Teledyne Max 5 Operating Instructions Manual Download Page 2

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INSTRUCTION MANUAL

MAX 5

PORTABLE COMBUSTION EFFICIENCY MONITOR

SALES

ORDER:

SERIAL NUMBER:

Teledyne

Analytical Instruments

16830 Chestnut Street
City of Industry, CA 91748

Phone: (626) 9341500
Fax: (626) 9612538
Web: www.teledyneai.com

Summary of Contents for Max 5

Page 1: ...T ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER DANGER P N M39218 08 06 99 ECO 99 032 OPERATING INSTRUCTIONS FOR MAX 5 Portable Combustion Efficiency Monitor ...

Page 2: ...NUAL MAX 5 PORTABLE COMBUSTION EFFICIENCY MONITOR SALES ORDER SERIAL NUMBER Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91748 Phone 626 934 1500 Fax 626 961 2538 Web www teledyne ai com ...

Page 3: ...ygen Section 10 Sensor Installation and Replacement 11 INSTRUMENT OPERATING PROCEDURE Installation of Thermocouple 12 Initiating Adjusting Air Sample Flow 13 Temperature Efficiency Carbon Dioxide Sections 13 Initial Calibration Automatic Calibration 13 Manual Span CO2 CO 14 Manual Calibration Optional 15 Special Functions 16 Temperature Simulation 16 Cost Savings 16 To Store Readings 17 To Display...

Page 4: ...TS Messages 22 Failure Warning Signs 23 APPENDIX To Print Stored Readings 24a Material Safety Data Sheets MSDS 24b g LIST OF SPARE PARTS DRAWINGS LIST OF FIGURES Figure 1 Display Panel 2 2 Membrane Keyboard 2 3 Back Panel 3 4 Location of Sensors Top View 11 5 Sample Probe With Built In Thermocouple 12 LIST OF TABLES Tables 1 Detector Response To Gases 8 ...

Page 5: ...er the calibration parameters and stored measurement readings are retained in RAM random access memory which requires operating power to protect it thus the information stored in RAM will be lost if battery power is interrupted during battery replacement for example The computer controls the display and reads the keyboard A 12 bit analog to digital A D converter converts the output signals from th...

Page 6: ...proven to be among the best in the instrumentation industry 7 CO Analysis Four ranges of CO analysis are available for the MAX 5 one standard 0 1000 ppm CO and three optional ranges 0 500 ppm CO 0 1 CO and 0 25 CO OPERATION OF CONTROLS DISPLAYS INDICATORS Initial Display Shortly after it is first switched on the computer will test all its internal functions and then automatically enter its normal ...

Page 7: ...u must choose one of the four pre selected fuels 2 fuel oil 6 fuel oil natural gas or solid fuels such as coal so that the computer calculations will be valid Pressing the FUEL key causes the fuel selection across the bottom of the display to toggle through the four selections When you see the fuel that you are using simply leave it that way and the calculations will be valid for that fuel CAL Cal...

Page 8: ...omponent in a concentration equivalent to 80 90 of the instrument s maximum fullscale value TBE AI sets the standard measurement range at 0 1000 PPM Combustibles The combustibles sensor is a low temperature catalytic bead type transducer in a constant current excited Wheatstone Bridge circuit Two legs of the bridge are exposed to the sample gas The other two legs are passive elements Gas diffuses ...

Page 9: ...n dioxide level The oxygen and combustibles section readings and the fuel type you selected at the front panel are factors in the calculation resulting in the carbon dioxide concentration on a dry basis U S Patent No 4 477 403 U K Patent No GB21405S6B France Patent No 2546626 Efficiency The computer calculates the efficiency level The reading calculated from the temperature and oxygen readings and...

Page 10: ...ng and cause readings on the combustibles section of the analyzer and in extreme cases damage the combustible sensor If too short a sample line is used the sample gas may not have sufficient time to cool resulting in water being condensed into the analyzer sampling system The introduction of liquid water into the system can damage the pumps and or temporarily affect performance of the oxygen senso...

Page 11: ...e 1 1 1 50 Cyclohexane 1 3 1 44 Heptane 1 05 1 59 Benzene 1 3 1 50 Pentane 1 5 1 45 Toluene 1 2 1 48 Ethylene Oxide 3 8 0 76 Methyl Ethyl Ketone 1 8 0 96 Methyl Acrylate 2 8 0 59 Taken from Fire Hazard Properties of Flammable Liquids Gases and Volatile Solids National Fire Protection Agency To determine the concentration of a compound present at the sensor from the MAX 5 reading when calibrated wi...

Page 12: ...s sampling period should not exceed 30 minutes followed by a 30 minute purge with atmospheric air INSTALLATION AND START UP PROCEDURES Upon receipt of the MAX 5 inspect the entire unit for damage If damage is found notify the shipper Check unit and included accessories for broken or loose parts DO NOT CONNECT THE INSTRUMENT UNTIL ALL INSTRUCTIONS HAVE BEEN READ If damage is not found check for the...

Page 13: ... expense will be required to take whatever measures may be required to correct the interference 5 DO NOT RUN UNIT OFF AC POWER UNIT IS MADE FOR PORTABLE APPLICATION NOT CONTINUOUS LINE APPLICATION ELECTRONIC ZEROING OF OXYGEN SECTION 1 Turn power switch on If a negative O2 reading is displayed proceed to step 2 If a negative reading is not displayed turn off unit and proceed to Sensor Installation...

Page 14: ...place the F 1R sensor unplug the connector from J6 at the top of the sensor remove the sensor by pulling up on it and throw away the old sensor Take a new F 1R sensor from its protective bag insert it into the recep tacle center bottom of the MAX 5 and attach the connector from J6 to the top of the sensor OXYGEN SENSOR See Interconnection Diagram CAUTION Do not scratch puncture or otherwise damage...

Page 15: ...sensor from the recep tacle detach the connector from the sensor and throw away the old sensor Remove the protective bag from a new sensor connect the sensor to J4 and then plug the sensor into the receptacle 6 Replace the bracket over the sensors insert the finger nuts and tighten them to secure the bracket 7 Replace the cover insert and tighten the side screws and tighten the screws on the back ...

Page 16: ...me equal to the operating time If water appears at the vent purge until water no longer appears CAUTION To avoid sucking in water turn off the pump before opening the filter drain 6 Empty the water condensate trap as required If necessary replace the filter element TEMPERATURE EFFICIENCY AND CARBON DIOXIDE SECTIONS Carbon dioxide and efficiency levels are calculated no calibration or adjustments a...

Page 17: ...the LCD will display bAd 2 For Combustibles Span Standard 0 5 Comb CH4 a Run span gas through the analyzer adjust the span gas pressure regulator until the analyzer s flowmeter indicates 2 0 SCFH Make sure the air flowmeter also reads 2 0 SCFH b Press the LOGO and CAL keys simultaneously followed by COMB TEMP and ENTER A number will appear in the COMB section of the LCD c When the number stabilize...

Page 18: ...will display the current combustibles reading and the word ZERO at the top Expose the combustibles sensor to its zero gas and use the arrow keys as needed to adjust the reading to the zero gas concentration usually zero To accept the value press ENTER SPAN is displayed at the top of the LCD display Run combustibles span gas through the instrument use the up or down arrow to adjust the number displ...

Page 19: ...perature reading To change the temperature press LOGO and CAL keys simultaneously followed by F C this key toggles between F C The simulated temperature is displayed Use the arrow keys to change reading as desired To store reading and return to normal mode press ENTER COST SAVINGS Keys 1 and 2 1 Press CO EFFIC key to display efficiency on the LCD 2 Activate Special Functions 3 Press O2 CO2 number ...

Page 20: ...bers can be printed under function 5 To DISPLAY readings that have been stored Key 4 1 Activate Special Functions 2 Press key 4 The instrument will display the first I D number Press the LOGO key to escape and other key to proceed The instrument will display the first set of readings Press any key except the LOGO key to display the second set of readings and repeat for all readings Press the LOGO ...

Page 21: ... output repeat steps 1 2 and set the time interval in step 3 to 000 followed by the ENTER key To PRINT an instruction manual Key 8 1 Connect a serial printer to the instrument s serial port Turn on the printer and switch it on line 2 Activate Special Functions then press key 8 3 This abridged version of the instrument s instruction manual will be printed 18 To check the VERSION of your instrument ...

Page 22: ...false readings if they are not removed from the flue gas sample The scrubber is disposable and must be periodically replaced Replace the scrubber when its granules have changed color from purple to gray When all traces of purple are gone the scrubber is not operating effectively To replace the scrubber proceed as follows 1 Obtain a new scrubber 2 Carefully pull the old scrubber out of its bracket ...

Page 23: ...eplace the batteries perform the following tests make sure the MAX 5 is unplugged from the wall To Test the Power Supply charging circuit 1 Open the MAX 5 as instructed in Steps 1 and 2 under the To Replace Batteries section below 2 Locate R39 resistor 3 Put test meter leads across R39 resistor The reading should be 40 mVDC 2 mVDC when you plug the AC power cord into the wall 4 If you get the corr...

Page 24: ... life sensitivity will decline rapidly and the readings will be very unstable Refer to Operator s Checks Adjustment Messages and Failure Warning Signs for further details For sensor replacement refer to Installation Procedures AFTER REPLACING ANY SENSOR PROCEED TO THE INSTRUMENT OPERATING PROCEDURE SECTION FOR CALIBRATION Important To avoid the possibility of not having a replacement cell availabl...

Page 25: ...perform the efficiency calculation which depends on temperature data and this error may occur the efficiency reading will be and the temperature reading will be OPt OFF Means off scale for CO reading LO BATT Indicates the batteries are depleted or near depletion after about 8 hours use REMEDY Recharge the batteries FAILURE WARNING SIGNS The MAX 5 indicates failure warning signs with a CELL FAIL me...

Page 26: ...d the printer see Figure 3 Align the paper Turn the power on Press the FF Form Feed Auto Sheet Load button to advance the paper one sheet Press the ONLINE button NOTE If the printer is purchased from TBE AI refer to the printer instruction manual for set up If the printer is not purchased from TBE AI any serial printer may be used if it complies with the following minimum specifications a It can a...

Page 27: ... Industry CA 91749 Phone Number 818 961 9221 MSDS Prepared By Chuck Molloy Date Prepared or Last Revised 3 31 88 Emergency Phone Number 818 961 9221 Section II Physical and Chemical Data Chemical and Common Names Potassium Hydroxide KOH 15 Granular Lead Pb pure CAS Number KOH 1310 58 3 Pb 7439 92 1 Melting Point Range 10 to 0 deg C Boiling Point Range 100 to 115 deg C Specific Gravity 1 09 20 deg ...

Page 28: ...2 mg cu m KOH Effects of Overexposure Ingestion The electrolyte could be harmful or fatal if swallowed Oral LD50 RAT 2433 mg kg Eye The electrolyte is corrosive and eye contact could result in permanent loss of vision Dermal Liquid inhalation is unlikely Signs Symptoms of Exposure Contact with skin or eyes will cause a burning sensation and or a soapy feeling for skin contact Medical Conditions Ag...

Page 29: ... under normal circumstances the contents of the sensors do not present a health hazard The following information is given as a guide in the event that a cell leaks Protective Clothing Rubber gloves chemical splash goggles Clean up Procedures Wipe down the area several times with a wet paper towel Use a fresh towel each time Protective Measures during Cell Replacement Before opening the bag contain...

Page 30: ...MSDS Prepared By Chuck Molloy Date Prepared or Last Revised 3 31 88 Emergency Phone Number 818 961 9221 Section II Physical and Chemical Data Chemical and Common Names Sulfuric Acid H2SO4 17 Silica SiO2 50 CAS Number H2SO4 7664 93 9 SiO2 7631 86 9 Melting Point Range 1700 deg C Boiling Point Range N A Specific Gravity 2 2 20 deg C pH Less than 1 Solubility in Water Insoluble Percent Volatiles by V...

Page 31: ...GIH TLV 1 mg cu m H2SO4 10 mg cu m Total Dust 5 mg cu m Respirable Dust SiO2 Effects of Overexposure Ingestion The electrolyte could be harmful or fatal if swallowed Oral LD50 RAT 2433 mg kg Eye The electrolyte is corrosive and eye contact could result in permanent loss of vision Dermal The electrolyte is corrosive and skin contact could result in a chemical burn Inhalation Solid inhalation is unl...

Page 32: ... and under normal circumstances the contents of the sensors do not present a health hazard The following information is given as a guide in the event that a cell leaks Protective Clothing Rubber gloves chemical splash goggles Clean up Procedures Wipe down the area several times with a wet paper towel Use a fresh towel each time Protective Measures during Cell Replacement Before opening the bag con...

Page 33: ...CORD 1 B 64942 PUMP ASSY 1 F 273 SAMPLE FLOWMETER 1 F 274 AIR FLOWMETER 1 B 25900 SCRUBBER 1 A 13455 FILTER ELEMENT 1 F 513 FILTER ASSY 1 A 40688 CAL KIT FOR 0 1000 PPM CO Replacement CAL Gas G 222 1 A 48231 CAL KIT FOR 0 1 CO Replacement CAL Gas G 41 G 259 CO 1 A 48232 CAL KIT FOR 0 2 CO Replacement CAL Gas G 41 G 162 CO 1 C 967 CARRYING CASE MAX 1 P 528 PRINTER 1 I 106 INTERFACE for printer 1 A ...

Page 34: ...SEND ORDERS TO TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry CA 91748 Telephone 626 934 1500 Fax 626 961 2538 Web www teledyne ai com or your local representative ...

Page 35: ...DRAWINGS MAX 5 MONITOR INSTALLATION DRAWINGS B 39437 OUTLINE DIAGRAM B 39430 PIPING DIAGRAM STANDARD B 43108RF PIPING DIAGRAM CO OPTIONAL C 39776 CONNECTION DIAGRAM ASSEMBLY DRAWING A 40342 ASSEMBLY PRINTER CABLE ...

Page 36: ... INSERT DRAWINGS ...

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