Cautions! WARNING High temperatures and toxic gases are produced when fossil fuels are burned. Only qualified individuals, thoroughly familiar with operating and adjusting fuel-burning equipment, should use combustion analysis instrumentation for the purpose of making equipment adjustments. Note: Best results are obtained if the CA-CALC Combustion Analyzer is allowed to stabilize at the temperature of the test environment before using.! Caution Always use the water trap when sampling. Check the trap frequently during operation to prevent overfilling with condensed water. Empty often.! WARNING This device is not intended for use as a continuous monitor or as a safety indicator. Note: To reduce sensor exposure to gas and to reduce build up of water vapor in the sampling lines and water trap, turn the sampling valve to the PURGE position when not making measurements. vii

Chapter 1. Instrument Description The Series 6300 CA-CALC TM Compliance Protocol Emissions Analyzer is a portable system designed for measuring pollutant gases, combustion gases, supply air and stack temperatures, and draft pressure. At the heart of the compliance analyzer is a CA-CALC Combustion Analyzer. The combustion analyzer calculates a variety of combustion parameters including excess air, CO 2 level, and combustion efficiency. For compliance monitoring, the combustion analyzer has special firmware which leads you stepwise through the gas measurement process following the EPA Conditional Test Method protocol 34 (CTM 34). The CTM 034 test protocol was designed for testing with instrumentation such as the CA-CALC TM analyzer using electrochemical gas sensor technology. Emission data is presented on a large LCD display screen, downloaded to a computer or printed to a portable printer. Standard Compliance Protocol Emissions Analyzers Model Gas Sensors Gas sampling probe type CA-6315D-Kit O 2, CO, NO, NO 2 Drying probe, lined, with water permeation dryer CA-6316D-Kit O 2, CO, SO 2, NO 2 Drying probe, lined, with water permeation dryer CA-6315E O 2, CO, NO, NO 2 Emission probe, lined CA-6316E O 2, CO, SO 2, NO 2 Emission probe, lined Other models are available with different gas sensor combinations. Contact TSI for a complete list of equipment options. 1

Chapter 2. Unpacking Unpack the CA-CALC TM Compliance Protocol Emissions Analyzer and accessories from the carrying case. Check the individual parts against the list of components in the table below. Some items are internal and will not be apparent. If items are missing or damaged, notify TSI immediately. Qty. Item Part/Model 1 Compliance Protocol Emissions Analyzers Includes combustion analyzers with O 2, CO, and NO 2 electrochemical sensors. And either an NO sensor (Model CA-6315 style) or SO 2 sensor (Model CA-6316 style) Models with the Drying Probe ( D in the model name) are kitted with the vacuum pump listed below. CA-6315E CA-6316E CA-6315D-Kit CA-6316D-Kit Also included are the following items. Compliance case/operation platform Printer (installed) Printer Paper 1040125 1 Emission gas sampling probe with 12 in. sampling tube, 801952 water trap, and 25 ft sample hose. For Models with E in the model name. or 1 Drying emission sampling probe with 12 in. sampling tube, 802402 water trap, 25 ft hose, and permeation drying system. For Models with D in the model name. Pump for drying emission probe above. 802401 1 Calibration adapter supplies w/flow meter 802406 1 Power cable 120 V or 230 V European or 230 V Great Britain or 240 V Australian 1303053 1303075 1303230 1303229 1 Calibration certification 1 Operation and Service manual 1980505 1 Computer cable, 9-pin 1303721 Accessories and replacement items 1 NO sensor (internal) Model CA-6315 802266 1 NO 2 sensor (internal) 802267 1 O 2 replacement sensor (internal) 802263 1 CO (hydrogen compensated) (internal) 802264 1 SO 2 sensor (internal) Model CA-6316 802268 Water trap filters 801947 Replacement kit, emission probe filter 801944 Gas Calibration kits (U.S. only) CO (hydrogen compensated) NO NO 2 SO 2 O 2 zero calibration kit (N 2 ) 801923 801937 801938 801936 801939 Probe heat shield 801969 Water trap replacement 802215 Lithium battery 1208028 3

4 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Chapter 3. Component Identification The compliance analyzer instrument module is shown below with key components identified. 1 2 3 4 11 8 5 9 6 10 7 13 12 1. Case and operation platform 8. Printer/computer switch 2. Probe for sampling gas 9. Serial interface for computer 3. Permeation dryer (not present for E models) 10. AC Power connection 4. Combustion analyzer 11. Printer 5. Thermocouple inputs 12. Purge air source fitting 6. Gas sampling ports 13. Platform panel 7. Purge/sample valve Figure 1: Compliance Protocol Emissions Analyzer 5

Case and Operation Platform The case provides storage for key components and has been designed as the operation platform for emission gas measurements. Probe for Gas Sampling The gas sampling is stored behind a hinged panel in the top of the instrument case. Two types of probes are available and are selected depending on gas measurement requirements. One is provided with a drying apparatus which facilitates water removal from the sampled gas stream. Water removal extends sampling duration and reduces loss of soluble gases (NO 2 and SO 2 ). A second probe model does not have the drying apparatus but is designed for measurement of NO 2 and SO 2. The gas probe is connected at ports on the platform panel. Permeation Dryer The permeation dryer is provided with compliance analyzer models having the D extension in the model name. The dryer enables the compliance analyzer to sample from high dew point exhaust flows for extended periods without needing to drain the water trap. The permeation dryer also inhibits losses of NO 2 (and SO 2, Model CA-6316) by removing water quickly, before the gases are dissolved out by condensing water. The permeation dryer is a sophisticated and expensive item and should be handled with care. The permeation dryer is stored as shown in the figure above. Not shown is the high-vacuum pump, a component for the drying probe. Combustion Analyzer The combustion analyzer is the heart of the CA-CALC TM Compliance Protocol Emissions Analyzer and measures flue gas concentrations, temperatures, and draft pressures. The combustion analyzer provides a display with detailed measurement information in real-time, performs calculations of combustion efficiency and as needed for pollutant emission gas assessment, and is capable of saving many gas measurements for immediate or future output to the onboard printer or a computer. The combustion analyzer is mounted in the operation platform using magnets and is not removed except for periodic maintenance such as electrochemical sensor replacement or battery replacement. Typically the compliance analyzer is used with AC power so battery replacement is not needed. Sample Ports and Thermocouple Inputs Sample ports and thermocouple inputs for connecting the gas sample probe are found at the lower left of the operation panel. Under the panel, tubing and thermocouple wiring is routed to the combustion analyzer. The sample gas line is identified by a yellow ring on the sample tube. This is matched to the yellow O-rings on the sample port. Purge/Sample Valve This valve switches gas flow from the sample port to the purge port. The valve should be turned to the Purge position (i.e., sampling room air), when not sampling exhaust gas. The valve must also be in the Purge position when performing baseline calibrations. 6 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Serial Port and Printer/Computer Switch The 9-pin serial connector is used to transfer saved data to a computer (PN 1303721). The switch to the left of the connector should be toggled in the direction of the connector for data transfer. Before you can successfully communicate with a computer, the baud rate of the CA-CALC analyzer must match that of the computer and the RS232 Device setting must be set to the same setting as the toggle switch Computer or Printer. To set the Device, refer to Instrument Setup in Chapter 6, MENU Selections and Menu Items. Combustion Analyzer The CA-CALC TM Combustion Analyzer is installed in the instrument module case with connections for gas sample, draft and temperature and power made at the connectors identified below as items 12-17. Combustion analyzer is secured by magnets (7) contacting the angled metal surface. The instrument is removed if batteries are required or for replacement of electrochemical sensors. Typically the instrument is not removed. Key components of the CA-CALC TM Combustion Analyzer are identified in Figure 2. The Gas Sensors The CA-CALC analyzer holds up to four electrochemical gas sensors. Oxygen (O 2 ) and hydrogen compensated carbon monoxide [CO(H 2 )] sensors are standard, included with all Series CA-6300 CA-CALC Combustion Analyzers. Two of the following sensors can also be added: nitric oxide (NO), nitrogen dioxide (NO 2 ), sulfur dioxide (SO 2 ) and high concentration carbon monoxide (COhi). The gas sensors are found under the sensor cover identified in Figure 2 below. Optional Combustion Supply Air Thermocouple Probe A measurement of the Combustion Supply air temperature is made using an optional thermocouple accessory probe (TSI PN 3013003). This probe is connected to the supply air temperature port. Combustion supply air temperature is an important value used in the determination of flue losses and efficiency. On-Board Temperature Measurement The CA-CALC analyzer uses an on-board resistance temperature detector (RTD) to provide the combustion supply air temperature when no supply-air accessory probe is present. Diaphragm Pump The CA-CALC analyzer samples exhaust gases from the flue and delivers them to the electrochemical sensors using a long-life diaphragm sampling pump. Draft Sensor A differential pressure transducer in the CA-CALC analyzer is used to measure draft pressure. The transducer has a measurement range of ±30 in. of H 2 O (7.47 kpa). Water Trap The water trap shown in figure 3b is used with Emission type probes to remove moisture that collects in the sample tubing when combustion gases are sampled. Water must be prevented from entering the instrument through the sample port. The water trap uses two chambers and a hydrophobic coalescing filter to maximize water removal. Chapter 3. Component Identification 7

2 1 3 4 7 8 9 5 6 12 13 15 14 16 17 11 10 1. Label buttons 10. Battery cover 2. LCD display 11. Battery cover tab 3. On-Off button 12. Port for stack gas thermocouple probe 4. Control buttons 13. Port for combustion supply air thermocouple, type K 5. Icon buttons 14. RS232 serial port 6. CO diversion valve 15. Power connection 7. Magnets 16. Draft sample port 8. Vent 17. Gas sample port 9. Sensor cover Figure 2: CA-CALC Combustion Analyzer Components Stack Probe Thermocouple The type K thermocouple probe extends through the SS sampling tube to its tip, where stack temperatures are measured. The thermocouple probe measures temperatures up to 1800 degrees F. The yellow or green thermocouple connector plugs into the stack thermocouple port (labeled). Note: When making temperature measurements, maintain the position of the probe in the flue until the temperature reading has stabilized. For faster temperature measurement, when determining combustion efficiency, a Model 801940 Sampling Probe is recommended. 8 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

CO Diversion Valve The CO diversion valve is used to divert high concentrations of carbon monoxide (>5000 ppm) away from the hydrogen compensated CO sensor. High CO concentrations cause the sensor baseline value to shift upward. Although the effect is temporary, it may take ten minutes or longer for the sensor to recover. A shift upward in the sensor baseline means the CO sensor indicates a concentration that is higher than the true concentration. Instrument Mounting The combustion analyzer is adhered to an angled metal bracket in the case using magnets. The bracket orients the instrument for convenient viewing and button operation. When removing the analyzer, lift up on the back and carefully lift up. Separate each electrical and flow connection by pulling down and away from the instrument. Schematic Representation of CA-Calc Combustion Analyzer Sampling Probe Gas Sensors [S1 & S2; NO, NO 2, SO 2, COhigh (optional)) O2 S1 S2 CO Orifice Pump CO Diversion Valve Exhaust Water Trap Draft Sensor Flue Gas Temperature Thermocouple Probe for Combustion Air Temperature (optional) Gas Sampling Probes The Model CA-6315D Compliance Protocol Emissions Analyzer is shown below. Models with a D at the end of the model number are supplied with TSI s Drying Probe. This probe is equipped with a permeation drying system which continually removes moisture from gas sample. Continuous moisture removal enables extending sampling without need to drain the water trap. Moisture removal also reduces the loss of sampled NO 2 and SO 2 gases which Chapter 3. Component Identification 9

are dissolved out in the presence of liquid water. The permeation dryer removes water in the vapor phase. A pump, pulling at a high vacuum, draws off the moisture without extracting the gases to be measured. Models having the E designation at the end of the model number, e.g., Model CA-6315E, are provided with a non-drying probe. This probe has a non-reactive lined sample tube to limit loss of reactive gases. Both the drying and emission probes have a sintered metal filter on the probe tip to reduce soot buildup in the sample line. Both probe types have integral thermocouples for stack measurements and separate color coded tubes for draft and gas sample measurements. Drying Probe D The drying probe shown below, uses a high vacuum pump (3) to pull air at low pressure across a tube bundle in the permeation drying tube (2). The orifice (7) creates a low pressure around the bundle facilitating the drying process. Tubing from the vacuum pump is connected using quick disconnect fittings (6). The water trap (1) retains moisture which may accumulate at high sampled dew points. 4 1 2 6 5 7 8 3 Figure 3a: Drying Probe Components 1. Water trap 6. Vacuum tube connection 2. Permeation dryer 7. Orifice 3. High vacuum pump 8. Vacuum tubing 4. Sampling probe 5. Sintered metal soot filter 10 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Standard Emission Probe E The standard emission probe is shown below. This probe is used for low moisture sampling or short duration sampling. 4 1 2 3 5 Figure 3b: CA-CALC Emission Probe Components 1. Water trap 4. Probe handle 2. Gas sample, draft tube with wires for thermocouple 5. Sintered metal soot filter 3. Probe sample tube Calibration Adapter Supplies The calibration adapter supplies consist of tubing, a tee, a tubing reducer, and flow meter. These components are used to connect the probe end to certified calibration gas during instrument calibration and for verification testing. The illustration below shows the attachment to the gas sampling probe end using the tubing. A schematic showing the complete calibration setup is provided in Chapter 8, Calibrations and Verifications. Probe Tip 3/8 tubing Adapter fitting To calibration gas Figure 4: Calibration Adapter Chapter 3. Component Identification 11

Chapter 4. Getting Started Supplying Power Power is supplied at the universal AC connector found at the lower right of the panel. Pull up on the connector to extend it or feed it back through the grommet to reduce its length. U.S., European and Asian voltages can be applied at this connector. The CA-CALC TM Portable Combustion Analyzer can use four C-cell batteries as an alternative to the AC power. Quality alkaline batteries enable the instrument to operate for 24 hours. If AC power is not used, the printer as well as the combustion analyzer will rely on batteries. Rechargeable batteries in the printer must be charged prior to use. Installing Batteries Lift the combustion analyzer up at the back, releasing the magnetic hold. If care is taken, there should be no need to disconnect tubing and thermocouple connections. Turn the combustion analyzer over and remove the battery cover by lifting up and out on the battery cover tab shown to the right. Remove the old batteries. Note: It is not necessary to remove the battery holder when removing or installing batteries. Best results are obtained if the batteries opposite the contact springs are removed first. Install four new C-cell batteries, noting the battery orientation depicted on the base of the battery holder. Install spring-side batteries first. Connecting the Gas Sampling Drying or Emission Probe The gas sampling probes depicted in Figure 3a, and 3b are connected to the instrument by pushing the sample and draft connectors over the matting fittings on the panel. Refer to figure 5. A bit of silicone grease on the O-rings is recommended. Stack Thermocouple (green or yellow connector, Type K ) Draft connection Gas sample connection Figure 5: Sampling Probe Tube and Thermocouple Connections 13

Setting the CO Diversion Valve Set the CO diversion in the orientation shown in the figure below. The valve is found at the back of the combustion analyzer. In the position shown, the valve is open, allowing gas to flow to the CO sensor. The valve should be closed under conditions where the CO level is very high (above 5000 ppm) for extended periods. To close the valve, turn it 90 degrees counterclockwise. Normal Orientation for the CO Diversion Valve Figure 6: Normal CO Diversion Valve Orientation Connecting the Optional Combustion Supply Air Temperature Probe A Type K thermocouple probe (TSI PN 3013003 or user provided) is used to measure the temperature of the air supplied to the burner; the Combustion Supply air. When a probe is not used, the supply air temperature is measured using the on-board resistance temperature detector (RTD) in the combustion analyzer. Connect the optional supply air thermocouple (see Optional Combustion Supply Air Thermocouple Probe ) to the Supply Air thermocouple port labeled on the lower left of the panel. The miniature thermocouple connector plugs in only one way. Do not force the connector. Printer The printer is found to the right of the combustion analyzer. The printer is secured with magnetic material applied to its base. A serial connection is made at the back, power is applied from the left. The printer and CA-CALC Combustion Analyzer have both been factory set for a baud rate of 1200. If baud rates are different, the printer will print random characters, question marks, or asterisks. Printer settings are described in the printer manual, along with illustrations identifying the correct DIP-switch configuration. You will also need to set the RS232 Device setting to Printer. To set the CA-CALC baud rate and device settings, refer to Chapter 6, MENU Selections and Menu Items. Connecting to a Computer Use the optional computer interface cable, Model 8940, to transfer (download) data directly serially from the compliance analyzer to a computer. When downloading from the case, the 9-pin serial connector is used to transfer saved data to a computer (PN 1303721). The switch to the left of the connector should be toggled in the direction of the connector for data transfer. 14 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

You will need to do two things before you can successfully communicate with a computer. First make sure the baud rate of the CA-CALC analyzer matches that of the computer. Second, make sure the RS232 Device setting is set to Computer and not Printer. To set the Device, refer to Instrument Setup in Chapter 6, MENU Selections and Menu Items. Default Instrument Settings The CA-CALC Combustion Analyzer uses a number of standard settings for presenting the data, performing calculations, and controlling instrument operation. These include the units displayed, the fuel used, the baud rate, and so on. When shipped, these have factory pre-set Default settings. The default settings are listed below. Default settings can be changed as described in Chapter 6, MENU Selections and Menu Items. Factory Defaults (U.S.) Gas Concentrations Temperature Fuel* O 2 REF O 2 Draft: Excess Air: Effc./Loss Fuel Heat Auto Draft Meas. PPM (parts per million), applicable for CO, NO, NO 2, SO 2 sensors Degrees F Natural Gas OFF (do not incorporate O 2 reference in calculation of gas concentration) Reference level: 3% (not used if OFF selected above) Inches H 2 O %EA Net Efficiency High heating value used in calculations, units are BTU OFF Baud Rate 1200 RS232 Device CO Shutoff level NO Shutoff level Printer, configured for output to printer rather than to computer 2000 ppm. Turns the pump off if the CO level exceeds this set level 1000 ppm. Turns the pump off if the NO level exceeds this set level *Defaults extend to include factory set fuel parameter values for eight fuels. These fuels are; natural gas, propane, #2 fuel oil, #6 fuel oil, coal, wood, baggasse, coke. Factory Defaults (Non-U.S.) Instruments sold outside the U.S. are often set up with default units and settings different than those identified in the table above. The defaults installed depend upon the letter designation present in the instrument s Model number. For example a -D in Model number CA-6315D D indicates that Germany is the destination country and has appropriate units and settings installed. Other letter designations have the following meanings: -EU European, -M metric units, -UK United Kingdom, -AU Australia. The following table shows defaults relating to the instrument designations. Remember it is always possible to change the default settings. Chapter 4. Getting Started 15

Default Settings For Different Model Letter Designations x = 5 or 6 Instrument Model number O2 ref. O2 ref. Excess Level Draft Temp Air Effc./Loss Basis Effc./Loss Fuel heat Gas Conc. Decimals Fuel Setup CA-631xE CA-631xD CA-631xE D CA-631xD D CA-631xE EU CA-631xD EU off 3% In. H20 F %EA ASME/heat loss Net Efficiency BTU HHV PPM periods fuel composition parameters off 0% mbar C lambda Siegert qa NA PPM commas Siegert fuel parameters off 0% mbar C lambda Siegert qa NA PPM commas Siegert fuel parameters CA-631xE M CA-631xD M CA-631xE UK CA-631xD UK CA-631xE AU CA-631xD AU off 0% kpa C %EA ASME/heat loss off 0% kpa C %EA ASME/heat loss off 0% kpa C %EA ASME/heat loss Net Efficiency Gross Efficiency Gross Efficiency kj/kg HHV PPM periods fuel composition parameters kj/kg LHV PPM periods fuel composition parameters kj/kg LHV PPM periods fuel composition parameters 16 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Chapter 5. Basic Operation Quick Start This chapter describes the steps needed to start making basic measurements. When used for the first time, the CA-CALC TM Combustion Analyzer parameter settings match the Defaults listed in the previous chapter. To select different instrument parameter settings refer to Instrument Setup in Chapter 6, MENU Selections and Menu Items. Steps to Quick Startup 1. Review Chapter 4, Getting Started. Perform the necessary hardware setups. 2. Turn the instrument on using the red ON-OFF red button identified in Figure 2. 3. Supply power through the AC power cord (preferred) or verify that you have adequate battery life for your measurement needs. A 50% reading for example, indicates 8 to 12 hours of additional operating life. Your printer must also have an adequately charged battery. 4. Press the ENTER button. A brief initialization follows. If the Error screen appears, refer to Chapter 9, Maintenance and Troubleshooting. 5. Review the Pre-Test screen. The O 2 sensor should indicate approximately 20.9% and other gas sensors indicate near 0 ppm. The draft reading should be 0. 6. Press ESC to bypass the baseline calibration. 17

Baseline Calibration To perform a baseline calibration, press ENTER from the Pre-Test screen. A baseline calibration reestablishes baseline levels for the electrochemical sensors and draft sensor. When performing a new baseline calibration, make sure the probe is in air free of exhaust gases (or disconnected). The baseline calibration takes about 40 seconds. To abort the baseline calibration, press ESC. The data display screen appears when the baseline calibration is complete or bypassed. Figure 7: Schematic Illustration of Quick Start Process 18 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

The Main Data Display Screen Refer to the figure below to identify the key components of the main Data Display screen. O2 Reference status Data Logging indication if in Data Logging mode. Time and date Message area Total Records indicated if in Data Logging mode Battery life Indication Fuel type Button icons Measured and calculated data, updated in real time. Appearance will depend on sensors present. Refer to the table which follows to identify measurements. Press Test Protocol button displays a options for emission gas measurements using CTM 034 test protocols. Pressing button under this label stops pump operation and zeros the draft sensor Button label for main menu. Used for instrument setups. See Chapter 6. Figure 8: The Main Data Display Screen Available Measurements The CA-CALC Combustion Analyzer in your compliance analyzer automatically detects the sensors installed. Only measurements for detected sensors appear on the display. For example, if no carbon monoxide sensor is present, CO will not appear on the display. For values that are calculated, such as efficiency (Effc), sensors that provide Chapter 5. Basic Operation 19

data for the calculation must be present. If the O 2 sensor data or stack temperature data is missing, efficiency will not be calculated and Effc will not be displayed on the Data Display. The following table presents a list of the measurements and calculations made by the CA-CALC analyzer. These will appear on the Data Display if the appropriate sensors are present. O 2 Oxygen concentration. 0 25% CO NO NO 2 NO X SO 2 (Model CA-6316x)* Carbon monoxide concentration measurement made using the hydrogen compensated CO sensor. 0 5000 ppm Nitric oxide concentration 0 4000 ppm Nitrogen dioxide concentration. 0 500 ppm Concentration combining NO and NO 2 concentrations. When a NO 2 sensor is not present, the NO X concentration is assumed to be 5% of the NO concentration. No NO X is displayed if the NO 2 sensor alone is present Sulfur dioxide concentration. 0 4000 ppm TA (optional) The combustion supply air temperature. Only present when the accessory probe is used. 20 392 F (0 200 C) TAint TS Draft The temperature measured using the on-board RTD. Stack temperature. Displayed when thermocouple is plugged in. 32 1800 F (0 1000 C) The Draft measurement. Only updated when the pump is off. ±30 in. H 2 O (80 mbar) CO 2 The carbon dioxide concentration in %. Based upon the O 2 measurement and fuel CO 2 Max parameter. COr The ratio of CO to CO 2. ppm CO/(%CO 2 x 10000) EA% Lambda (λ) Effc Loss % Excess air. Alternative excess air representation to %. Combustion Efficiency, Net or Gross and (100 qa) Dry gas loss and Siegert (qa). * Special note: The SO 2 sensor has a negative response to NO 2 gas proportional to the NO 2 concentration. The CA-CALC analyzer corrects for the effect of NO 2 on the SO 2 sensor if an NO 2 sensor is present. A correction is also performed for the effects of NO 2 when a NO sensor is installed. In this case, the NO 2 concentration is assumed to be 5% of the NO measured concentration. The response of each SO 2 sensor to NO 2 is determined at the factory as part of the SO 2 sensor calibration. 20 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Buttons and Button Operations ON-OFF Control Button (red) Turns the instrument on and off. Pressing this button is accompanied by a beep. The ENTER Control Button Press the ENTER button to execute a command, such as selecting a menu item. Most instrument display screens have a message indicating the ENTER button function. Note: Pressing ENTER does not cause entered values to be saved to the instrument memory. Buttons with display labels such as SAVE & EXIT or ACCEPT are designed for saving. The ESC Control Button Press the ESC button to exit the current screen and operation, in most cases returning to the previous screen. Arrow Control Buttons The arrow buttons are used for three purposes: Purpose 1. To move the display cursor to a menu item for selection using the ENTER key. The display cursor appears as a dark background over light characters. Example: Instrument Setup Purpose 2. To move the character cursor to a character or character space. Example: Name: NAT GAS Character cursor on letter T. Purpose 3. To increment a numerical value or select a character from the character menu. When a blinking cursor box is present, the arrow keys cause the value in the box to change; ON toggles to OFF, a Name character steps through a set of characters, or a number value increases or decreases. Chapter 5. Basic Operation 21

Icon Buttons Button Icons appear on the right side of the display and are connected to an Icon button by an indicator line. The button icons correspond to the button functions described below. You will see that some icons change when the button is pressed, indicating a change in a current status (e.g., pump on/off). Icons Icon Description Back Light button icon. Left icon indicates light off, right icon indicates light on. Pump On-Off button icon. Left icon indicates pump off, right icon indicates pump on. Print a Sample. Press the button to the right of this icon to output the current data displayed on the Data Display screen through the serial port to the portable printer or a computer. Fuel. Press this button to change fuel types Draft Measurement. Press this key to take a draft measurement. This causes the pump to stop. A countdown begins during which time the draft reading is stabilized and taken. Log Data. Select for continuous data logging functions. Labeled Buttons Button labels appear in boxes such as those shown below. The labels have tabs that connect to a button, performing the labeled function, by an indicator line. Examples are shown in the illustration below. Label Box Indicator Line Button Tab 22 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

If no tab is present on a box, it is not linked to a button and is a message box. A good example of a message box is shown below. Message Box Selecting Menu Items Menus are lists of items or options you select to perform a needed operation. Selection of a menu item begins by moving the display cursor to the item and pressing the ENTER button. The display cursor is moved using the Arrow buttons. Example: Display Cursor Display Cursor Instrument Setup Calibrate Sensors Restore Factory Cal Set Contrast... Once the ENTER button is pressed, a new menu may appear with a new list of option items, or you may see a blinking cursor indicating that a number value, or unit value can be changed. If you want to back-out of a selection, simply press the ESC button. Changing a Number Value The CA-CALC Combustion Analyzer has a variety of number values that are changeable. Examples are the Contrast level, Time and Date, O 2 Reference, and so on. Press the ENTER button on the list item to initiate a change. A value becomes changeable when a blinking cursor box surrounds it. Example: Changeable number value. Contrast: 50 Blinking cursor indicates value can be changed using the Arrow buttons. Use the Arrow buttons to increase or decrease the indicated value. Note there are upper and lower limits on values. When an upper or lower limit is reached, the numbers wrap around. Use the SAVE & EXIT button to install the new value. Chapter 5. Basic Operation 23

Changing Units Data displayed by the CA-CALC analyzer can be presented in different units. To change units, first select Instrument Setup from the main MENU. Use the Arrow buttons to select from the list of available units. Press ENTER to make a selection. A blinking cursor box over the selected unit indicates that it is changeable. Use the Arrow buttons to change between available units. Press ENTER once the desired units are shown, then use the SAVE & EXIT button to install the new unit. Refer to Instrument Setup in Chapter 6, MENU Selections and Menu Items, for specific information on unit types. Entering and Changing Names Names include the fuel types, source tests, and logged data identifications:. To create or edit a name, use the Arrow buttons to move the cursor to the desired character space and press the ENTER button (see the example below). The blinking cursor indicates that a character can be changed or added if none exists. Note: A character table is displayed when ENTER is pressed. Use the Arrow buttons to choose any character in the table. Press ENTER to install the selected character. Repeat this process to enter all your required characters. When the entries are complete, press the SAVE & EXIT button to install the name. Example: Name entry for fuel setup Move character cursor with Arrow buttons. Select A B C D using the ENTER button. Name: Blinking cursor after ENTER. Change character with the Name: A B C D Arrow buttons. Use ENTER to accept character. Finish by pressing the SAVE & EXIT button to install new name. To select an item from a menu list use the Arrow buttons to highlight the item, then press ENTER. Using the Sampling Probe Gas and Temperature Measurements Connect the sampling probe to the compliance analyzer as described in Chapter 4. Place the Sampling probe through a hole in the exhaust flue, following recommendations presented below. Placement of the probe is important, and certain considerations must be given when choosing a sampling location. To ensure that the gas measurements are not diluted or cooled by outside air, place the probe before any draft damper or regulator as illustrated in Figure 9. Tilt the probe tip up slightly so vapor condensing in the sampling tube does not run back to the probe tip and cool the thermocouple tip. 24 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

1. Sampling probe 3. Exhaust flue 2. Draft regulator 4. Hot exhaust gases Figure 9: Sampling Probe Location Stack temperature measurement is important to establish the heat loss from the exhaust gases and determine combustion efficiency. The Sampling Probe with its integral thermocouple measures temperature at the probe tip. The tip should be placed at the point of highest exhaust gas temperature when determining efficiency. This means at the base of the flue, before heat is lost to the flue side-walls, and towards the center, especially for small ducts. If the stack gas temperature is underestimated, the operating efficiency will be overstated. When an economizer or air heater is used, the stack temperature is measured after these devices. Note: Allow adequate time for the temperature to stabilize before accepting the combustion efficiency measurement (5 10 minutes). The metal filter must come to temperature.! Cautions Hot probe! When removed, the sampling probe will be extremely hot. Avoid touching the probe tip, and avoid placing the probe on or near plastic materials such as the instrument case. These will melt. Maintain a minimum 2 in. (5 cm) clearance between the probe handle and position collar when the probe is mounted in flue. Empty Water Trap! Watch the water trap and empty it frequently to prevent the possibility of flooding the instrument. See Chapter 9 for instructions. Chapter 5. Basic Operation 25

Dryer Installation The permeation dryer is installed in the gas sample path, beneath the probe handle, using the quick-connect fitting. Connect the vacuum supply tube to the mating fitting on the dryer and to the vacuum pump using the quick-connect fittings. To operate, simply turn the pump on during sampling. Moisture from the gas sample is drawn through multiple tubes in the dryer and transported to the exhaust of the vacuum pump. Refer to the section on the drying probe in Chapter 3 for an additional picture of the drying probe assembly. Permeation dryer Quick-connect fittings Connect pump tubing to the dryer using the quick-connect fittings Connect the dryer to the probe handle. Probe handle Connect the back of the dryer to the sample tubing using the quickconnect fittings Vacuum supply tube Pump handle Vacuum Pump Connect the vacuum supply tubing to the pump. 26 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

Making a Draft Measurement Before making a draft measurement, zero the draft pressure transducer by pressing the ZERO DRAFT option button in the Data Display. For zeroing, make sure the sampling probe is out of the flue, or that the draft and sample fittings are disconnected from the instrument. Once zeroed, reinsert the sample probe and press the Draft Measurement icon button to initiate a draft measurement. During the draft measurement, the sampling pump is automatically turned off. When the draft measurement is complete, the pump turns on again. Note: Draft readings are also taken continuously whenever the pump is turned off. When the pump is turned on again, the current draft reading is captured, and remains displayed until the next time the pump is turned off or the Draft Measurement icon button is pressed. Auto Draft Meas. Feature The Auto Draft Meas. feature is used so that a draft reading is automatically taken whenever a sample is saved using the Save Data icon button. To activate automatic draft saving, set the Auto Draft Meas. item to On from the Instrument Setup menu. Printing to the Portable Printer and to a Computer Printing Instrument data can be output through the RS232 serial port to on board printer. Printer and instrument baud rate is factory pre-set. To print the information on the Data Display, press the Print a Sample icon button. The printer responds immediately once the button is pressed, producing a printout. Example printouts are shown in Figure 10. Data is also printed during when using the Test Protocol functions. Details are provided in Chapter 7. Printing to a Computer Use the print buttons and print functions to output data to a computer as well as to the portable printer. First refer to Connecting a Computer in Chapter 4, Getting Started.. The toggle switch depicted below must be set to the COMPUTER. Also, the RS232 Device must be properly set to Computer for error-free data transfer. This is selected in the Instrument Setup MENU option described in Chapter 6. Data transferred to a computer is the same as that output to a printer (see Figure 10); however, it is formatted differently and uses the Windows character set rather than DOS characters. Setting the RS232 Device tells the CA-CALC Combustion Analyzer how to output the data. Data transferred to a computer is tab-delimited so it can be more conveniently parsed when using spreadsheet applications such as Microsoft Excel. Data can be downloaded to a terminal emulator program such as the HyperTerminal, which accompanies the Windows operating system program. Look for HyperTerminal in the Accessories folder. In HyperTerminal, use the Capture Text option from the Transfer menu for recording instrument data. Windows and Excel are a registered trademarks of Microsoft Corporation. Chapter 5. Basic Operation 27

Communications Protocol Baud rate 1200 (default) Data bits 8 Parity none Stop bit 1 Flow none DATE: 01/01/99 TIME: 15:00:18 Fuel: Nat Gas O2REF: Off O2 6.0 CO 5 PPM NO 0 PPM NO2 0 PPM NOx 0 PPM TA 70 F TS 300 F Draft 0.01 inh2o CO2 8.4 % Lambda OVER Effc 84% DATE: 01/01/99 TIME: 15:00:18 O2REF: Off Fuel: Nat Gas Fuel Parameters: Carbon wt.: 79.9% CO2 max vol.: 11.8% Sulfur wt. 0.0% Moisture. 0.0% HHV(BTU/lb): 21869 O2 6.0 CO 5 PPM NO 0 PPM NO2 0 PPM NOx 0 PPM TA 70 F TS 300 F Draft 0.01 inh2o CO2 8.4 % Lambda OVER Effc 83.8 % Printout using the Icon button. Figure 10: Example Printouts for Standard Tests 28 Series CA-6300 CA-CALC Compliance Protocol Emissions Analyzer

The Test Protocol Option Your CA-CALC TM Compliance Protocol Emissions Analyzer provides a test protocol based on EPA conditional test method CTM-034. The test protocol has been designed specifically for use when making gas measurements using electrochemical sensor technology. The test protocol is supported by internal software in the combustion analyzer. The software provides the data structure, test interval timing, emission calculations, error checking, printouts and a stepwise procedure to perform pollutant emission gas measurements simply and accurately. Data is presented for use in report generation. Details are presented in Chapter 7 on the features and use of the Test Protocol. To begin use of the test protocol select button under the TEST PROTOCOL indication in the main data display. TEST PROTOCOL Logging Data Continuously A key feature of your CA-CALC TM Combustion Analyzer is the ability to save combustion and emission test data, automatically at pre-set intervals. Saved data can be retrieved later for printouts, downloaded to a computer, or used for comparison with other tests. Data is maintained by power supplied from a 2-year lithium battery on-board the instrument. Use the Data Logging option button to save up to 600 separate data sets automatically. When the data logging key is pressed, a list of options is presented. Data can be recorded at the interval selected, every 5 seconds, 1 minute, or 5 minutes. To begin testing and logging continuously, highlight a time interval and press the ENTER key. Testing begins immediately. Each test record is numbered beginning with one (1) until the maximum records are saved (600). The current sample record number is displayed at the top of the display, indicating the Total Records saved. To stop Data logging, press the Data Logging option key and select Stop Data Logging (highlight, press ENTER). Note that unless test records are deleted using the Delete All Logged Data option, new test record numbers will begin with the next number after that indicated by Total Records. To return to the Main Display screen press ESC after logging is stopped. Note: If the instrument is dropped, lithium battery power can be lost with subsequent loss of data. Important data stored on-board should be saved frequently to a computer or printed for a permanent record. Reviewing the Saved Data Data can be viewed and printed by selecting the View, Print Logged Data option. To view, set the Starting Record Number, using the up and down arrow keys, and press ENTER. To print the sample in the view, use the print button icon appearing on the right of the display. Chapter 5. Basic Operation 29