ENERAC 700 Instruction Manual Download Page 63 | Manualshive

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Summary of Contents for 700

Page 1: ...N MANUAL INTEGRATED EMISSIONS SYSTEM MODEL 700 ENERAC LLC 1320 LINCOLN AVE HOLBROOK N Y 11741 800 695 3637 Outside USA 631 256 5903 After Hours 631 379 3502 E mail sales enerac com FAX 516 997 2129 www enerac com ...

Page 2: ...2 ENERAC 700 MANUAL EDITION 4 M700 FIRMWARE 3 0 M 700 HARDWARE H ...

Page 3: ... 19 CHAPTER 4 SAMPLE EXTRACTION CONDITIONING 21 CHAPTER 5 SENSORS 27 CHAPTER 6 ANALYZER SETUP 33 CHAPTER 7 INTERNAL DATA STORAGE 37 CHAPTER 8 INTERNAL PRINTER 39 CHAPTER 9 CALIBRATION 41 CHAPTER 10 COMMUNICATIONS 50 CHAPTER 11 MAINTENANCE 58 APPENDIX A MODEL 700 SPECIFICATIONS 64 APPENDIX B FIRMWARE PROGRAMMING 68 ...

Page 4: ...4 APPENDIXC EPA TEST METHODS 70 ...

Page 5: ...mperature stack temperature stack draft and oxygen The available options are separated into three categories 1 SAMPLE PROBES CONDITIONING SYSTEMS A Inconel probe 9 typical with latex sampling line and water trap B Inconel probe 9 typical with Viton sampling line and thermoelectric condenser C Stack Velocity probe Stainless Steel S type Pitot tube for stack velocity measurements in feet second and ...

Page 6: ...uring stack temperature and oxygen concentration Measuring the ambient temperature inside the analyzer where the sensors are located as specified by the EPA method CTM 030 Measuring the emissions of carbon monoxide oxides of nitrogen and sulfur dioxide from stationary and mobile combustion sources by means of high quality SEM electrochemical sensors Measuring the oxide of nitrogen emissions in acc...

Page 7: ...izing its performance and saving fuel It can be used as a management tool to assist the plant manager with keeping records and controlling costs Basic instrument operation is as follows You insert the probe in the exhaust stack of an operating combustion source such as a boiler furnace or combustion engine A pump located inside the instrument draws a small sample of the stack gas The sample is con...

Page 8: ...ions Analyzer with Carry case Carry Strap A stack probe A sampling line assembly A sample conditioning system either a water trap or a thermoelectric condenser A battery charger An extra roll of printer thermal paper If printer option is ordered PTFE membrane For NDIR option only One extra disposable filter ...

Page 9: ...press ENTER to begin an autozero countdown At the end of the countdown you are ready to use the instrument 4 IF YOU DON T HAVE THE INFRARED OPTION you may bypass the initial autozero although it is recommended that you zero the instrument once before beginning your tests To bypass the autozero press the DISPLAY DATA key 5 After an autozero if the status line of the display shows AUTOZERO COMPLETE ...

Page 10: ...eters read OVER on the display you must withdraw the probe from the stack immediately to prevent sensor saturation DUAL RANGE OPTION 7 If you suspect HIGH concentrations of gases in your stack or if your emissions sensors read OVER in the LOW RANGE press the PUMP key to switch the instrument to its HIGH RANGE mode THE DATA SCREEN EFF OVER CO 0PPM ST 80 F NOX 0PPM OXY 20 9 NO 0PPM HC 0PPM NO2 0PPM ...

Page 11: ...e from entering the analyzer If the electrochemical sensors get wet they will not work until they can dry out If the NDIR bench gets wet it will not read properly and afterward it may not autozero successfully Once dried typically overnight the electrochemical sensors will usually recover However the NDIR optics will probably require cleaning at the factory 4 Do not expose the probe tip to open fl...

Page 12: ...cement Stack Temperature Thermocouple is hot Probe tip should be cool Stack Draft Thermo electric cooler or water trap not connected Draft voltage will be high Connect probe and re zero or ignore draft readings Filters are dirty Draft voltage will be low Check filters Hose is kinked possibly Internally Draft voltage will be zero Check for suction at end of probe Infrared CO CO2 HC 00 No response f...

Page 13: ... in the charger Analyzer should turn on Battery is not charging Check charger and jack Internal initialization problem Reset the analyzer Analyzer turns on but screen has no text or is faded Internal initialization problem Reset the analyzer Analyzer is overheating Unplug charger Check fan Turn on off to reinitialize ...

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Page 15: ...Four keys will bring up a menu SETUP ZERO SPAN STORE PRINT The menus are navigated with the UP DOWN LEFT RIGHT ENTER keys The HELP key provides a brief explanation of each menu s functions The PUMP key controls the analyzer s measurement mode There are four states o LOW RANGE o HIGH RANGE Dilution option o PURGE Dilution option o OFF At the end of this manual is a useful chart which summarizes the...

Page 16: ...played in the middle of the bottom line of the display Its condition is marked by the shaded fraction of the icon If the unit is powered by the battery charge then a small plug icon will replace the battery icon When connecting the battery charger to the analyzer make sure that the plug icon appears on the DISPLAY DATA screen This ensures a proper power connection and charging of the batteries 4 I...

Page 17: ...he stack or engine exhaust Use the DISPLAY DATA key to read the stack parameters 9 To obtain a printout of the data displayed press the PRINT key The cursor reverse color will point to Print Test Record Press the ENTER key to execute a printout on the ENERAC S printer 10 To store the data displayed press the STORE key The cursor reverse color will point to Press the ENTER key Store Current Buffer ...

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Page 19: ...t of electrical power even when the analyzer is off Do not allow the batteries to discharge completely When not in daily use remember to charge your analyzer periodically If the analyzer has been without power for a long time you may need to wait a few hours after recharging the battery for the sensors to be restored You can check the condition of the battery at any time 1 Press the DISPLAY DATA k...

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Page 21: ... having a diameter larger than 24 inches attach an inconel extension tube The sampling line connects to the probe and delivers the gas to the conditioning system The hose may be made of Viton Teflon or EPDM The integrated yellow wire is for connecting the thermocouple to the analyzer The ENERAC Model 700 can accommodate a variety of available sample conditioning systems 1 WATER TRAP This is the le...

Page 22: ...y between 5 and 20 of water vapor most of which will condense in the probe and sample line To prevent significant loss of NO2 and SO2 during transport of the sample from the probe to the analyzer the following conditions must be satisfied 1 Rapid sample transport This is accomplished by maintaining a high flow rate over a relatively small diameter sampling line 2 Use of a sample line made from a h...

Page 23: ...the analyzer must be held either in a face up horizontal or an upright vertical position Do not turn the unit upside down when there is water in the condensation trap The thermo cooler will maintain the sample at a certain temperature below ambient temperature to ensure no further condensation inside the analyzer You can control this temperature differential by adjusting the COOLER DUTY CYCLE if n...

Page 24: ...r longer operation The condensation trap will fill with water after 2 to 4 hours depending on the fuel used To empty the condensation trap simply disconnect it from the manifold by unscrewing it When replacing it be careful to seat the O ring properly The thermo cooler is typically equipped with two filters 1 A cylindrical filter for particulates 2 A disc shaped filter for condensation The optiona...

Page 25: ...ent at a certain angle as required by the EPA specifications of 40CFR60 Appendix A Method 2 for measuring stack gas velocities The Pitot tube measures the pressure differential between the lower tip and the upper tip which is mathematically converted to gas velocity in FPS and gas flow rate in CFM The Pitot tube assembly is connected by means of two flexible hoses connected to the velocity inputs ...

Page 26: ...ering the probe housing The filter is reusable and can be cleaned in a detergent and by blowing air from inside out Maximum filter temperature is 1900ºF Inconel probe extension This tube screws into the end of the sample probe to extend its reach This is needed if you cannot reach the center of your stack with the sample probe alone ...

Page 27: ...ision control module PCM The PCM sets the sensitivity of the sensor and also contains filter material to remove the effect of any interfering gases present PCMs are uniquely designed for each sensor type Do not interchange a PCM designed for one gas type with a PCM made for another gas type Electrochemical sensors produce an electrical current that is proportional to the detected gas These sensors...

Page 28: ...ade of exclusively noble metals Sensor life is estimated at 2 years The SEMTM NO sensor of the ENERAC Model 700 is superior to the typical electrochemical type sensor in accuracy interference rejection and its design for continuous operation Its inboard disposable filter has an estimated life in excess of 100 000 PPM hours against sulfur dioxide This sensor requires a constant bias voltage for pro...

Page 29: ...h charge once every 2 3 months E Oxygen sensor O2 sensor This is a standard two electrode electrochemical cell It has a silver cathode and a lead anode Oxygen diffuses through a tiny hole and reacts with the lead anode The reaction produces an electric current The unit software linearizes the current vs oxygen response The cell becomes exhausted when all the lead is consumed It takes about two yea...

Page 30: ...the analyzer operates in its low range only the sample pump is on When the analyzer operates in its high range both pumps are on and the duty cycle for the sample pump is automatically reduced In the purge mode only the air pump is on The optional NDIR sensor bench is not affected by the setting of the analyzer range 2 INFRARED NDIR SENSORS The Model 700 emissions analyzer can be equipped with inf...

Page 31: ...ing operation NOTE If the analyzer is equipped with the NDIR option the analyzer must always enter an autozero each time it is turned on Consequently you must not turn on the analyzer and complete an autozero if the probe is currently connected to an engine or stack exhaust The NDIR bench is designed for operation primarily with measurements of engine exhausts according to the California BAR 97 re...

Page 32: ...o drifts d Stack Draft Stack Velocity sensor The draft sensor is a piezoelectric sensor located inside the analyzer Because of the pressure drop caused by sample flow through the sampling line and filters the sensor zeroes itself every time an autozero is carried out Consequently you must not allow the filter to get clogged with soot as this would give an erroneous reading For accurate draft measu...

Page 33: ... the parameter The value will be highlighted This indicates that you are in edit mode 3 Use the UP DOWN keys until the desired value of the selected parameter appears on the display 4 Press the ENTER key to confirm the selection If you want to cancel any changes made simply press any MENU key A more detailed explanation of each parameter follows 1 DATE TIME The analyzer s internal clock is display...

Page 34: ...r B Pounds of pollutant per million BTU of fuel GBH Grams of pollutant per brake horsepower hour To choose the desired emission units toggle the UP DOWN keys until the proper units are displayed Then confirm with the ENTER key If you select GBH grams brake horsepower hour as the desired units you must not forget to set the value of the engine thermal efficiency also You can obtain this figure from...

Page 35: ...To return to uncorrected measurements press the UP key until the display reads Oxygen Reference TRUE NOTE Setting the OXYGEN REFERENCE to a value other than TRUE affects values of emissions concentrations in PPM and MGM It does not affect values in B or GBH 6 PUMP The current pump status is displayed here followed by the duty cycle of the sample pump The pump states are a SAMPLE This is the standa...

Page 36: ...E UNITS above 11 BAUD RATE This is the speed at which the analyzer is set to communicate with a computer The computer usually manages the baud rate 12 VELOCITY UNITS Velocity Option Select between feet per second FPS and cubic feet per minute CFM Computation of CFM requires setting the stack size 13 STACK SIZE Velocity Option When measuring cubic feet per minute CFM be sure that you have entered y...

Page 37: ... 1 STORE CURRENT BUFFER The unit will store one set of data into the buffer currently selected The index number and the name of the current buffer is shown at the bottom of the STORE screen 2 SELECT BUFFER Selecting this item will display an index of the analyzer s 500 internal storage buffers Buffers that are used have an icon next to their index number The selected storage buffer is indicated by...

Page 38: ...first buffer s name and the EFF OVER CO 0PPM ST 80 F NOx 0PPM OXY 20 9 NO 0PPM HC 0PPM NO2 0PPM CO2 0 0 SO2 0PPM AIR OVER DFT 0 0 000 BUFFER 000 JAN 01 12 12 45 00 NAME BUFFERS Starting Buffer 00 Ending Buffer 00 Name xxxxxxxxxxxxxxxx 1 2 3 4 5 6 7 8 9 0 A B C D E F G H sym I J K L M N O P shift Q R S T U V W X Y Z alphanumeric keyboard will appear Use the UP DOWN LEFT RIGHT keys to navigate aroun...

Page 39: ...te when the data was stored appear at the bottom empty buffers show the word empty To print the contents of a specific buffer use the UP DOWN keys to move the arrow to the desired buffer and press ENTER If you wish to print all of the analyzer s stored data in sequence move the arrow to the entry ALL BUFFERS and press ENTER EDIT CUSTOMER NAME This will display a screen where you can change the inf...

Page 40: ...The arrows in the corner will move the cursor forward or backward through the name CALIBRATION RECORD This option will print a record of each sensor s last calibration including the date of calibration and span gas value used PAPER FEED This toggles the printer s motor on and off advancing the paper out the top of the analyzer as needed The motor will not turn if there is no paper present ...

Page 41: ...ond calibration point has to be set by using some known value of the parameter being calibrated For example certified 200 PPM carbon monoxide gas is fed to the analyzer in order to calibrate the CO sensor at 200 PPM For temperature sensors the second point is not required You must always span calibrate the instrument whenever you replace a sensor unless you have requested a pre calibrated sensor S...

Page 42: ... HC will also be zeroed AUTOZERO ERRORS If any sensors were out of range during the last autozero they will be listed on the AUTOZERO ERRORS screen SENSOR HISTORY The SENSOR HISTORY screen is a record of the last calibration for each electrochemical and NDIR sensor AMBIENT TEMPERATURE The ambient temperature as measured inside the analyzer is shown here Press the ENTER key to adjust the ambient te...

Page 43: ...ce Check that the probe s sampling line and electrical connections are secure Check that the probe tip is at room temperature It is very important that at the moment of zeroing the probe tip is at room temperature and the environment is clean and free of carbon monoxide or other gases It may be a good idea to zero the analyzer outdoors before entering the facility Some protocols such as EPA s Meth...

Page 44: ...n concentration you expect to measure Make sure the concentration of the calibration gas is within the range of each sensor Do not under any circumstances use gas that will over range the sensor You must not feed gas to the analyzer under pressure and you must not starve the analyzer s pump for gas When feeding the gas to the analyzer you must maintain a reasonably constant pressure This is a requ...

Page 45: ...regulator will automatically supply an adequate flow of gas to the analyzer without wasting any span gas and without venting any toxic gas to your ambient environment This accessory shown in the figure below is available from the factory ...

Page 46: ... 9 0 20 0 balance air The hydrocarbons span gas can be in the range of 1000 30 000 PPM preferably propane CALIBRATION PROCEDURE 1 The instrument should be autozeroed before a span calibration Before calibrating any NDIR channel an autozero is required In addition the NDIR calibration must be carried out within 5 minutes of the autozero 2 Connect the calibration apparatus and gas cylinder to the in...

Page 47: ...alue 7 When the calibration is finished check that the display is reading correctly C STACK DRAFT CALIBRATION To span calibrate the draft sensor connect a manometer to the end of the probe through a T fitting Leave one side of the T open Restrict the open side of the T with a suitable valve In the SPAN MENU use the UP DOWN keys to select a draft calibration of 10 Press the ENTER key The pump will ...

Page 48: ...or connect a manometer directly to the velocity input on the side of the analyzer Apply 1 inch of pressure In the SPAN MENU use the UP DOWN keys to select a velocity calibration of 1 0 Press the ENTER key The pump will be on and the display will read PRESS ENTER AT 1 0 H2O ...

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Page 50: ...rs for Windows computers are located on the ENERAC website www enerac com When you plug the USB cable from the computer to the analyzer you should hear a small da ding sound indicating that the USB connection has been made If you have the FTDI USB driver already installed in your computer the computer will know and will NOT initialize the New Hardware Wizard If the New Hardware Wizard appears you ...

Page 51: ...will be assigned a unique comport number Remember the comport number as it will be needed to open an Enercom session You can find the comport associated with your ENERAC in the Windows Device Manager To open the Device Manager Go to the Windows START menu click RUN and type devmgmt msc Or go to the Control Panel choose the System icon then the Hardware tab and click the Device Manager button A win...

Page 52: ...ons 4 Retrieve stored data 5 Enter custom fuel information 6 Open a terminal window to communicate directly using serial commands The Enercom software can be downloaded from the website at www enerac com Consult the Enercom manual for details on installing and operating the program STARTING ENERCOM 1 Before starting Enercom have your analyzer turned on and connected via RS 232 USB or Bluetooth 2 S...

Page 53: ...ould appear on the left side of the Enercom window Enercom will look for an analyzer on this port After a moment the ENERAC analyzer icon should appear You are now connected to your analyzer 6 Click on the ENERAC icon A menu will appear Choose Monitor from the menu Follow the ENERCOM manual for further instructions ...

Page 54: ...it no parity HANDSHAKE None All commands start with a four letter ASCII word If the command is followed by a question mark then the analyzer will respond with one or more lines of information For example Send TIME Response 12 45 01 Without a question mark the command will cause the analyzer to set some parameter to the value sent with the command or take some other action such as erasing a specifi...

Page 55: ...s the present value of the stack temperature TEXT Returns a complete record of all current stack parameters VELO Returns the present value of stack velocity or flow rate SETUP COMMANDS COMMAND FUNCTION ATOF Returns the ambient temperature offset in C ATOF XX Sets the ambient temperature offset to XX C COOL Returns the thermoelectric cooler duty cycle COOL XX Sets the thermoelectric cooler duty cyc...

Page 56: ...Option Returns the stack size for flow rate only SIZE NNN Velocity Option Sets the stack size in square inches used in calculating the flow rate VORF Velocity Option Returns the current flow velocity selection VORF X Velocity option Selects between stack flow rate and stack velocity as follows X V Stack Gas Velocity feet second X F Stack Gas Flow Rate cubic feet minute MEMORY COMMANDS COMMAND FUNC...

Page 57: ...10 500 XX SO2 Sulfur Dioxide 10 1000 XX CMB Combustible Gases 0 1 10 0 XX DFT Stack Draft Inches H2O 20 20 XX COIR NDIR Carbon Monoxide 1 125 15 0 XX CO2 NDIR Carbon Dioxide 9 0 20 0 XX HC NDIR Hydrocarbons 450 20000 ZERO Executes an autozero of all analyzer sensors ZERR Returns a list of sensors that failed autozero MASTER COMMANDS COMMAND FUNCTION LOGO Returns its current model name ENERAC M700 ...

Page 58: ...eplacement After approximately 200 printouts 5 The rechargeable battery pack After a few years of service 1 Condensation removal At the end of a measurement or whenever the trap is full unscrew and empty the cylindrical water trap Check that the O ring is seated correctly before replacing the trap The CTM probe has a drain valve located at the bottom of the trap Before storing the instrument shake...

Page 59: ...culates Replace it when it becomes dirty When installing a new filter be sure to observe the correct flow orientation as indicated by the large arrow on filter The disc filter if equipped is to prevent condensation from entering the unit If this filter absorbs too much moisture it will stop any further flow to the analyzer If a replacement filter is not available the wet condensation filter should...

Page 60: ...nted circuit board Align the pins correctly when inserting a new sensor When replacing a CO NO2 or SO2 sensor remove any shorting springs on the sensor pins Each sensor has a different pin arrangement to prevent it from being accidentally inserted in the wrong socket pin configuration Be careful not to bend the sensor pins when inserting the new sensor Replace the bottom section of the back plate ...

Page 61: ...igh quality 2 thermal paper Keep any spare paper rolls in a cool dark place to prevent paper discoloration To replace the thermal paper a Unfasten the two screws that secure the top cover of the printer b Unroll approximately 6 inches of a new roll of thermal paper c Cut the end of the paper square with scissors d Orient the roll so that the paper unrolls from the bottom of the roll e Locate the s...

Page 62: ...t any time by pressing SETUP DISPLAY DATA keys together The battery voltage will be listed as BAT For Ni MH rechargeable batteries the battery voltage will stay at approximately 4 8 volts for a long time and then drop rapidly A minimum of 4 2 volts is required to operate the analyzer The instrument will warn you when the batteries become weak A BATTERY LOW warning will appear After a few hundred c...

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Page 64: ...iodic data printouts D calibration history 2 PUMPS A Sample pump high quality long life motor 5000 hours B Dilution Purge pump option Pumping system operates in one of the following modes 1 Continuous sampling LOW RANGE concentrations 2 Continuous sampling HIGH RANGE concentrations 3 Automatic ranging low or high range 4 Purge mode also periodic sampling with purge CTM 22 CTM 30 CTM 34 5 Pumps OFF...

Page 65: ... SENSOR RANGE RESOLUTION ACCURACY CARBON MONOXIDE CO LOW RANGE 0 2 000 PPM 1 PPM 2 PPM OR 2 OF READING HIGH RANGE 10 000 20 000 PPM 1 PPM 10 PPM OR 5 OF READING NITRIC OXIDE NO LOW RANGE 0 300 PPM 0 1 PPM 2 PPM OR 2 OF READING HIGH RANGE 2 000 4 000 PPM 1 PPM 5 PPM OR 5 OF READING NITROGEN DIOXIDE NO2 LOW RANGE 0 300 PPM 0 1 PPM 2 PPM OR 2 OF READING HIGH RANGE 1 000 PPM 1 PPM 5 PPM OR 5 OF READIN...

Page 66: ...DING CARBON DIOXIDE NON INFRARED 0 40 0 1 CALCULATED FROM O2 EXCESS AIR 0 1000 1 CALCULATED FROM O2 OXIDES OF NITROGEN NOX NO NO2 RANGES 0 1 SEM SENSORS 1 NO NO2 SPEC S EMISSIONS 1 CO NO NO2 NOX SO2 0 2500 MG M3 2 MG M3 CALCULATED BASED ON PPM O2 AND FUEL EMISSIONS 2 CO NO NO2 NOX SO2 0 00 99 99 LBS MBTU 0 01 LBS MBTU CALCULATED BASED ON PPM O2 AND FUEL EMISSIONS 3 CO NO NO2 NOX SO2 0 00 99 99 GMS...

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Page 68: ...etup screen Updating the firmware 1 Download the firmware installation package You can save it to your desktop 2 Extract all of the files in the ZIP archive 3 Turn on the analyzer 4 Connect the analyzer with a USB or RS 232 cable Close the ENERCOM program if it running on your computer 5 Run the firmware update program EneracFWP700 exe in the extracted folder 6 Enter the comport number when prompt...

Page 69: ...The firmware will now be reprogrammed and verified This will take 2 3 minutes 10 When prompted toggle the programming switches off and replace the back cover 11 Turn on the analyzer Check the firmware version on the SETUP screen ...

Page 70: ...analyzer must not get wet and scrub the NO2 gas The sample line must be designed to prevent condensation Unlike Method 7E a single calibration span gas is required for each CO NO and NO2 calibrations The sample flow rate must be monitored before and after each test and not vary by more than 10 or cause the readings to change by more than 3 During a measurement cycle the temperature of the sensors ...

Page 71: ...ired for measurements in pounds million BTU The probe must be heated until it reaches the moisture removal system Dry transport line required from the moisture removal system to the analyzer Fig 7E 1 Here ENERAC CTM probe meets this requirement Dual range analyzers are allowed but they must meet the specifications listed for single range For analyzers that are designed ONLY for very low range NOX ...

Page 72: ...ibration span gas concentration B System bias 5 difference between gas introduced at the probe and also directly into the analyzer C Drift 3 D Interference check 2 5 for the sum of all interfering gases E Analyzer resolution 2 of range F Data recording 1 minute average each run Example If the analyzer has an NO range of 1 000 PPM and the measured NO emissions are 150 PPM you can select a high leve...

Page 73: ...a minimum every 5 minutes if the analyzer cannot measure negative values It is not needed if it measures negative values Author s note This requirement does not address large positive NO drifts with rising temperatures It is preferable to monitor the NO ambient cell temperature at all times A single calibration span gas labeled upscale calibration gas is required and no linearity tests are require...

Page 74: ... SENSOR SNS COSEM8CM 495 00 NO SENSOR NITRIC OXIDE SNS NOSEM8NO 495 00 NO2 SENSOR NITROGEN DIOXIDE SNS NO2SEM8ND 495 00 SO2 SENSOR SULFUR DIOXIDE SNSSO2SEM8SN 495 00 COMBUSTIBLE SENSOR ASSHOUCMB3K1 225 00 3 GAS SENSOR CO CO2 HC OPTNDIR 3GAS 1495 00 HASTELLOY FILTER SPECIFY MODEL FILTER 2KE 2 150 00 THERMAL PAPER 3 PER PKG ASSPAKTHR200 30 00 BATTERY PACK OF 4 BAT 1 2DNIPK 80 00 POWER CHARGER BATCHR...

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