TSI Incorporated CA-CALC, CA-6200 Operation And Service Manual

Combustion Analysis

Series 6200

TM

CA-CALC

Combustion Analyzers

Operation and Service Manual

1980431 Rev. F

January 2004

Series CA-6200
CA-CALC

TM

Combustion Analyzers

Operation and Service

Manual

January 2004
P/N 1980431 Rev. F

U.S. AND CANADA OTHER COUNTRIES

Sales & Customer Service:
[phone]/[phone] (001 651) 490-2811

Fax:

Fax:
[phone] (001 651) 490-3824

MAIL/SHIP TO: E-Mail

TSI Incorporated [e-mail]
ATTN: Customer Service
500 Cardigan Road WEB SITE
Shoreview, MN 55126 www.tsi.com
USA

Sales & Customer Service:

Copyright ©
TSI Incorporated / 2001–2004 / All rights reserved.

Part Number

1980431 / Revision 5

Address

TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA

Fax No.

[phone]

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 [phone].

ii

CONTENTS

Introduction ..............................................................................................................................................vii

Manual Purpose .................................................................................................................................. vii

Using This Manual...............................................................................................................................vii

Warnings and Cautions.......................................................................................................................vii

Chapter 1. Instrument Description...........................................................................................................1

Gas Sampling Probes............................................................................................................................1

Chapter 2. Unpacking................................................................................................................................3

List of Standard Components................................................................................................................3

Optional Accessories.............................................................................................................................3

Chapter 3. Component Identification.......................................................................................................5

The Gas Sensors...................................................................................................................................6

Optional Combustion Supply Air Thermocouple Probe.........................................................................7

On-Board Temperature Measurement..................................................................................................7

Diaphragm Pump...................................................................................................................................7

Draft Sensor...........................................................................................................................................7

Water Trap.............................................................................................................................................7

Stack Probe Thermocouple...................................................................................................................7

Emission Probe (Supplied with Models CA-6213 and CA-6215 ).........................................................7

CO Diversion Valve...............................................................................................................................8

Mounting Magnets.................................................................................................................................8

Schematic Representation of CA-CALC.................................................................................................8

Chapter 4. Getting Started ........................................................................................................................9

Supplying Power....................................................................................................................................9

Installing Batteries...........................................................................................................................9

Connecting the AC Adapter............................................................................................................9

Connecting the Sampling Probe............................................................................................................9

Setting CO Diversion Valve................................................................................................................ 10

Connecting the Optional Combustion Supply Air Temperature Probe............................................... 10

Connecting the Optional Portable Printer........................................................................................... 10

Connecting to a Computer.................................................................................................................. 10

Default Instrument Settings................................................................................................................ 11

Factory Defaults (U.S.)....................................................................................................................... 11

Factory Defaults (Non-U.S.)............................................................................................................... 11

Default Settings For Different Model Letter Designations ........................................................... 12

Chapter 5. Basic Operation.................................................................................................................... 13

Quick Start.......................................................................................................................................... 13

Steps to Quick Startup................................................................................................................. 13

Baseline Calibration........................................................................................................... ..........13

The Data Display Screen.................................................................................................................... 14

Available Measurements.................................................................................................................... 15

Buttons and Button Operations .......................................................................................................... 16

ON-OFF Control Button (red)....................................................................................................... 16

The ENTER Control Button.......................................................................................................... 16

The ESC Control Button .............................................................................................................. 16

Arrow Control Buttons.................................................................................................................. 16

Icon Buttons................................................................................................................................. 17

Labeled Buttons........................................................................................................................... 17

Selecting Menu Items .................................................................................................................. 18

Changing a Number Value................................................................................................................. 18

Changing Units................................................................................................................................... 19

Entering and Changing Names.......................................................................................................... 19

iii

Using the Sampling Probe.................................................................................................................. 19

Gas and Temperature Measurements......................................................................................... 19

Making a Draft Measurement............................................................................................................. 21

Auto Draft Meas. Feature............................................................................................................. 21

Printing to the Portable Printer and to a Computer............................................................................ 21

Printing.........................................................................................................................................21

Printing to a Computer.................................................................................................................21

Chapter 6. MENU Selections and Menu Items ..................................................................................... 23

Zoom Settings..................................................................................................................................... 24

Instrument Setup................................................................................................................................ 24

Calibrate Sensors............................................................................................................................... 27

Restore Factory Cal............................................................................................................................ 28

Set Contrast........................................................................................................................................ 28

Set Time and Date.............................................................................................................................. 28

Select Fuel Type................................................................................................................................. 28

Fuel Setup .......................................................................................................................................... 29

Fuel Setup When Siegert Loss Calculation Used.............................................................................. 30

Restore Fuel Settings......................................................................................................................... 30

Erase Logged Data............................................................................................................................. 31

Chapter 7. Saving Data and LOGGING FUNCTIONS........................................................................... 33

Overview............................................................................................................................................. 33

Saving Data When no Site or Device is Selected .............................................................................. 34

Saving Data to Selected Site or Device ............................................................................................. 34

LOGGING FUNCTIONS .................................................................................................................... 36

Sites ............................................................................................................................................. 36

Devices ........................................................................................................................................ 37

Samples....................................................................................................................................... 38

Chapter 8. Calibrations........................................................................................................................... 39

Gas Sensors....................................................................................................................................... 39

The Calibration Setups....................................................................................................................... 40

Calibrating the O2 Sensor................................................................................................................... 40

Calibration Steps.......................................................................................................................... 40

Calibration of the CO (Hydrogen Compensated) Sensor................................................................... 40

Calibration Steps.......................................................................................................................... 40

Calibration of NO, NO2, SO2 and COhi (High Concentration) Sensors.............................................. 41

Calibration Steps.......................................................................................................................... 41

Draft Sensor Calibration..................................................................................................................... 41

Calibration Procedure.................................................................................................................. 41

Stack and Supply Air Thermocouple Calibration................................................................................ 42

Calibration Procedure.................................................................................................................. 42

Chapter 9. Maintenance and Troubleshooting..................................................................................... 43

Emptying Water Trap.......................................................................................................................... 43

Changing the Water Trap Filter................................................................................................. .........44

Cleaning the Sample Probe................................................................................................................ 44

High Concentration Overload.............................................................................................................44

Adding or Replacing a Gas Sensor.................................................................................................... 44

Gas sensors are warranted for one year, however sensors (O2 excluded) typically last two or three years.44

Sensor Positions.......................................................................................................................... 44

Replacing a Sensor...................................................................................................................... 45

Adding a New Sensor......................................................................................................................... 47

Troubleshooting Chart........................................................................................................................ 48

iv Series CA-6200 CA-CALC Combustion Analyzer

Appendix A. Calculations....................................................................................................................... 49

O2 Reference Concentration Calculation ........................................................................................... 49

Excess Air Calculation........................................................................................................................ 49

Calculating Combustion Efficiency..................................................................................................... 49

Determining CO2 Using the O2 Concentration ................................................................................... 50

Emission Rate Calculations Using Emission Factors......................................................................... 50

A General Equation for the Combustion of a Simple Hydrocarbon in Air .......................................... 51

Calculating CO2 Max From the Carbon Content................................................................................ 51

Calculation of Combustion Air............................................................................................................ 51

Appendix B. Series CA-6200 CA-CALC Combustion Analyzers Detailed Specifications................. 53

TÜV Reg. No. 213 *

* Instruments supplied with the Model 801940, 41 Sampling Probe have been approved for
measurements of O
probe do not meet the temperature response requirement.
.

, temperature, CO and NO. Instruments supplied with the Model 80151,52 Emission

2

Contents v

Introduction

Manual Purpose

This manual describes the operation and maintenance of TSI Series CA-6200 CA-CALCTM portable combustion
analyzers (Models 6210, 6211, 6212, 6213, 6214, 6215 and 6216).

Using This Manual

Before using the CA-CALC combustion analyzer for the first time, review this manual in its entirety.

The manual assumes that you have a basic understanding of combustion analysis and are thoroughly familiar with
your fuel burning equipment. When performing equipment adjustments, rely on good judgment and experience
along 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.

Warnings and Cautions

WARNING

High temperatures and toxic gases are produced when fossil fuels are burned. Only

!

Note: Best results are obtained if the CA-C

temperature of the test environment before using.

!

qualified individuals, thoroughly familiar with operating and adjusting fuel-burning
equipment, should use combustion analysis instrumentation for the purpose of
making equipment adjustments.

Always use the water trap when sampling. Check the trap frequently during operation
to prevent overfilling with condensed water. Empty often.

This device is not intended for use as a continuous monitor or as a safety indicator.

ALC combustion analyzer is allowed to stabilize at the

Caution

WARNING

!

Note: 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.

vii

Chapter 1. Instrument Description

The CA-CALCTM combustion analyzer is a portable instrument measuring combustion gases, combustion gas and
supply air temperatures and draft pressure for evaluating the performance of burners in boilers, furnaces, and hot
water tanks. From the measured data, the CA-C
parameters including excess air, CO

level, and combustion efficiency. When fitted with NO, NO2, and SO2 gas

2

sensors, emission rates and NOX are calculated. Combustion data is presented on a large display screen, making it
possible to display multiple parameters simultaneously. This data can be saved or printed with the p ress of a button.

The basic CA-C

ALC analyzer Model 6210 comes standard with two electrochemical gas sensors for stack gas

measurements, one sensor for measuring oxygen (O
the model ordered, your CA-C

ALC may have one or two additional electrochemical gas sensors. The table below

shows the available models and sensor combinations. It is also possible to add additional gas sensors later to
upgrade your CA-C

ALC combustion analyzer.

Model Gas Sensors

CA-6210 O2, CO
CA-6211 O2, CO, NO
CA-6212 O2, CO, CO(high concentration)
CA-6213 O2, CO, NO, SO2
CA-6214 O2, CO, NO, CO(high concentration)
CA-6215 O2, CO, NO, NO2
CA-6216 O2, CO, SO2 , NO2

ALC combustion analyzer calculates a variety of combustion

), and one for measuring carbon monoxide (CO). Depending on

2

Gas Sampling Probes

One of two basic gas sampling probe types is provided with the CA-CALC, depending on the model chosen. For
instruments measuring O
sampling tube, and has an exposed thermocouple tip for fast-response temperature measurements. For instruments
supplied with NO

2

tube to limit loss of the reactive gases. The Emission Probe also has a sintered metal filter on the probe tip to reduce
soot buildup in the sample line.

, CO, and NO, the standard Sampling Probe is provided. This probe has an unlined

2

or SO2 gas sensors, the Emission Probe is supplied. This probe has a non-reactive “lined” sample

1

Chapter 2. Unpacking

Carefully unpack the CA-CALCTM 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 Part/Model

1 Series CA-6200 CA-CALC combustion analyzer CA-62XX (XX = 10-16)
1 Carrying case 1319319
1 Standard probe 12” with water trap or 801940
Emission probe 12” with water trap or 801951
Other probe and hose lengths available (24” probe, 25’ hose) Consult factory
1 Power supply 7.2V

120V or
230V European, or
230V Great Britain, or

240V Australian
1 Calibration certification
4 C cell alkaline batteries
1 Operation and Service manual 1980431

2613033
2613078
800169
2613106

Optional Accessories

Item Part/Model

Combustion supply air thermocouple, Type K 3013003
Portable printer 801994
Carrying strap tether 2913011
Computer cable 8940
NO sensor 802266
NO

sensor 802267

2

CO sensor (high concentration) 802265
O

replacement sensor 802263

2

CO (hydrogen compensated) replacement sensor 802264
SO

sensor 802268

2

Water trap filters 801947
Replacement kit, emission probe filter 801944
Gas Calibration kits (U.S. only)
CO (hydrogen compensated)
NO
NO

2

SO

2

O

zero calibration kit (N2)

2

801923
801937
801938
801936

801939
Probe adapter kit 801970
Probe heat shield 801969
Replacement filter kit 801944
Water trap replacement 802215
Lithium battery 1208028

3

Chapter 3. Component Identification

Key components of the CA-CALCTM combustion analyzer and sampling probe are identified in Figures 1 and 2 and
under section headings in the text that follows.

2

1

5

3

4

7

8

9

6

12

13

14

15

1. Label buttons 10. Battery cover

2. LCD display 11. Battery cover tab

3. On-Off button 12. Port for stack gas thermocouple probe

4. Control buttons 13. Port for combustion supply air thermocouple, type K

5. Icon buttons 14. RS232 serial port

6. CO diversion valve 15. Power connection

7. Magnets 16. Draft sample port

8. Vent 17. Gas sample port

9. Sensor cover

Figure 1: CA-C

16

17

ALC Combustion Analyzer Components

11

10

5

1

9

2

3

4

10

5

7

8

6

1. Sample tube retaining fitting 7. Tri-plex tubing

2. Probe handle 8. Water trap

3. Position collar 9. Emission Probe for NO2, SO2, with SS filter

4. SS sampling tube 10. Plastic filter

5. Sample and Draft connectors 11. Detail of standard probe tip

6. Thermocouple connector

Figure 2: CA-C

ALC Sampling Probe Components

The Gas Sensors

The CA-CALC analyzer holds up to four electrochemical gas sensors. Oxygen (O2) and hydrogen compensated
carbon monoxide [CO(H
Two of the following sensors can also be added: nitric oxide (NO), nitrogen dioxide (NO
and high concentration carbon monoxide (COhi). The gas sensors are found under the sensor cover identified in
Figure 1 above.

)] sensors are standard, included with all Series CA-6200 CA-CALC combustion analyzers.

2

), sulfur dioxide (SO2)

2

6 Series CA-6200 CA-CALC Combustion Analyzer

Optional Combustion Supply Air Thermocouple Probe

A measurement of the Combustion Supply air temperature is made using an optional thermocouple accessory probe
(TSI PN 3013003). This probe is connected to the supply air temperature port.

Combustion supply air temperature is an important value used in the determination of flue losses and efficiency.

On-Board Temperature Measurement

The CA-CALC analyzer uses an on-board resistance temperature detector (RTD) to provide the combustion supply
air temperature when no supply-air accessory probe is present.

Diaphragm Pump

The CA-CALC analyzer samples exhaust gases from the flue and delivers them to the electrochemical sensors using
a long-life diaphragm sampling pump.

Draft Sensor

A differential pressure transducer in the CA-CALC analyzer 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. Water must be prevented from entering the instrument through the sample port. The water trap
uses two chambers and a hydrophobic coalescing filter to maximize water removal.

Stack Probe Thermocouple

The type K thermocouple probe extends through the SS sampling tube to its tip, where stack temperatures are
measured. The thermocouple probe measures temperatures up to 1800 degrees F.

The yellow thermocouple connector plugs into the stack thermocouple port (see Figure 1).

Emission Probe (Supplied with Models CA-6213 and CA-6215 )

An “Emission” gas sample probe (Model 801951) is required when NO2 and SO2 gases are measured. This gas
sampling probe has an internal liner (TFE), which does not absorb NO
a sintered stainless steel filter at the probe tip to reduce soot buildup in the sampling lines. Soot, combined with
moisture from condensation, readily absorbs NO
Emission probe slows the response of the temperature sensor.

Note: When making temperature measurements, maintain the position of the probe in the flue until the
temperature reading has stabilized. For faster temperature measurement, when determining combustion
efficiency, a Model 801940 Sampling Probe is recommended.

and SO2. Note that the sintered metal filter on the tip of the

2

and SO2 gases. The Emission Probe also has

2

Chapter 3. Component Identification 7

CO Diversion Valve

The CO diversion valve is used to divert high concentrations of carbon monoxide (>5000 ppm) away from the
hydrogen compensated CO sensor. High CO concentrations cause the sensor baseline value to shift upward.
Although the effect is temporary, it may take ten minutes or longer for the sensor to recover. A shift upward in the
sensor baseline means the CO sensor indicates a concentration that is higher than the true concentration.

Mounting Magnets

The CA-CALC combustion analyzer can be adhered to a flat metal surface using the magnets on the case bottom.
This orients the instrument for convenient viewing and button operation. When mounted in this way it is advisable
to use the optional strap/tether (see optional accessories) as a safety harness in case the instrument is pulled away
from the metal surface. Metal surface must not be hot.

Schematic Representation of CA-CALC

Sampling Probe

Gas Sensors [S1 & S2; NO, NO
COhigh (optional))

O2

Orifice

Probe for Combustion
Air Temperature
(optional)

S1

Draft
Sensor

S2

CO Diversion
Valve

Pump

, SO2,

2

CO

Exhaust

Water Trap

Flue Gas
Temperature
Thermocouple

8 Series CA-6200 CA-CALC Combustion Analyzer

Chapter 4. Getting Started

Supplying Power

The CA-CALC
Quality alkaline batteries enable the instrument to operate for 24 hours. Use of the plug-in AC adapter conserves
battery life and can be substituted for batteries.

TM

portable combustion analyzer operates using 4 C-cell batteries or using the AC adapter provided.

Installing Batteries

Turn the combustion analyzer over and remove the battery cover by lifting up and
out on the battery cover tab shown to the right. Remove the old batteries.

Note: It is not necessary to remove the battery holder when removing or
installing batteries. Best results are obtained if the batteries opposite
the contact springs are removed first.

Install four new C-cell batteries, noting the battery orientation depicted on the base of the battery holder. Install
spring-side batteries first.

Connecting the AC Adapter

Find the supplied 7.2-volt AC Adapter included with the instrument. Connect the corresponding connector plugs to
the AC wall source and instrument power connection located on case bottom (see Figure 2). When using the power
supply, the batteries are bypassed.

Note: The CA-C

ALC analyzer does not charge rechargeable batteries.

Connecting the Sampling Probe

The sampling probe depicted in Figure 2 is connected to the instrument by pushing the sample and draft connectors
over the bulkhead ports on the instrument. Refer to Figure 3 below showing the probe connection. Make sure the
connectors are pushed fully over the bulkhead ports. Finish the connection by plugging the yellow thermocouple
connector into the Stack temperature thermocouple port. The thermocouple plugs in only one way. Don’t force the
connector.

Thermocouple Connector

Figure 3: Sampling Probe Connection

Sample Connector

Draft Connector

9

Setting CO Diversion Valve

Set the CO diversion in the orientation shown in the figure below. In this position, the valve is open, allowing gas to
flow to the CO sensor. Only under conditions where the CO level is very high (above 5000 ppm), should the valve
be closed. To close the valve, turn it 90 degrees counterclockwise.

Figure 4: Normal CO Diversion Valve Orientation

Normal Orientation for the
CO Diversion Valve

Connecting the Optional Combustion Supply Air Temperature Probe

An optional type K thermocouple probe (TSI PN 3013003) is used to measure the temperature of the air supplied to
the burner; the Combustion Supply air. When a probe is not used, the supply air temperature is measured using the
on-board resistance temperature detector (RTD). Connect the optional supply air thermocouple (see “Optional
Accessories”) to the supply air thermocouple port depicted in Figure 1. The thermocouple plugs in only one way.

Do not force the connector.

Connecting the Optional Portable Printer

Find the printer interface cable included with the Model 8925 portable printer. Connect the large 9-pin connector on
the cable to mating connector on the printer. Connect the opposite end to the instrument’s RS232 communications
and printer port. See Figure 1 for port location.

The printer and CA-C
different, the printer will print random characters, question marks or asterisks. Printer settings are described in the
printer manual, along with illustrations identifying the correct DIP-switch configuration. You will also need to set
the RS232 Device setting to Printer. To set the CA-C
“MENU Selections and Menu Items.”

ALC combustion analyzer have both been factory set for a baud rate of 1200. If baud rates are

ALC baud rate and device settings, refer to Chapter 6,

Connecting to a Computer

Use the optional computer interface cable, Model 8940, to transfer (download) data serially from the CA-CALC
analyzer to a computer. Connect the large 9-pin connector on the computer interface cable to the 9-pin serial
connector on your computer. Connect the opposite end to the instrument’s RS232 communications and printer port.
See Figure 1 for port location.

10 Series CA-6200 CA-CALC Combustion Analyzer

You will need to do two things before you can successfully communicate with a computer. First make sure the baud
rate of the CA-C

ALC analyzer matches that of the computer. Second, make sure the RS232 Device setting is set to

Computer and not Printer. To set the Device, refer to “Instrument Setup” in Chapter 6, “MENU Selections and
Menu Items.”

Default Instrument Settings

The CA-CALC combustion analyzer uses a number of standard settings for presenting the data, performing
calculations, and controlling instrument operation. These include the units displayed, the fuel used, the baud rate
and so on. When shipped, these have factory pre-set Default settings. The default settings are listed below. Default
settings can be changed as described in Chapter 6, “MENU Selections and Menu Items.”

Factory Defaults (U.S.)

Gas Concentrations
Temperature
Fuel*
O2REF
O2
Draft:
Excess Air:
Effc./Loss
Fuel Heat
Auto Draft Meas.
Baud Rate
RS232 Device
CO Shutoff level
NO Shutoff level

PPM (parts per million), applicable for CO, NO, NO
Degrees F
Natural Gas
OFF (do not incorporate O

reference in calculation of gas concentration)

2

Reference level: 3% (not used if OFF selected above)
Inches H

O

2

%EA
Net Efficiency
High heating value used in calculations, units are BTU
OFF
1200
Printer, configured for output to printer rather than to computer
2000 ppm. Turns the pump off if the CO level exceeds this set level
1000 ppm. Turns the pump off if the NO level exceeds this set level

, SO2 sensors

2

*Defaults extend to include factory set fuel parameter values for eight fuels. These fuels are; natural gas, propane,
#2 fuel oil, #6 fuel oil, coal, wood, baggasse, coke.

Factory Defaults (Non-U.S.)

Instruments sold outside the U.S. are often set up with default units and settings different than those identified in th e
table above. The defaults installed depend upon the letter designation present in the instrument’s Model number.
For example a -D in Model number CA-6210–D indicates that Germany is the destination country and has
appropriate units and settings installed. Other letter designations have the following meanings: -EU European,

-M metric units, -UK United Kingdom, -AU Australia. The following table shows defaults relating to the instrument
designations. Remember it is always possible to change the default settings.

Chapter 4. Getting Started 11

Default Settings For Different Model Letter Designations

Instrument Model
number

O2

O2 ref.

ref.

Level Draft Temp

Excess
Air

Effc / Loss
Basis

Effc / Loss Fuel heat

Gas
Conc. Decimals Fuel Setup

CA-621X off 3% " H20 F %EA ASME/heat

loss

CA-621X – D off 0% mbar C lambda Siegert qA NA PPM commas Siegert fuel

CA-621X - EU off 0% mbar C lambda Siegert qA NA PPM commas Siegert fuel

CA-621X - M off 0% kPa C %EA ASME/heat

loss

CA-621X - UK off 0% kPa C %EA ASME/heat

loss

CA-621X - AU off 0% kPa C %EA ASME/heat

loss

Net
Efficiency

Net
Efficiency

Gross
Efficiency

Gross
Efficiency

BTU HHV PPM periods fuel

composition
parameters

parameters

parameters

kJ/kg HHV PPM periods fuel

composition
parameters

kJ/kg LHV PPM periods fuel

composition
parameters

kJ/kg LHV PPM periods fuel

composition
parameters

12 Series CA-6200 CA-CALC Combustion Analyzer

Chapter 5. Basic Operation

Quick Start

This chapter describes the steps needed to start making basic measurements. When used for the first time, the
CA-C
different instrument parameter settings refer to “Instrument Setup” in Chapter 6, “MENU Selections and Menu Items.”

TM

ALC

combustion analyzer parameter settings match the Defaults listed in the previous chapter. To select

Steps to Quick Startup

1. Review Chapter 4, “Getting Started.” Perform the necessary hardware setups.

2. Turn the instrument on using the red ON-OFF button identified in Figure 1.

3. Verify that you have adequate battery life for your measurement needs. A 50% reading for example, indicates 8 to

12 hours of additional operating life.

4. Press the ENTER button. A brief initialization follows.

If the Error screen appears, refer to Chapter 9, “Maintenance and Troubleshooting.”

5. Review the Pre-Test screen. The O

near 0 ppm. The draft reading should be 0.

6. Press ESC to bypass the baseline calibration.

sensor should indicate approximately 20.9% and other gas sensors indicate

2

Baseline Calibration

To perform a baseline calibration press ENTER from the Pre-Test screen. A baseline calibration reestablishes
baseline levels for the electrochemical sensors and draft sensor. When performing a new baseline calibration, make
sure the probe is in air free of exhaust gases (or disconnected). The baseline calibration takes about 40 seconds. To
abort the baseline calibration, press ESC. The data display screen app ears when the baseline calibration is complete or
bypassed.

Figure 5: Schematic Illustration of Quick Start Process

13

The Data Display Screen

Refer to the figure below to identify the key components of the main Data Display screen.

Site name for data logging

Device name for data logging

Date and time

O2 reference status

Site: Not Selected

Device: Not Selected Bat:99%
15:00:00 01/01/00 Fuel: NAT GAS
O2REF: OFF

Message area

O2 20.9 % TAint 77 °
CO 1 PPM C O r 0.0000
NO 0 PPM CO2 0.0
NOx 0 PPM EA
SO2 0 PPM Effc
TS 500 °
Draft - 0.00

LOGGING
FUNCTION

F

inH2O

ZERO

DRAFT

OVER %

OVER %

Button label for instrument setups. See Chapter 6.

F

%

MENU

Battery life indication

Fuel type

Button Icons

Button label for re-zeroing the draft sensor.

Button label for data saving and management
functions. See Chapter 7.

Measured and calculated data. Updated in
real-time.

Figure 6: The Main Data Display Screen

14 Series CA-6200 CA-CALC Combustion Analyzer

Available Measurements

The CA-CALC analyzer automatically detects the sensors installed. Only measurements for detected sensors appear on
the display. For example, if no carbon monoxide sensor is present, CO will not appear on the display. For values that
are calculated, such as efficiency (Effc), sensors that provide data for the calculation must be present. If the O
data or stack temperature data is missing, efficiency will not be calculated and Effc will not be displayed on the Data
Display.

The following table presents a list of the measurements and calculations made by the CA-C

ALC analyzer. These will

appear on the Data Display if the appropriate sensors are present.

O

2

CO

Oxygen concentration. 0–25%
Carbon monoxide concentration measurement made using the hydrogen compensated CO

sensor. 0–5000 ppm

sensor

2

NO (optional)
NO2 (optional)
NOX (optional)

SO2 (optional)*
COhi (optional)

TA (optional)

TAint
TS
Draft
CO2

COr

EA%

Nitric oxide concentration 0–4000 ppm
Nitrogen dioxide concentration. 0–500 ppm
Concentration combining NO and NO

the NO
if the NO

concentration is assumed to be 5% of the NO concentration. No NOX is displayed

X

sensor alone is present

2

concentrations. When a NO2 sensor is not present,

2

Sulfur dioxide concentration. 0–4000 ppm
Measurement of carbon monoxide made using the high concentration CO sensor. 0–20000

ppm
The combustion supply air temperature. Only present when the accessory probe is used. –

20–392 °F (0–200°C)
The temperature measured using the on-board RTD.
Stack temperature. Displayed when thermocouple is plugged in. 32–1800°F (0–1000°C)
The Draft measurement. Only updated when the pump is off. ±30” H
The carbon dioxide concentration in %. Based upon the O

measurement and fuel CO2

2

O (80 mbar)

2

Max parameter.
The ratio of CO to CO

. ppm CO/(%CO2 x 10000)

2

% Excess air.

Lambda (λ)
Effc
Loss

Alternative excess air representation to %.

Combustion Efficiency, Net or Gross and (100 – qA)
Dry gas loss and Siegert (qA).

Special note: The SO
concentration. The CA-C
present. A correction is also performed for the effects of NO
the NO
sensor to NO

concentration is assumed to be 5% of the NO measured concentration. The response of each SO2

2

is determined at the factory as part of the SO2 sensor calibration.

2

sensor has a negative response to NO2 gas which is proportional to the NO2

2

ALC analyzer corrects for the effect of NO

2

on the SO2 sensor if an NO2 sensor is

2

when a NO sensor is installed. In this case,

Chapter 5. Basic Operation 15

Buttons and Button Operations

ON-OFF Control Button (red)

Turns the instrument on and off. Pressing this button is accompanied by a beep.

The ENTER Control Button

Press the ENTER button to execute a command, such as selecting a menu item. Most instrument display screens have
a message indicating the ENTER button function.

Note: Pressing ENTER does not cause entered values to be saved to the instrument memory. Buttons

with display labels such as SAVE & EXIT or ACCEPT are designed for saving.

The ESC Control Button

Press the ESC button to exit the current screen and operation, in most cases returning to the previous screen.

Arrow Control Buttons

The arrow buttons are used for three purposes:

Purpose 1. To move the display cursor to a menu item for selection using the ENTER key. The display cursor appears
as a dark background over light characters. Example: Instrument Setup

Purpose 2. To move the character cursor to a character or character space.

Example:
Name: NAT GAS Character cursor on letter T.

Purpose 3. To increment a numerical value or select a character from the character menu.

When a blinking cursor box is present, the arrow keys cause the value in the box to change; ON toggles to OFF, a
Name character steps through a set of characters, or a number value increases or decreases.

16 Series CA-6200 CA-CALC Combustion Analyzer

Icon Buttons

Button Icons appear on the right side of the display and are connected to an Icon button by an indicator line. The
button icons correspond to the button functions described below. You will see that some icons change when the button
is pressed, indicating a change in a current status (e.g., pump on/off), or indicate that a new operation will be
performed when the button is pressed again. This is true of the Display button that changes from the graph icon to the
zoom icon to the un-zoom icon.

Icons

Print a Sample. Press the button to the right of this icon to output the current data

displayed on the Data Display screen through the serial port to the portable printer
or a computer.

Draft Measurement. Press this key to take a draft measurement. This causes the
pump to stop. A countdown begins during which time the draft reading is stabilized
and taken.

Icon Description

Back Light button icon. Left icon indicates light off, right icon indicates

light on.

Pump On-Off button icon. Left icon indicates pump off, right icon
indicates pump on.

Display Icons. Button to the right toggles from the Graph
display to the Zoom display to the Un-zoomed, standard
Data Display.

Save Data. Save (log) current data on the Data Display screen.

Labeled Buttons

Button labels appear in boxes such as those shown below. The labels have tabs that connect to a button, performing
the labeled function, by an indicator line. Examples are shown in the illustration below.

Chapter 5. Basic Operation 17

Label Box

Button

Indicator Line

Tab

If no tab is present on a box, it is not linked to a button and is a message box. A good example of a message box is
shown below.

Message Box

Selecting Menu Items

Menus are lists of items or options you select to perform a needed operation. Selection of a menu item begins by
moving the display cursor to the item and pressing the ENTER button. The display cursor is moved using the Arrow
buttons.

Example: Display Cursor

Zoom Settings
Instrument Setup

Calibrate Sensors

Restore Factory Cal
Set Contrast

.
.

Once the ENTER button is pressed, a new menu may appear with a new list of option items, or you may see a
blinking cursor indicating that a number value, or unit value can be changed. If you want to back-out of a selection,
simply press the ESC button.

Display Cursor

Changing a Number Value

The CA-CALC combustion analyzer has a variety of number values that are changeable. Examples are the Contrast
level, Time and Date, O
becomes changeable when a blinking cursor box surrounds it.

Example: Changeable number value.

Contrast:

Use the Arrow buttons to increase or decrease the indicated value. Note—there are upper and lower limits on values.
When an upper or lower limit is reached, the numbers wrap around.

Use the SAVE & EXIT button to install the new value.

Reference, and so on. Press the ENTER button on the list item to initiate a change. A value

2

Blinking cursor indicates value can be changed using

50

the Arrow buttons.

18 Series CA-6200 CA-CALC Combustion Analyzer

Changing Units

Data displayed by the CA-CALC analyzer can be presented in different units. To change units, first select Instrument
Setup from the main MENU. Use the Arrow buttons to select from the list of available units. Press ENTER to make

a selection. A blinking cursor box over the selected unit indicates that it is changeable. Use the Arrow buttons to
change between available units. Press ENTER once the desired units are shown, then use the SAVE & EXIT button
to install the new unit.

Refer to “Instrument Setup” in Chapter 6, “MENU Selections and Menu Items,” for specific information on unit types.

Entering and Changing Names

Names include the fuel types and data saving identifications: Sites, Devices and Samples. To create or edit a name,
use the Arrow buttons to move the cursor to the desired character space and press the ENTER button (see the
example below). The blinking cursor indicates that a character can be changed or added if none exists.

Note: A character table is displayed when ENTER is pressed. Use the Arrow buttons to choose any

character in the table. Press ENTER to install the selected character. Repeat this process to enter
all your required characters.

When the entries are complete, press the SAVE & EXIT button to install the name.

Example: Name entry

Name: __ __ __ __ __ __ __ __ __ __ __ __

A B C D

Name: __ __ __ __ __ __ __ __ __ __ __ __

Finish by pressing the SAVE & EXIT button to install new name.

To select an item from a menu list use the Arrow buttons to highlight the item, then press ENTER.

A B C D

Move character cursor with Arrow buttons. Select
using the ENTER button.

Blinking cursor after ENTER. Change character with the

Arrow buttons. Use ENTER to accept character.

Using the Sampling Probe

Gas and Temperature Measurements

Connect the sampling probe to the CA-Calc as described in Chapter 4.

Place the Sampling probe through a hole in the exhaust flue, following recommendations presented below. Placement
of the probe is important, and certain considerations must be given when choosing a sampling location.

To ensure that the gas measurements are not diluted or cooled by outside air, place the probe before any draft damper
or regulator as illustrated in Figure 7. Tilt the probe tip up slightly so vapor condensing in the sampling tube does not
run back to the probe tip and cool the thermocouple tip. Important: Twist sampling tube to ensure that the

thermocouple tip is exposed directly to exhaust flow (see figure below).

Chapter 5. Basic Operation 19

2

3

1

Minimum 2” (5 cm)

4

Rotate the tube to window to
ensure proper thermocouple
exposure. Models CA-6210,

CA-6211, CA-6212, CA-6214

1. Sampling probe 3. Exhaust flue

2. Draft regulator 4. Hot exhaust gases

Figure 7: Sampling Probe Location

Stack temperature measurement is extremely important to establish the heat loss from the exhaust gases and
determine combustion efficiency. The Sampling Probe with its integral thermocouple measures temperature at the
probe tip. The tip should be placed at the point of highest exhaust gas temperature when determining efficiency. This
means at the base of the flue, before heat is lost to the flue side-walls, and towards the center, especially for small
ducts. If the stack gas temperature is underestimated, the operating efficiency will be overstated. When an
economizer or air heater is used, the stack temperature is measured after these devices.

Note: When an Emission Probe is used, allow adequate time for the temperature to stabilize before

accepting the combustion efficiency measurement (5–10 minutes).

Cautions

Hot probe! When removed, the sampling probe will be extremely hot. Avoid touching

!

20 Series CA-6200 CA-CALC Combustion Analyzer

the probe tip, and avoid placing the probe on or near plastic materials such as the
instrument case. These will melt. Maintain a minimum 2” (5 cm) clearance between
the probe handle and position collar when the probe is mounted in flue.

Empty Water Trap! Watch the water trap and empty it frequently to prevent the
possibility of flooding the instrument. See Chapter 9 for instructions.

Making a Draft Measurement

Before making a draft measurement, zero the draft pressure transducer by pressing the ZERO DRAFT option button
in the Data Display. For zeroing, make sure the sampling probe is out of the flue, or that the d raft and sample fittings
are disconnected from the instrument. Once zeroed, reinsert the sample probe and press the Draft Measurement
icon button to initiate a draft measurement.

During the draft measurement, the sampling pump is automatically turned off.

When the draft measurement is complete, the pump turns on again.

Note: Draft readings are also taken continuously whenever the pump is turned off. When the pump is

turned on again, the current draft reading is captured, and remains displayed until the next time the
pump is turned off or the Draft Measurement icon button is pressed.

Auto Draft Meas. Feature

The Auto Draft Meas. feature is used so that a draft reading is automatically taken whenever a sample is saved using
the Save Data icon button. To activate automatic draft saving, set the Auto Draft Meas. item to On from the

Instrument Setup menu.

Printing to the Portable Printer and to a Computer

Printing

Instrument data can be output through the RS232 serial port to the optional Model 8925 portable printer. First refer to
“Connecting the Optional Portable Printer” in Chapter 4, “Getting Started.” Make sure the baud rate is set correctly.

To print the information on the Data Display, press the Print a Sample icon button.

The printer responds immediately once the button is pressed, producing a printout. Example printouts are shown in
Figure 8.

Data is also printed using the logging functions accessed by pressing the LOGGING FUNCTIONS option button.
The logging functions enable you to print saved data as a single Sample, or as many Samples saved under a Site or
Device name. Chapter 7, “Saving Data and LOGGING FUNCTIONS,” identifies the buttons used to perform these
printing operations.

When data is printed from LOGGING FUNCTIONS, the Site and Device names are presented as well as the
Sample name. In addition, fuel parameters used in the calculations are also printed. An example of a Sample
printout from LOGGING FUNCTIONS is shown on the right in Figure 8.

Printing to a Computer

Use the print buttons and print functions to output data to a computer as well as to the portable printer. First refer to
“Connecting a Computer” in Chapter 4, “Getting Started.” Make sure the RS232 Device is properly set to
Computer, and that the baud rate is set correctly.

Data transferred to a computer is the same as that output to a printer (see Figure 8); however, it is formatted differently
and uses the Windows
combustion analyzer how to output the data. Data transferred to a computer is tab-delimited so it can be more
conveniently parsed when using spreadsheet applications such as Microsoft Excel

®

Windows and Excel are a registered trademarks of Microsoft Corporation.

®

character set rather than DOS characters. Setting the RS232 Device tells the CA-CALC

®

.

Chapter 5. Basic Operation 21

Data can be downloaded to a terminal emulator program such as the HyperTerminal, which accompanies the
Windows

®

operating system program. Look for HyperTerminal in the Accessories folder. In HyperTerminal,

use the Capture Text option from the Transfer menu for recording instrument data.

Communications Protocol

Baud rate 1200 (default)
Data bits 8
Parity none
Stop bit 1
Flow none

DATE: 01/01/99
TIME: 15:00:18
Fuel: Nat Gas
O2REF: Off

O2 6.0
CO 5 PPM
NO 0 PPM
NO2 0 PPM
NOx 0 PPM
TA 70 °F
TS 300 °F
Draft 0.01 inH2O
CO2 8.4 %
Lambda OVER
Effc 84%

Printout using the Icon button.

Site: 1( site name
Device: 1( device name
Sample: 1(sample name)
DATE: 01/01/99
TIME: 15:00:18
O2REF: Off
Fuel: Nat Gas

Fuel Parameters:
Carbon wt.: 79.9%
CO2 max vol.: 11.8%
Sulfur wt. 0.0%
Moisture. 0.0%
HHV(BTU/lb): 21869

O2 6.0
CO 5 PPM
NO 0 PPM
NO2 0 PPM
NOx 0 PPM
TA 70 °F
TS 300 °F
Draft 0.01 inH2O
CO2 8.4 %
Lambda OVER

Effc 83.8 %

Printout from LOGGING FUNCTIONS.

Figure 8: Example Printouts

22 Series CA-6200 CA-CALC Combustion Analyzer

Chapter 6. MENU Selections and Menu Items

Select from items in the main menu to perform setup operations. Access the main menu by pressing the button
labeled MENU. Following is a list of the main menu items and the underlying menus. In this chapter, main menu
items are described in sections in the order they appear in the menu, beginning with the Zoom Settings followed
by Instrument Setup and so on.

It will be useful to review sections of the previous chapter dealing with selecting menu items, changing number
values, units and names before proceeding. Recognize that for most operations, the procedure is as follows: use the
Arrow buttons to highlight a menu item, use the ENTER button to select the menu item, use the Arrow buttons
make modifications, and finally use SAVE & EXIT to implement the change.

(MENU main menu)
Zoom Settings
Instrument Setup
Calibrate Sensors
Restore Factory Cal
Set Contrast
Set Time and Date
Select Default Fuel
Fuel Setup
Restore Fuel Settings
Erase All logged Data

CALIBRATE SENSORS

O2
CO
NO
NO2
SO2
TS
TA
Draft

SELECT FUEL TYPE
Nat GAS
Propane
Oil #2
Oil #6
Coal
Wood(dry)
Bagasse
Coke
User Type
User Type
User Type
User Type
User Type

ZOOM SETTINGS
O2
CO
NO
NO2
NOX
SO2
TS
TA
Draft
CO2
EA

RESTORE FACTORY CAL
O2
CO
NO
NO2
SO2
TA
TS
Draft

FUEL SETUP

Nat GAS
Propane
Oil #2
Oil #6
Coal
Wood (dry)
Bagasse
Coke
User Type
User Type
User Type
User Type
User Type

INSTRUMENT SETUP
O2REF
O2REF Level
Temp:
Draft:
Excess Air
Effc./Loss
Fuel Heat
Gas Conc.
Decimals:
Auto Draft Meas:
Baud rate:
RS232 Device
CO Alarm Level
NO Alarm Level:
Effc/Loss Basis

SET DATE AND TIME
Date:
Time:

23

Zoom Settings

In the Zoom Settings screen you can select two parameters to be displayed in large characters. The large character
display appears when the Zoom Display Icon button is pressed.

NO -0 PPM CO2 0.0 %
NOx -0 PPM EA OVER %
SO2 -0 PPM Effic OVER %
TS 500 °F
TA 75 °F
Draft - 0.00 inH2O

O2 20.9 %
CO 1

LOGGING
FUNCTIONS

ZERO
DRAFT

PPM

MENU

ZOOM SETTINGS

= Measurement Zoomed

*

* O2
* CO

NO
NOx

SO2

Figure 9: Example Zoom Display and Zoom Settings Screen

To set the parameters for large display select Zoom Settings from the MENU items.
Choose a parameter from the list in the Zoom Settings menu by moving the cursor to a list item using the Arrow

buttons, and pressing ENTER. An asterisk appears by the selected parameter. Two parameters can be chosen.

Instrument Setup

Below is a list of Instrument Setup options. These are discussed on the following pages. Some of the items
below are calculated. Refer to Appendix A, “Calculations,” later in this manual for information.

REF

O

2

REF Level

O

2

Temp:
Draft:
Excess Air
Effc./Loss
Fuel Heat
Gas Conc.
Decimals:

….more….
Auto Draft Meas:

Baud rate:
RS232 Device
CO Alarm Level
NO Alarm Level:
Effc/Loss Basis

This indicates additional items are available
beyond those currently displayed. Use the
down Arrow button to access these items.

24 Series CA-6200 CA-CALC Combustion Analyzer

Instrument Setup

Item Description Options

REF:

O

2

Enable or disable the O

reference calculation. The O2

2

reference applies to the CO, NO, NO

and SO2

2

Select between:
On
Off

measurements. Refer to the next item below.

reference level can be adjusted between 0 and

O2REF Level:

This option is used to set a value for the O

reference

2

The O
18%.

2

level used in the reference calculation. Refer to
Appendix A, “Calculations,” at the back of this
manual.

Temp:

This option is used to select temperature units for
display.

Temperature units are:
Degrees Fahrenheit, °F

Degrees centigrade, °C

Draft:
This option is used to select draft units for display.

Optional Draft units are:

O

inH

2

kPa
mbar
hPa

Excess Air:

This option is used to select between options for the
display of excess air.

Options for displaying excess air are:

%EA
Lambda,(

Effc./Loss:

Choose to display Net Efficiency, Gross Efficiency
Loss or qA and Effic. for the Data Display. Options
for display will depend upon the Effc/Loss Basis
selected (ASME or Siegert).

Refer to the Fuel Setup section and Appendix A,
“Calculations,” later in this manual.

To change the Effc/Loss Basis, refer to the item
description found later in this section.

Fuel Heat:

This option allows you to select whether the high
heating value (HHV) of the fuel, or the low heating
value (LHV) of the fuel. Fuel heating value is used
when calculating combustion efficiency or loss. Units
for fuel heat are also selectable between BTUs/lb. and
kJ/kg.

The options for the display of fuel combustion
efficiency are:

ASME

Effc. Net,
Effc Gross,
Loss

Siegert

qA
Effic. = 100 – qA

Fuel heat options:

BTU/lb HHV
BTU/lb LHV
kJ/kg HHV
kJ/kg LHV

Note: Emission factors will change to metric
units when kJ/kg fuel heat units selected (see
Appendix A).

λ)

Chapter 6. MENU Selections and Menu Items 25

Instrument Setup (continued)

Item Description Options

Gas Conc.:

Change gas concentration units for display gas

concentration using this option. The selections of

units applies to all gases accept the O

and CO2.

2

These are expressed as percent only.

Units relating the weight of the gas to the fuel energy

input use the conversion factors, FNOx, FSO

, FCO

2

displayed in the Fuel Parameters screen.

Decimals:

Select between periods or comas to use when

expressing decimal notation.

Auto Draft Meas:

When On is selected, this option causes the

instrument to automatically take a new draft

measurement each time the Save Data icon button is

pressed.

Baud Rate:

This option is used to select the baud rate for the

serial output to an attached computer or printer. The

default baud rate is 1200, which matches the default

printer setting.

If the baud rate is changed in the instrument, make

sure it is also changed for your computer or printer.

RS232 Device:

Select the Device (printer or computer) receiving the

serial data. Sending data to the wrong Device results

in the presence of bad characters.

CO Shutoff Level:

Extended CO sensor exposures above the stated

maximum overload concentration of 4000 PPM can

cause temporary shifts in the CO readings. To help

avoid this, the instrument automatically turns the

pump off and displays a warning when the Shutoff

level is exceeded for three seconds.

NO Shutoff Level:

Extended NO sensor exposures to NO concentrations

above the recommended maximum overload

concentration (5000 PPM) can cause temporary shifts

in NO sensor measurements. To avoid this, the

instrument turns the pump off when concentrations

remain over the Shutoff level for three seconds.

Select units for concentration display from the
following:

PPM parts per million
g/MWh grams per megawatt hour
mg/MJ milligrams per mega-joule
ng/J nanogram per Joule
mg/kJ milligrams per kilo-joule
#/Mbu pounds per million Btus
mg/m3 milligrams per cubic meter
g/bhph grams per brake horsepower hour
mg/kWh milligrams per kilowatt hour
g/kWh grams per kilowatt hour

Select from:

Commas
Periods

Chose between:

On
Off

Select from the following baud rates.
1200

2400
4800
9600
19200

Choose device to receive serial data:

Printer
Computer

The CO shutoff level can be set over the range:

1000-5000 PPM:

The default level is set to 2000 PPM.

See Chapter 9, “High Concentration Overload”..
The NO shutoff level can be set over the range:

1000-5000 PPM:

The default shutoff level is 1000 PPM

See Chapter 9, “High Concentration Overload”.

26 Series CA-6200 CA-CALC Combustion Analyzer

Instrument Setup (continued)

Item Description Options

Effc/Loss Basis:

Efficiency and loss are calculated based upon heat-

loss (ASME) or Siegert calculations. Select between

ASME or Siegert using the Effc/Loss Basis

instrument setup option.

Select from the following options:

ASME
Siegert

In the U.S. select the ASME calculation to determine

Net Efficiency. Use the high fuel heating value

(HHV). Use the Siegert formula in Europe. Refer to

the Default Instrument Setting section in

Chapter 2.

Note: Depending upon the basis selected for

the efficiency and loss calculations, default fuels

and fuel parameters in the Fuel Setup menu

change. Refer to the Fuel Setup section later in

this chapter and Appendix A for more

information.

Note: If you use this option to change the basis

of your efficiency/loss calculations, it is

necessary to use the Restore Fuel Setting

following the change. Select YES for both factory

and user fuels.

Calibrate Sensors

Calibrate Sensors is the third selection in the main MENU. This is used when performing calibrations of the on-

board sensors. Gas sensors, thermocouples and the draft sensor can all be calibrated. When the Calibrate Sensors
option is selected, the display menu appears as in the example below (Figure 10). Only installed sensors are listed.
Select the sensor for calibration using the Arrow buttons and ENTER.

For specific information regarding calibrations, refer to Chapter 8, “Calibrations,” found later in this manual.

Calibration:

Name Reading Units Serial Last cal

O2 20.9

CO -1 PPM 01200002

NO -1 PPM 01200003 01/02/99
NO2 -1 PPM 01200004 01/02/99

SO2 -1 PPM 01200005 01/02/99
TS 75 F 01/02/99
TA 75 F 01/02/99

Draft inH20 01/02/99

<--> move cursor
<ENTER> to calibrate

% 01020001 01/02/99

Figure 10: Screen to Select Sensor for Calibration

Chapter 6. MENU Selections and Menu Items 27

Restore Factory Cal

In the event that a sensor calibration is performed in error, or the calibration(s) becomes corrupted, the initial sensor
calibration performed at the factory can be re-installed. This is possible because factory calibration data is saved,
either in the gas sensor electronics, or in the instrument. The initial data is never discarded. Calibrations are restored
for individual sensors by selecting the appropriate sensor from the list in the Restore Factory Cal screen, and
pressing ENTER.

Set Contrast

The Set Contrast option is used to lighten or darken the display, improving visibility. Once Set Contrast is
selected with ENTER, set the contrast using the Arrow buttons to increase (darken), or decrease (lighten) the
contrast value. The default is value is 50. Use the SAVE & EXIT button to save the new contrast setting.

Set Time and Date

Once selected from the main MENU using ENTER, a blinking cursor in the Set Time and Date screen indicates
the number field is changeable. The up/down ( ) Arrow buttons are used to increase or decrease the indicated
value. To move between entry fields use the left/right ( ) Arrow buttons. Time and date have the following
format:

Date: Month/Day/Year

Time: Hour:Min.:Sec.

Use the SAVE & EXIT button to save new settings.

Select Fuel Type

Use this selection from the main MENU to choose the type of fuel being burned. When you select a fuel type, you
install fuel parameters for this fuel. Fuel parameters are used to perform calculations of CO
loss, and emission rates. These calculated values are not correct if the wrong fuel is specified! The fuel list includes
eight standard fuel types (five when Siegert basis used), with nominal fuel parameter values, and five User fuels.
More information on fuels is included in the next section “Fuel Setup.”

, combustion efficiency,

2

28 Series CA-6200 CA-CALC Combustion Analyzer

Fuel Setup

This menu selection lets you change fuel parameters for existing fuel types and add new fuel types to the fuel list.
When the Fuel Setup is selected from the main MENU, the fuel list is displayed together with a table of fuel
parameters. Use the Arrow buttons to move to a fuel in the fuel list. The fuel parameters in the table automatically
update for the highlighted fuel. See the example display in Figure 11 below.

Fuel Setup

Nat Gas

Propane…....

Oil #2
Oil #6
Coal
Wood(dry)
Bagasse
Coke
User 1
User 2
User 3
User 4
User 5

Figure 11: Fuel Setup Screen—Selecting Fuel to Change Parameter

To modify parameters for the highlighted fuel, Press ENTER. The fuel parameters screen appears as in Figure 12
below.

Use the Arrow buttons to move the cursor to the field to be changed. This can be a letter in the fuel name, or a fuel
parameter with a number value. Press the ENTER button to choose the highlighted field. A blinking cursor appears,
indicating that the field is changeable.

Use the Arrow buttons to increase or decrease a value in the chosen field, or select a character from the character
table. The character table appears when a character in the fuel name is highlighted and ENTER is pressed. A fuel
name can be comprised of any character in the character table.

Press the SAVE & EXIT to install your new entries. ESC will abort any changes.

Fuel parameters
Carbon wt.: 81.8 %

Hydrogen wt.: 18.2 %
CO2 max vol.: 13.8 %
Sulfur wt.: 0.00 %
HHV(BTU/lb): 21669
LHV(BTU/lb) 19693
Moisture: 0.0%
F.SO2: 0.00145
F.NOx: 0.00104
F.CO: 0.00063

Table of fuel parameters for
highlighted fuel (Propane).

Chapter 6. MENU Selections and Menu Items 29

Figure 12: Fuel Parameters Screen—Select and Change Fuel Parameters

Fuel Parameters:

Name: PROPANE

Carbon wt…: 81.8 % Moisture 0.0%

Hydrogen wt.: 18.2 %
CO2 max vol.: 13.8 % Emission Factors:
Sulfur wt.: 0.00 % FSO2: 0.00145
HHV(BTU/lb): 21669 FNOx: 0.00104
LHV(BTU/lb) 19693 FCO 0.00063

move cursor
<ENTER> = select
<ESC> = exit

SAVE & EXIT

Fuel Setup When Siegert Loss Calculation Used

When Siegert is selected from the Effc/Loss Basis option, flue losses and fuel efficiency are calculated using
the Siegert formula (see Appendix A). The fuel parameters are different than those identified in the section above.
The Siegert formula for flue gas loss uses constants A1 and B, replacing the weight percents of C, H, S and the
fuel heating values (HHV and LHV). These constants are derived from the fuel’s composition and incorporate the
low heating value into the loss calculation.

To change these values, or enter values for new fuel types, follow the same procedur e outlined in the previous
sections above. Remember to use the SAVE & EXIT button when complete. For information on the Siegert
calculation, refer to Appendix A.

Restore Fuel Settings

Fuels one through eight (1-8) in the fuel list are set at the factory, together with their fuel parameters. These fuel
values are saved in the instrument, and can be changed if desired using the Fuel Setup option. Fuels 1-8 can also
be restored to the initial factory setting if needed. To return values to the factory settings after changes have been
made, select Restore Fuel Settings from the main MENU. Choose the YES option button when required.
Restore Fuel Settings does not affect the User fuels (9-13), however, you are given a chance to clear your user
fuels by selecting YES when requested. Skip this process by selecting NO or pressing ESC.

Remember to use this option after changing the Effc/Loss Basis.

30 Series CA-6200 CA-CALC Combustion Analyzer

Erase Logged Data

Use the Erase Logged Data function to clear the instrument’s logging memory. When this option is selected,
press YES to perform the clean-up operation. Choose NO or ESC to abort the erasing process.

Caution

This option permanently erases all user entered Sites, Devices and Samples from

!

the CA-CALC combustion analyzer logging memory.

Chapter 6. MENU Selections and Menu Items 31

Chapter 7. Saving Data and LOGGING FUNCTIONS

A key feature of the CA-CALCTM combustion analyzer is the ability to save combustion and emission test data to
memory in the instrument. This data can be retrieved later for printouts, downloaded to a computer, or used for
comparison with other tests. Data is maintained by power supplied from a 2-year lithium battery on-board the
instrument. There is the possibility that if the instrument is dropped, lithium battery power could be lost with
subsequent loss of data. Important data stored on-board should be saved periodically to a computer or printed for a
permanent record.

Overview

The CA-CALC analyzer saves data Samples when the Save Data icon button is pressed. A Sample is a snapshot
or log of the data appearing on the Data Display screen.

The Save Data icon button

Data Samples consist of all the sensor data, units, time and date, and O
data includes fuel type and fuel parameters. The CA-C

To improve data retrieval for comparisons, printing or downloading to a computer, the CA-C
analyzer relies on structured saving environment with data management functions. The data management functions
are accessed using the LOGGING FUNCTIONS button on the main Data Display.

Data management functions.

LOGGING FUNCTIONS

The structured data environment provided by the LOGGING FUNCTIONS is particularly useful for the testing
contractor who has numerous customers (Sites), who may in turn have multiple furnaces or boilers (Devices)
requiring service.

Samples can be saved under a Device name. Multiple Devices can be saved under a Site name. Refer to the
schematic below. This shows the data saving organization.

CA-Calc Data Management Structure

ALC analyzer saves up to 350 Samples.

reference values. In addition, the saved

2

ALC combustion

Sites (35 possible)

Devices (75 possible)

1)Device 1

2)Device 2

.

.

Samples (350 possible)

1) sample name

2) sample name

3) sample name

4) sample name

.

33

Before saving a Sample, it is necessary to define a Site and Device. This is discussed in the following two
sections.

Saving Data When no Site or Device is Selected

It is necessary to choose a Site name and Device name before saving data Samples.
If a Site and Device has not been selected when the Save Data button is pressed, the following message is

displayed:

Store Data:

A Site and Device need to be
selected for logging
Press <ENTER> to continue

By pressing ENTER, a screen appears which is similar to that displayed when the LOGGING FUNCTION button
is pressed. You will be given a chance to select from previously created Sites and Devices, or to ADD a Site and
Device. Other functions will be available too, giving you a chance to DELETE or EDIT Sites and Devices. Once
a Site and Device are selected or created press <CONTINUE LOG> to proceed with data sampling. Figure 13 on
the next page outlines the data saving process.

Creating or selecting Site and Device and other logging functions are described in “LOGGING FUNCTIONS,”
immediately following the next section.

Message appears if no Site and/or Device
selected.

Saving Data to Selected Site or Device

Once a Site and Device have been created and selected, Samples can be saved using the Save Data icon button.
Before saving data, decide if you want a draft measurement to be taken and saved with each sample. If yes, turn
Auto Draft Meas. On from the Instruments Setup menu option in the main MENU. Refer to Chapter 6,
“MENU Selections and Menu Items,” for more on the Auto Draft Meas. function.

The Save Data icon button

When the Save Data button is pressed, and once an automatic draft is completed or skipped, the instrument
displays a screen allowing you to: confirm the current Site and Device selection, save to another Site/Device, or
choose not to save at all. To continue, press the button under the label YES. You will be asked to enter a name for
the sample. If you select YES, a name entry screen will appear. When complete, press SAVE & EXIT to save your
data under the entered name. If you do not want to enter a name, simply press NO. Data will be saved under a
number designation. For example, Sample 5 appears as 5) in the sample list, (i.e., number followed by open
parentheses). The number and parentheses become the sample name.

Samples are automatically incremented so you will not overwrite previously saved sample data. The number
designation preceding the name becomes part of the name itself, so the same name can be repeated.

34 Series CA-6200 CA-CALC Combustion Analyzer

The data saving process is presented in the schematic in Figure 13. Information introduced in the schematic
regarding creating, deleting and editing Sites and Devices is provided in the next section, “LOGGING
FUNCTIONS.“

The Save Data icon button

Site and Device have not been
selected.

Site and Device have been selected

A Site and Device need to be
selected for logging.
Press ENTER to continue

Store Data:

Site 3: ABC CO.
Device 1: BOILER#1
Sample 5

Save th this Site/Device?

NO YES

Quit the save process.

Quit save

Store Data:

Site 3: ABC CO.
Device 1: BOILER#1
Sample 5

Sample taken
Enter a Sample name?

YES

Save

Save

SAVE

ELSEWHERE

Select Log Site:

Sites:

1) ABC CO.

2) TSI

3)

ENTER

Select Log Devices:
Devices:

*= selected for log
*1) BOILER #1

2) BOILER #2

3) BOILER#3

ESC

ESC

Data is saved using the Sample number
designation as the Sample name. For this
case, the Sample number “5)” becomes the

Sample name.

Edit Sample Name:

Name: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

<--> move cursor
<ENTER>=select
<ESC>=exit

SAVE & EXIT

Select or create a Device name
and press CONTINUE LOG
to install the data under the
new headings.

Save the data under the new sample name
and return to the Data Display screen

.

Figure 13: Schematic of the Data Saving Process

Chapter 7. Saving Data and LOGGING FUNCTIONS 35

LOGGING FUNCTIONS

When using the logging routines, be sure to pay attention to all the information on the display screen, particularly in
the message boxes. This will help steer you through the logging process and reduce confusion.

Note: When ADDing or EDITing Site, Device or Sample names, follow the procedure described in

“Entering and Changing Names” in Chapter 5, “Basic Operation.” Also, refer to the message box
in the lower left of the display screens. These outline the steps to add or change characters.

Sites

When the LOGGING FUNCTION button is pressed, the Log Functions: Sites display screen appears. Here you
are given the option to review existing site data, edit it, add n ew data, print the Site data and delete Site data.

To use options in the Sites display, shown schematically in Figure 14 below, first move the display cursor to a Site
using the Arrow buttons. Next, select one of the button options on the right side of the display (e.g., ADD,
DELETE...), or press ENTER to view Devices within the Site.

If no were Sites are created, you will need to add a Site using the ADD SITE button.

Log Functions: Sites

Sites:

1) site name

2) site name 2

3) site name 3

↑↓ Select Site
<ENTER> = View Site
and select Devices

ESC>=exit

<

ENTER

Once a Site is selected, press the ENTER button
to display the Devices screen. See the next
schematic, Figure 15.

Figure 14: Schematic of the Log Functions: Sites Display Screen

Selected Site using Arrow buttons

Button options

ADD SITE

DELETE SITE

EDIT SITE NAME

PRINT ALL DEVICES
IN SITE

DELETE ALL SAMPLES
IN SITE

Add a site to the Sites list from the Edit
Site Name screen. Use Save & Exit

when finished entering name characters.

Delete a Site from the Sites list using
this option. When a Site is deleted all
samples and Devices associated with it
are removed.

Edit a Site name using this option.
Press Save & Exit to accept changes.

Prints all samples in the Site beginning
with samples in the first Device, second
Device and so on.

This options deletes all the samples stored
in the chosen Site but does not eliminate
the Site name or underlying Device
names

36 Series CA-6200 CA-CALC Combustion Analyzer

Devices

From the Log Function: Sites display screen, a Site is selected using the ENTER key. This display screen
which follows, shows the Devices in the Site and enables options for reviewing, selecting, adding, modifying
Devices, and printing Samples.

Figure 15 below, provides a schematic representation of the Devices screen, and describes the purpose of each
button option.

To use options in the Devices display, first move the display cursor to a Device with the Arrow buttons. Next
select one of the button options on the right side of the display (e.g., ADD, DELETE...), or press ENTER to view
Samples in the Device.

If no Devices were created, you will need to add a Device using the ADD DEVICE button.

Site 1: site name

Devices:

1) Device name

2)Device name 2

3)Device name 3

↑↓ Select Site
<ENTER> = View Site
and select Devices
<ESC> = exit

ENTER

Once a Device is selected, use
ENTER to display the Samples

display screen. See the next section.

Figure 15: Schematic of the Devices Display Screen

Device selected using Arrow buttons

Button options

SELECT DEVICE
FOR LOGGING

Select a Device from the list of
Devices to store Samples.

ADD DEVICE

DELETE DEVICE

EDIT DEVICE NAME

PRINT ALL SAMPLES
IN DEVICE

Add a Device to the Devices list from
the Edit Device Name screen. Use
Save & Exit when finished entering
name

Delete a Device from the Devices list
using this option. When a Device is
deleted, all Samples associated with
it are removed.

Edit a Device name using this option.
Press Save & Exit to accept changes

Prints all Samples in the selected
Device.

Chapter 7. Saving Data and LOGGING FUNCTIONS 37

Samples

If there are Samples present for a Device, they are displayed when a Device is selected from the Devices
screen using ENTER. This was described in the previous section. The Samples display screen enables you to view
your saved data, and also provides buttons letting you delete or print saved data.

Figure 16 below, provides a schematic representation of the Samples screen and describes the purpose of each
button.

To use options in the Samples screen, highlight a Sample using the Arrow buttons, then select the button option.
To view the highlighted Sample, press ENTER.

Site 1: site name
Device 1: device name

Samples:

1)sample name

2)sample name

3)

4)

5)

6)

↑↓ Select Sample
<ENTER> = view
Sample

ENTER

Review data stored in the highlighted

Sample.

Figure 16: Schematic of Samples Display Screen

Select Sample using Arrow
buttons.

Button options

DELETE ALL SAMPLES

DELETE ONE SAMPLE

EDIT SAMPLE NAME

PRINT SAMPLE

RECALLED DATA: SITE: site name DEVICE: device name
SAMPLE: sample name
15:28:05 03/05/99 FUEL: Nat Gas

O2: 5 %
CO 104 PPM
NO 10 PPM
NOx

Deletes all Samples in the Device but

Device name

retain the

Delete the selected Sample.

Edit the selected Sample from the Edit
Sample display. Use Save & Exit to
save changes.

Print the selected Sample to the portable
printer or computer.

38 Series CA-6200 CA-CALC Combustion Analyzer

Chapter 8. Calibrations

Gas Sensors

Gas sensors can be calibrated periodically to maintain the accuracy of your gas measurements. Gas sensors do drift
over time, depending upon the operating environment and gas exposure history. With the exception of the O
sensor, gas sensors may have a loss in signal of up to 2% per month. The O

sensor is subject to a possible loss of

2

signal of 5% per year. With the proper equipment, such as that shown in the figures below, it is easy to calibrate
your CA-C

ALC analyzer gas sensors. If you wish, you may also return your instrument to TSI for a new factory

calibration.

The equipment needed to calibrate individual gas sensors can be purchased from TSI as calibration kits. Model
numbers for these kits are found in Chapter 2, “Unpacking.” You may also elect to put together your own
calibration system. Two calibration setups are presented in Figures 17 and 18. A brief discussion of these calibration
setups is presented in the following section.

Demand Flow Regulator

Sample Probe

Probe Adapter
Tubing and
Filling

Calibration Gas
Cylinder

2

Figure 17: Calibration Setup Using TSI Calibration Kit Accessories

Standard Regulator and Valve

Probe Adapter Tubing and Fitting

Sample Probe

Flow

Flow meter Indicating
.5 to 2 lpm.

Calibration Gas Cylinder

Figure 18: Alternative Calibration Setup

39

The Calibration Setups

A TSI supplied calibration kit (Figure 17) uses a demand flow regulator to supply gas to the CA-CALC analyzer in
response to the draw of the instrument sampling the pump. If a conventional regulator and valve are used
(Figure 18), the generic setup, supplies gas to the instrument using a tee to a bleed-off extra gas. This prevents a
forced flow at the instrument inlet. The bead-type flow meter depicted in the figure is used to verify there is extra
flow (.5 to 2 LPM recommended). Extra flow is required to prevent room air from being drawn in, diluting the
sample.

Calibrating the O2 Sensor

To calibrate the O2 sensor, ambient air (room air) is used as the span gas. Ambient air is almost universally 20.9%
oxygen by volume. To calibrate the zero point, nitrogen (N
801939 provides the zero gas, consisting of a cylinder of pure nitrogen.

Calibration Steps

From MENU, highlight Calibrate Sensors. Press ENTER. Highlight O2 in the Calibration screen (refer back to
Figure 10). Press ENTER. You will be given a chance to span the O
Once the span is complete (150 sec.), accept the calibration by pressing ACCEPT.

Note: Leave the Actual value at 20.9 as indicated. Press ENTER to return.

Connect a bottle of pure nitrogen as shown in Figure 17 or 18. Start the calibration by selecting YES. Follow the
instructions as indicated.

Special Note: Once exposed to pure nitrogen, the O
probably see a low room air concentration when returning to the main data display screen. For best
accuracy, avoid performing a baseline calibration (which calibrates O
after zeroing the O

sensor.

2

) gas is used, free of O2. The O2 Calibration kit Model

2

sensor with room air. Press ENTER to begin.

2

sensor takes time to fully recover. You will

2

span) for at least fifteen minutes

2

Calibration of the CO (Hydrogen Compensated) Sensor

The hydrogen compensated carbon monoxide sensor comes standard with the CA-CALC analyzer. Although
electrochemical CO sensors are sensitive to the presence of hydrogen (H
designed sensor can be made non-sensitive to H

. To perform a full calibration on this sensor, it is necessary to use

2

two gas mixtures, one containing CO in air or nitrogen, and one containing a mixture of CO and H
nitrogen. The calibration kit, TSI Model number 801923 is recommended. This kit contains two calibration gas
bottles, one containing 500 ppm CO, and one containing 500 ppm CO, 500 ppm H

Calibration Steps

From MENU, highlight Calibrate Sensors. Press ENTER. Highlight CO in the Calibration screen (Figure 10)
and press ENTER. Select YES when requested to re-zero the sensor. Make sure the sampling probe is in clean air
and press ENTER. After 60 seconds, accept the new baseline reading by pressing YES. Follow the instructions that
appear on the CO Span Calibration screen, and connect the CO calibration gas bottle. Refer to Figure 17 or
Figure 18. Press ENTER. When the calibration is complete, use the Arrow buttons to adjust the CO concentration
value in the blinking cursor box, to match the gas concentration in the CO calibration bottle. ACCEPT the new
value. Next perform the calibration using the gas mixture of CO and H
instrument screen, repeating the process outlined above. When finished, press ENTER to return.

40 Series CA-6200 CA-CALC Combustion Analyzer

), when calibrated properly, this specially

2

, also in air or

2

.

2

. Follow the instructions presented on the

2

Note: It is possible to do only the CO part of the calibration, bypassing calibration using the CO and H2

mixture. Accuracy is not impaired if there is no hydrogen in your sampled gas.

WARNING

Toxic Gases!

!

Familiarize yourself with the toxic properties of the calibration gases by reading the
supplied Material Safety Data Sheets (MSDS) accompanying the gas cylinders. Do
not perform calibrations in a confined space. Make sure calibrations are performed in
an area with proper ventilation, or under an exhaust hood.

Calibration of NO, NO2, SO2 and COhi (High Concentration) Sensors

The process of calibrating NO, NO2, SO2 and high concentration CO sensors are all similar. Recommended
calibration kits are TSI Model 801937 for NO, Model 801938 for NO
for CO high concentration.

Calibration Steps

From MENU, highlight Calibrate Sensors. Press ENTER. Highlight the gas for calibration. The Calibration
screen is referenced in Figure 10. Press ENTER. Select YES when requested to re-zero the sensor. Make sure the
sampling probe is in clean air and press ENTER. After 60 seconds, accept the new baseline reading by pressing
YES. Follow the instructions that appear on the Span Calibration screen, and connect the gas calibration gas
bottle. Refer to Figure 17 or Figure 18 for the appropriate connection method. Press ENTER. When the calibration
is complete, use the Arrow buttons to adjust the gas concentration value in the blinking cursor box, to match the
gas concentration in the gas calibration bottle. ACCEPT the new value. Press ENTER to return.

, Model 801936 for SO2 and Model 801945

2

Draft Sensor Calibration

The draft sensor should be routinely zeroed using the ZERO DRAFT button on the main Data Display. This is
especially important when draft pressure is below 1” of water column. A complete calibration of the draft sensor
requires the use of accurate pressure standards. Your calibration will only be as good as the reference pressures used
for the calibration. A calibration of the draft sensor is typically not recommended unless there is evidence that the
sensor span has drifted.

Calibration Procedure

Required: An apparatus to provide stable calibration pressures of between plus 10-30 inches of water

(2.5–7.5 kPa), and stable calibration pressures of between minus 10-30 inches of water
(minus 12.5–7.5 kPa). Both are necessary for a calibration.

From MENU, highlight Calibrate Sensors. Press ENTER. Highlight the Draft option in the Calibration screen
shown in Figure 10. Press ENTER. Disconnect any tubing from the Draft port (see Figure 2). Re-zero the Draft
sensor when requested to do so by pressing ENTER. When the baseline calibration is complete (13 seconds), press
YES to accept or NO to redo. Once the baseline is accepted, connect a positive calibration pressure of between 10
and 30 inches of water to the Draft sample port (15” is recommended). When the pressure is stable, press ENTER
to begin the positive span calibration. When complete, adjust the draft reading within the blinking box to the exact
value of your supplied calibration pressure. Then press ACCEPT. Next perform the negative pressure span
calibration. This calibration is similar to that of the positive calibration just performed, with a negative pressure
supplied rather then a positive pressure. Repeat the previo us steps using your negative pressure calibration standard.

Chapter 8. Calibrations 41

Note: For a calibration to be accepted by the CA-CALC combustion analyzer, the calculated calibration

factor must be in the range of 14 to 17 inches of water (±) per volt. If not, an error is indicated and
the calibration is not used. If this happens, it may mean there is a problem with the pressure
transducer, your calibration pressure is not what you think it is, or you simply made a mistake in
your calibration procedure. Redo the calibration.

Stack and Supply Air Thermocouple Calibration

Remember, your CA-CALC combustion analyzer may also be returned to the factory for this and other calibrations.

Calibration of the Stack and Supply air thermocouples is generally not recommended. The Type K thermocouples
are inherently stable and repeatable. Nevertheless, a calibration is possible, and may be of value to compensate for
electronic instrument drift occurring over time.

Note: Calibrations should only be performed by individuals having the proper equipment and training.

Calibration Procedure

Plug in the thermocouple to be calibrated. Select Calibrate Sensors from MENU. Highlight either TS or TA,
depending upon the calibration of interest, and press ENTER. Place your thermocouple in an ice bath, 32 degrees
Fahrenheit (0°C). Allow the probe to stabilize in the bath for 60 seconds, then press ENTER. When the test is
complete (13 seconds), enter the true temperature as instructed, and ACCEPT. Perform the second part of span test
at the high temperature, placing the probe in the hot reference (300 to 600°F recommended). Allow the probe to
stabilize for a minimum of 60 seconds. Then begin the calibration by pressing ENTER. Once complete, enter the
true temperature and ACCEPT the calibration. The instrument evaluates the calibration data and determines if it is
reasonable. If not, an error message is displayed and the calibration data reverts to the previous calibration.

Caution

When the sampling probe is submerged in the ice bath, the sampling pump must not

!

be operated.

42 Series CA-6200 CA-CALC Combustion Analyzer

Chapter 9. Maintenance and Troubleshooting

Emptying Water Trap

Refer back to Figure 2 showing the water trap in the sample line, and to Figure 19 below. Liquid water forms in the first
chamber of the water trap as gases are sampled from the flue. The water trap is designed so even when shaken, or when
its orientation is changed, water does not pass to the second chamber. The water level must remain below the level
depicted in the figure, however.

To empty the water trap:

1. First separate it from the sampling tube by pulling the tube ends off the barbs on the end caps.

2. Remove the probe side end cap by pulling outward with a twisting motion.

3. Pour out the water.

4. Replace the end cap and re-install the trap.

Important: Make sure the water trap is oriented so that end-cap 1 below is toward the instrument.

1. Instrument side end-cap 5. Second chamber

2. First chamber 6. Plastic filter

3. Probe side end-cap 7. Maximum water level

4. Polycarbonate trap body

1

2

4

5

6

Figure 19: In-line Water Trap

3

7

43

Changing the Water Trap Filter

Identify the water trap filter (refer to Figure 19). This filter is designed to remove soot particles before they contaminate
the instrument. The filter can be removed for cleaning or replacement by following these steps:

1. Remove the instrument side end cap by pulling it out with a twisting motion.

2. Grasp the filter using a needle-nose pliers and pull it out.

3. To clean the filter, remove the bulk of the soot by tapping the filter. The soot may be removed by rinsing with water

or isopropyl alcohol. The effectiveness of the rinse depends on the soot composition—is it dry or oily. Avoid
rubbing, which may drive contaminates into the filter causing permanent plugging.

4. Whether cleaned or replaced, install the filter by pushing it over the stub in the filter body, then replace the end cap.

Cleaning the Sample Probe

Cleaning may be necessary in high-soot sampling environments. Much of the soot will probably accumulate in the SS
sampling tube identified in Figure 2. The sampling tube is easily removed by loosening the sampling tube retaining
fitting completely.

1. Separate the tube from the handle by pulling straight out so as not to bend the thermocouple.

2. Carefully wipe the thermocouple off and rinse the soot from the SS sampling tube.

3. Examine the interior of the probe handle. If there appears to be little build up of soot here, simply replace the

sampling tube and retaining fitting. If significant buildup exists, water or isopropyl alcohol may work well to clean
the tubing. Remove the water trap and pour the liquid through the elevated sample tube until it exits the probe end.
Allow the tubing to dry prior to reuse.

High Concentration Overload

When the CO or NO concentration exceeds the shutoff level, as described in Chapter 6, “Instrument Setup,” the
sample pump shuts off, preventing sensor exposure to very high gas concentrations. Before continuing use of the
instrument, clean air must be supplied to reduce the gas concentration below the shutoff level. To do this, remove the
probe from the sampling location then press the Pump ON key. The pump will run for sixty seconds. If the
concentration is still above the shutoff level, the pump turns off. Turn the pump on again, and continue this process until
the pump stays on. Before reusing, wait until the affected sensor reads at or near zero gas concentration.

The shutoff level set at the factory is low (1000 for NO, 2000 for CO). Increase the shutoff level to the maximum
value of 5000 PPM to make measurements without the pump shutting off, refer to Chapter 6 “Instrument Setup.”

If the affected sensor is CO, you can close the CO diversion to prevent exposing the CO sensor to high CO gas
concentrations and prevent pump shut-off.

Adding or Replacing a Gas Sensor

Gas sensors are warranted for one year, however sensors (O2 excluded) typically last two or three years.

Sensor Positions

Up to four different gas sensors can be used together with the CA-CALC analyzer. The sensors are installed in four
positions identified as CO, S1, S2, O
with an oxygen (O
the only sensor that can occupy this position. The carbon monoxide sensor occupies the CO position after the CO
diversion valve. Other sensors are placed in either S1 or S2.

) sensor and a carbon monoxide (CO) sensor. The oxygen sensor must occupy the O2 position, and is

2

(refer to Figure 20 on the following page). The standard instrument is supplied

2

44 Series CA-6200 CA-CALC Combustion Analyzer

Replacing a Sensor

When a replacement sensor is received from TSI, the package may include a new sensor cup, fitting and tubing. These
additional supplies are generally not needed for a replacement and may be put aside.

To replace a sensor:

1. Remove the sensor cover by removing the four cover screws.

2. Disconnect the sensor cups from the valve fittings shown in Figure 20, by pulling the fittings away from the

attached sensor cups.

3. Grasp the sensor cups and pull up to separate them from the tops of the sensors. It is okay if the sensors come too.

When removing the cups, keep the tube connecting the O
case it can be difficult to retrieve.

4. Note the location of the sensor being replaced. Remove it and set it aside. The replacement sensor goes in the same

location.

5. When installing the replacement sensor, note the orientation of the notch on the sensor electronics board. This notch

must align with the notch depicted by the outline drawn on electronics board. See the illustration in upper right
corner of Figure 20.

6. Once the sensor is oriented, mate the four pins on the bottom of the sensor with the holes in the electronics board,

aligning the sensor connector.

7. Push down gently to seat the sensor.

8. Replace the sensor cups. It is helpful to place a small amount of silicone vacuum grease on the inside surfaces of the

sensor cups when replacing them. This will facilitate the assembly.

sensor cup from separating. If this tubing falls into the

2

9. Push the cups down firmly over the sensors.

10. Before replacing th e sensor cover, twist the sensor cups as necessary so the sensor cup fittings are on a common

axis as shown at the bottom of Figure 20.

11. Once the sensor cover is replaced, make sure the outlet hole on the CO sensor cup is clearly visible through the

sensor cover vent (see Figure 21).

12. Replace the sensor cover and cover screws. If the sensor cover does not fit readily over the sensor cups, it may mean

the sensors or sensor cups are not properly installed.

(continued on next page)

Chapter 9. Maintenance and Troubleshooting 45

3

4

1

2.75"

5

2

6

1.4"

9

10

1. CO (hydrogen compensated) sensor position #4 6. Line on electronics board
sensor position #1 7. Sensor cup

2. O

2

3. Sensor matting connector 8. Sensor cup fitting

4. Holes for alignment pins 9. Valve fittings and tubing connections

5. Alignment notch 10. Axis for sensor fitting alignment

Figure 20: Gas Sensor Installation

S1

S2

O2

8

CO

7

46 Series CA-6200 CA-CALC Combustion Analyzer

Adding a New Sensor

Sensors can be added to sensor S1 and S2 as shown in Figure 20. Positions O2 and CO are reserved for the Oxygen (O2)
and hydrogen compensated carbon monoxide (CO) sensors, respectively. A third sensor should be added to S1, a fourth
sensor to S2.

When your new sensor is received, the package will include a sensor, sensor cup, sensor cup fitting and tubing. These
will be necessary for the installation.

1. Begin by removing the tube (1.4” or 2.75”) connecting the sensor to the CO diversion valve, see Figure 20. Leave

the fittings intact.

2. When installing the new sensor, note the orientation of the notch on the sensor electronics board. This notch must

align with the notch depicted by the outline drawn on instrument electronics board. See the illustration in upper
right corner of Figure 20. Once the sensor is oriented, match the four pins on the bottom of the sensor with the holes
in the instrument electronics board, aligning the sensor connector. Push down gently to seat the sensor. When seated
properly, the sensor will not rock or twist.

3. Install the sensor cup fitting and tubing as shown in Figure 20. If the new sensor is in position 3, connect the 1.4”

tube to the CO diversion fitting. If in position 4, push the diversion valve fitting directly into the sensor cup.

4. Replace the sensor cups. Note: It is helpful to place a small amount of silicone vacuum grease on the inside

surfaces of the sensor cups when replacing them. This will facilitate the assembly. Push the cups down firmly over
the sensors. Replace the sensor cover and cover screws. If the sensor cover does not fit readily over the sensor cups,
it may mean the sensors are not properly seated. Reseat the sensors. Also, make sure the valve fittings are aligned
with the sensor cup fittings.

1

2

1. Sensor cover

2. Sensor cover hole

3

Figure 21: Alignment of Sensor Cup Hole with Sensor Cover Exhaust Vent

Chapter 9. Maintenance and Troubleshooting 47

3. Exhaust vent

Troubleshooting Chart

Error message(s) after
startup.

Pump vacuum out of range.

Gas concentration is
indicated when none is
present.

Bad characters or
unexpected results when
printing or saving.

No display or display hard
to see.

Gas sensor baseline errors.

“NOTE-O2REF: correction
out of range” error appears.

Span error during
calibration.

CO sensor does not
respond.

Sensor installed but not
indicated.

Efficiency, %CO2, excess
air readings not indicated.

Low lithium battery.

Sensor calibration factor
out of range.

“Unrecognized sensor error” requires sensor replacement. “Ref. Voltage factor”
and “A/D cal factor” errors require factory service. Other errors, regarding the
chemical sensors, draft measurement or thermocouples can usually be solved by
re-calibrating the affected device.

This message indicates that the sample line or probe is plugged, the pump is
damaged or dirty, or ice from condensed water vapor has formed in the pump at
freezing temperatures. In the latter case, allow the instrument to warm up, then
dry by operating at least one hour. Consult the factory if problem persists.

If small gas concentrations are indicated when no gas is present, it means a new
baseline calibration is required. Baseline calibrations should be done routinely.

When exposed to very high concentrations, the CO and NO sensors may require a
lengthy purge before zero concentrations are indicated correctly.

The wrong RS232 Device is selected (Printer or Computer) or the baud rate is
set incorrectly.

This may occur at extremes in temperature. Make sure the instrument is within its
operating temperature range.

Adjust the contrast setting.
Make sure the probe is not in the flue during the baseline measurement. Remove

the probe from the flue and allow the instrument to purge (operate) in clean air for
10 minutes before repeating the baseline calibration. Note: the presence of NO
the flue gas may trigger a baseline error for the SO

sensor.

2

2

in

Perform a baseline calibration.
The probe is sampling room air and O2Ref is On. Turn the O2Ref correction Off

or ignore the reading. Once the probe is inserted in the in the flue, and the O

2

concentration drops, this message disappears.
Recalibrate. Make sure the correct gases are connected at the correct time. Make

sure internal fittings and tubing are connected after adding or replacing a sensor.
Make sure CO diversion valve is oriented to the “CO” position when calibrating
the CO(H

compensated) sensor.

2

Turn CO diversion valve to the “CO” position. Make sure pump is on.

If an electrochemical sensor or thermocouple is not installed properly or is
damaged, its presence may not be indicated on the data display screen. Try
reseating electrochemical sensors. See Chapter 9 “Adding or Replacing a Gas
Sensor.”

These values are calculated from measurements made by installed sensors. If
these sensors are not present, the calculated values are not displayed.

Lithium battery needs to be replaced. Find lithium battery in the opening on the
right side of the battery compartment, under white foam insert. Replace with
instrument ON to prevent loss of logged data. Replace foam insert when
complete.

Properly working gas, temperature, and draft sensors have predictable voltages in
response to calibration input parameters. The CA-C

ALC combustion analyzer

checks to make sure that the calibration factors, determined from calibration, are
within an acceptable range. If not, an error message is generated and the
calibration is aborted.

Reasons for an aborted calibration can include poor calibration procedures, bad
calibration standards or damaged sensor.

48 Series CA-6200 CA-CALC Combustion Analyzer

Appendix A. Calculations

O2 Reference Concentration Calculation

O

reference is value entered as O2REF level

2

Excess Air Calculation

reference O- 20.9

×=

(PPM) ionconcentratgas )(PPM ionConcentratGas Corrected

2

measured O- 20.9

2

- %CO/%O

ir % Excess A

Another expression of excess is
shown below:

%EA

λ

100

1+=

2

2

2

100

×=

2920

) - %CO/ - (%O.

λ (Greek letter Lambda) also used. The relationship between % EA and Lambda is

Calculating Combustion Efficiency

Net combustion efficiency (Effic Net)

100 EfficiencyCombusion % ×−=

lossesheat flue

valueheating fuel

flue heat losses = heat loss from dry gas
+ heat loss due to moisture from burning hydrogen
+ heat loss due to moisture in fuel
+ heat loss from the formation of CO

Heat losses are per unit weight of fuel
Fuel heating value: HHV or LHV (high heating and low heating, respectively).

This basic method is described in the ASME (American Society of Mechanical Engineers) Power Test Code 4.1.
Note, however, the calculation of Combustion Efficiency considers only flue losses. In ASME PTC 4.1 losses from
other sources (e.g. radiation, convection) are also considered.

Gross Combustion Efficiency (Effic Gross)

In Europe combustion efficiency is often calculated without the latent heat loss from the formation of water. The
dry gas alone is subtracted from 100 percent.

(dry) Efficiency Combusion % −= 100

losses dry

value heating fuel

100

49

Remember either heating value, (HHV) or (LHV) can be applied in this calculation.

Siegert Formula

This formula is widely used in Europe to determine flue gas losses

(qA) and efficiency.

−=

⎜

()

21

O

−

⎝

⎛

2

A

⎜

Ta) x(Ts qA

⎞
⎟

B

+

⎟

2

⎠

Efficiency = 100 – qA

where:

qA = dry gas losses
Ts = flue temperature
Ta = supply air temperature

= measured volumetric oxygen concentration expressed as a percent

O

2

A2, B = fuel dependent constants

The constants A2 and B are based on the composition of combustibles in the fuels. In Germany, the following
prescribed values are provided for common fuels.

Fuel Type A2 B

Natural gas .66 .009
Fuel oil .68 .007
Town gas .63 .011
Coking oven gas .60 .011
LPG .63 .008

Determining CO2 Using the O2 Concentration

measured) %O- (20.9

max CO volume) (by OC %

×=

22

2

20.9

max is the theoretical maximum concentration produced for the fuel used.

CO

2

Emission Rate Calculations Using Emission Factors

The emission rate calculation presented below is described in EPA Method 19. This uses the dry gas factor Fd. Dry
factors are incorporated into the values found in the Table I, below. The table values (Ft), convert the measured
concentrations of emission gases, CO, NO

⎛
⎜

×=

Ft CgE

⎜

−

⎝

20.9

measured O 20.9

2

where:

E = Emission Rate (pounds/MBtu of fuel)
Cg = Gas Concentration (PPM)
Ft = factor from Table I (below)

measured = Oxygen concentration from flue measurement (%)

O

2

, and SO2 from PPM to pounds per million Btu of fuel.

X

⎞
⎟

⎟
⎠

50 Series CA-6200 CA-CALC Combustion Analyzer

TABLE I.

Factor (Ft) Nat. Gas Propane Oil #2

Oil #6 Coal

Wood (dry) Bagasse Coke

Methanol

SO2 .00145 .00145 .00153 .00153 .00164 .00153 0.0016 0.00164 .00143
NOX .00104 .00104 .00110 .00110 .00118 .00110 0.001 0.00118 .00103
CO .00063 .00063 .00067 .00067 .00072 .00067 0.00067 0.00072 .00062

Ft units: lb./MBtu PPM

For those familiar with Method 19, Ft is related to Fd in the following way:

Ft, in units lbs/(MBtu ppm)
Fd, in units scf/MBtu
Ft = Fd

x lb/(scf ppm)

Important note: When the

F.SO2, F.NOx and F.CO are presented in units of ng/J PPM. Make sure entries or changes are made in the

factors

Fuel Heat option in the Instrument Setup menu is selected for kg/kJ(metric), the Ft

appropriate units.

A General Equation for the Combustion of a Simple Hydrocarbon in Air

+

y 4x

4

⎞
⎟

2yx 22

⎠

COO

⎛

+

HC

⎜
⎝

y

+⇒

OH

2

x and y are the number of atoms of carbon and hydrogen in the fuel.

Calculating CO2 Max From the Carbon Content

COmoles

=

maxCO%

2

2

+

2

100

×

N2)moles CO(moles

moles CO

= x moles

2

N moles×+=2

3.76y)(4x

4

Calculation of Combustion Air

Pounds Air / Pound Fuel = 11.5C + 34.3(H2 - O2/8) + 4.3S
C, H2, O2 and S are the fractions, by weight, of each chemical constituent of the fuel.

Appendix A. Calculations 51

Appendix B. Series CA-6200 CA-CALC Combustion Analyzers Detailed Specifications

Oxygen (O2*):

Sensor Type Electrochemical
Range: 0–25%
Accuracy: ±0.3% O

Resolution: 0.1% O

2

2

Response Time*: <30 seconds to 90% of step

change

Carbon Monoxide (CO)– H

compensated†:

2

Range: 0-5000 ppm
Accuracy: 0–400: ±20 ppm
400–2000: ±5% of reading
2000–5000: ±10%
Resolution: 1 ppm
Response Time*: <30 seconds to 90% of step

change

Carbon Monoxide (CO)- High Range:

Range: 0–20000 ppm
Accuracy: 0–500: ±25 ppm
500–10000: ±5% of reading
>10000–20000: ±10%
Resolution: 5 ppm
Response Time*: <30 seconds to 90% of step

Nitric Oxide (NO)

†

:

change

Range: 0–4000 ppm
Accuracy: 0-100: ±5 ppm
>100–1000: ±5% of reading
>1000–4000: ±10% of reading
Resolution: 1 ppm
Response Time*: <60 seconds to 90% of step

change

Sulfur Dioxide (SO

):

2

Range: 0–4000 ppm
Accuracy: 0–200: ±10 ppm
>200–1000: ±5% of reading
>1000–4000: ±10% of reading
Resolution: 1 ppm
Response Time*: <40 seconds to 90% of step

change.

Nitrogen Dioxide (NO

):

2

Range: 0–500 ppm
Accuracy: 0–100: ±5 ppm
>100–200: ±5% of reading
>200–500: ±10% of reading
Resolution: 1 ppm
Response Time*: <40 seconds to 90% of step

change.

Carbon Dioxide (CO

Range: 0–CO

) –calculated from O2 and fuel type:

2

Max

2

Resolution: 0.1%

†

Note: These specifications assume the instrument is allowed to stabilize at the operating temperature before being turned on.

*With a 9’sampling tube length and water trap.

Excess Air (%EA): 0–1000%
Efficiency (E

and Egr):

net

Range: 0–125%
Resolution: 0.1%

Stack Loss: 0–100%
Supply Temperature: -22–392

Accuracy: ±2

±.5% of reading
Flue Gas Temperature: 32–1800

Accuracy: ±2
±0.5% of reading

Draft Pressure: ±30” H

0

F (-30-2000C)

0

F(10C)

0

F (0-10000C)

0

F(10C) to 3900F(1990C)

0

F(1990C)

>390

O (±80 mBar)

2

Accuracy: ±1% of rdg. or 0.01” H
Resolution: 0.01

Operating Conditions:

Electronics Component Temperature Range:

Operating range: 32 to 122°F (0 to 45°C)
Storage range: -20 to 140°F (-30 to 60°C)
Maximum probe temp: 1800

o

F (1000°C)

Instrument Humidity Range:

Continuous: 15 to 90% non-condensing
Intermittent: 0 to 99%

General Data

Pump:

Flow rate: nominal 700 cc/min
Maximum Flue Pressure: ±30” H

O (±80 mBar)

2

Sampling Probe:

Probe type: stainless steel/neoprene
Probe length: 12” std (30cm)
Hose length 9’ std (2.75m)
Probe diameter: 5/16” (0.8cm)

External dimensions: 6x10x2½” (15x25.4x6.4cm)
Weight: 2.5 lbs/3.9 lbs w/probe

(1.14/1.75 kg)

Display: approx. ¼-VGA B/W
Communication Interface:

Type: Serial
Baud rate: 1200–19200 selectable

Power Requirements:

Batteries: 4 “C” Cell alkaline batteries
Battery life: >24 hours (pump on)
AC Adapter: use only TSI supplied adapter
Backup battery: Lithium
Backup battery life 3 yrs

O (zeroed)

2

53

TSI Incorporated

500 Cardigan Road, Shoreview, MN 55126 U.S.A.

Web: www.tsi.com