the TPI 716 manual - Gas & Environmental Services Ltd
Contents
1. TPI 716 Flue Gas Analyzer Version 2 12 F Date 19 01 2012 S No 25221440034 Calibration Date CO bd 19 01 2012 O bd 19 01 2012 NO bd 19 01 2012 TPI Inc The initial start up screen displays the following information Model number of the analyzer Firmware version Firmware date serial number of the analyzer Last calibration date of the sensors Note The NO sensor calibration date will only display for 716N models After the initial start up screen displays for approximately 5 seconds the Main menu will be displayed Main menu 17 03 2012 02 44 Measurements Memory Fuel Type Analyzer Setup Units of Measure sensor Info BTP Ener The main menu displays the following information Battery status Date dd mm yyyy format and time 24hr clock Menu Selections Left blue soft key activates Bluetooth Only models equipped with this option Center blue soft key confirms selection 9 Turning The Analyzer Off Always Before turning off return the instrument to a clean air environment and allow the Carbon Monoxide level to return below 15ppm and the Oxygen level to return to 20 9 0 3 Press the Power Key to turn the instrument off NOTE The Instrument will not allow itself to be switched off if the CO is above 15ppm When the 716 is turning off the following screen is seen im The instrument has an auto shut off facto ry set for 10 minutes should no keys have bee2. gt Press the center Blue Soft Key Start and the pump will start Q i 14 E CALIBRATION amp SERVICE lt is recommended that your analyzer be calibrated every 12 months Please consult Test Products International for further details or send your analyzer to the address below for service TPI Attn Repair 9615 SW Allen Blvd Suite 104 Beaverton OR 97005 Please include your name contact information return address and a brief description of the service required The following are consumable parts for the instrument In Line Filter Element pkg of 5 User Replaceable A 94F Disc water filter User Replaceable A 94W Mini Pump Protection Filter Assem User Replaceable A 63 Oxygen Sensor User Factory Replaceable A761 Carbon Monoxide Sensor User Factory Replaceable A760 Nitric Oxide Sensor User Factory Replaceable A793 Sensor replacement requires calibration gas These items require periodic replacement as the analyzer is used Please see Appendix A on page 37 for general maintenance informa tion WARRANTY Your TPI 716 Flue Gas Analyzer is guaranteed free from defects in materials and workmanship for 3 Years from the date of purchase The sensors carry a 2 Year warranty This guarantee does not affect your statuary rights For addi tional information please refer to the included warranty card or contact TPI at 800 368 5719 To obtain warranty performance or maintenance on your analyzer Include
3. Plug the charger into the charger socket on the instrument see page 7 When the charger is plugged in the battery level display will turn on This dis play indicates the analyzer is being charged and the status of the charge ga lt The plug symbol confirms the analyz er is connected to the charger The Battery level battery symbol shows the charge 17 03 2012 02 44 level when the analyzer is on too 0 50 100 o lhe charge level is represented in graph form as well The charge is dis played in percentage 0 to 100 During operation the analyzer will display charge status and battery condition in the top right corner of the display Battery is at full capacity Battery is at 1 3 capacity The charger should be connected soon IFEA i i Battery is at 2 3 capacity d i Battery is very low and needs to be recharged immediately A E Indicates the analyzer is connected to the charger lf a beeping noise is heard during charging disconnect the charger This is an indication the battery pack needs to be replaced Please see Appendix G for bat tery replacement instructions Appendix C ERROR CODES amp TROUBLESHOOTING Code Code Definition Possible Causes Corrective Action Displayed Pump not drawing sample at Blockage kink in flue probe Check and rectify See correct flow rate hose Appendix A Dirty or blocked filter s Replace filter s See Appendix A Worn pump Return
4. in your analyzer will no longer charge no longer hold a charge or if beeping is heard while charging this is usually an indication the battery pack requires replacement For best results use a TPI replacement battery part number A007 The battery in your analyzer is 3 6V NiMH 1600mAn rated Never replace the battery with any other type of battery or damage to the charge circuit will result The battery pack is replaced as follows 1 Turn the analyzer over and locate the phillips head battery cover screw See picture below Battery Cover Screw Battery Cover 2 Loosen the screw Pull out on the screw to remove the battery cover 3 Remove the old battery pack from the battery compartment Pull the battery wire out of the connector 4 Install the new battery pack by inserting the connector from the battery pack into the connector on the analyzer Install the battery pack into the battery com partment 4 Re install the battery cover by fitting the bottom part in first 5 Tighten the battery cover screw 46 Instrument Overview Area Rubber etre eos Boot LCD Display 0 ___0 ppm Keypad Front View Rubber Boot Protects the instrument from accidental damage Display Large graphical backlit LCD Display Keypad selects all available functions NOTE When selecting oil as fuel be sure to use the optional oil filter A773 or readings could become erratic See Appendix E for installation instructions Do NOT use t
5. is used prior to measuring e Pressing Zero left blue soft key zeros the ressure e Pressing Zero left blue soft key zeros the manometer This is used prior to measuring The 716 incorporates a differential manometer Pressure applied to the port is prea subtracted from the pressure applied to the port Examples of pressures f i being measured NOTE Analyzer shown in picture above with optional second y P GK11M probe Analyzer ships with one GK11M as standard port 10 H90 port Not Connected Displayed reading 10 20 port 10 H90 port 5 H90 Displayed reading 5 H50 24 e
6. on the Flue Probe side of the A773 sulfur filter pull the yellow thermocouple cord out of the channel of the flue probe tube Pull out approx imately the length of the water trap that was removed 5 Being careful not to cut the yellow cord cut out a section of the flue probe tubing the length of the water trap on the Flue Probe side of the A773 sul fur filter See picture below A773 Sulfur Filte 4 Flue lt lt Hose Taal 6 Install the water trap in the flue probe hose where the piece was cut out Make Sure the water trap is positioned correctly The water trap lid should face the Hose End side of the hose See picture below Water A773 Trap Flue m3 Hose Sulfur Filter he Probe End fis Jal Awe x 3 x P ab Ai TEI r Ma j a gt liwe H ailn r j 5 We r A773 SULFUR FILTER MAINTENANCE The A773 should be replaced when most of the pellets become discolored usual ly white or black lf the A773 begins to trap condensate and fill with water but the pellets are not discolored to the point replacement is required it should be removed and allowed to dry Once it is dry it can be reused 40 Turning The Analyzer On Always Before turning on please ensure nothing is connected to the Gas Sample Port see page 7 Press and hold the ON OFF key down for approximately 3 seconds The 716 will beep and the initial start up screen will be displayed
7. part of the dis play 5 If necessary the flue probe can be attached to test in ducts and plenums 6 Refer to the chart on page 50 for a list of exposure times and levels of carbon monoxide in ambient test applications and page 51 for carbon monoxide facts 7 When testing is complete turn the analyzer off as outlined on page 8 43 Appendix C ERROR CODES amp TROUBLESHOOTING Continued Possible Cause Corrective Action Efficiency reading incorrect Readings are erratic when working on oil fired equipment One or all of the following parame ters Ratio CO air free excess air and efficiency read and print dashes Pressure prints as N A on my com bustion analysis print out Battery will not charge or hold a charge Beeping noise heard during charg ing Analyzer won t turn off Pressure sensor will not zero Pressure sensor needs to be reset Send to TPI for calibration 42 NET efficiency selected Ambient temperature probe not plugged in to T2 Incorrect fuel selected Oil filter not installed or installed incorrectly 716 only Measured values are such that the calculated values of these parame ters are out of range During combustion analysis if a pres sure measurement is not being made this parameter will print as not being used Defective charger or battery Defect in charging circuit or shorted battery Select GROSS efficiency See page 13 Plug ambient probe in
8. soft key to confirm the selection Measurements Temperature amp Pressure i From the Main menu screen using the Up Down Arrow keys select Measurements in the menu 17 03 2012 02 44 Press Enter center blue soft key to confirm the selection Measurements Memory Fuel Type Analyzer Setup Units of Measure Sensor Info FA Measurements 17 03 2012 02 44 BTP Enter From the Measurements menu use the Up Down Arrow keys to select Temp Pressure in the menu Temp Pressure CO room test Tightness test Leak detection Press Enter center soft blue key to confirm the selection FA The Temperature Pressure screen will display Temp Pressure 17 03 2012 02 44 This screen displays both T1 and 12 channels of temperature as well as the difference between T1 TIST s and T2 AT If no probe is connected to the input will 0 000inH20 be displayed indicating and open connection Pressure Prsu is also displayed in this screen Zero Send Save 23 Measurements Temperature amp Pressure continued Measurements Temperature amp Pressure continued Measuring Temperature Measuring Pressure 1 Ensure you have a K type probe connected to one or both of the thermo 1 Ensure you have Pressure Sampling Tube connected to one or both of the couple sockets T1 T2 refer to figure below Pressure Ports and there are no restrictions in the tubing
9. the probe is directly over the source of the leak Zero Exit 6 Press the Exit key center blue soft key to return the 716 to the Measurements menu 28 MEASUREMENTS Flue Gas continued Test data can be saved to a memory location if A Flue gas required 17 03 2012 02 44 Natural gas 1 Press the Save key right blue soft key and CO 85ppm __ Real Data Save and Address will be dis 10 2 played 2 Using the Up and Down Arrow keys select the memory location to save the data NO NO Address L oK Save 3 Press the OK key center blue soft key to save the data HA Test data can be sent to an optional infrared print er p n A740 or to a PC using optional cable and 17 03 2012 opzag SOftware Natural gas CO 85ppm CO2 c 10 2 1 Press the Send key left blue soft key and Real Data Print and Real Data PC Out will be displayed Ratio 0 003 82 3 A 3 2 Using the Up and Down arrow keys select the type of output you require If printing data to the printer align the window of the analyzer with the window on the printer about 6 to 8 inches apart If sending data to a PC connect the USB cable to the analyzer and computer and run the 716 PC software Real Data Print Real Data PC Out 3 Press the OK key center blue soft key to print or send data to a PC 21 Typical Test Results Actual test results vary depending on the equipment unde
10. with the product your name address phone number written description of the problem and proof of purchase date Carefully package and return to TPI Attn Repair 9615 SW Allen Blvd Suite 104 Beaverton OR 97005 35 SPECIFICATIONS Continued Gases Range Resolution Accuracy Oxygen 0 25 0 1 0 3 Carbon Monoxide 0 10 000 ppm ppm 5 ppm or 5 Whichever is greater Nitric Oxide 0 5000ppm ippm 5ppm lt 100ppm 5 lt 1000ppm 10 gt 1000ppm Carbon Dioxide 0 25 0 1 Calculated CO C02 Ratio 0 0 999 0 001 Calculated Combustion Efficiency 0 100 0 1 Calculated Gas Leak Sensor 100 10 000 ppm calibrated to methane 716N Model Only Pressure Measurement selectable Ranges mbar psi inH20 mH20 kPa hPa inHg mmHg Range 150 mbar to 150 mbar 15 kPa to 15 kPa 60 inH 0 to 60 inH 0 Resolution 0 01 mbar 0 001 kPa 0 001 inH O Accuracy 0 5 fsd Temperature Measurement Input Type K Type thermocouple Range 58 F to 1832 F 50 C to 1000 C Resolution 1 F 1 C Accuracy 0 3 of rdg 2 F or 0 3 of rdg 1 C The thermocouple supplied GK11M has the ability to measure tempera tures in the 50 F to 950 F range 34 MEASUREMENTS Flue Gas continued IMPORTANT Prior to taking a sample the device under test should be on and at operating temperature Putting the flue probe in the sample area prior to starting the device may cause saturation o
11. NO 0 ppm e Carbon Monoxide CO reading in parts per mil lion ppm e Carbon Monoxide Air Free COAF in parts per million ppm calculated CO air free takes into account excess air make up air and factors this out of the displayed reading Some systems inject extra air to ensure complete combustion This can T1 ST T2 AT AOD Prsu Pump Send Save 20 dilute the CO sample resulting in a low CO read 58 F ing when the standard CO display is being read 352 F e Nitric Oxide NO measured 716N Model 0 000inH20 Only 1150 cc min e Temperature T1 ST stack temperature T2 AT ambient temperature e Temperature T1 T2 AT e Pressure Prsu e Pump draw rate in cc min 420 F NOTE COAF should only be used if the manufacturer specifications are stated as CO air free If used on a system that is not specified in CO air free the reading may appear abnormally high as compared to the specification soft key to confirm the selection 3 Depending on the memory type selected all or some of the options shown below will be available Memory IR Print Allows information printed in specific addresses to be printed to the optional infrared printer p n A740 Memory All Clear Clears information out of all memory locations Memory PC Out Sends all information stored in memory to a PC Requires optional USB cable and software Memory Recall Enables information from memory locations to be recal
12. Overview The TPI 716 combustion analyzer uses state of the art electrochemical sensors This sensor technology provides the longest lasting most accurate and reliable means for performing combustion tests The sen sors in your analyzer will need to be replaced periodically and calibra tion is recommended once every year Electrochemical sensors by nature are always active Therefore the time the analyzer is off and not being used must be taken into account when determining sensor life The sensors in your analyzer are war ranted for two years This warranty does not cover sensors damaged through misuse of the analyzer You should keep the battery of your 716 charged so power is constant ly being supplied to your sensors The following guidelines will help prevent damage to your sensors Always use the mini pump filter when testing flue gases Always periodically check and replace the mini pump filter as needed Always make sure the in line filter water trap is installed properly Always periodically check and replace the in line filter as needed Always remove water or condensation from the inside of the in line fil ter water trap assembly prior to performing tests Always use the optional oil filter p n A773 when performing tests on oil burning equipment unless you are using the 716N Do not use the A773 with the 716N because the A773 will filter out Nitric Oxide NO 1 General Overview Continued Notes Never over satu
13. Test Products International Inc 9615 SW Allen Blivd Ste 104 Beaverton OR 97005 Tel 503 520 9197 Fax 503 520 1225 www tpi thevalueleader com Test Products International Ltd 342 Bronte Road South Unit 9 Milton Ontario Canada L9T5B7 Tel 905 693 8558 Fax 905 693 0888 Flue Gas Analyzer 716 716N CO2 Ratio Effin 02 The Value Leader www tpi thevalueleader com Contents Notes Miodu esisiini 1 General OVErvieW cccceeceeceecceceeceeeeeeeeeeneeeees 1 2 Instrument OvervieW ccceeeeeeeseeeceeeeeaeeeeenass 3 7 Front VIGW vsncxiedvatennnt scones eeedsavetunconen 3 OV AG ses ree tde ce ctee etch cocecccecetenceteeeeeetnteans 4 BACK VIO Wa coctatoegaccecctesstsceteeesbhousaettetaiens D Side VIEWS iacniserans naonnana 6 NOD VIGW E A E E 7 Basic Analyzer FUnctions ccccceeeeeeeeeeeeenees 8 10 Charging The Amalyzer scceceeeeeceeees 8 Turning The Analyzer On 2 2ceeeee0e 9 Turning The Analyzer Off c2eceeeeees 10 Display Backlight ccccsceeeeceeeeeeeees 10 Combustion Analysis Overview 2ccseeeeeeeeees 11 MeasurementtS ccccccseceeeccecceceesucececeesuceeness 12 28 Flue GOS csisecdi aratacevcdssannceccetaasanasanasasene 12 21 Typical Test Results ccccceeeeeeeeeees 22 Temperature amp PreSSUre ccccccceeeeeeeeees 23 24 Tightness TOS tiiiuscncssn
14. address where i the data will be stored can be changed as neces eee oa sary Press the Chang key left blue soft key Sampling time 1min and use the Arrow keys to change the address Page Address 0 location CO Real 4 Press the Start key center blue soft key to begin CO monitoring The pump will start and the 716 will begin storing readings every minute The number of readings stored can be seen at the bot tom of the screen The real minimum maximum and average CO measured will be displayed too 5 When the desired number of readings have been taken press the Stop key center blue soft 17 03 2012 key 6 Stored readings can be sent to a PC or printer by pressing the Send key left blue soft key and selecting Print Out or PC Out Send Star Chang 27 Measurements Temperature amp Pressure continued Tightness Test The tightness test function enables the 716 to check for pressure leaks in valves fittings and pressure switches with an elapsed time reference 1 From the main menu select Measurement as outlined on page 12 From the Measurements menu select Tightness test and the following screen will ount down may be repeated several times until the sensor initiates TE 2 If necessary press the Chang key right blue soft key and then use the Arrow keys to change the address location where the test data will be 17 03 2012 02 44 s
15. ch filters and probes These items are user serviceable and can be taken care of by the operator The consumable items that will require operator attention are the water trap fil ter assembly flue probe pump protection filter and ambient temperature probe The recommended maintenance schedule for your analyzer is as follows Frequency Once per week Once per day for analyzers that see heavy use or are used in oil fired applications Pump Operation Check Once per month More often for analyzers Flue Probe Integrity Check that see heavy use or are used in oil fired Thermocouple Probe Check applications Water Trap Check Visually check the water trap for Maintenance Performed Water trap Check Filter Check 1 Cracks in the bowl 2 Broken ears on the bowl where the lid locks on 3 Broken ears on the lid 4 Worn out o ring on the lid 5 Loose connection to the flue probe tubing Filter Check signs of dirty or water saturated filters are a slow pump flow error displayed when the flue probe is connected and measurements that take longer than nor mal TPI analyzers use three filters to protect the pump and sensors The first filter to check is the A763 mini pump protection filter See picture below Inspection Window Pm sree mes U SRE b asan pm ae _ m l Pump Protection Filter Look in the inspection window to check the filter When the filter material becomes dark pu
16. displayed Using the Arrow keys select Measurements by highlighting it Press the Enter key center soft key to con firm the selection Measurements Memory Fuel Type Analyzer Setup Units of Measure Sensor Info BTP enter The Measurements menu will be displayed FA Measurements 17 03 2012 02 44 Using the Arrow keys select Flue gas by high lighting it Temp Pressure CO room test Tightness test Leak detection Make sure the analyzer is in a clean air environ ment with only the pump protection filter con nected to the input Press the Enter key center soft key to confirm the selection BTP Erer FA The pump will start and the Zeroing screen will 17 03 2012 02 44 display The analyzer IS Initializing and self Wait 28 testing the sensors during this 30 second 1296 ce min cycle The selected fuel type will be displayed and can be changed as necessary see pg 13 Fuel Change Natural gas Efficiency change Gross The selected unit of efficiency is displayed and can be changed as necessary See pg 13 If the analyzer is ready for use Skip will Chang Skip Next appear above the center soft key Pressing this will bypass the 30 second countdown 12 Appendix A General Maintenance continued Filter Check Continued The other two filters are located in the water trap The main filter is the A794F particle filter This filter stops debris and dust from traveling dow
17. e probe tube where the water trap was removed See picture below A773 pam Hose Sulfur Filter Flue End a ETN Probe 39 Appendix A General Maintenance continued Flue Probe Integrity Check NOTE Perform this check after performing the Pump Operation Check outlined on the previous page 1 Turn the analyzer on as outlined on page 8 Do not connect anything to the inlet Wait until the analyzer has completed the initial purge and sensor check and is operating normally prior to proceeding to step 2 2 Connect the A763 mini pump protection filter and flue probe assembly to the inlet of the analyzer and the yellow thermocouple connector to input T1 3 Repeatedly press the Scroll Enter key until temperature is displayed If the displayed temperature is approximately the ambient temperature the thermo couple is operating properly and you may proceed to the next step to continue the test If the displayed temperature is OL the thermocouple is open and the probe is in need of factory service 4 Cover the end of the flue probe with a small piece of tube and pinch the end close After a short period of time the analyzer should display Flow Error and a rapid beeping should be heard If this happens the flue probe his operating properly and the integrity test is complete If the analyzer does not display Flow Error this is an indication of a possible leak somewhere in the flue probe and you may proceed to the next step f
18. e to be set The timer can be disabled or set to one of the following times 5 10 20 30 or 60 minutes If a key has not been pressed during the time set the analyzer will automatically begin to turn off Memory Enables memory maintenance as outlined on page 29 31 Menu Navigation Fuel Type aa 1 From the main menu use the Arrow keys to select Fuel Type and press the Enter key cen 17 03 2012 02 44 ter blue soft key Measurements Memory Fuel Type Analyzer Setup Units of Measure sensor Info p Enter 2 Use the Arrow keys to select the fuel type Scrolling down displays the rest of the available fuel types d A Fuel Type 17 03 2012 02 44 FA Fuel Type 17 03 2012 02 44 Natural gas Bituminous Coal Light oil Heawy oil LPG gas Bituminous Coal Anthracite Coal 3 press the OK key center blue soft key to confirm the selection Fuel type can also be changed from the flue gas zeroing screen as outlined earlier in this instruction manual 30 MEASUREMENTS Flue Gas continued Insert the flue probe into the sample hole of the device under test The probe tip should be in the middle of the flue pipe or exhaust stream Ensure the In Line Filter Water Trap hangs below the analyzer in the proper ver tical position when readings are being taken Failure to comply reduces the effec tiveness of the water trap and may result in damage to the instrument Refer t
19. f the sensors due to the higher initial concentration of carbon monoxide that may be encountered upon start up If this happens allow your analyzer to purge in fresh air until the carbon monoxide level returns to 0 ppm and the oxygen level returns to 20 9 This may take more than an hour depending on how saturated the sensors are Drill a 1 4 inch hole into the flue of the device under test For most applica tions flue gas samples should be taken prior to the draft diverter or any other opening that allows room air to enter the system This prevents room air from mixing with gases in the flue and diluting the test sample It is important to use manufacturers recommended test locations whenever possible Refer to the figure below for calculating the sample hole location The figures on the following pages show typical test locations on commonly encountered equipment Flue pipe diameter x 1 5 proper hole location Example for a 4 inch flue 4 inches x 1 5 6 inches Flue Pipe Diameter The hole should be drilled 6 inches above the furnace exhaust Distance above furnace exhaust to drill hole 15 MEASUREMENTS Flue Gas continued 16 TYPICAL TEST LOCATIONS Atmospheric Gas Fired Fan Assist Boiler Furnace Typical Test Locations ur Flue probe location for 02 CO and Stack temperature measurement This location is also used to measure draft by using the ATTO static tip Figure 1 It is i
20. he A773 with the 716N analyzer 3 Keypad Blue Soft Keys The function of these keys is shown in the lower part of the display and changes depending on what menu the analyzer is in In the picture center soft key controls the start function and the left and right soft keys are disabled Up Arrow Key This key is used to scroll up in Down Arrow Key This key is used to scroll menus Home Key This key is used to return to the Main Menu from any Back Key This key is On Off Key This key is used to go back one menu level used to turn the analyz er on and oft other menu down in menus Appendix F CARBON MONOXIDE FACTS Carbon Monoxide CO is invisible odorless and tasteless It is the byproduct of combustion and levels are elevated when there is incomplete combustion sources of CO include Unvented kerosene and gas space heaters Leaking chimneys amp furnaces Gas water heaters Back drafting from furnaces Wood stoves amp fireplaces Gas Stoves Automobile exhaust Tobacco smoke Carbon Monoxide is picked up quickly in the body by red blood cells At high lev els of CO the body replaces oxygen with carbon monoxide The most common symptoms of CO poisoning are headache dizziness weak ness nausea vomiting chest pain and confusion High levels of CO inhalation can cause loss of consciousness and death Unless suspected CO poisoning can be difficult to diagnose because the sym
21. led and displayed for viewing 4 Use the Arrow keys and blue soft keys to access these functions 29 Measurements Leak Detection The Leak Detection function enables the 716 to test for combustible gas leaks in gas valves and fittings using the included gooseneck probe 1 Connect the combustible gas probe to the USB connector located on the top of the 716 See picture below Combustible Gas Probe A806 Connect the com bustible leak wa probe here 17 03 2012 02 44 2 From the main menu select Measurement as outlined on page 12 From the Measurements menu select Leak detection and the following Low High Screen will display dd The 716 will begin to countdown from 30 Leak gas level During this time the combustible sensor is being warmed up and prepared for use A light in the sensor cage will illuminate and can be used to aid Zero exit __ in Seeing fittings in dark areas EE 4 After the warm up period is complete the Leak 7 detection screen will display and a constant tick 17 03 2012 ae will be heard Use the combustible gas probe to ee ep begin looking for leaks Wait 6 Warm up Wait 6 5 When a leak is encountered the tick rate will bau High increase and the Low to High bar graph will visu A ally indicate a leak Press the Zero key left blue Leak gas level soft key to reset nullify the tick and continue looking for the leak Repeat this process until
22. ll the black nose cone out of the tubing and replace the ball fil ter inside 36 MEASUREMENTS Flue Gas continued As necessary the fuel type can be changed to E match the fuel type of the equipment under test The fuel type IS used in the efficiency calculation 17 03 2012 02 44 and therefore it is important the fuel type is cor Wait 23 rect in order for the calculation to be accurate 1296 cc min To change the fuel type use the Arrow keys to highlight Fuel change Fuel Change Natural gas Efficiency change Gross Press the Chang key left soft key and the fuel menu will display Chang Skip _ Next d wa The Arrow keys are used to scroll through the avaiable fuel ype 17 03 2012 02 44 The available fuels are Natural gas Light oil Wait 28 Heavy oil LPG Bituminous coal Anthracite coal Coke Butane Wood dry and Bagasse 1296 cc min Fue Natural gas Light oil Once the desired fuel type is highlighted press Heavy oil the center soft key OK to confirm the selection LPG gas Bituminous Coal Anthracite Coal The analyzer will return to the Zeroing display and the countdown will continue The unit of efficiency can be changed as needed EA between Nett and Gross Nett eficiency doesn t take into account wet losses while Gross efficien 17 03 2012 02 44 cy does In the USA Gross efficiency is used If eri ne Nett is selected the efficiency will be displayed as 4296 i a cc min
23. mportant to use manufacturers recommended test locations whenever possible SPECIFICATIONS Instrument Operating Temperature Range Battery Battery Life Charger Input Voltage Fuels Pressure Ranges Display Data Storage single Logging Time amp Date Dimensions Weight Conforms to Flue Temperature Probe Construction Hose Length Insertion Length K Type Thermocouple Accuracy Maximum Temperature 14 F to 122 F 10 C to 50 C Rechargeable Ni MH gt 6 Hours 115V or 230V 50 60 Hz AC Natural Gas LPG Light Oil Heavy Oil Bituminous Coal Anthracite Coal Coke Butane Wood Bagasse mbar psi inH20 mH20 kPa hPa inHg mmHg Backlit Graphic LCD 100 sets of readings multiple pages 150 sets of time stamped readings 24 Hour Real Time Clock 7 8 200mm x 3 5 90mm x 2 4 60mm 1 1Ibs 500g BS 927 and the draft BS7967 Pistol Grip with Stainless Steel Shaft 8 2 2500mm 7 9 200mm 0 3 of fullscale 2 F 1 C 1472 F 800 C 33 Menu Navigation Units of Measure 1 From the main menu use the Arrow keys to select Units of Measure and press the Enter key center blue soft key 2 The Units of Measure menu will display The following parameters are accessi ble in this menu Use the Arrow keys and center blue soft key to select the appro priate parameter Temperature Select between C and F for temperature measurements Pressu
24. much higher than it is Press the right soft key Next to highlight Efficiency in the display Press the Chang key left soft key and the effi ciency menu will display Fuel Change Natural Fe Efficiency Gross V Use the Arrow keys to select the desired efficien cy unit and press the center soft key OK to con firm the selection 13 MEASUREMENTS Flue Gas continued After the initial purge cycle is complete or skip is ek pressed the Flue gas measurement screen will display 17 03 2012 02 44 This screen displays all combustion parameters Natural gas including temperature and pressure COs 85 ppm CO2 c 10 2 Ratio 0 003 Effi g 82 3 02 4 3 XAIr 10 NO 0 ppm NOx 0 ppm Send Save Connect the Pump Protection Filter assembly and Flue Probe Tubing complete with In Line Filter to the Gas Sample Port and the K Type Thermocouple Plug from the Flue Probe into Thermocouple T1 Socket The GK11M ambient air temperature probe is connected to the T2 socket See below amp page 7 WARNING Ensure the K type thermocouple probes are inserted into the sock ets correctly see page 7 The plugs are polarity marked and forcing the plug into the socket the wrong way may result in damage to the instrument Ambient Air x gt Connection T2 Thermocouple Connection from Flue Probe GK11M Probe a r Y Flue Probe Tubing Pump Protection Filter T In line Filter a f Assembly
25. n pressed for this period and the CO level is below 15ppm The auto power off can be set to a different time or disabled Please refer to Menu Navigation Analyzer setup on page 31 lf the CO level is close enough to Oppm and the 02 level is close enough to 20 9 the analyzer will display Skip This allows you to skip the purge by pressing the middle soft key Display Backlight The display backlight is factory set to Auto A sensor located on the side of the analyzer detects the amount of ambient light and automatically adjusts the backlight intensity The backlight can be manually adjusted to a desired level by the user Please refer to Menu Navigation Analyzer Setup on page 31 10 Appendix B A773 SULFUR FILTER INSTALLATION amp MAINTENANCE USE THE A773 ONLY WITH THE 716 DO NOT USE WITH THE 716N When using a 16 and performing combustion tests on oil fired equipment it is important to use the optional A773 sulfur filter Failure to do so can result in incorrect and readings This filter also protects the sensors from the affects of sulfur The A773 does not have to be removed when working with other types of fuels PROCEDURE 1 Begin with the water trap section of the flue probe oriented as shown in the picture below Water Trap Hose gg Flue End X Probe 2 Remove the water trap from the flue probe hose See picture below Flue ae Hose Probe _ End 3 Insert the A773 sulfur filter flu
26. n to the analyz er The secondary filter is the A794W water block filter This filter stops flow in the event the water trap fills with condensate Refer to the picture below Water trap bowl A794 water trap pictured A795 A 94W water trap is similar but A794F Water longer Particle Filter Block Filter e e am R per e f A794D Filter Spacer Disc Water trap lid O ring is located in the lid recess Open the water trap and look at the A794F particle filter The filter will typically get dirty from the inside first If the filter is dark on the inside a replacement fil ter should be installed If the A794F is clean but saturated with water a replacement should be installed to ensure proper flow The saturated filter can be left to dry and reused later Pump Operation Check 1 Turn the analyzer on as outlined on page 8 Do not connect anything to the inlet Wait until the analyzer has completed the initial purge and sensor check and is operating normally prior to proceeding to step 2 2 Cover the analyzer inlet with your finger The analyzer should display FLO ERR and a rapid beeping should be heard lf the analyzer does not beep and display FLO ERR this may be an indication the flow sensor requires calibration the pump is faulty or there is an internal leak The analyzer should be returned for factory service 3 Appendix A General Maintenance All combustion analyzers use consumable items su
27. ng in parts per mil lion ppm e Carbon Dioxide C02 figure in percentage calculated e CO CO2 Ratio figure The 716 calculates this number by first converting the CO2 measure ment from percentage to ppm The formula for this conversion is CO2ppm C02 10 000 This ratio is not used in any other calculations 10 000ppm 1 e Oxygen 02 reading in percentage e Excess Air X Air in percentage Menu Navigation Memory From the Main menu there are several sub menus that allow analyzer set up memory maintenance and other parameters to be accessed Here is a list of each and what function they perform eo 1 Memory can be accessed from the main menu to enable maintenance to be performed Use the 17 03 2012 02 44 Arrow keys to select Memory and press the Enter key center blue soft key Memory im 7 17 03 2012 02 44 Fuel Type Analyzer Setup Units of Measure Sensor Info Temp Prsu store e Calculated Efficiency Eff figure in percentage Note Gross Efficiency is used in the USA e Nitric Oxide NO measured and Nitrogen Oxide NOx calculated 776N Model Only CO room logger Tightness store 2 Use the Arrow keys to select the memory type Pressing the Up Down Arrow keys enables the rest of the screen to be dis to be accessed Press the Enter key center blue played Enter mt AA Flue gas 17 03 2012 Natural gas CO 85 ppm COAF 85 02 44
28. o the pictures below for correct and incorrect use WARNING Should the CO reading rise above 2 000ppm a continuous series of Alarm Beeps will be heard The Probe should immediately be disconnected from the instrument and the instrument returned to a clean air environment This Alarm alerts the user that there is a high concentration of CO and this procedure will protect the sensors within the instrument The alarm level can be changed Please see Appendix D Make sure to check the water trap periodically during testing to ensure it does not fill with condensate and empty it as necessary If the filter begins to fill during a test open the lid and empty out the condensate After closing the lid allow read ings to stabilize again IMPORTANT The water trap is fitted with a water block filter p n A794W in the lid to prevent water from flowing down into the pump If the water trap fills the water block filter will stop the flow to the analyzer and FLO ERR will display The water trap should be emptied immediately if this happens The water block filter may need to be dried out or replaced before testing can resume US MEASUREMENTS Flue Gas continued Allow the readings to stabilize Multiple parameters can be seen in the display FA AA Flue gas 17 03 2012 Natural gas CO 85 ppm CO2 c 02 44 10 2 Ratio 0 003 Effi g 82 3 OO 4 3 XAIr 10 NO 0 ppm NOx 0 ppm Send Save e Carbon Monoxide CQ readi
29. op of the heat exchanger Figure 3 It is important to use manufacturers recommended test locations whenever possible Menu Navigation Analyzer Setup 1 From the main menu use the Arrow keys to select Analyzer Setup and press the Enter key center blue soft key 2 The Analyzer Setup menu will display The following parameters are accessible in this menu Use the Arrow keys and center blue soft key to select the appropri ate parameter Display type Allows the display to be switched between 8 line and 4 line Date Time Used to set the current date and time The date is in dd mm yyyy format and the time Is a 24 hour clock Contrast Lighten or darken the display contrast Backlight Adjust the backlight level from off to full brightness or set it to auto and the 716 s internal sensor will control the backlight brightness depending on ambient light Alarm limits Set the level at which the CO alarm sounds The level is adjustable from 10ppm to 3000ppm and can be turned off Default level is 2000ppm Print Header Enables the two line header on printouts to the infrared printer to be set with your companies information After pressing Enter you will be asked for a password Enter 7160 and press OK Select Header Line 1 and then use the Arrow keys to enter line one of the header Press Enter then repeat the process for line 2 of the header Auto Power Enables the auto power off tim
30. or further tests 5 Pinch the hose below the handle of the flue probe If the analyzer displays Flow Error there is a leak in the handle assembly and the probe needs to be factory serviced If the analyzer does not display Flow Error proceed to the next step for further tests 6 Pinch the hose between the analyzer and the water trap If Flow Error still does not display there may be an internal leak pump problem or other issue and the analyzer needs to be factory serviced If Flow Error is displayed there is a leak in the water trap assembly and the water trap assembly should be checked as outlined on page 36 amp 37 38 COMBUSTION ANALYSIS OVERVIEW Performing combustion analysis is very important to the overall safety and efficiency of heating equipment The following guidelines and descriptions are generic and meant to provide you with a basic understanding of combustion testing TPI always recommends you contact the manufacturer of the device under test obtain information specific to the device and follow the proce dures and safety guidelines for performing tests and affecting repairs In general for most applications flue gas samples should be taken prior to the draft diverter or any other opening that allows room air to enter the sys tem This prevents room air from mixing with gases in the flue and diluting the test sample To ensure accurate and consistent combustion tests it is important gas and tem
31. perature samples be taken at the same location This is easy with the TPI flue probe because the temperature sensor is an integral part of the probe Prior to taking a sample the device under test should be on and operating Putting the flue probe in the sample area prior to starting the device may cause Saturation of the sensors due to the higher initial concentration of car bon monoxide that may be encountered upon start up If this happens allow your analyzer to purge in fresh air until the carbon monoxide level returns to 0 ppm and the oxygen level returns to 20 9 This may take more than an hour depending on how saturated the sensors are The figures on pages 16 through 18 show locations for performing tests on commonly encountered equipment Remember to consult with the manufac turer of the device under test for specific test information Pressing the Func Key enables access to the different functions available on the 716 The default function is Combustion Analyzer Other available func tions are Thermometer Manometer Tightness Test Combustible Gas Leak Detector and Date Time display 11 MEASUREMENTS Flue Gas Note It is recommended you perform routine general maintenance on your analyzer to ensure proper function Please refer to Appendix A for general maintenance schedule and function tests FA Turn the 716 on as outlined on page 8 After the initial start up screen the Main Menu will 17 03 2012 02 44 be
32. ptoms mimic other illnesses People who are sleeping or intoxicated can die from CO poisoning before ever experiencing symptoms Please see the next page for a list of exposure times and symptoms 45 Appendix E Carbon Monoxide in Ambient Air Chart Back View This chart contains maximum exposure levels and times for carbon monoxide This is a general guideline only It is recommended you check with your local government for guidelines in your area 2 CARBON MONOXIDE API the SILENT KILLER Calibration and Information a j Label Exposure times and toxic symptoms 9 The maximum allowable concentration for short term ppm exposure in a living area according to ASHRAE Rubber The maximum allowable concentration for continuous Boot 35ppm exposure in any 8 hour period according to federal law US federal law Maximum concentration allowable any time according to OSHA Battery 200ppm si igue dizi Slight headaches fatigue dizziness nausea after 2 3 hours Compartment Frontal headaches within 1 2 hours life threatening after 3 hours 400ppm Maximum allowable limit in flue gas according to EPA and AGA 800ppm Headache dizziness nausea and convulsions with 45 minutes Unconsciousness within 2 hours Death within 2 3 minutes Calibration and Information Label Displays calibration information and 1600 k Headache dizziness and nausea within 20 minutes serial number ppm Death within 1 hour 5 7 Batter
33. r test TPI recommends you check with the manufacturer of the equipment being tested to determine specific acceptable results Power Burners Gas Fired Carbon Monoxide Less than 100ppm air free Stack Temperature 300 F to 500 F Power Burners Oil Fired 4 to 7 Carbon Monoxide Less than 100ppm air free 320 F to 625 F Oxygen Stack Temperature Gas Fired Burners Atmospheric Fan Assist Oxygen 7 to 9 Carbon Monoxide Less than 100ppm air free Stack Temperature 325 F to 500 F ee 0 15 inH20 to 0 4 inH2O0 22 Measurements CO Room Test The CO room test function enables the 716 to monitor and log ambient CO levels in a room or office space at 1 minute intervals This data can be retrieved later via the optional infrared printer or serial cable and software E 1 Begin with the 716 in a fresh air environment a the test area danta main My 17 03 2012 o gt aqa S ect easurement as out Ined on page Salt From the Measurements menu select CO room Wait 28 esi test and the zeroing screen will display 1296 cc mi 2 If Skip is displayed the analyzer sensor is l zeroed and ready for use Press the center blue soft key to move to the next screen If Skip is not displayed wait for the zero process to finish and the next screen will be displayed automatical y C fse j THA 3 After the zero process the CO room test display will appear At this time the page
34. rate your sensors by performing tests on equipment with gas levels beyond the capability of you analyzer Always keep the A795 water trap filter assembly clean and replace the filter as necessary Replacement filter part number is A 94F This manual will guide you through the functions of the TPI 716 which will give you many years of reliable service Your TPI 716 Flue Gas Analyzer comes complete with the following Standard accessories Denotes part number TPI 716 Analyzer Combustible Gase Leak Probe A806 Rubber Boot A765 1 each installed on analyzer soft Carrying Case A 68 1 each Flue Sampling Probe A770 1 each In Line Filter Water Trap installed on Flue probe A795 1 each Disc water filter installed in water trap A 94W 1 each Spare In Line Filter 1 each A794F is a package of 5 filters Temperature Probe GK11M 1 each Battery Charger A766 1 each Mini Pump Protection Filter Assembly A763 1 each Exhaust Spigot Removable A764 1 each Pressure Tubing A774 1 each piece Static Pressure Tips A776 2 each 1 4 barbed to 1 8 NPT fitting A603 2 each Gas Valve Adapter A611 1 each Adapter Tubing A791 1 each 4 piece Instruction Manual Your TPI 716 Flue Gas Analyzer has the following options available e A807 PC Software and cable for communication to a PC e A740 infrared printer Included with 716A740 Appendix G Battery Replacement When the battery
35. re Select between mbar psi inH20 mmH20 kPa hPa inHg and mmHg units of measure for pressure readings Efficiency Select between Nett and Gross efficiency Gross efficienc is used in the USA and factors in wet losses Using Nett efficiency in the USA will result in abnormally high efficiencies Menu Navigation Sensor Info Allows the user to see the last and next calibration date of the sensors that are installed in the 716 Menu Navigation Instrument Info Provides the serial number firmware version and firmware date for reference Also shows the last calibration date of the unit and batter voltage condition Menu Navigation Calibration Mode This is for factory use only 32 ur MEASUREMENTS Flue Gas continued TYPICAL TEST LOCATIONS Condensing Boiler Furnace Typical Test Locations Flue probe location foi OF CO and Stack temperature measurement This location is also used to measure draft by using the ATTO static tip Figure 2 It is important to use manufacturers recommended test locations whenever possible 17 MEASUREMENTS Flue Gas continued TYPICAL TEST LOCATIONS Atmospheric Forced Air Furnace Typical Test Locations Draf measurement location using AFTO static tip Flue Probe Flue probe location for 02 CO and stack temperature measurements Static pressure Measurement location using the ATTO static tips Test all exhaust ports at the t
36. see figure below WARNING There is ONLY one correct way to connect the K type thermo couple plug into the socket see page 7 Forcing the plug into the socket the 2 Zero the display by pressing the Zero Key left blue soft key wrong way may result in damage to the instrument 3 Connect the tube s to the device under test and read the pressure on the 2 Touch the temperature probe to the item under test and read the displayed aa Other Features temperature e Pressing Send center blue soft key acti wa Other Features 17 03 2012 02 44 vates a sub menu and allows information to be 7 sent to the optional A740 infrared printer or to a e Pressing Send center blue soft key acti SSS 0 p p i Prsu Unit inHzO PC using the optional USB interface cable and 17 03 2012 02 44 vates a sub menu and allows information to be 9 P l i i Prsu Real 0 000 software sent to the optional A740 infrared printer or to a 7i SF_ fea PC using the optional USB interface cable and T2 AT 74 9 F e Pressing Save right blue soft key activates 03 F software a sub menu that allows the screen data to be saved in a memory location 0 to 99 for later retrieval A MoE Prsu _0 000inH20 e Pressing Save right blue soft key activates a sub menu that allows the screen data to be saved in a memory location 0 to 99 for later retrieval Zero Send Save Zero Send Save display manometer This
37. snsavecuenenvsteatanecscceaaen 29 26 CO Room TOS occcetaccsaesennccenesaudacenameanoaccnaue 27 Combustible Gas Leak Detection 28 Menu Navigation ccccecccesceeseeeeseeeeseenseees 29 32 Me VEY erresen E 29 ULA o EE EE E 30 Analyzer Setup ccsccecesceeceeeeeeeceeeees 31 Units of Measure Sensor Info Instrument Info 32 SPeECifiCAtIONS ccceeeseeeceeeeeaeeeeeeaeeeeeaseeneeas 33 34 Calibration amp Service ccccceeceeeeeeeeeeeeeeeeeeaees 35 MN AN cect pase nes rans ces eaeede ane ccuec acersneeateecnnenzee 30 Appendix A General Maintenance amp Function Tests 36 38 Appendix B A773 Sulfur Filter Installation amp Maintenance 39 40 Appendix C Error Codes and Troubleshooting 41 42 Appendix D Testing for Carbon Monoxide in Ambient Air 43 Appendix E Carbon Monoxide Limits in Ambient Air Chart 44 Appendix F Carbon Monoxide Facts ccsseeseeeeees 45 Appendix G Battery Replacement 2ccsceeeeeeeeees 46 Notes Introduction Thank you for purchasing TPI brand products The TPI 716 Flue Gas Analyzer is a state of the art easy to use analyzer designed not only to display and calculate the required readings from a flue but also to cover most of the other measurements associated with combustion The instrument is ruggedly constructed and comes with a 3 Year unit and 2 Year sensor Guarantee General
38. to T2 See page 14 Select the proper fuel for the equip ment being tested See page 13 Make sure the optional sulfur filter A773 is installed See Appendix B Redo combustion test Since these are calculated values the measure values must be within certain levels for these to display If the measured oxygen level is above 19 9 these parameters won t read These parameters might not display or be applicable in some tests Perform the combustion test and also connect the manometer and monitor pressure Replace the charger or battery Send to TPI for service Disconnect from the charger and contact TPI at 800 368 5719 Oxygen and or carbon monoxide lev Allow the analyzer to purge longer els outside limits Top View T2 Socket USB Port Charger Socket T1 Socket T2 Socket Gas Sample Port P Port P Port USB Port Charger Socket T1 Socket P Gas P Port Sample Port Port Connection for 220V 115V charger Connection for thermocouple plug on flue probe Connection for any K type thermocouple probe Connection for ambient K type thermocouple probe Connection for any K type thermocouple probe Connection for Mini Pump Protection Filter and Flue Probe Connections for Pressure Tubing Connection for optional A807 cable for communication to a PC or connection for A806 combustible gas leak detection probe BASIC ANALYZER FUNCTIONS Charging The Analyzer
39. to TPI for service Oxygen sensor failed to ini Flue probe connected to 716 Disconnect probe and tialize prior to power up restart 716 did not purge completely Purge for 20 minutes and from last sample restart Worn or defective oxygen Return to TPI for sensor sensor replacement Init Carbon monoxide sensor Flue probe connected to 716 Disconnect probe and CO failed to initialize prior to power up restart Err 716 did not purge completely Purge for 20 minutes and from last sample restart Worn or defective carbon Return to TPI for sensor monoxide sensor replacement Lo Low battery Battery needs to be charged Charge battery If the battery bat won t hold a charge replace the battery oFL Overflow indication The Pressure being measured is _ Remove pressure source pressure being measured is too high or low outside the maximum mea surement capability Pressure sensor damaged or Return to TPI for service defective oFL Overflow indication The tem Temperature being measured Remove pressure source perature being measured is_ is too high or low outside the maximum mea surement capability Connect temperature probe to analyzer Replace temperature probe or flue probe Unable to read thermocouple Temperature probe not con temperature nected to input Worn temperature sensor 41 Appendix B A773 SULFUR FILTER INSTALLATION amp MAINTENANCE 4 Beginning
40. tored Address 0 Prsu Unit inHz20 Preu Real 0 000 9 Connect pressure sampling tube to the pressure port and make sure there are no restric tions in the tubing Press the Zero key left blue soft key to zero the manometer start P1 Finish P2 Diff P2 P1 Elapsed time 00 00 4 Connect the tubing to the device under test Zero Save1 Chang Pressurize the device to the required level 5 Press the Savet key center blue soft key This saves the initial pressure Start P1 and activates the elapsed time clock 6 When the elapsed time has reached the level outlined by the manufacturer of the device under aa test press the Save2 key center blue soft key Tightness test 17 03 2012 02 44 Address 0 Prsu Unit inHz Prsu Real 0 000 Start P1 Finish P2 Diff P2 P 1 Elapsed time 00 00 Zero Save1 Chang 26 The start pressure finish pressure and pressure difference along with the elapsed time of the test will be displayed This data is stored in the address location selected earlier 7 Press the End key center blue soft key to end the test or press the Send key left blue soft key activates a sub menu that allows you to print to the optional A740 printer Print Out or send the test data to a PC using the optional cable and software PC Out Use the Arrow keys to select the desired output method and press the Ok key left blue
41. y Compartment Holds rechargeable battery Headache dizziness and nausea within 5 10 minutes AOLE aaa Rubber Boot Protects the instrument Headache dizziness and nausea within 1 2 minutes Death within 10 15 minutes 44 5 Side Views Exhaust Port Infrared Window Rubber Boot Exhaust Port Port for connection of Exhaust Adapter Infrared Window Window for sending stored data to IR Printer Rubber Boot Protects the instrument from accidental damage 6 Measurements Temperature amp Pressure Appendix D Testing for Carbon Monoxide in Ambient Air The 716 can be used to test for carbon monoxide in ambient air For example tests can be performed in work spaces and living areas like offices and houses to ensure safety 1 Following the steps outlined on page 8 turn the analyzer on in a clean air environment away from the area to be tested 2 Select Measurement from the Main Menu Select Flue gas from the Measurements Menu After a purge cycle the display below will be seen FA JA Flue gas 17 03 2012 02 44 Natural gas CO 85ppm CO2 c 10 2 Ambient CO levels will be seen in the top line of the display CO in ppm Ratio 0 003 Effi g 82 3 02 4 3 AI 10 NO 0 ppm NOx 0 ppm Send Save 3 Connect the Pump Protection filter to the analyzer 4 Begin testing for carbon monoxide Move from space to space to detect any CO that may be present The CO reading will be seen in the top
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