Teledyne Max-5 User Manual

OPERATING INSTRUCTIONS FOR

4/09/12

MAX 5

Portable Combustion Efficiency Monitor

D ANGER

HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING
SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS V OL TAGES EXIST ON CER T AIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR
A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
ONL Y A UTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SER VICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/

MANAGER.

P/N M39218

08/06/99

ECO # 99-032

INSTRUCTION MANUAL

MAX 5

PORTABLE COMBUSTION EFFICIENCY MONITOR

SALES ORDER:

SERIAL NUMBER:

Teledyne Analytical Instruments

16830 Chestnut Street
City of Industry, CA 91748

Phone: (626) 9341500
Fax: (626) 9612538
Web: www.teledyneai.com

TABLE OF CONTENTS

MAX 5 PORTABLE COMBUSTIBLE EFFICIENCY MONITOR

GENERAL DESCRIPTION

Introduction 1
Main Features 1

OPERATION OF CONTROLS, DISPLAYS, & INDICATIONS
Front Panel Controls 3
Back Panel Controls 4

PRINCIPLE OF OPERATION

Sensor Description 4
Temperature & Calculated Values 5
Sampling System Description 6

INSTALLATION AND START UP PROCEDURES
Precautions 9
Electronic Zeroing of Oxygen Section 10
Sensor Installation and Replacement 11

INSTRUMENT OPERATING PROCEDURE
Installation of Thermocouple 12
Initiating & Adjusting Air & Sample Flow 13
Temperature, Efficiency, & Carbon Dioxide Sections 13
Initial Calibration/Automatic Calibration 13
Manual Span (CO

& CO) 14

2

Manual Calibration (Optional) 15
Special Functions 16
Temperature Simulation 16
Cost Savings 16
To Store Readings 17
To Display Readings 17
To Print Readings (Optional) 18
To Test Keyboard 18
Automatic Data Output 18
To Print Instruction Manual 18
To Check the Version of Software 19
Electronic Zeroing of Oxygen

19

TABLE OF CONTENTS (continued)

ROUTINE MAINTENANCE

Scrubber 19
Battery Recharging 20
Battery Replacement 20
Sensor Replacement 21

OPERATOR’S CHECKS & ADJUSTMENTS
Messages 22
Failure Warning Signs

APPENDIX

To Print Stored Readings 24a
Material Safety Data Sheets (MSDS) 24b-g

LIST OF SPARE PARTS
DRAWINGS

LIST OF FIGURES

Figure
1 Display Panel 2
2 Membrane Keyboard 2
3 Back Panel 3
4 Location of Sensors (Top View) 11
5 Sample Probe With Built-In Thermocouple 12

LIST OF TABLES

Tables
1 Detector Response To Gases 8

23

MAX5 PORTABLE COMBUSTION EFFICIENCY MONITOR

GENERAL DESCRIPTION

INTRODUCTION

The MAX 5 Portable Combustion Efficiency Analyzer provides several special features and
applications. It directly measures oxygen, carbon monoxide, combustibles, and temperature
levels in a subject sample stream. The MAX 5 also includes microprocessor-based special
functions enabling the computer to calculate levels of carbon dioxide and combustion efficiency.
As an added bonus, the computer can calculate and display actual fuel cost savings (Compu­CentsTM), by using the efficiency level prior to an adjustment, the level after an adjustment, and
an average fuel cost as reference points.

The MAX 5 incorporates an internal microcomputer. The computer program resides in ROM
(read only memory) and is not affected by shutdown periods, loss of power, or battery failure.
However, the calibration parameters and stored measurement readings are retained in RAM
(random access memory) which requires operating power to protect it; thus, the information
stored in RAM will be lost if battery power is interrupted (during battery replacement, for
example).

The computer controls the display and reads the keyboard. A 12-bit analog-to-digital (A-D)
converter converts the output signals from the various measurement sensors and the
thermocouple into digital data that goes to the computer. The computer interprets this and
compares the data to calibration data you have entered. The computer displays the corrected
values on the LCD.

Also, the computer performs error checking and reporting, as well as the other special functions
available for selection via the special function keys.

The actual program that runs the computer is compiled into machine language for faster
execution and more efficient use of memory. It is not accessible by high-level interpreters, such
as Basic, and it is not available to the user for modification in any way.

MAIN FEATURES

1. Auto Zero. MAX 5 offers automatic zero calibration for carbon monoxide and
combustibles and automatic span calibration for oxygen. Also, you can adjust
them manually. You have to adjust the span calibration manually for carbon
monoxide and combustibles.

2. Stored Readings. The computer stores up to 20 sets of readings and reports them
to the LCD (Liquid Crystal Display) or to an optional serial printer.

3. Computer Memory. A 16-bit microprocessor and 40 kilobytes of memory are
standard.

4. ROM Instruction Manual. The MAX 5 stores an abbreviated but complete
instruction manual in ROM and prints the manual upon request.

5. Rechargeable Batteries. Nickel-cadmium batteries provide power to the unit for up
to 8 hours of continuous operation. You recharge the batteries by plugging a standard
power cord into a 115V receptacle. TBE/AI also offers 220V and 100V versions.

6. Proven Sensors. The MAX 5 uses Teledyne’s standard line of sensors, already proven
to be among the best in the instrumentation industry.

7. CO Analysis. Four ranges of CO analysis are available for the MAX 5; one standard
0-1000 ppm CO and three optional ranges - 0-500 ppm CO, 0-1% CO and 0-25% CO.

OPERATION OF CONTROLS, DISPLAYS & INDICATORS

Initial Display. Shortly after it is first switched on, the computer will test all its internal

functions and then automatically enter its normal operating mode. During this time, it will
display random segments on the LCD.

Temperature Display. Readings below 1000 degrees (Fahrenheit or centigrade) are read
directly (for example, 100 means 100 degrees). If a reading is over 1000 degrees, it will be
displayed as a number with two decimal places, and you must multiply by 1000 to get the actual
temperature. For example, 1.50 means 1.50 x 1000, or 1500 degrees.

Display Panel. A continuous updated LCD monitors O

, CO, CO2, Combustibles, Temperature,

2

& Net Combustion Efficiency. The membrane keyboard includes all needed controls to select
functions; display three parameters at once, control the sampling pump, and choose degrees
Centigrade or Fahrenheit as shown in Figures 1 & 2.

(INSERT FIGURES 1 & 2)

FRONT PANEL CONTROLS

Temp Key (°F or °C). This key, when pressed, determines which of the two available
temperature scales (toggles between degrees Fahrenheit or degrees Centigrade) will be used to
display temperature readings. See “Initial Calibration/Automatic Calibration” - “Temperature”.

O2 / CO2. Because both the oxygen and carbon dioxide readings occupy the top row of the

LCD, you press this key to display one or the other. To get a valid CO2 reading, you must select
the proper fuel (see “FUEL” below).

COMB/TEMP. You select either the combustibles or the temperature readings for display by
pressing this key. The readings appear in the center row of the display.

CO/EFFIC. You press this key to toggle between the carbon monoxide and calculated
efficiency readings. The readings appear in the bottom row of the display.

FUEL. This key is primarily used for CO2 calculation and efficiency readings. You must
choose one of the four pre-selected fuels (#2 fuel oil, #6 fuel oil, natural gas, or solid fuels such
as coal) so that the computer calculations will be valid. Pressing the FUEL key causes the fuel
selection (across the bottom of the display) to toggle through the four selections. When you see
the fuel that you are using, simply leave it that way, and the calculations will be valid for that
fuel.

CAL. Calibration is automatic for O2. MAX 5 also includes auto-zeroing for Carbon Monoxide
(CO) and combustibles, so the user need only set the spans. Calibration settings remain in
memory even when the power is off.

TELEDYNE LOGO. Used to exit from calibration procedures and used in conjunction with
calibration functions.

(INSERT FIGURE 3)

BACK PANEL CONTROLS

A. Thermocouple Connections for type “K” thermocouple supplied in probe (type “J”

optional).

B. Vent.

C. AC Power connection for recharging NiCad batteries, which provide up to eight hours

of operation.

D. Battery Power ON-OFF switch.

E. RS-232-C Serial output to provide:

* short-form Operations Manual
* up to 20 sets of stored data

* continuous flow of all six readings

F. Air Flowmeter with flow set valve to regulate air flow.

G. Sample Flowmeter with flow set valve to regulate sample flow.

H. Chemical Scrubber for removal of corrosive compounds, such as SO2,, H2S, and NOx.

I. Sample-in Port.

J. Coalescing Filter (to remove particulates and water) and filter-drop out pot.

PRINCIPLE OF OPERATION

SENSOR DESCRIPTION

Oxygen. The oxygen section uses Teledyne’s Micro-Fuel Cell, Class B-3 oxygen sensor (U.S.

Patent No. 3,429,796). The B-3 Micro-Fuel Cell measures the concentration of oxygen in a gas
stream. The analysis is specific for oxygen; i.e., the measuring cell will not generate an output
current unless oxygen is present in the sample gas. Therefore, the oxygen channel has absolute
zero, and no zero gas is required to standardize the analyzer. The standard range is 0-25%
oxygen, and you perform span calibration with atmospheric air as the span gas, where feasible.

Carbon Monoxide. The class F-1R* solid-state electrochemical sensor measures CO. The
solid- state design eliminates leakage. You zero the CO section against air and span with a span
gas that contains the measured component in a concentration equivalent to 80-90% of the
instrument’s maximum fullscale value. TBE/AI sets the standard measurement range at 0-1000
PPM.

Combustibles. The combustibles sensor is a low-temperature, catalytic bead type transducer in
a constant current-excited Wheatstone Bridge circuit. Two legs of the bridge are exposed to the
sample gas. The other two legs are passive elements.

Gas diffuses into the sensing element and oxidizes at the catalytic surface of the active or
measuring bead, causing its temperature to rise. The reference head is not catalytically coated,
so it is not heated by the combustibles. The difference in temperature and therefore resistance of
the otherwise matched pair of catalytic beads creates a signal in the bridge circuit.

Use of the uncoated reference bead compensates for the effects of temperature variations,
humidity changes, ambient pressure changes, and variations in line resistance. The beads are
installed in a housing that has a flashback arrestor screen at the sensing aperture to prevent flame
propagation into the process.

The combustibles readout is expressed in percentage LEL (methane equivalents). Air is the zero
gas, and the span gas follows the 80-90% fullscale rule. By far the most common range is 0-5%
methane equivalence (0-100% LEL), and the span gas for that range would be 3% to 4%

methane in nitrogen. In other cases, a hydrogen and carbon monoxide mixture might be used. In
the presence of catalyst poisons, the combustibles sensor will hold its sensitivity to a
hydrogen/CO mixture far longer than to methane; therefore, it is important to calibrate it with the
right mixture.

TEMPERATURE AND CALCULATED VALUES

Temperature. The MAX 5 uses a type “K” thermocouple. The temperature section includes

circuitry and software to linearize the thermocouple signal and provide a zero-point reference.
The temperature display reads in degrees Centigrade or degrees Fahrenheit depending on which
temperature you select.

Carbon Dioxide. Because carbon dioxide is a combustion product, and its concentration level at
any given time depends on how completely a given fuel is burned and its by-product of carbon
monoxide is oxidized, the computer is able to calculate the carbon dioxide level. The oxygen
and combustibles section readings and the fuel type you selected at the front panel are factors in
the calculation resulting in the carbon dioxide concentration on a dry basis.

*U.S. Patent No. 4,477,403; U.K. Patent No. GB21405S6B; France Patent No. 2546626.

Efficiency. The computer calculates the efficiency level. The reading, calculated from the
temperature and oxygen readings and the type of fuel selected, is not absolute; rather, it is a
relative indication of the degree of improvement achieved by adjusting the burner. The
efficiency is based on British Standards recommendations and is calculated from this formula:

Efficiency = 100--K3 -- _____K1 x T_____
K2 x (1 - O2)
21

Where: T = net temperature °C
O

= oxygen concentration %

2

K1 = fuel factor on hydrocarbon composition
K2 = theoretical maximum CO

concentration of flue gas

2

K3 = correction factor for latent heat (“wet” losses)

The values of K1, 2 and K3 for the four fuels covered by the MAX 5 are:

K1

K2 K3

Natural Gas 0.38 11.8 11.0
#2 oil 0.56 15.6 6.0
#6 oil 0.6 15.9 5.0
Coal 0.63 18.6 3.0

SAMPLING SYSTEM DESCRIPTION

The analyzer should be inspected and calibrated each time it is used. This includes inspecting
the filter/water trap and scrubber, checking the condition of the batteries, and calibrating the
instrument.

The sample gas and the ambient temperature must be between 32° and 122°F (0° to 50°C) for the
temperature compensation to operate properly. For maximum accuracy, the analyzer should be
calibrated at the same pressure, flow rate, and temperature anticipated in the sample gas. To
minimize water condensation in the instrument, the sample gas temperature should be
approximately the same as the ambient temperature of the analyzer. The sample gas temperature
should never be more than 10°F (5°C) above the analyzer temperature.

Measurement accuracy can be affected by abrupt changes in the ambient temperature. If
possible, place the analyzer in the environment where it will be used for at least one hour before
operation. This permits temperature stabilization of the thermistor and oxygen cell. Or, if
desired, recalibrate the oxygen analyzer section in the environment where it will be used.

All sample line tubing and fittings must be leak-free. Air entering the sample line under pump
suction can dilute the sample gas to a point where errors in readings will result. The sample line
can be connected to the analyzer with a short section of tubing.

Note: Certain types of plastic tubing (e.g. silicone tubing) contain plasticizers which can leach
from the tubing and cause readings on the combustibles section of the analyzer, and in extreme
cases damage the combustible sensor.

If too short a sample line is used, the sample gas may not have sufficient time to cool, resulting
in water being condensed into the analyzer sampling system. The introduction of liquid water
into the system can damage the pumps and/or temporarily affect performance of the oxygen
sensor (cause erroneous readings, etc.) and certain other components.

If the flue gas sample contains more water than the condensate trap can reasonably handle, it
may be necessary to install a larger trap upstream of the sample intake into the analyzer.

If span gas is connected to the analyzer sample intake without the pumps operating, “coking” (or
carbonizing) of the combustible sensor will occur. In most cases, the concentration of any
particular compound you expose the combustibles sensor should not exceed the LEL (Lower
Explosive Limits) of that compound.

Response factors have been determined to relate the sensor output of a specific compound to the
output obtained using methane. Table 1 shows a list of some typical compounds and their LEL
(Lower Explosive Limits) values. To determine the output of the sensor to any of the gases
listed, compared to the same concentration of methane, multiply the MAX 5 reading obtained by
the factor listed. For example, if the output is calibrated with methane at 2%, the output for
ethylene at 2% would be 2.0% X 1.26 = 2.52% methane equivalent.

If you want to establish a reading for a particular gas, you can calibrate with that gas.
Alternately, you can calculate what the Methane equivalency is for that particular gas and

calibrate the instrument with Methane, but make it read as if it were exposed to the gas of
interest. For example, if you calibrate with Methane and the MAX 5 reads 3%, but Propane
would read 4%, you calibrate with Methane and adjust the MAX 5 to read 4%.

TABLE 1

DETECTOR RESPONSE TO GASES

COMPOUND LEL* RESPONSE FACTOR

Methane 5.0 1.00
Hydrogen 4.0 0.86
Carbon Monoxide 12.5 0.32
Ethane 3.0 1.20
Ethylene 2.7 1.26
Acetylene 2.5 1.39
Propane 2.2 1.42
Propylene 2.0 1.33
Butane 1.9 1.54
Hexane 1.1 1.50
Cyclohexane 1.3 1.44
Heptane 1.05 1.59
Benzene 1.3 1.50
Pentane 1.5 1.45
Toluene 1.2 1.48
Ethylene Oxide 3.8 0.76
Methyl Ethyl Ketone 1.8 0.96
Methyl Acrylate 2.8 0.59

*Taken from Fire Hazard Properties of Flammable Liquids, Gases and Volatile Solids, National
Fire Protection Agency.

To determine the concentration of a compound present at the sensor from the MAX 5 reading,
when calibrated with Methane, divide the MAX 5 reading (in percent Methane) by the factor.
For example, if Ethylene is flowing by the sensor, and a MAX 5 reading of 2.0% is obtained, the
concentration of Ethylene would be:

MAX 5 Reading = 2.0% = 1.59%
Factor 1.26

For Hydrogen:

2.0
.86

For Carbon Monoxide:

2.0

= 2.32%

= 6.25%