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DDS CALORIMETERS OPERATIONS MANUAL V1.1     

2022 

Website: 

www.ddscalorimeters.com

 

Digital Data Systems (Pty) Ltd. 

CAL3K Advanced Bomb Calorimeters 

www.ddscalorimeters.com

  

5.4.3

 

TEST VESSEL LEAK 

 

This test INCLUDES the vessel.  Depending on the type of vessel used there are O-rings in the vessel lid 

which could leak and require replacement. Use the same CMD=94 command: 

 

94    SYSTEM LEAK TEST    1 

 

Note that the filling is much slower because the vessel is filled. Monitor the pressure and if it is steadily 

declining than a leak is present. It is normal that the pressure declines rapidly in the beginning and then 

settles down. This is because a flow restriction is present in the vessel lid. 

 

 

6

 

PRINCIPLE OF COMBUSTION CALORIMETER  

 

In short, a known substance is burned in a contained environment (Vessel) and the resultant 

temperature rise is recorded as a calibration. Then un-known samples are burned and the temperature 

rise is compared to the calibration and the unknown calorific value is calculated. 

 

The following sequence applies to a determination and a calibration. The broad difference is that the 

calibration saves more data for further reference. 

 

Here is a more detailed, but short sequence of events, assuming default settings. 

 

1.

 

Approx. 0.5g (0.2-0.8g) is precisely weighed and entered in to the CAL3K (electronic or manual 

transfer) 

2.

 

The vessel is prepared (cotton, crucible, firing wire) and the CAP is closed 

3.

 

Manual filling: Place the vessel in the filling station and fill it with oxygen. 

4.

 

Place the prepared vessel in to the well and close the lid 

5.

 

If this vessel was never calibrated then the unit will ask you to do so. 

6.

 

CAL3K-AP automatic filling only

: If everything is fine the unit will go into the filling period, open 

the fill oxygen solenoid and monitor the filling progress. At the end of the filling process the unit 

will switch to the INITIAL PERIOD. 

7.

 

All manual filling units

: the CAL3K will switch to the INITIAL PERIOD 

8.

 

It waits approx. 3 minutes for the vessel to stabilise. 

9.

 

After 3 minutes the sample is fired: 25 volts are connected to the firing wire and a very large 

current passes through it, the wire glows, the cotton ignites and the sample burns. 

10.

 

The unit enters the MAIN state (Final Period) and monitors the temperature rise of the vessel. 

11.

 

The temperature increases rapidly, peaks at approx. 1 minute and decreases thereafter.  

12.

 

At the end of the main period the Result is displayed on the screen and the End period starts. 

13.

 

CAL3K-AP

:  the vessel deflates automatically to the exhaust port and the lid opens. 

14.

 

CAL3K-A/F

: The lid opens  automatically. 

15.

 

CAL3K-S/ST

: The lid must be opened manually. 

16.

 

Remove the vessel for cooling and subsequent new preparation. 

 

 

 

Summary of Contents for CAL3K Series

Page 1: ...DDS CALORIMETERS OPERATIONS MANUAL VERSION NO 1 1 DATE 2022 MANUFACTURED BY DIGITAL DATA SYSTEMS...

Page 2: ...EST VESSEL HARDWARE 7 5 3 TEST THE FAN 8 5 4 TESTING FOR OXYGEN LEAKS 8 5 4 1 TEST OXYGEN SUPPLY 8 5 4 2 TEST OXYGEN INTERNAL PLUMBING 8 5 4 3 TEST VESSEL LEAK 9 6 PRINCIPLE OF COMBUSTION CALORIMETER...

Page 3: ...MEASURE 22 12 CALIBRATION 23 12 1 CALIBRATION CONDITIONS 23 12 2 CALIBRATION IN DIFFERENT MODES 24 12 3 PERFORMING A CALIBRATION 24 12 4 CALIBRATION AND RESULT GRADING 24 12 5 AVERAGE CALIBRATION 25...

Page 4: ...ON DUMP 43 24 REAL TIME PRINTING 43 25 CLEARING 44 25 1 CLEAR RESULT MEMORY 44 25 2 CLEAR HELP EVENTS 45 25 3 CLEAR VESSEL CAL HISTORY 45 25 4 CLEAR CAL3K MAXIMUM 45 25 5 CLEAR VESSEL MAXIMUM 45 25 6...

Page 5: ...igital Data Systems Pty Ltd CAL3K Advanced Bomb Calorimeters www ddscalorimeters com 33 1 PURPOSE OF PRODUCT WARRANTY 71 33 2 OWNER S WARRANTY 71 33 3 EXCLUDED NON WARRANTY PARTS 71 33 4 WARRANTY REPA...

Page 6: ...2 PURPOSE OF THIS MANUAL It serves as a short introduction to the CAL3K system It saves as a reference for all keyboard and interface operations It explains the very basics of operation and guides you...

Page 7: ...DO NOT use oil on any part of the calorimeter It may ignite under pressure and elevate the temperature and may cause destruction of the apparatus 3 2 SAFE ELECTRICAL INSTALLATION Connect the safety ea...

Page 8: ...filling operation will fill to the fill target setting unless the time option is selected We do not recommend time filling The CAL3K AP has a high pressure CUT OUT It deflates the vessel pressure whe...

Page 9: ...ible every week and discard it when it has lost 10 of its original mass Discard the crucible when the bottom is distorted and extremely discoloured Remove the deflector plate every week and clean the...

Page 10: ...tion AP A F F12 The CAL3K has many keyboard commands of which you need only a few The most popular and frequent used are readily accessible the others require a password to get access to You are welco...

Page 11: ...then use the UP Down keys to show the full command Once you have the full command on the screen go to Command execution C Use a function key when available Then go to Command execution D Use the comma...

Page 12: ...by the number you need to know its Index first Type XX once to enable command number execution No password entry is needed for command number execution The XX entry is cleared after the standard passw...

Page 13: ...t not visible Open the oxygen bottle and observe that the regulated pressure increases to the prescribed setting Then close the bottle and observe that the pressure holds If it decreases even slightly...

Page 14: ...0 8g is precisely weighed and entered in to the CAL3K electronic or manual transfer 2 The vessel is prepared cotton crucible firing wire and the CAP is closed 3 Manual filling Place the vessel in the...

Page 15: ...3 Each mode and Vessel must be calibrated if you intend using this mode Once calibrated the mode can be changed without re calibration Note that a max of 4 vessels are allowed per mode The CAL3K S ST...

Page 16: ...2 PORTD1 This is a RS232 port and good for everything as seen later on Of course it can be connected to a PC but it is called the printer port 8 3 PORTD2 This port is a RS232 port only available on th...

Page 17: ...dows Software App to suit any of the above methods If a BLUETOOTH BRIDGE is used then the D1 CAL3K port speed must set to 115200 by CMD 54 The BLUETOOTH BRIDGE has a special application It converts th...

Page 18: ...ated A PC DDS Windows Software App external 9 1 OUTPUT PRINTING RESULTS TO PAPER KEYBOARD INITIATED An Output appears when one of the PRT commands are executed The following command require that an ou...

Page 19: ...nter the day number 1 31 and all results recorded at this day are printed The result memory should be cleared every month CMD 39 64 PRT RESULT GID 0 Each result in memory has a GID Group Identificatio...

Page 20: ...RITY 85 PRT MAX DATA 0 The CAL3K Chassis accumulates maximum data This command prints all maximums The maximum readings can be reset by CLEAR CAL3K MAX CMD 40 112 PRT HELP HISTORY 0 This feature appli...

Page 21: ...n be printed with 53 PRT RTIME HEADER 0 The CAL3K has a REAL TIME RT printout facility It must be enabled by selecting one of the 4 output formats WXYZ CMD 61 Then the header Data descriptor is printe...

Page 22: ...on by using a standard terminal emulator like TERATERM VT Then the data can be transferred to a spreadsheet via its own file saving method or transferring it to the Windows Notepad Important is that t...

Page 23: ...essages as follows Vessel calibration M101 M103 System setup M378 Mass and Vessel data M110 M106 M108 M111 M112 M109 Vessel Inspection and faults M116 M118 M180 Lid closed M184 Firing wire M186 If eve...

Page 24: ...vessel M360 M307 M305 M309 Remove vessel M370 Calibration average check M372 10 6 CYCLE COOL CAL3K S ST only The vessel is cooled down M524 M525 M514 10 7 HELP DISPLAY The messages any message is iden...

Page 25: ...ORD ENTRY 0 All commands with a priority 1 are password protected not accessible The password is DDS3K to make priority 1 commands visible The password is active for 5 minutes If you hear a loud audib...

Page 26: ...D then only 8 characters are used YY MM DD If the date is used as a GID CMD 122 YES then only 8 characters are used YY MM DD 11 7 BALANCE MASS The supplied balance cable Part No 3K 1 117 can be connec...

Page 27: ...CAL3K AP It will write a terminated result in to the memory and print it if enabled It will not save a calibration It will open the lid CAL3KAP A F The ABORT is the same as a RESET It can be performed...

Page 28: ...tors are used with a regular sample to fine tune the result The AI process applies every calibration to all other calibration and computes the compensations it needs to apply for best result consisten...

Page 29: ...very much on the laboratory operation 12 2 CALIBRATION IN DIFFERENT MODES A calibration is saved for a particular vessel and a particular mode Note that not all CAL3K products have a mode parameter Th...

Page 30: ...ration for use with a sample If average calibration is enabled by setting it to a number higher than ZERO then the next BEST FIT calibrations are averaged and used for the determination The Bomb Facto...

Page 31: ...at different times of the day and whenever something changes After about 8 calibration the AI will analyse your calibration performance and may event reject a calibration because it is not good or it...

Page 32: ...gelatine capsule is also known but the cover disk needs to be determined This is best done by burning let say 10 cover disk and dividing the result by 10 to obtain the CV of a single disk This obtaine...

Page 33: ...mpleted Once the determination is complete the result is the calculated calorific value of the sample The calorimeter will automatically take the end result minus the spike energy and present the fina...

Page 34: ...during the combustion process 14 1 COTTON CORRECTION Some energy is added to the burning process as a result of Firing energy Wire oxidation Electronic heating Cotton thread 9 COTTON WIRE CORR 1 This...

Page 35: ...he default setting is ZERO Disabled The moisture content reduces the mass to a nett mass and increases the CV 14 4 GELATINE CAPSULE CORRECTION If a gelatine capsule is used during the process to conta...

Page 36: ...takes place automatically after a pre set time The sample can be fired manually 17 FIRE MANUAL 1 The firing wire can be heated at any time as long as the vessel is in the well and the firing wire is p...

Page 37: ...you need to calibrate once a day to once a week The unit was calibrated about 8 12 times before shipment You can use these calibrations or you can delete them and start fresh For more details see CALI...

Page 38: ...g the unit at relatively high ambient temperatures However this limit can be set up to warn the operator The default setting is 36C 102 LOW AMBIENT LIMT 1 The ambient temperature affects the unit s op...

Page 39: ...have a date and time circuit which keeps the time The data and time are attached to every calibration result and event The following command set the time and date 4 TIMESET HH MM SS 1 This command se...

Page 40: ...a zero offset of 1bar This error can be eliminated by using this command The offset can be checked when the lid is open and the READ PRESSURE CMD 89 it should read ZERO 0 2bar If not use the PRESS ZER...

Page 41: ...monitored and if it declines leaks by more than the limit a warning is issued Theoretical the pressure should be constant but it requires approx 1 bar to equalise The default setting is 1 5bar After t...

Page 42: ...A leaking vessel produces a LOW result After the MAIN PERIOD the vessel is deflated This process is monitored in time 92 PRESS DEFLAT SEC After the main period the vessel is deflated The time is moni...

Page 43: ...PRINTING The unit has a PRINTING port RS232 PORT D1 To operate the RS232 port the speed of the CAL3K output must match that of the receiving input The receiving input can be 1 PRINTER with RS232 inpu...

Page 44: ...re cryptic but you get the idea 56 PRT A H HEADER 0 20 4 PRINT FILTER If required a filter can be applied before printing Results memory entries which are Calibrations Faulty determinations can be sup...

Page 45: ...results of today can be printed in the specified form by 57 PRT TODAY FORM 0 Enter a form A H The above command does not change the output form selected by the CMD 63 SET OUTFORM A H command The day...

Page 46: ...y the keyboard command text and by the accessibility 0 No password required always visible 1 Password DDS3K required to operate 2 Not accessible reserved 107 PRT KEY CMD LIST 0 21 PRINTING TO A PC Som...

Page 47: ...1 The dump data are preceded by a header to explain what the columns are 22 PRINTING REAL TIME These commands apply to the CAL3K AP A F only It refers to a print output while the determination is in...

Page 48: ...requires an interpreter to understand If you struggle to master this please email us for assistance 23 1 PRINT CALIBRATION DUMP 84 DUMP CALIBR S N 1 Enter the vessel serial number and all max 15 calib...

Page 49: ...n C Customer P Parameter then this info is printed as well 60 SET RTHEAD EN CP 1 The REAL TIME output from 30 seconds before firing can be preceded by Customer C and Parameters P If none is desired en...

Page 50: ...moved from the CAL3K The deletion is permanent This command should be used when memory space is needed for a new vessel CMD 106 displays all used vessel serial numbers Once a vessel calibration is cle...

Page 51: ...ing refers to retrieving information and displaying it on the LCD display 49 READ AMB TEMP 0 This causes the display of the present ambient temperature until ESC is pressed 78 READ ATC TEMP 0 Only app...

Page 52: ...s command reads the recordings from the memory Press enter for the next and ESC to terminate reading The pressure recordings can be cleared by CMD 38 and printed by CMD 101 A pressure record can be si...

Page 53: ...e CAL3K RS232 port to a PC USB port and if you have more than one BLUETOOTH device The name identifies the link to your PC The BLUETOOTH link can t be used for a connection to a computer because a vir...

Page 54: ...print output is enabled CMD 63 SET OUTFORM A H and a printer is connected then the junk data appear on the output All results in memory can be cleared with 39 CLEAR RESULTS 1 This command clears all...

Page 55: ...O The Demonstration DEMO feature prepares the unit for demonstration to a customer This demo mode requires A vessel with firing wire attached Power supply for CAL3K A calibration If not available then...

Page 56: ...o calibrations CMD 108 The unit doesn t differentiate between them but the data are different and flagged 28 7 SIMULATING AN OVER PRESSURE RECORD This command applies to the CAL3K AP only It simulates...

Page 57: ...A YES entry enables the printing of Calibrations and Results A C entry enables calibrations only and a R entry Results See PRINTING for details 63 SET OUTFORM A H 1 Each letter A H selects a print for...

Page 58: ...he same as the F2 key The sample identification are 8 16 characters They are auto incremented if the Time is SID is not selected 3 GROUP IDENTIFIER The Group Identification GID is an 8 16 character te...

Page 59: ...RA DEFAULTLOAD 0 This command loads ALL default values in to the operating parameters Any changes done to the parameters are over written lost This command should be used whenever the parameters were...

Page 60: ...S Then close the LID and wait You will notice that the calibration operation is indicated in the top left corner Once done remove the vessel and repeat the procedure with the other vessels Except CAL3...

Page 61: ...adjusted from 1200 to 38400 baud 25 FIBRE CV VALUE 1 The Fibre CV value is used during food analysis the default is 16 736KJ g Unit conversion is active 26 AVERAGE ACCEPT 1 The entered value should fo...

Page 62: ...e selection process needs to check that the calibrations are acceptable It averages the bomb factors heat capacity for the best fitting calibrations 33 MOISTURE PERCENT 1 This entry is important when...

Page 63: ...g count at max Temperature Date and time of max Temperature The vessel must be inserted for the clearing The command should be repeated with each vessel 42 CLEAR B_CAL S N 1 This command CLEARS all ca...

Page 64: ...s WXYZ CMD 61 Then the header Data descriptor is printed If the SET RTHEAD EN CP CMD 60 has a selection C Customer P Parameter then this info id printed as well 54 D1 PORT SPEED 0 This command sets th...

Page 65: ...cters The GID can be an entered text CMD 3 or the date CMD 122 Enter the GID Up to 16 characters and results are printed 65 READ RESULT DAY 0 This command displays the number of results for the entere...

Page 66: ...dition temperature can be set The default value is 9C 76 COOL MAX TEMP 2 The air cooler maximum temperature is set The default setting is 42C 77 SIMULATE RESULT 1 This command simulates a result junk...

Page 67: ...86 SET RESULT ENABL 1 This command enables YES or disables NO the spontaneous printing of results after a determination The results are entered in memory and can be printed later by any of the print c...

Page 68: ...n deflated Default value is 3 seconds In the CAL3K S ST models the flushing is applied before a determination 94 SYSTEM LEAK TEST 1 Note that the filling is much slower because the vessel is filled Mo...

Page 69: ...AR PRESS RCRD CMD 38 The records can be read out on the display with CMD 115 and a junk record can be simulated with CMD 126 102 LOW AMBIENT LIMT 1 The ambient temperature affects the unit s operation...

Page 70: ...ed A blocked calibration is used by the next calibration 110 UNBLOCK CALI S N 2 The first calibration which is blocked in the specified vessel is un blocked 111 PRT E_CALIBRA SN 1 Enter the vessel ser...

Page 71: ...ailable on the CAL3K S 122 DATE IS GID 1 This YES NO entry allows for replacing the GID with the DATE in the form YY MM DD The GID Group Identification is attached to every sample recording Note that...

Page 72: ...cid 26 454KJ g 0 5g Food 17KJ g 0 75g Other 10KJ g 1 0g Oil Fett Fuel 37KJ g 0 3g The following commands are valuable 81 READ LAST N_RISE 0 This reads the Net Rise of the last sample The display is va...

Page 73: ...omplete run read 81 READ LAST N_RISE 0 This reads the Net Rise of the last sample Since the cotton correction 0 it is the RAW TEMPERATURE RISE Enter the obtained reading with CMD 9 31 3 HOW TO MEASURE...

Page 74: ...ring surface and cracks the O ring Corrosive materials effect the crucible and the deflector plate But the effects are highly visible and can be sustained 32 3 ENVIRONMENT Dust temperature installati...

Page 75: ...0 120 samples TOP BOTTOM O RINGS 3K 4 022 Worst conditions 2 5 samples Average conditions 40 50 Samples Good Conditions 100 samples CAL3K AP O rings 3K AP NOZZEL O RINGS 3K 1 080 Worst conditions 10 2...

Page 76: ...er or the authorised Dealer to which he she returns the unit is proven to be defective Replacement of a defective part will be made only within the applicable warranty period of 12 twelve months from...

Page 77: ...tory in 100 working order It is the Owner s responsibility to inspect any repaired product on receipt thereof and confirm in writing any faults errors or problems with the said product If a fault erro...

Page 78: ...______________________________________________ DATE INSTALLED ____________________________ REPRESENTATIVE OF DEALER AGENT CUSTOMER ORDER NUMBER AND DATE _______________________________________ INSTALL...

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