TSI Alnor 6203 Operating Manual
ENERGY AND COMFORT
Combustion Analysis
CA-CALC™
Combustion Analyzers
Model 6203 Series
Operation and Service Manual
P/N 1980472 Revision C
August 2010
3
Copyright ©
TSI Incorporated / 2002–2010 / All rights reserved.
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
(651) 490-3824
LIMITATION OF WARRANTY AND LIABILITY (effective July 2000)
Seller warrants the goods sold hereunder, under normal use and service as described in the
operator's manual, shall be free from defects in workmanship and material for twenty-four (24)
months, or the length of time specified in the operator's manual, from the date of shipment to the
customer. This warranty period is inclusive of any statutory warranty. This limited warranty is
subject to the following exclusions:
a. Batteries are warranted for 90 days from the date of shipment to the customer.
Electrochemical gas sensors are warranted for a period of twelve (12) months from the date
of shipment to the customer.
b. Parts repaired or replaced as a result of repair services are warranted to be free from defects
in workmanship and material, under normal use, for 90 day s 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 (800) 874-2811 or 651-490-2811.
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Contents
Introduction ........................................................................................ 1
Manual Purpose ............................................................................ 1
Using This Manual ......................................................................... 1
Warnings and Cautions ................................................................. 1
Chapter 1 Instrument Description .................................................. 3
CA-6203 CA-CALCTM Combustion Analyzer Measurements
and Calculations ......................................................................... 3
Chapter 2 Unpacking ....................................................................... 5
List of Standard Components ........................................................ 5
Accessories and Replacement Parts ............................................ 5
Chapter 3 Component Identification .............................................. 7
The Gas Sensors .......................................................................... 8
The Sampling Probe ...................................................................... 9
Flue Probe Thermocouple ............................................................. 9
On-Board Temperature Measurement .......................................... 9
Diaphragm Pump .......................................................................... 9
Draft Sensor .................................................................................. 9
Water Trap ..................................................................................... 9
Optional Combustion Supply Air Thermocouple Probe ................ 9
Schematic Representation of CA-CALC Analyzer ........................ 10
Chapter 4 Getting Started ............................................................. 11
Supplying Power ......................................................................... 11
Installing Batteries ....................................................................... 11
Connecting the Sampling Probe ................................................. 11
Connecting the Optional Combustion Supply Air Temperature
Probe ........................................................................................ 12
Connecting the Optional Portable Printer .................................... 12
Connecting to a Computer .......................................................... 12
Default Instrument Settings ......................................................... 13
Factory Defaults and Language Selection .................................. 13
Chapter 5 Basic Operation ............................................................ 15
Buttons and Button Operations ................................................... 15
Startup ......................................................................................... 16
Characters and Display Icons ..................................................... 18
Measurements and Calculations ................................................. 20
Data Display, Viewing Measurements and Calculations............. 22
Error Indications .......................................................................... 22
Using the Sampling Probe ........................................................... 22
Making a Draft Measurement ...................................................... 24
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Printing to the Portable Printer and to a Computer ..................... 24
Handling Data .............................................................................. 27
Chapter 6 MENU Options .............................................................. 29
BASE.L MENU—Option Update Sensor Baselines .................... 30
FUEL MENU Option—Select Fuel .............................................. 30
FP MENU Option—Fuel Parameters .......................................... 31
UNITS MENU Option (changing units) ........................................ 31
INT.SA MENU Option—Sampling Interval for Saving Data ........ 31
TIME MENU Option—Set Time and Date for Printout ................ 32
CALIB MENU Option (select sensor for calibration) ................... 32
O2 Gas Sensor Calibration .......................................................... 33
Calibration of the CO (hydrogen compensated) Sensor ............. 33
Calibration Steps ......................................................................... 33
NO Gas Sensor Calibration ......................................................... 34
Draft Calibration ........................................................................... 34
Temperature Calibration .............................................................. 35
CAL.FA MENU Option—Setting the Calibration Factor for a
Replacement Gas Sensor ........................................................ 35
CO Sensor ................................................................................... 35
NO Sensor ................................................................................... 36
BAUD Rate MENU Option ........................................................... 37
COMM MENU Option—Set the Output Communications
Device ....................................................................................... 37
FP MENU Option—Fuel Parameters .......................................... 37
LANG MENU Option .................................................................... 40
Chapter 7 Setup for Gas Calibration ............................................ 41
The Calibration Setups ................................................................ 41
Chapter 8 Maintenance and Troubleshooting ............................. 45
Emptying Water Trap ................................................................... 45
Changing the Water Trap Filter ................................................... 45
Cleaning the Sample Probe ......................................................... 46
Lithium Battery Replacement ...................................................... 46
Replacing a Gas Sensor .............................................................. 47
Appendix A Error Codes ............................................................... 49
Appendix B Calculations ............................................................... 51
Undiluted Gas Concentration Calculation (COu, NOu, NOxu) ...... 51
Excess Air Calculation ................................................................. 51
Calculating Combustion Efficiency for U.S. Fuels ....................... 51
Siegert Formula ........................................................................... 52
Determining CO2 Using the O2 Concentration ............................ 53
Emission Rate Calculations Using Emission Factors .................. 53
Emission Rate Factors ................................................................ 53
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A General Equation for the Combustion of a Simple
Hydrocarbon in Air ................................................................... 54
Calculating CO2 Max From the Carbon Content ......................... 54
Calculation of Combustion Air Requirement ............................... 54
Appendix C Series CA-6203 CA-CALCTM Combustion
Analyzer Specifications ............................................................ 55
TÜV Reg. No. 229
Tested and approved for Measurement of O2, CO, and
Temperature.
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1
!
!
Introduction
Manual Purpose
This manual describes the operation and maintenance of TSI
ALC™ portable combustion analyzer.
CA-C
Using This Manual
®
CA-6203
Before using your CA-C
its entirety.
Warnings and Cautions
The manual assumes that you have a basic understanding of combustion
safety 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 for safety. Remember when
adjusting equipment always follow the 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.
Notes: Best results are obtained if the CA-C
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.
ALC™ combustion analyzer is
2
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Oxygen concentration
O2, electrochemical
Carbon monoxide
CO, electrochemical
Nitric oxide
NO, electrochemical
Flue temperature
Thermocouple
Supply air temperature
On-board sensor or Thermocouple probe
Draft pressure
Pressure transducer, internal solid state
CO2, Carbon Dioxide
Excess air / λ
Stack/Flue loss / qA
Combustion efficiency
Differential temperature
NOx CO undiluted
NO undiluted
COr index
NOx undiluted
Emission Rates CO, NO
Chapter 1
Instrument Description
The Model CA-6203 CA-CALC™ combustion analyzer is used to evaluate
the performance of burners in boilers, furnaces, and hot water tanks. The
Model CA-6203 has sensors for the direct measurement of combustion
gases; O
Model CA-6203 performs a complete list of combustion and emission
parameters for a variety of system performance evaluations. Different units
and different fuel types are readily selectable.
CA-6203 CA-C
Calculations
Measurement Sensor
, CO, NO; combustion gas temperatures and draft pressure. The
2
TM
ALC
Combustion Analyzer Measurements and
Calculations
The Model 6203 is supplied with a sampling probe having an in-line water
trap and particulate filter.
The Model 6203 operates using either an AC power supply or C-size
batteries.
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4
The Model 6203 stores individual data samples (up to 100), and prints the
data to a portable printer or computer. Stored data can be saved over a userdefined interval and averaged.
The Model 6203 has a variety of standard fuels, and enables you to modify
the fuel parameters, or install your own user-defined fuel.
Loss and efficiency are calculated from standard ASME heat-loss
calculations or using the Siegert formula (refer to Appendix B
).
Chapter 1
1
Sample probe with water trap, draft line and
801989
4
C cell alkaline batteries
1 Operation and Service manual
1980472
Combustion Supply Air thermocouple
3013003
Portable printer kit
801994
Computer cable
8940
Hard side Carrying case
1319319
CO replacement sensor
802014
O2 replacement sensor
802012
NO replacement sensor
802007
Water trap filters
801947
Calibration Kit O2 (N2 gas) and CO
802003
Calibration Kit CO
801999
Calibration Kit NO
801937
Replacement bottled gas, CO (requires Cal. Kit)
801941
Replacement bottled gas, NO (requires Cal. Kit)
801930
Replacement bottled gas, N2 (requires Cal. Kit)
801980
Bottled gas, CO with H2 (requires Cal. Kit)
801942
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-6203 CA-CALC™ combustion analyzer 1083618
temperature
1 Universal Power supply 7.2 V with assorted plug
types
Accessories and Replacement Parts
2182003
Item Part/Model
5
6
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Chapter 2
1. Data buttons
9. Battery cover
2. LCD display
10. Battery cover tab
3. On-Off button
11. Port for flue gas thermocouple
4. Control buttons
12. Port for supply air thermocouple
5. Icon buttons
13. RS-232 serial port
6. Magnets
14. Power connection
7. Vent
15. Draft sample port
8. Sensor cover
16. Gas sample port
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.
Figure 1: CA-6203 CA-CALCTM Combustion Analyzer
7
8
1. Tube retaining fitting 6. Thermocouple connector
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
The Gas Sensors
The CA-6203 CA-C
oxygen (O
), carbon monoxide (CO) and nitric oxide (NO). CO and NO
2
sensors are capable of operating from two to three years. The O
ALC™ analyzer uses three gas sensors for measuring
sensor
2
typically lasts one year. Best accuracy is obtained by routine user calibration
(automatic for the O
sensor). Calibrated replacement CO and NO sensors
2
are also available from the factory.
Chapter 3
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