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The Value Leader 716N
User Manual
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TPI The Value Leader 716N, The Value Leader 716 User Manual

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716 / 716N
Flue Gas Analyzer
The Value Leader
TM
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Introduction
Thank you for purchasing TPI brand products. The TPI 716 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.
General Overview
The TPI 716 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 sen- sors 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 battery of your 716 charged so power is constant- ly 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 fil- ter / water trap assembly prior to performing tests. Always use the optional oil filter (p/n A773) when performing tests on oil burning equipment
unless you are using the 716N. Do not use the A773 with the 716N because the A773 will filter out Nitric Oxide (NO).
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Instrument Overview
Front View
Rubber Boot Protects the instrument from accidental damage
Display Large graphical backlit LCD Display
Keypad Selects all available functions
Rubber Boot
LCD Display
Keypad
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.
Do NOT use the A773 with the 716N analyzer.
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Appendix F: CARBON MONOXIDE FACTS
Carbon Monoxide (CO) is invisible, odorless, and tasteless. It is the byproduct of combustion and levels are elevated when there is incomplete combustion.
Sources of CO include:
Unvented kerosene and gas space heaters Leaking chimneys & furnaces Gas water heaters Back drafting from furnaces Wood stoves& fireplaces Gas Stoves Automobile exhaust Tobacco smoke
Carbon Monoxide is picked up quickly in the body by red blood cells. At high lev- els of CO the body replaces oxygen with carbon monoxide.
The most common symptoms of CO poisoning are headache, dizziness, weak­ness, nausea, vomiting, chest pain, and confusion. High levels of CO inhalation can cause loss of consciousness and death. Unless suspected, CO poisoning can be difficult to diagnose because the symptoms mimic other illnesses.
People who are sleeping or intoxicated can die from CO poisoning before ever experiencing symptoms.
Please see the next page for a list of exposure times and symptoms.
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Back View
Calibration and Information Label: Displays calibration information and
serial number
Battery Compartment: Holds rechargeable battery
Rubber Boot Protects the instrument
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Calibration and Information Label
Battery Compartment
Rubber Boot
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Appendix D: Testing for Carbon Monoxide in Ambient Air
The 716 can be used to test for carbon monoxide in ambient air. For example tests can be performed in work spaces and living areas like offices and houses to ensure safety.
1. Following the steps outlined on page 8, turn the analyzer on in a clean air environment away from the area to be tested,
2. Select “Measurement” from the Main Menu. Select “Flue gas” from the Measurements Menu. After a purge cycle the display below will be seen.
Ambient CO levels will be seen in the top line of the display. (CO in ppm)
3. Connect the Pump Protection filter to the analyzer.
4. Begin testing for carbon monoxide. Move from space to space to detect any CO that may be present. The CO reading will be seen in the top part of the dis­play.
5. If necessary, the flue probe can be attached to test in ducts and plenums.
6. Refer to the chart on page 50 for a list of exposure times and levels of carbon monoxide in ambient test applications and page 51 for carbon monoxide facts.
7. When testing is complete, turn the analyzer off as outlined on page 8.
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Charger Socket Connection for 220V/115V charger
T1 Socket Connection for thermocouple plug on flue probe
Connection for any 'K' type thermocouple probe
T2 Socket Connection for ambient 'K' type thermocouple probe
Connection for any 'K' type thermocouple probe
Gas Sample Port Connection for Mini Pump Protection Filter and Flue
Probe
P (+) Port Connections for Pressure Tubing P (-) Port
USB Port Connection for optional A807 cable for communication
to a PC or connection for A806 combustible gas leak detection probe.
Top View
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Charger Socket
USB Port
P(+) Port
P(-) Port
Gas Sample Port
T1 Socket
T2 Socket
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Appendix C: ERROR CODES & TROUBLESHOOTING
Code
Displayed
Code Definition Possible Causes Corrective Action
Flow
Error
Pump not drawing sample at correct flow rate.
Blockage / kink in flue probe hose.
Dirty or blocked filter(s).
Worn pump.
Check and rectify. See Appendix A.
Replace filter(s). See Appendix A.
Return to TPI for service.
InIt O2 Err
Oxygen sensor failed to ini­tialize
Flue probe connected to 716 prior to power up.
716 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.
InIt CO Err
Carbon monoxide sensor failed to initialize.
Flue probe connected to 716 prior to power up.
716 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.
Lo 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 pressure being measured is outside the maximum mea­surement capability.
Pressure being measured is too high or low.
Pressure sensor damaged or defective.
Remove pressure source.
Return to TPI for service.
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.
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Turning The Analyzer On
Always: -
Before turning on please ensure nothing is connected to the Gas
Sample Port (see page 7)
Press and hold the ON/OFF key down for approximately 3 seconds. The 716 will beep and the initial start up screen will be displayed.
After the initial start up screen displays for approximately 5 seconds the Main menu will be displayed.
The initial start up screen displays the following information:
Model number of the analyzer
Firmware version Firmware date Serial number of the analyzer
Last calibration date of the sensors
Note: The NO sensor calibration date will only display for 716N models.
The main menu displays the following information:
Battery status
Date (dd.mm.yyyy format) and time (24hr clock)
Menu Selections
Left blue soft key activates Bluetooth (Only models equipped with this option.)
Center blue soft key confirms selection
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Appendix B: A773 SULFUR FILTER INSTALLATION & MAINTENANCE
USE THE A773 ONLY WITH THE 716. DO NOT USE WITH THE 716N.
When using a 716 and performing combustion tests on oil fired equipment it is important to use the optional A773 sulfur filter. Failure to do so can result in incorrect and readings. This filter also protects the sensors from the affects of sulfur. The A773 does not have to be removed when working with other types of fuels.
PROCEDURE
1. Begin with the water trap section of the flue probe oriented as shown in the picture below.
2. Remove the water trap from the flue probe hose. (See picture below)
3. Insert the A773 sulfur filter flue probe tube where the water trap was removed. (See picture below)
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COMBUSTION ANALYSIS OVERVIEW
Performing combustion analysis 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 car- bon 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 figures on pages 16 through 18 show locations for performing tests on commonly encountered equipment. Remember to consult with the manufac-
turer of the device under test for specific test information. Pressing the Func Key enables access to the different functions available on
the 716. The default function is Combustion Analyzer. Other available func­tions are: Thermometer, Manometer/Tightness Test, Combustible Gas Leak Detector, and Date / Time display.
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Appendix A: General Maintenance (continued)
Filter Check Continued
The other two filters are located in the water trap. The main filter is the A794F particle filter. This filter stops debris and dust from traveling down to the analyz- er. The secondary filter is the A794W water block filter. This filter stops flow in the event the water trap fills with condensate. Refer to the picture below.
Open the water trap and look at the A794F particle filter. The filter will typically get dirty from the inside first. If the filter is dark on the inside a replacement fil- ter should be installed.
If the A794F is clean but saturated with water a replacement should be installed to ensure proper flow. The saturated filter can be left to dry and reused later.
Pump Operation Check
1. Turn the analyzer on as outlined on page 8. Do not connect anything to the inlet. Wait until the analyzer has completed the initial purge and sensor check and is operating normally prior to proceeding to step 2.
2. Cover the analyzer inlet with your finger. The analyzer should display “FLO ERR” and a rapid beeping should be heard.
If the analyzer does not beep and display “FLO ERR” this may be an indication the flow sensor requires calibration, the pump is faulty, or there is an internal leak. The analyzer should be returned for factory service.
Water trap bowl. A794 water trap pictured. A795 water trap is similar but longer
A794F Particle Filter
A794W Water Block Filter
Water trap lid. O-ring is located in the lid recess
A794D Filter Spacer Disc
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MEASUREMENTS - Flue Gas (continued)
As necessary, the fuel type can be changed to match the fuel type of the equipment under test. The fuel type is used in the efficiency calculation and therefore it is important the fuel type is cor­rect in order for the calculation to be accurate.
To change the fuel type use the Arrow keys to highlight “Fuel change”.
Press the Chang key (left soft key) and the fuel menu will display.
The Arrow keys are used to scroll through the available fuel types.
The available fuels are Natural gas, Light oil, Heavy oil, LPG, Bituminous coal, Anthracite coal, Coke, Butane, Wood (dry), and Bagasse.
Once the desired fuel type is highlighted press the center soft key (OK) to confirm the selection.
The analyzer will return to the Zeroing display and the countdown will continue.
The unit of efficiency can be changed as needed between Nett and Gross. Nett eficiency doesn’t take into account wet losses while Gross efficien­cy does. In the USA Gross efficiency is used. If Nett is selected the efficiency will be displayed as much higher than it is.
Press the right soft key (Next) to highlight “Efficiency” in the display.
Press the Chang key (left soft key) and the effi­ciency menu will display.
Use the Arrow keys to select the desired efficien­cy unit and press the center soft key (OK) to con­firm the selection.
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CALIBRATION & SERVICE
It is recommended that your analyzer be calibrated every 12 months. Please consult Test Products International for further details or send your analyzer to the address below for service.
TPI / Attn. Repair 9615 SW Allen Blvd. Suite 104 Beaverton, OR 97005
Please include your name, contact information, return address, and a brief description of the service required.
The following are consumable parts for the instrument:
In-Line Filter Element (pkg of 5) User Replaceable A794F Disc water filter User Replaceable A794W Mini Pump Protection Filter Assem. User Replaceable A763 **Oxygen Sensor User / Factory Replaceable A761 **Carbon Monoxide Sensor User / Factory Replaceable A760 **Nitric Oxide Sensor User / Factory Replaceable A793
**Sensor replacement requires calibration gas.
These items require periodic replacement as the analyzer is used. Please see Appendix A on page 37 for general maintenance informa­tion.
WARRANTY
Your TPI 716 Flue Gas Analyzer is guaranteed free from defects in materials and workmanship for 3 Years from the date of purchase. The sensors carry a 2 Year warranty. This guarantee does not affect your statuary rights. For addi- tional information please refer to the included warranty card or contact TPI at 800-368-5719.
To obtain warranty performance or maintenance on your analyzer: - Include with the product your name, address, phone number, written description of the problem and proof of purchase date. Carefully package and return to:
TPI / Attn. Repair 9615 SW Allen Blvd. Suite 104 Beaverton, OR 97005
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IMPORTANT: Prior to taking a sample, the device under test should be on and at operating temperature. 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.
Drill a 1/4 inch hole into the flue of the device under test. 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.
It is important to use manufacturers recommended test locations whenever possible.
Refer to the figure below for calculating the sample hole location. The figures on the following pages show typical test locations on commonly encountered equipment.
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MEASUREMENTS - Flue Gas (continued)
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SPECIFICATIONS
Instrument
Operating Temperature Range 14°F to +122°F (-10°C to +50°C)
Battery / Battery Life Rechargeable Ni-MH / > 6 Hours
Charger Input Voltage 115V or 230V : 50/60 Hz AC
Fuels Natural Gas, LPG, Light Oil, Heavy Oil,
Bituminous Coal, Anthracite Coal, Coke, Butane, Wood, Bagasse
Pressure Ranges mbar, psi, inH2O, mH2O, kPa, hPa,
inHg, mmHg
Display Backlit Graphic LCD
Data Storage 100 sets of readings, multiple pages
Single Logging 150 sets of time stamped readings
Time & Date 24 Hour Real Time Clock
Dimensions
7.8” (200mm) x 3.5” 90mm x 2.4” (60mm)
Weight 1.1lbs (500g)
Conforms to BS7927 (and the draft BS7967)
Flue Temperature Probe
Construction Pistol Grip with Stainless Steel Shaft
Hose Length 8.2’ (2500mm)
Insertion Length 7.9” (200mm)
'K' Type Thermocouple Accuracy +/- 0.3% of fullscale, +/- 2°F (1°C)
Maximum Temperature 1472°F (800°C)
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Condensing Boiler / Furnace
Typical Test Locations
Figure 2
It is important to use manufacturers recommended test locations whenever possible.
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MEASUREMENTS - Flue Gas (continued)
TYPICAL TEST LOCATIONS
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Menu Navigation - Analyzer Setup
1. From the main menu use the Arrow keys to select “Analyzer Setup” and press the “Enter” key (center blue soft key).
2. The Analyzer Setup menu will display. The following parameters are accessible in this menu. Use the Arrow keys and center blue soft key to select the appropri- ate parameter.
Display type - Allows the display to be switched between 8 line and 4 line.
Date / Time - Used to set the current date and time. The date is in dd:mm:yyyy
format and the time is a 24 hour clock.
Contrast - Lighten or darken the display contrast.
Backlight - Adjust the backlight level from off to full brightness or set it to auto
and the 716’s internal sensor will control the backlight brightness depending on ambient light.
Alarm limits - Set the level at which the CO alarm sounds. The level is adjustable from 10ppm to 3000ppm and can be turned off. Default level is 2000ppm.
Print Header - Enables the two line header on printouts to the infrared printer to be set with your companies information. After pressing “Enter” you will be asked for a password. Enter “7160” and press “OK”. Select Header Line 1 and then use the Arrow keys to enter line one of the header. Press “Enter” then repeat the process for line 2 of the header.
Auto Power - Enables the auto power off time to be set. The timer can be disabled or set to one of the following times; 5, 10, 20, 30, or 60 minutes. If a key has not been pressed during the time set, the analyzer will automatically begin to turn off.
Memory - Enables memory maintenance as outlined on page 29.
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MEASUREMENTS - Flue Gas (continued)
Insert the flue probe into the sample hole of the device under test. The probe tip should be in the middle of the flue pipe or exhaust stream.
Ensure the In-Line Filter / Water Trap hangs below the analyzer in the proper ver- tical position when readings are being taken. Failure to comply reduces the effec- tiveness of the water trap and may result in damage to the instrument. Refer to the pictures below for correct and incorrect use.
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. The alarm level can be changed. Please see Appendix D
Make sure to check the water trap periodically during testing to ensure it does not fill with condensate and empty it as necessary. If the filter begins to fill during a test, open the lid and empty out the condensate. After closing the lid, allow read- ings to stabilize again.
IMPORTANT: The water trap is fitted with a water block filter (p/n A794W) in the lid to prevent water from flowing down into the pump. If the water trap fills the water block filter will stop the flow to the analyzer and FLO ERR will display. The water trap should be emptied immediately if this happens. The water block filter may need to be dried out or replaced before testing can resume.
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Menu Navigation - Memory
From the Main menu there are several sub menus that allow analyzer set up, memory maintenance and other parameters to be accessed. Here is a list of each
and what function they perform.
1. Memory can be accessed from the main menu to enable maintenance to be performed. Use the Arrow keys to select “Memory” and press the “Enter” key (center blue soft key).
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2. Use the Arrow keys to select the memory type to be accessed. Press the “Enter” key (center blue soft key) to confirm the selection.
3. Depending on the memory type selected all or some of the options shown below will be available.
Memory IR Print - Allows information printed in specific addresses to be printed to the optional infrared printer (p/n A740)
Memory All Clear - Clears information out of all memory locations.
Memory PC Out - Sends all information stored in memory to a PC. Requires optional USB cable and software.
Memory Recall - Enables information from memory locations to be recalled and displayed for viewing.
4. Use the Arrow keys and blue soft keys to access these functions.
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MEASUREMENTS - Flue Gas (continued)
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Test data can be saved to a memory location if required.
1. Press the Save key (right blue soft key) and “Real Data Save” and “Address:” will be dis­played.
2. Using the Up and Down Arrow keys select the memory location to save the data.
3. Press the OK key (center blue soft key) to save the data.
Test data can be sent to an optional infrared print- er (p/n A740) or to a PC using optional cable and software.
1. Press the Send key (left blue soft key) and “Real Data Print” and “Real Data PC Out” will be displayed.
2. Using the Up and Down arrow keys select the type of output you require. If printing data to the printer, align the window of the analyzer with the window on the printer about 6 to 8 inches apart. If sending data to a PC, connect the USB cable to the analyzer and computer and run the 716 PC software.
3. Press the OK key (center blue soft key) to print or send data to a PC.
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Measurements - CO Room Test
The CO room test function enables the 716 to monitor and log ambient CO levels in a room or office space at 1 minute intervals. This data can be retrieved later via the optional infrared printer or serial cable and software.
1. Begin with the 716 in a fresh air environment outside of the test area. From the main menu select “Measurement” as outlined on page ##. From the “Measurements” menu select “CO room test” and the zeroing screen will display.
2. If “Skip” is displayed the analyzer sensor is zeroed and ready for use. Press the center blue soft key to move to the next screen. If “Skip” is not displayed, wait for the zero process to finish and the next screen will be displayed automatical-
ly.
3. After the zero process the CO room test display will appear. At this time the page address where the data will be stored can be changed as neces­sary. Press the “Chang” key (left blue soft key) and use the Arrow keys to change the address location.
4. Press the “Start” key (center blue soft key) to begin CO monitoring. The pump will start and the 716 will begin storing readings every minute. The number of readings stored can be seen at the bot- tom of the screen. The real, minimum, maximum, and average CO measured will be displayed too.
5. When the desired number of readings have been taken press the “Stop” key (center blue soft key).
6. Stored readings can be sent to a PC or printer by pressing the “Send” key (left blue soft key) and selecting “Print Out” or “PC Out”.
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Measurements - Temperature & Pressure
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From the Main menu screen using the Up / Down Arrow keys select “Measurements” in the menu.
Press “Enter” (center blue soft key) to confirm the selection.
From the Measurements menu use the Up / Down Arrow keys to select “Temp/Pressure” in the menu.
Press “Enter” (center soft blue key) to confirm the selection.
The Temperature / Pressure screen will display.
This screen displays both T1 and T2 channels of temperature as well as the difference between T1 and T2 (DT).
If no probe is connected to the input “-----” will be displayed indicating and open connection.
Pressure (Prsu) is also displayed in this screen.
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Measurements - Temperature & Pressure (continued)
Measuring Pressure -
1. Ensure you have Pressure Sampling Tube connected to one or both of the Pressure Ports and there are no restrictions in the tubing (see figure below)
2. Zero the display by pressing the “Zero” Key (left blue soft key).
3. Connect the tube(s) to the device under test and read the pressure on the
display.
The 716 incorporates a differential manometer. Pressure applied to the (-) port is
subtracted from the pressure applied to the (+) port. Examples of pressures being measured: (+) port = 10”H2O, (-) port = Not Connected, Displayed reading = 10”H2O
(+) port = 10”H2O, (-) port = 5”H2O, Displayed reading = 5”H2O
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Other Features:
• Pressing “Send” (center blue soft key) acti­vates a sub-menu and allows information to be sent to the optional A740 infrared printer or to a PC using the optional USB interface cable and software.
• Pressing “Save” (right blue soft key) activates a sub-menu that allows the screen data to be saved in a memory location (0 to 99) for later retrieval.
• Pressing “Zero” (left blue soft key) zeros the manometer. This is used prior to measuring pressure.
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