TSI Alnor 6130, 6140 Operating Manual
ENERGY AND COMFORT
Combustion Analysis
CA-CALC™
Combustion Analyzers
Series CA-6100
Operation and Service Manual
P/N 1980451 Revision G
August 2010
3
Copyright ©
TSI Incorporated / 2002–20010 / All rights reserved.
Part Number
1980451 / Revision G
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, M N 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) 490-2811 or (800) 874-2811.
4
(This page intentionally left blank)
i
Contents
Introduction ........................................................................................ 1
Manual Purpose ............................................................................ 1
Using This Manual ......................................................................... 1
Warnings and Cautions ................................................................. 1
Chapter 1 Instrument Description ................................................... 3
Chapter 2 Unpacking ........................................................................ 5
List of Standard Components ........................................................ 5
Accessories and Replacement Parts ............................................ 5
Chapter 3 Component Identification ............................................... 7
The Gas Sensors .......................................................................... 9
The Sampling Probe ...................................................................... 9
Flue Probe Thermocouple (CA-6120, CA-6130, CA-6140) .......... 9
On-Board Temperature Measurement (CA-6120, CA-6130,
CA-6140) .................................................................................... 9
Diaphragm Pump .......................................................................... 9
Draft Sensor (CA-6110, CA-6140) .............................................. 10
Water Trap ................................................................................... 10
Optional Combustion Supply Air Thermocouple Probe
(CA-6120, CA-6130, CA-6140) ................................................ 10
Optional Protective Boot .............................................................. 10
Schematic Representation of Series CA-6100 CA-CALC
Analyzer ................................................................................... 11
Chapter 4 Getting Started .............................................................. 13
Supplying Power ......................................................................... 13
Connecting the Sampling Probe ................................................. 13
Connecting the Optional Combustion Supply Air
Temperature Probe (CA-6120, CA-6130, CA-6140) ............... 14
Connecting the Optional Portable Printer .................................... 14
Connecting to a Computer .......................................................... 15
Default Instrument Settings ......................................................... 15
Factory Defaults and Language Selection .................................. 15
Chapter 5 Basic Operation ............................................................. 17
Buttons and Button Operations ................................................... 17
Startup ......................................................................................... 18
Characters and Display Icons ..................................................... 19
Measurements and Calculations ................................................. 20
ii
Chart of Measurements for Series CA-6100 CA-CALC
Instrument Models .................................................................... 20
Data Display, Viewing Measurements and Calculations ............. 22
Using the Sampling Probe ........................................................... 23
Draft Measurement (CA-6110, CA-6140) .................................... 24
Printing to the Portable Printer and to a Computer
(All Models)............................................................................... 25
Handling Data .............................................................................. 27
Chapter 6 MENU Options ............................................................... 31
LITE Menu Option........................................................................ 32
FUEL Menu Option ...................................................................... 32
UNIT Menu Option (Changing Units) .......................................... 33
INT.S MENU Option .................................................................... 34
TIME MENU Option (Set Time and Date) ................................... 34
CAL MENU Option ...................................................................... 34
CAL.F MENU Option—Setting the Calibration Factor ................. 39
BAUD Rate MENU option ............................................................ 40
COMM MENU Option—Set the Output Communications
Device ....................................................................................... 41
FP MENU Option—Fuel Parameters (CA-6120, CA-6130,
CA-6140) .................................................................................. 42
Fuel Parameter Descriptions for U.S. Fuels ................................ 43
FP Fuel Parameters for Siegert Calculation—Siegert Fuel
Parameters ............................................................................... 43
LANG MENU Option .................................................................... 44
Chapter 7 Setup for Gas Calibration ............................................. 45
The Calibration Setups ................................................................ 45
Chapter 8 Maintenance and Troubleshooting .............................. 49
Emptying Water Trap ................................................................... 49
Changing the (optional) Water Trap Filter ................................... 49
Cleaning the Sample Probe ......................................................... 50
Installing a Gas Sensor ............................................................... 50
Adding a CO Sensor to the Model CA-6120 ............................... 52
Disabling CO Sensor Recognition by a Model CA-6130 ............. 52
Appendix A Error Codes ................................................................ 53
Appendix B Calculations ................................................................ 55
COu Undiluted CO Concentration Calculation ............................ 55
Excess Air Calculation ................................................................. 55
Calculating Combustion Efficiency for U.S. Fuels ....................... 55
Siegert Formula ........................................................................... 56
Determining CO2 Using the O2 Concentration ............................ 57
iii
A General Equation for the Combustion of a Simple
Hydrocarbon in Air ................................................................... 57
Calculating CO2 Max From the Carbon Content ......................... 57
Calculation of Combustion Air Requirement ............................... 57
Appendix C Series CA-6100 CA-CALCTM Combustion
Analyzer Specifications ............................................................ 59
iv
(This page intentionally left blank)
1
!
!
Introduction
Manual Purpose
This manual describes the operation and maintenance of TSI Series
CA-6100 CA-C
6130, and 6140).
Using This Manual
ALC™ portable combustion analyzers (Models 6110, 6120,
Before using your CA-C
its entirety.
Much of the information in this manual is applicable for all Series CA-6100
instruments. Where information is applicable to a particular model, notation
is made.
Warnings and Cautions
The manual assumes that you have a basic understanding of combustion
safety concerns and are thoroughly familiar with the fuel burning equipment
being tested. If you are using measurements as the basis for equipment
adjustments, rely on your good judgment and experience together 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.
ALC™ Combustion Analyzer, review this manual in
WARNING
High temperatures and toxic gases are produced when
fossil fuels are burned. Only qualified individuals,
thoroughly familiar with operating and adjusting fuelburning equipment, should use gas measurements for
the purpose of making equipment adjustments.
Note
The CA-CALC™ analyzer is not intended for use as a
continuous monitor.
2
Notes: Best results are obtained if the CA-CALC™ combustion analyzer is
allowed to stabilize at the temperature of the test environment before
using.
To reduce sensor exposure to gas and to reduce build up of water
vapor in the sampling lines and water trap, turn the pump off when
not making measurements.
Model
Description
Measurements
CA-6110
Safety Monitor, CO and Draft,
CO, Draft
CA-6120
Boiler and Furnace Efficiency Monitor
O
2,
Temperature
CA-6130
Boiler and Furnace Tune-up Monitor
CO, O
2,
Temperature.
with Draft
Draft
CA-6110
CO and Draft
n/a
2
CA-6130
O2, CO, Flue/stack and
Excess air, Fuel Efficiency,
CO, CO ratio
CA-6140
O2, CO, Flue and Supply
Excess air, Fuel Efficiency,
Chapter 1
Instrument Description
The Series CA-6100 CA-CALC™ Combustion Analyzers are portable
instruments designed for measuring combustion gases, combustion gas
temperatures and draft pressure. These measurements are used to evaluate
the performance of burners in boilers, furnaces, and hot water tanks. From
the measured data, the CA-C
of combustion parameters including CO concentration, excess air, CO
combustion efficiency and draft. Measurements for your CA-C
analyzer will depend upon its Model number designation.
Series CA-6100 CA-C
ALC™ combustion analyzers calculate a variety
ALC™
TM
ALC
Combustion Analyzer Models
level,
2
CA-6140 Boiler and Furnace Tune-up Monitor
Series CA-6100 CA-C
Model
Number
CA-6120 O2, Flue/stack and
The Series CA-6100 CA-C
probe having an in-line water trap and particulate filter. For instruments
measuring temperature, the sample probe has an integral thermocouple.
The Series CA-6100 CA-C
power supply or AA-size batteries.
CO, O
ALC™ Measurements and Calculations
Measured with
Sensor
Calculations
Excess air, Fuel Efficiency,
Supply Air Temperature
Supply Air Temperature
Air Temperature, Draft
Loss, qA, %CO
Loss, qA, %CO2, undiluted
Loss, qA, %CO2, undiluted
CO, CO ratio, draft and
differential pressure.
ALC™ Analyzers are supplied with a sampling
ALC™ Analyzers operate using either an AC
Temperature,
2,
3
4
The Series CA-6100 CA-CALC™ Analyzers can store individual data
samples (up to 24), and print the data to a portable printer or computer.
Stored data can be saved over a user-defined interval and averaged if
required.
The Series CA-6100 CA-C
ALC™ Analyzers (not CA-6110) have a variety of
standard fuels, and enable you to modify the fuel parameters, or to install
your own user defined fuel. Loss and efficiency are calculated from standard
heat-loss calculations or using the Siegert formula (refer to Appendix B
).
Chapter 1
1
Sample probe with water trap, draft line and
801991
Sample probe with water trap and draft line
801992
4
AA cell alkaline batteries
1 Operation and Service manual
1980451
1
Combustion Supply Air thermocouple Type K
3013003
1
Portable printer kit
801994
1
Universal Power supply 7.2 V with assorted plug
2182003
1
Boot with magnet and carrying strap
801995
1
Computer cable
8940
1
Hard side Carrying case
1500134
1
Replacement pump
801996
1
CO replacement sensor
802006
1
O2 replacement sensor
802012
1
Water trap filters
1602309
1
Lithium battery
1208028
1
Calibration kit O2 (N2 gas) and CO
802003
Chapter 2
Unpacking
Carefully unpack your CA-CALC™ combustion analyzer and accessories
from the carrying case. Check the individual parts against the list of
components in the table below. If items are missing or damaged, notify TSI
immediately.
List of Standard Components
Qty. Item Component Part/ Model
1 Series CA-6100 CA-CALC combustion analyzer,
carrying case, and boot (case and boot not
included with Model CA-6110)
temperature
Sample probe with water trap and temperature
Accessories and Replacement Parts
Item Part/Model
types
801990
5
6
(This page intentionally left blank)
Chapter 2
Chapter 3
Component Identification
Key components of the CA-CALC™ combustion analyzer and sampling
probe are identified in Figures 1 and 2, and under section headings in the
text that follows.
1. Buttons 9. RS-232 interface connector
2. Display 10. AC power input connector
3. Top cover 11. Sample port*
4. Case bottom 12. Flue/stack thermocouple port*
5. Battery cover 13. Port for supply Air temperature probe*
6. Sensor cover 14. Optional draft measurement ports [left
side (reference), right side (stack)]*
7. Damping chamber 15. Sample port Models CA-6120, CA-6130*
8. Gas vent
Figure 1. Series CA-6100 CA-CALC™ Combustion Analyzer
*For 11–15 see Figure 4 for Model details.
7
8
1. Tube retaining fitting
(some models)
2. Probe handle 7. Flexible sample line
3. Position collar 8. Water Trap
4. Sample tube 9. Water trap filter
5. Probe tip with thermocouple
Figure 2. CA-C
ALC™ Sampling Probe Components
6. Thermocouple connector
(some models)
Chapter 3
9
CA-6110
CO and Draft, Safety Monitor
CO
CA-6120
Boiler and Furnace Efficiency Monitor
O2
CA-6130
Boiler and Furnace Tune-up Monitor
CO, O2
CA-6140
Boiler and Furnace Tune-up Monitor with
Draft
CO, O2
The Gas Sensors
Your CA-C
ALC™ analyzer has the following electrochemical gas sensors.
Model
Description
Gas
Sensor
The Sampling Probe
Your combustion analyzer comes equipped with a sampling probe similar to
that depicted in Figure 2. If the model has temperature measurement
capability (Models 6120, 6130, 6140), a thermocouple is present and
extends to the end of the stainless sampling tube. For Model CA-6140
instruments, the probe tube is removable for cleaning. For instruments
measuring draft (Models 6110 and 6140), a draft sampling line is present.
Flue Probe Thermocouple (CA-6120, CA-6130, CA-6140)
For instruments measuring temperature (Models 6120, 6130, 6140), a
Type K thermocouple probe extends through the SS sampling tube on the
probe to its tip, where flue temperatures are measured. The thermocouple
probe measures temperatures up to 700 degrees C (1300 degrees F).
The Type K thermocouple connector plugs into the flue (stack)
thermocouple port (see Figure 1).
On-Board Temperature Measurement (CA-6120, CA-6130, CA-6140)
Your CA-C
ALC™ analyzer uses an on-board temperature detector to provide
the combustion supply air temperature when no supply-air accessory probe
is present.
Diaphragm Pump
The CA-C
ALC™ analyzer, samples exhaust gases from the flue, and delivers
them to the electrochemical sensors using a diaphragm sampling pump. The
pump is accessed through the sensor cover (see Figure 1), and can be
removed for cleaning or for replacement. Typical pump life is 1000 hours.
Component Identification
10
Draft Sensor (CA-6110, CA-6140)
A differential pressure transducer in CA-C
ALC™ analyzer models CA-6110
and CA-6140 is used to measure draft pressure. The transducer has a
measurement range of ±30” of H
O (7.47 kPa).
2
Water Trap
The water trap shown in Figure 2 is used to remove moisture that collects in
the sample tubing when combustion gases are sampled. The water trap uses
two chambers and a hydrophobic coalescing filter to maximize water
removal.
Optional Combustion Supply Air Thermocouple Probe (CA-6120, CA-6130, CA-6140)
A measurement of the Combustion Supply Air temperature is made using a
Type K thermocouple probe having a “miniature” type connector. The probe
is plugged into the receptacle identified in Figure 1, reference 13.
When a Supply Air temperature probe is not used, the supply air temperature
is assumed to be the instrument temperature, and is measured automatically
by an on-board temperature sensor.
Optional Protective Boot
An optional protective boot is available for your instrument. The boot
provides drop protection for the instrument and is supplied with a magnet,
enabling the instrument to be mounted on a flat, vertical metal surface. The
boot is equipped with a carrying strap.
Chapter 3
Loading...