TPI 709 User Manual

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Combustion Efficiency Analyzer

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Contents

1. Introduction

2. General Overview

3. Instrument Overview

3.1 Front View

3.2 Back View

3.3 Side Views

3.4 Top View

4. Basic Analyzer Controls

4.1 Turning The Analyzer On

4.2 Turning The Analyzer Off

4.4 Activating The Backlight

5. Combustion Analysis Overview

5.1 Procedure

5.2 Combustion Displays

5.3 Typical Test Locations

5.4 Typical Test Results

6. Function Selection

6.1 Function 1 - Thermometer

6.2 Function 2 - Manometer

6.3 Function 3 - Date / Time

6.4 Default Function - Combustion Analyzer

7. Saving Data

8. Recalling Data

9. Printing Data

Appendix A Specifications Appendix B Calibration & Service Appendix C Guarantee Appendix D Installing the Optional A773 Filter Appendix E Error Codes and Trouble Shooting Appendix F CO Alarm & Auto Power Off Settings Appendix G Manually Initializing Sensors Appendix H Resetting Pressure Sensor Zero Appendix I Technical Notes

1. Introduction

Thank you for purchasing TPI brand products. The TPI 709 Flue Gas Analyzer is a state of the art, easy to use analyzer designed not only to display and calculate the required readings from a flue but also to cover most of the other measurements associated with combustion. The instrument is ruggedly constructed and comes with a 3 Year unit and 2 Year sensor Guarantee.

2. General Overview

The TPI 709 combustion analyzer uses state of the art electrochemical sensors. This sensor technology provides the longest lasting, most accurate and reliable means for performing combustion tests. The sensors in your analyzer will need to be replaced periodically and calibration is recommended once every year.

Electrochemical sensors by nature are always active. Therefore the time the analyzer is off and not being used must be taken into account when determining sensor life. The sensors in your analyzer are warranted for two years. This warranty does not cover sensors damaged through misuse of the analyzer.

You should keep the batteries of your 709 fresh so power is constantly being supplied to your sensors.

The following guidelines will help prevent damage to your sensors:

Always use the mini pump filter when testing flue gases. Always periodically check and replace the mini pump filter as needed. Always make sure the in-line filter / water trap is installed properly. Always periodically check and replace the in-line filter as needed. Always remove water or condensation from the inside of the in-line filter / water trap assembly prior to performing tests. Always use the optional oil filter (p/n A773) when performing tests on oil burning equipment.

General Overview (Continued)

Never over saturate your sensors by performing tests on equipment with gas levels beyond the capability of you analyzer.

Always keep the A794 water trap / filter assembly clean and replace the filter as necessary. Replacement filter part number is A794F.

This manual will guide you through the functions of the TPI 709 which will give you many years of reliable service.

Your TPI 709 Flue Gas Analyzer comes complete with the following standard accessories:

• TPI 709 Instrument

• Rubber Boot (A765)

• Soft Carrying Case (A768)

• Flue Sampling Probe (A770)

• In-Line Filter assembly installed on Flue probe (A794)

• Temperature Probe (GK11M)

• Mini Pump Protection Filter Assembly and spare filters (A763)

• Exhaust Spigot (removable) (A764)

• Instruction Manual

( ) Denotes part number

Your TPI 709 Flue Gas Analyzer has the following options available:

• Infrared printer (A740)

• Spare In-Line Filter (A794F is a package of 5 filters)

NOTE: When selecting oil as fuel be sure to use the optional

3. Instrument Overview

3.1 Front View

Rubber Boot Protects the instrument from accidental damage

Display Large 3 Parameter Backlit LCD Display

Battery Condition Icon Shows condition of batteries.

Keypad Selects all available functions

Selected Fuel Type N GAS, LPG, LIGHT OIL, HEAVY OIL, OPT 1

(Bituminous Coal), OPT 2 (Anthracite Coal), OPT 3 (Coke), OPT 4 (Butane), OPT 5 (Wood), OPT 6 (Bagasse)

Rubber Boot

LCD Display

Keypad

Battery Condition Icon

Selected Fuel Type

NOTE: When selecting oil as fuel be sure to use the optional

oil filter (A773) or readings could become erratic. See Appendix E for installation instructions.

Scrolls through selectable fuels (see 3.1 ) Switches between Gross and Newt Efficiency (see 4.1.2) Switches between ºC and ºF (see 4.2.1) Moves up through the Stored Data Addresses (see 5, 6 & 7)

Moves down through the Stored Data Addresses (see 5, 6 & 7)

Scrolls through Combustion Analysis Displays Scrolls through Function Screens (see 4.1)

Turns temperature differential calculation ON/OFF (see 4.2.1) Turns ch2 temperature ON/OFF (see 4.3.1) Allows you to change the Date and Time (see 4.5) Allows you to choose a Stored Data Address (see 5, 6, 7, & 8)

Sends stored data to a separate infrared printer (see 7)

Allows you to view stored data on the display (see 6)

Stores readings to memory (see 8)

Scrolls through and selects analyzer functions (see 4) Turns Backlight ON and OFF (see 4)

Turns the instrument ON and OFF (see 3.1 & 3.2)

Recall

Store

Func

Scroll

Enter

3.2 Back View

Sample and Pressure Inlet Ports: Connection for Gas Sampling Probe (see

3.4, 5.2, 6.2)

Connection for Mini Pump Protection Filter (see 3.4 & 6.2)

Connections for Pressure Tubing: (see 3.4 & 6.2)

Calibration and Information Label: Displays calibration information and

Displays serial number

Battery Compartment: Holds batteries

Rubber Boot Protects the instrument

Calibration and Information Label

Battery Compartment

Rubber Boot

Connection for Mini Pump Protection Filter

Connections for Pressure Tubing

Sample and Pressure Inlet Ports

3.3 Side Views

Exhaust Port Port for connection of Exhaust Adapter

Infrared Window Window for sending stored data to IR Printer

(see 9)

Rubber Boot Protects the instrument from accidental damage

Exhaust

Port

Infrared Window

Rubber Boot

3.4 Top View

P (+) P (-)

Gas Sampling Port

T1 Socket Connection for thermocouple plug on flue probe

(see 5.2) Connection for any 'K' type thermocouple probe (see 6.1)

T2 Socket Connection for any 'K' type thermocouple probe

(see 5.2 & 6.1)

Gas Sample Port Connection for Gas Sampling Probe (see 5.2) P (+) Port Connections for Pressure Tubing (see 6.2) P (-) Port Connections for Pressure Tubing (see 6.2)

4. Basic Analyzer Controls

4.1 Turning The Analyzer On

Always: - Before turning on please ensure that the Mini Pump Protection Filter

assembly and the Temperature Sampling Probe complete with In-Line Filter or the Tubing & In-Line Filter for Leak Detection are not

connected to the Gas Sample

Port (see 2.2 or 2.4)

Press and hold down the Power Key and the TPI 709 will start its 30 second

countdown 'PURGE' will be displayed: - The instrument MUST be turned on in a clean air environment as the 30 second purge will set the Carbon Monoxide level to Zero and the Oxygen to 20.9%.

Ensure that the filters are clean and dry as dirty or wet filters will result in a loss

of flow rate and 'Lo Flo' will be displayed to inform you that filters should be changed

During the last 20 seconds of the 30 second purge time the user can scroll

through the following Fuels: - Natural Gas, LPG, Light Oil, Heavy Oil, OPT1 : Bituminous Coal, OPT 2 : Anthracite Coal, OPT 3: Coke, OPT 4: Butane, OPT 5: Wood (Dry), OPT 6: Bagasse by pressing the Up Arrow Key to select the Fuel they are working with. When desired fuel is displayed release the key, displayed fuel is now selected.

After the 30 second countdown the instrument is ready to take Flue, Temperature,

Pressure or Leak Detection readings and Combustion Display 1 will be the first display.

The 709 will auto power off if no keys have been pressed for 10 minutes and the CO level is below 15ppm. This feature can be disabled see Appendix F.

The Scroll/Enter Key allows you to scroll through the combustion displays as outlined in section 5.3. The Func Key is used to select the 709 function mode and allows you to set it to be a combustion analyzer, manometer, thermometer, or combustible leak detector. In addition, the Func Key is used to access the date and time display. See section 6 for more information on the Func Key.

4.2 Turning The Analyzer Off

NOTE: When selecting oil as fuel be sure to use the optional

oil filter (A773) or readings could become erratic. See Appendix E for installation instructions.

4.2 Turning The Analyzer Off

Always: - Before turning off return the instrument to a clean air environment and allow the Carbon Monoxide level to return to below 15ppm and the Oxygen level to return to 20.9% (± 0.3%) Press the Power Key to turn the instrument off:NOTE Should you attempt to turn the instrument Off and the CO reading is above 15ppm then the instrument will remain On and a short Beep will be heard. The Instrument can only be switched off if the CO is below 15ppm

The instrument has an auto shut off after 10 minutes should no keys have been pressed for this period and as mentioned above that the CO is below 15ppm. Should the CO be above 15ppm then the 10 minute auto shut off countdown will not begin till the CO has gone below 15ppm

4.3 Activating the Backlight

The display backlight can be activated at any time by pressing and holding down the Func Key for approximately 2 seconds. The backlight will automatically shut off after approximately 20 seconds to preserve battery life.

5. COMBUSTION ANALYSIS OVERVIEW

Testing for carbon monoxide, oxygen, and stack temperature is very important to the overall safety and efficiency of heating equipment. The following guidelines and descriptions are generic and meant to provide you with a basic understanding of combustion testing. TPI always recommends you contact the manufacturer of the device under test, obtain information specific to the device, and follow the procedures and safety guidelines for performing tests and affecting repairs.

In general, for most applications flue gas samples should be taken prior to the draft diverter or any other opening that allows room air to enter the system. This prevents room air from mixing with gases in the flue and diluting the test sample. To ensure accurate and consistent combustion tests, it is important gas and temperature samples be taken at the same location. This is easy with the TPI flue probe because the temperature sensor is an integral part of the probe.

Prior to taking a sample, the device under test should be on and operating. Putting the flue probe in the sample area prior to starting the device may cause saturation of the sensors due to the higher initial concentration of carbon monoxide that may be encountered upon start up. If this happens, allow your analyzer to purge in fresh air until the carbon monoxide level returns to 0 ppm and the oxygen level returns to 20.9%. This may take more than an hour depending on how saturated the sensors are.

The included figures show locations for performing tests on commonly encountered equipment. Remember to consult with the manufacturer of the device under test for specific test information.

NOTE: When selecting oil as fuel be sure to use the optional

oil filter (A773) or readings could become erratic. See Appendix E for installation instructions.

COMBUSTION ANALYSIS (Continued)

5.1 Procedure

1. Turn the 709 on as outlined in section 4.1. At any time you can activate the Backlight by holding down the Func/Backlight Key for 2 seconds. The backlight will automatically shut off after 20 seconds to preserve battery life.

2. Ensure you have connected the Mini Pump Protection Filter assembly and Temperature Sampling Probe complete with In-Line Filter to the Gas Sample Port (see 3.2 or 3.4) and the 'K' Type Thermocouple Plug into Thermocouple (T1) Socket (see 3.4). The GK11M ambient air temperature probe must be connected to the (T2) socket. (refer to figure below for correct hookup)

WARNING: - Ensure that the In-Line Filter hangs in a vertical position when readings are being taken, particularly if water is visible. Failure to comply may result in damage to the instrument.

WARNING: - There is ONLY one correct way to connect the 'K' type thermocouple plug into the socket (see 2.4). Forcing the plug into the socket the wrong way round may result in damage to the instrument.

3. Insert the flue probe into the test location of the device under test. The probe tip should be in the middle of the flue pipe or exhaust stream. Refer to figures 1 through 3 for typical test locations.

Mini Pump Protection Filter Assembly

Ambient Air Connection (T2)

GK11M Probe

Flue Probe Connection (T1)

In-line Filter Assembly

Flue Probe Tubing

COMBUSTION ANALYSIS (Continued)

4. As seen below, use the Scroll/Enter Key to move through the various combustion displays.

5.2 Combustion Displays

You can move through the following Combustion Analysis Screens by repeatedly pressing Scroll/Enter:

• Combustion Display 1 (Default Start Up Display)

• Displays Carbon Monoxide (CO) reading in parts per million (ppm)

• Displays calculated Carbon Dioxide (CO2) figure in percentage (%)

• Displays calculated CO/CO2 (Ratio) figure

WARNING: - Should the CO reading rise above 2,000ppm a continuous series of Alarm Beeps will be heard. The Probe should immediately be disconnected from the instrument and the instrument returned to a clean air environment. This Alarm alerts the user that there is a high concentration of CO, and this procedure will protect the sensors within the instrument.

• Combustion Display 2

• Displays Oxygen (O2) reading in percentage (%)

• Displays calculated Excess Air (X Air) figure in percentage

• Displays calculated Efficiency (Eff.) figure in percentage

• Pressing the Up Arrow Key will toggle between Gross &

Net Efficiency (Note: Gross Efficiency is used in the USA)

• Combustion Display 3

• Displays Carbon Monoxide (CO) reading in parts per million (ppm)

• Displays Oxygen (O2) reading in percentage (%)

COMBUSTION ANALYSIS (Continued)

5.2 Combustion Displays (continued)

• Combustion Display 4

• Displays CO air free (-CF-)

• Combustion Display 5

• Displays Temperature reading of Channel 1 (T1) in degrees Centigrade (ºC)

• Displays Temperature reading of Channel 2 (T2) in degrees Centigrade (ºC)

• Displays the Differential Temperature (Diff.) between ch1 and ch2 in ºC

• 'oPEn' will be displayed if no 'K' type probe is connected to the thermocouple socket

5.. During a combustion test you can save, print, and send data to a computer. See section 7 through 11. Allow readings to stabilize before saving or printing the data.

6. After the test is complete, remove the flue probe from the test location and allow the analyzer to purge in a fresh air environment. Turn the analyzer off as outlined in section 4.2.

NOTE: When selecting oil as fuel be sure to use the optional

oil filter (A773) or readings could become erratic.

5.3 TYPICAL TEST LOCATIONS

Atmospheric Gas Fired Fan Assist Boiler / Furnace

Typical Test Locations

COMBUSTION ANALYSIS (Continued)

Figure 1

COMBUSTION ANALYSIS (Continued)

Condensing Boiler / Furnace

Typical Test Locations

Figure 2

COMBUSTION ANALYSIS (Continued)

Test all exhaust ports at the top of the heat exchanger.

Atmospheric Forced Air Furnace

Typical Test Locations

Figure 3

COMBUSTION ANALYSIS (Continued)

5.4 TYPICAL TEST RESULTS

Actual test results vary depending on the equipment under test. TPI recommends you check with the manufacturer of the equipment being tested to determine specific acceptable results.

Oxygen 3% to 6%

Carbon Monoxide Less than 100ppm (air free)

Stack Temperature 300

°F to 500°F

Draft -0.15 inH2O

Oxygen 4% to 7%

Carbon Monoxide Less than 100ppm (air free)

Stack Temperature 325

°F to 625°F

Draft -0.15 inH2O

Power Burners (Gas Fired)

Power Burners (Oil Fired)

Oxygen 7% to 9%

Carbon Monoxide Less than 100ppm (air free)

Stack Temperature 325°F to 500°F

Draft -0.15 inH2O to -0.4 inH2O

Gas Fired Burners (Atmospheric / Fan Assist)

6. FUNCTION SELECTION

Pressing the Func Key enables access to the different functions available on the 709. Available functions are: Combustion Analyzer, Thermometer,

Manometer, and Date / Time display.

6.1 Function 1: - Thermometer

Press the Func Key repeatedly to access the thermometer function. In this mode the 709 functions like a K-Type thermocouple thermometer. The pump will stop running when in this function.

1. Ensure you have a 'K' type probe connected to one or both of the thermocouple sockets T1 or T2 (refer to figure below) WARNING: - There is ONLY one correct way to connect the 'K' type thermocouple plug into the socket (see 4.2). Forcing the plug into the socket the wrong way may result in damage to the instrument.

2. Touch the temperature probe to the item under test and read the displayed

temperature.

Other Features:

• Pressing the Up Arrow Key will toggle between ºC and ºF

• Pressing the Scroll/Enter Key will toggle the Differential Temperature ON and OFF

• 'oPEn' will be displayed if no 'K' type probe is connected to the thermocouple socket

The thermometer function allows you to perform temperature tests.

Function 1 Display (Temperature)

T1 Temperature T2 Temperature Differential Temperature

6.2 Function 2: - Manometer

Press the Func Key repeatedly to access the thermometer function. In this mode

the 709 functions like a differential manometer. The pump will stop running when in this function.

1. Ensure you have Pressure Sampling Tube connected to one or both of the Pressure Ports and there are no restriction in the tubing (see figure below)

2. Zero the display by pressing the Down Arrow Key.

3. Connect the tube(s) to the device under test and read the pressure on the display.

Other Features:

• Pressing the Up Arrow Key will scroll through mbar, kPa and inH2O

• Pressing the Down Arrow Key will Zero the Pressure reading

• Pressing the Scroll/Enter Key will toggle the ch2 temperature reading ON and OFF

The 709 incorporates a differential manometer. This means when a single hose is connected to the (+) port and pressure is applied, the 709 will read positive pressure. If a single hose is connected to the (-) port and pressure is applied, the 709 will read a negative pressure. If both ports are connected to a pressure, the 709 will read the difference (P1 - P2) between the two.

The pressure function allows you to perform draft and pressure tests.

Function 2 Display (Pressure)

Pressure reading

7. SAVING DATA

6.3 Function 3: - Date/Time

Press the Func Key repeatedly to access the date/time screen. From this function Time, Date and Year can be changed.

1. Once the Time, Date, and Year screen is displayed, press the Scroll/Enter Key once to allow you to change the data.

2. Press the Up Arrow Key to Increase the Minutes

3. Press the Down Arrow Key to Decrease the Minutes

4. Press the Scroll/Enter Key to confirm the desired Minute and move onto the Hours

5. Repeat steps 2 to 4 to change the Hour, the Day, the Month and the Year

6. The unit will return to normal after the desired Year has been confirmed

6.4 Default Function - Combustion Analyzer

Press the Func Key repeatedly to return to Combustion Analyzer mode and the default display (Combustion display 1)

• Combustion Display 1 (Default Start Up Display)

• Displays Carbon Monoxide (CO) reading in parts per million (ppm)

• Displays calculated Carbon Dioxide (CO2) figure in percentage (%)

• Displays calculated CO/CO2 (Ratio) figure

Function 3 Display (Date / Time)

Time Date / Month Year

7. SAVING DATA

During testing data can be stored for later retrieval.

When data is saved, all data previously in the address will be overwritten.When saving pressure/draft readings, select an address different from the one used to save combustion readings.

1. Press the Store Key.

To cancel storing information press the Store Key and use

the Up/Down Arrow Keys to select “Yes” and press the Scroll/Enter Key.

2. “Addr” and an address location from 0 to 49 will flash on the display. Use the Up/Down Arrow Keys to select the desired location to store the data and press the Scroll/Enter Key.

To cancel storing information press the Store Key and use

the Up/Down Arrow Keys to select “Yes” and press the Scroll/Enter Key.

3. The data is stored and “End” will display. Use the Up/Down Arrow Keys to select “Yes” to stop storing data and return to normal operation or select “No” to store data again. Press the Scroll/Enter Key.

You have just successfully stored a set of readings which can be reviewed on screen (see 8) or sent to the IR printer (see 9)

8. RECALLING DATA

The recall feature allows you to display stored data or retrieve the last date of calibration.

Recalling Saved Data or Calibration Date

1. Press the Recall button once.

2. The display will show “Stor” and “Cal”. Use the Arrow buttons to select the desired function.

To cancel recalling information press the Recall Key and use the Up/Down Arrow Keys to select “Yes” and press the Scroll/Enter Key.

Stor - Selecting “Stor” allows you to display the information in a

memory location.

1. Press the Recall button once. The display will show “Stor” and “Cal”. Using the Arrow buttons select “Stor” by making it blink. Press the Scroll/Enter button.

2. “Addr” will be displayed and a number from 0 to 49 will flash.

3. Using the up and down arrows, select the memory location of the readings you want to display.

4. Press the Scroll/Enter key once. The 709 will display the date and time screen showing when that reading was stored.

5. Use the up and down arrows to scroll through the data that was saved.

6. Press the Scroll/Enter button and “End” will be displayed and

“Yes” will flash. Press the Scroll/Enter button if you are finished

recalling data or use the Arrow buttons to select No to recall data from other locations.

CAL - Selecting “CAL” allows you to display the last date of cali-

bration.

1. Press the Recall button once. The display will show “Stor” and “Cal”. Using the Arrow buttons select “Cal” by making it blink. Press the Scroll/Enter button.

2. “CAL” will blink and the last calibration date will be displayed in DD/MM.YYYY format.

3. Press the Scroll/Enter button, “End” will be display and YES will blink. Press the Scroll/Enter button to return to normal opera tion.

9. PRINTING DATA

WARNING: - To operate correctly there must be a clear line of sight between

the Infrared Window on the instrument (see 3.3) and the Infrared Window on the IR Printer (see Printer instructions). Place the printer so it is no closer than approximately 6 inches from the analyzer.

1. Press the Print Key once 'rEAL', “Stor’, and “Cal” will be displayed and ‘rEAL’ will be flashing.

To cancel printing press the Print Key and use the

Up/Down Arrow Keys to select “Yes” and press the Scroll/Enter Key.

Selecting ‘rEAL’ will cause the 709 to print the test data currently on the display (real time data). Selecting ‘Stor’ will cause the 709 to print data stored in memory. Selecting “Cal” will cause the 709 to print the last date of calibration. Use the Up and Down Arrow Keys to select the desired print mode and press the Scroll/Enter Key.

REAL Print Mode - If rEAL print mode is selected, the analyzer will display ‘Wait’ ‘out’ and bars will change position on the LCD until printing is complete.

STOR Print Mode - If Stor mode is selected, 'Addr' will be displayed on the top line along with 'SA ' and a location number from 0 to 49 will be flashing on the screen. Select the required address location that you wish to print data from by pressing the Up and Down Arrow Keys and press the ‘Scroll/Enter’ Key. The analyzer will display ‘Wait’, ‘out’ and bars will change position on the LCD until printing is complete.

CAL Print Mode - If Cal print mode is selected, the analyzer will display ‘Wait’ ‘out’ and bars will change position on the LCD until printing is complete.

After printing is complete, ‘End’ will be displayed and ‘YES’ (or ‘no’) will blink. Selecting ‘YES’ will return the 709 to normal operation, selecting ‘no’ will return the 709 to the print selection screen so you can print again. Use the Up and Down Arrow Keys to make the selection and press the Scroll/Enter Key.

Combustion and pressure/draft printouts must be performed separately. Perform a combustion test and save the data. Perform a pressure/draft test and save the data in a different address. Print each address separately.

Instrument

PRINTING DATA (Continued)

Printout Interpretation

Data from combustion test is printed here.

Smoke Test Result. For use on oil fired equipment. (Circle one to indicate the result of a smoke test performed using the optional A788 smoke test pump.)

Date and time of combustion test.

Fuel type selected during test.

Customer information and signed confirmation of test. (Fill in this data and have the customer sign for confirmation.)

Appendix A : SPECIFICATIONS (Continued)

Pressure Measurement

Selectable Ranges mbar, kPa and inH2O Range - 150 mbar to + 150 mbar

-15 kPa to + 15 kPa

-60 inH2O to 60 inH2O

Resolution 0.01 mbar, 0.001 kPa, 0.001 inH

Accuracy +/- 0.5% fsd

Temperature Measurement

Input Type K-Type thermocouple Range -58°F to 1832°F (-50°C to 1000°C)* Resolution 1°F (1°C) Accuracy +/- (0.3% of rdg + 2°F) or +/- (0.3% of rdg + 1°C)

* The thermocouple supplied (GK11M) has the ability to measure temperatures in the -50°F to 950°F range. The 712 accepts industry standard K-type thermocouple probes with sub-mini connectors.

Appendix E: ERROR CODES & TROUBLESHOOTING

*Sensor replacement requires calibration gas.

Appendix D: INSTALLING THE OPTIONAL A773 OIL FILTER

When performing combustion tests on oil fired equipment it is important to use the optional A773 oil filter to ensure stable readings. The A773 does not have to be removed when working with other types of fuels.

PROCEDURE

1. Pull the yellow thermocouple out of the cord channel in the tubing up to the cord stop.

2. Cut the tubing approximately 1 1/2 inches from the end of the A762 water trap / filter assembly.

3. Insert the A773 oil filter into the tube below the A762.

4. Cut the remaining piece of tube into a 1 1/2 inch piece and connect it onto the end of the A773 oil filter.

5.. Press the thermocouple cord into the cord channel.

The A773 should be replaced when most of the pellets become discolored.

Appendix E: ERROR CODES & TROUBLESHOOTING

The 709 analyzer will display certain codes to let you know of a malfunction.

Code

Displayed

Code Definition Possible Causes Corrective Action

Flo Err

Pump not drawing sample at correct flow rate.

Blockage / kink in flue probe hose.

Dirty or blocked filter(s). Worn pump.

Check and rectify.

Replace filter(s). Return to TPI for service.

InIt

Err

Oxygen sensor failed to initialize

Flue probe connected to 709 prior to power up.

709 did not purge completely from last sample.

Worn or defective oxygen sensor.

Disconnect probe and restart.

Purge for 20 minutes and restart.

Return to TPI for sensor replacement or install new sensor.*

Try manually initializing the sensor. See Appendix G.

InIt CO Err

Carbon monoxide sensor failed to initialize.

Flue probe connected to 709 prior to power up.

709 did not purge completely from last sample.

Worn or defective carbon monoxide sensor.

Disconnect probe and restart.

Purge for 20 minutes and restart.

Return to TPI for sensor replacement or install new sensor.*

Try manually initializing the sensor. See Appendix G.

bat

Low battery.

Battery needs to be charged.

Charge battery. If the battery won’t hold a charge, replace the battery.

oFL

Overflow indication. The carbon monoxide being measured is above the instruments capability.

CO being measured is too high or low.

Remove the CO source and allow the 709 to purge.

oFL

Overflow indication. The temperature being measured is outside the maximum measurement capability.

Temperature being measured is too high or low.

Remove pressure source.

oPEn

Unable to read thermocouple (temperature).

Temperature probe not connected to input. Worn temperature sensor.

Connect temperature probe to analyzer. Replace temperature probe or flue probe.

*Sensor replacement requires calibration gas.

Appendix E: ERROR CODES & TROUBLESHOOTING (Continued)

Problem Possible Cause Corrective Action

Efficiency reading incorrect NET efficiency selected.

Ambient temperature probe not plugged in to T2.

Incorrect fuel selected.

Select GROSS efficiency. See section 5.3.

Plug ambient probe into T2. See section 5.2.

Select the proper fuel for the equipment being tested. See section 4.1.

Readings are erratic when working on oil fired equipment.

A773 oil filter not installed or installed incorrectly.

Make sure the optional oil filter (A773) is installed. See Appendix D.

One or all of the following parameters; Ratio, CO air free, excess air, and efficiency read and print dashes.

Measured values are such that the calculated values of these parameters are out of range.

Redo combustion test. Since these are calculated values, the measure values must be within certain levels for these to display. If the measured oxygen level is above 19.9% these parameters won’t read.

These parameters might not display or be applicable in some tests.

Analyzer won’t turn off

Oxygen and/or carbon monoxide levels outside limits.

Allow the analyzer to purge longer.

Appendix F: CO ALARM & AUTO OFF SETTINGS

Setting the Carbon Monoxide Alarm Point and/or Auto Power Off Mode

The CO alarm and auto power off settings can be changed as necessary by performing the following procedure.

WARNING : Changing parameters in field calibration mode can adversely affect the operation of your analyzer. Follow the instructions carefully.

1. Press and hold the Scroll/Enter Key down until ‘FILD CAL’ is displayed. The 709 will cycle through a 30 second countdown then display ‘CAL’, Air’, gAS’.

2. Use the Up Arrow Key to select ‘Air’ by making it blink. Press the Scroll/Enter Key to accept the selection.

3. 709 Display: ‘CAL’, ‘FLo’, ‘oPEn’. Action : Press the Func Key to bypass.

4. 709 Display: ‘CAL’, ‘FLo’, ‘CLos’. Action : Press the Func Key to bypass.

5. 709 Display: ‘0ppm’, ‘Co’, ‘rEF’. Action : Press the Func Key to bypass.

6. 709 Display: ‘20.9%’, ‘o2’, ‘rEF’. Action : Press the Func Key to bypass.

7. 709 Display: ‘2000’, ‘A-r’, ‘SEt’. Action : If you are not changing the CO alarm point press the Func Key. Otherwise press the Up and Down Keys to set the ppm level the alarm will sound at. Factory default is 2000ppm. Press the Scroll/Enter Key to accept the selection.

8. 709 Display: ‘Auto’, ‘oFF’, ‘En’. Action : If you are not changing the auto power off mode press the Func Key. Otherwise press the Up and Down Arrow Keys to enable (En) or disable (dis) the auto off function. Factory default is enabled (En). Press the Scroll/Enter Key to accept the selection.

9. 709 Display: ‘CAL’, ‘StoP’, ‘go’. Action : Press the Up Arrow Key to select ‘StoP’ by making it blink and press the Scroll/Enter Key to accept the selection. The 709 will return to normal operation

Appendix G: MANUALLY INITIALIZING SENSORS

Manually Initializing the Carbon Monoxide and Oxygen Sensors

If the CO or O2 sensor fails to initialize, this procedure can be performed to try and manually initialize the sensor(s).

WARNING : Changing parameters in field calibration mode can adversely affect the operation of your analyzer. Follow the instructions carefully.

1. Press and hold the Scroll/Enter Key down until ‘FILD CAL’ is displayed. The 709 will cycle through a 30 second countdown then display ‘CAL’, Air’, gAS’.

2. Use the Up Arrow Key to select ‘Air’ by making it blink. Press the Scroll/Enter Key to accept the selection.

3. 709 Display: ‘CAL’, ‘FLo’, ‘oPEn’. Action : Press the Func Key to bypass.

4. 709 Display: ‘CAL’, ‘FLo’, ‘CLos’. Action : Press the Func Key to bypass.

5. 709 Display: ‘0ppm’, ‘Co’, ‘rEF’. Action : Press the Scroll/Enter Key. After the 10 second countdown is complete press the Scroll/Enter Key twice.

6. 709 Display: ‘20.9%’, ‘o2’, ‘rEF’. Action : Press the Scroll/Enter Key. After the 10 second countdown is complete press the Scroll/Enter Key twice.

7. 709 Display: ‘2000’, ‘A-r’, ‘SEt’. Action : Press the Func Key to bypass.

8. 709 Display: ‘Auto’, ‘oFF’, ‘En’. Action : Press the Func Key to bypass.

If the 709 continues to fail to automatically initialize or this procedure fails to initialize the sensors, return your analyzer to Test Products International.

Appendix H: RESETTING PRESSURE SENSOR ZERO

Manually resetting the pressure sensor zero point

If the pressure sensor will not zero as described in section 6.2 use the procedure below to reset the zero point of the sensor.

WARNING : Changing parameters in field calibration mode can adversely affect the operation of your analyzer. Follow the instructions carefully.

1. Press and hold the Scroll/Enter Key down intil ‘FILD CAL’ is displayed. The 709 will cycle through a 30 second countdown then display ‘CAL’, Air’, gAS’.

2. Use the Up Arrow Key to select ‘Air’ by making it blink. Press the Scroll/Enter Key to accept the selection.

3. 709 Display: ‘CAL’, ‘FLo’, ‘oPEn’. Action : Press the Func Key to bypass.

4. 709 Display: ‘CAL’, ‘FLo’, ‘CLos’. Action : Press the Func Key to bypass.

5. 709 Display: ‘CAL’, ‘LEAK’, ‘rEF’. Action : Press the Func Key to bypass.

6. 709 Display: ‘0ppm’, ‘Co’, ‘rEF’. Action : Press the Func Key to bypass.

7. 709 Display: ‘20.9%’, ‘o2’, ‘rEF’. Action : Press the Func Key to bypass.

8. 709 Display: ‘0.0mbar’, ‘0.0’, ‘oFS’. Action : Press the Func Key to bypass.

9. 709 Display: ‘2000’, ‘A-r’, ‘SEt’. Action : Press the Func Key to bypass.

10. 709 Display: ‘Auto’, ‘oFF’, ‘En’. Action : Press the Func Key to bypass.

11. 709 Display: ‘CAL’, ‘StoP’, ‘go’. Action : Press the Up Arrow Key to select ‘StoP’ by making it blink and press the Scroll/Enter Key to accept the selection. The 709 will return to normal operation

If the 709 continues to fail to automatically initialize or this procedure fails to initialize the sensors, return your analyzer to Test Products International.

Notes:Appendix I: Technical Notes

Note 1: When performing a pressure or draft test during a combustion test, the

pump can be turned on to provide a continuous sample to the sensors. This enables pressure adjustments to be made and the affect to the combustion process can be seen by returning to combustion analyzer mode. Use the FUNC Key to activate manometer mode. Press and hold the Up Arrow Key until the pump reactivates. Perform a pressure test and then use the FUNC key to activate combustion analyzer mode. Repeat this process until pressure adjustments are complete.

Note 2: Several factors affect combustion efficiency. Dirty or clogged air filters reduce the amount of air available for combustion therefore reducing efficiency. Obstructions in the flue block exhaust gases and alter the air mixture in the combustion chamber which reduces efficiency. Air leaks in the combustion chamber also alter the mixture causing decreased efficiency.

Note 3: The primary way to affect change in combustion efficiency when working with modern gas fired equipment is through gas manifold pressure adjustment. Confirm manifold pressures are within maufacturers specifications prior to performing a combustion test. Once manifold pressures are within limits a combustion test can be performed to provide information regarding any adjustments that may be needed.