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Appendix D: Field Sensor Replacement (continued)

6. Once the hoses are off the sensor, pull the sensor straight out of the holder

(see below).

7. Install the new sensor into the holder by orienting the flat corner of the sen-

sor with the flat corner of the sensor holder. Align the socket of the sensor
with the pins on the main board and press the sensor down onto the pins
and into the holder.

41

Smart Sensor

Sensor connector after removal

Flat corner of the
sensor holder.

Pins on main
board.

Flat corner on
sensor.

www.

.com

[email protected]

1.800.561.8187

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Summary of Contents for 717

Page 1: ...717 Combustion Efficiency Analyzer The Value LeaderTM www com information itm com 1 800 561 8187 ...

Page 2: ...ermometer Mode 20 Manometer Mode 21 Let By Pressure Test Mode 22 23 Setting Date Time 24 Storing Data 25 Recalling Data 26 Printing Data 27 28 Specifications 29 30 Calibration Service 31 Warranty 31 Appendix A General Maintenance Function Tests 32 34 Appendix B A773 Sulfur Filter Installation Maintenance 35 36 Appendix C Error Codes and Troubleshooting 37 38 Appendix D Field Sensor Replacement 39 ...

Page 3: ...ture 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 batteries of your 717 fresh so power is constantly being supplied to your sensors The following guidelines wi...

Page 4: ...lyzer comes complete with the following standard accessories TPI 717 Instrument Rubber Boot A765 Soft Carrying Case A768 Flue Sampling Probe A770 In Line Filter assembly installed on Flue probe A796 Temperature Probe GK11M Mini Pump Protection Filter Assembly and spare filters A763 Exhaust Spigot removable A764 Instruction Manual Denotes part number Your TPI 717 Flue Gas Analyzer has the following...

Page 5: ...nctions Selected Fuel Type N GAS LPG LIGHT OIL HEAVY OIL OPT 1 Bituminous Coal OPT 2 Anthracite Coal OPT 3 Coke OPT 4 Butane OPT 5 Wood OPT 6 Bagasse Rubber Boot LCD Display Keypad Battery Condition Icon Selected Fuel Type 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 3 www com information i...

Page 6: ... through Combustion Analysis Displays See 17 18 Turns ch2 temperature ON OFF see page 20 Allows you to choose a Stored Data Address Sends stored data to a separate infrared printer see pg 25 Allows you to view stored data on the display see pg 24 Stores readings to memory see pg 23 Scrolls through and selects analyzer functions see 20 22 Turns Backlight ON and OFF see 9 Turns the instrument ON and...

Page 7: ...bration information and serial number Battery Compartment Holds 3 AA Alkaline Batteries Rubber Boot Protects the instrument Smart Sensor Access For field replaceable sensors See appendix L Calibration and Information Label Battery Compartment Rubber Boot Connection for Mini Pump Protection Filter Connections for Pressure Tubing Sample and Pressure Inlet Ports 5 Access area to smart sensors www com...

Page 8: ...tion of Exhaust Adapter Infrared Window Window for sending stored data to IR Printer see page 25 Rubber Boot Protects the instrument from accidental damage Exhaust Port Infrared Window Rubber Boot 6 www com information itm com 1 800 561 8187 ...

Page 9: ...uple probe see page 20 T2 Socket Connection for ambient K type thermocouple probe see page 11 Connection for any K type thermocouple probe see page 20 Gas Sample Port Connection for Mini Pump Protection Filter and Flue Probe see pages 7 11 P Port Connections for Pressure Tubing see page 21 P Port 7 www com information itm com 1 800 561 8187 ...

Page 10: ... complete with In Line Filter or the Tubing In Line Filter fare not connected to the Gas Sample Port see page 7 The instrument MUST be turned on in a clean air environment as the initial purge will set the Carbon Monoxide level to Zero and the Oxygen to 20 9 Press and hold down the Power Key and the TPI 717 will start its 30 second countdown Purging will be displayed After the 717 has completed pu...

Page 11: ...rbon Monoxide level to return to below 15ppm and the Oxygen level to return to 20 9 0 3 Press the Power Key to turn the instrument off NOTE Should you attempt to turn the instrument Off and the CO reading is above 15ppm then the instrument will remain On and a short Beep will be heard The Instrument can only be switched off if the CO is below 15ppm The instrument has an auto shut off after 10 minu...

Page 12: ... 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 ...

Page 13: ...xide CO in parts per million ppm 2 Connect the Mini 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 page 7 WARNING Ensure the K type thermocouple probes are inserted into the socket...

Page 14: ...y take more than an hour depending on how saturated the sensors are 3 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...

Page 15: ...OCATIONS Atmospheric Gas Fired Fan Assist Boiler Furnace Typical Test Locations Figure 1 It is important to use manufacturers recommended test locations whenever possible 13 www com information itm com 1 800 561 8187 ...

Page 16: ...densing Boiler Furnace Typical Test Locations Figure 2 TYPICAL TEST LOCATIONS It is important to use manufacturers recommended test locations whenever possible 14 www com information itm com 1 800 561 8187 ...

Page 17: ...of the heat exchanger Atmospheric Forced Air Furnace Typical Test Locations Figure 3 TYPICAL TEST LOCATIONS It is important to use manufacturers recommended test locations whenever possible 15 www com information itm com 1 800 561 8187 ...

Page 18: ...he 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 th...

Page 19: ...play 2 Displays Oxygen O2 reading in percentage Displays Carbon Dioxide CO2 calculation in percentage Displays calculated CO CO2 Ratio figure The 717 calcu lates this number by first converting the CO2 measurement from percentage to ppm The formula for this conversion is CO2ppm CO2 10 000 This ratio is not used in any other calculations 10 000ppm 1 Pressing the Scroll Enter key changes the display...

Page 20: ...em that is not specified in CO air free the displayed reading may appear abnormally high as compared to the manufacturer specification Pressing the Scroll Enter key again will make the display return to combus tion display 1 Default display 6 During a combustion test you can save print and send data to a comput er See pages 25 through 31 Allow readings to stabilize before saving or printing the da...

Page 21: ...ess than 100ppm air free Stack Temperature 300 F to 500 F Draft 0 15 inH2O Oxygen 4 to 7 Carbon Monoxide Less than 100ppm air free Stack Temperature 325 F to 625 F Draft 0 15 inH2O Power Burners Gas Fired Power Burners Oil Fired Oxygen 7 to 9 Carbon Monoxide Less than 100ppm air free Stack Temperature 325 F to 500 F Draft 0 15 inH2O to 0 4 inH2O Gas Fired Burners Atmospheric Fan Assist 19 www com ...

Page 22: ...7 Forcing the plug into the socket the wrong way may result in damage to the instrument 2 Touch the temperature probe to the item under test and read the displayed temperature Other Features Pressing the Up Arrow Key will toggle between ºC and ºF oPEn will be displayed if no K type probe is connected to the thermocou ple socket NOTE Analyzer shown in picture above with optional second GK11M probe ...

Page 23: ...isplay Other Features Pressing the Up Arrow Key will scroll through mbar kPa and inH2O Pressing the Down Arrow Key will Zero the Pressure reading The 717 incorporates a differential manometer This means when a single hose is connected to the port and pressure is applied the 717 will read positive pressure If a single hose is connected to the port and pressure is applied the 717 will read a negativ...

Page 24: ...r test and press Go Enter Key 4 Once GO is pressed the analyzer will begin a 60 second countdown and Wait will display in the lower left corner of the display 5 After the countdown is displayed Pass and Fail will be displayed If the pressure bled down out of specficiation for the device under test then Fail should be pressed Down Arrow Key and the test is over The results can be printed by pressin...

Page 25: ...e under test then Fail should be pressed Down Arrow Key and the test is over The results can be printed by pressing the print key or stored by pressing the save key 12 If the device did not leak down then Pass is pressed Up Arrow Key and the screen changes to Finish The test results can be printed by pressing the print key or stored by pressing the save key CO Room Test In this mode the 717 will l...

Page 26: ... the Time Date and Year screen is displayed press and hold the Print and Down Arrow Keys until Clock Set is displayed 2 Use the Print Key and Recall Key to change the cursor location 3 Use the Up Arrow and Down Arrow Keys to change the value 4 Once the time and date has been entered press the Enter Key to store the time and date 24 The 717 uses a 24 hour clock The first lin is the time in HH MM fo...

Page 27: ...y 2 Addr and an address location from 0 to 99 will flash on the display Use the Up Down Arrow Keys to select the desired location to store the data and press the Scroll Enter Key To cancel storing information press the Function Key 3 The data is stored and the analyzer returns to normal operation You have just successfully stored a set of readings which can be reviewed on screen see pg 26 or sent ...

Page 28: ...on date function To cancel recalling infor mation press the Function Key 3 Press the Enter Key 4 Addr will be displayed and a number from 0 to 99 will flash Note If CAL was selected the calibration date will be dis played Proceed to step 6 3 Using the up and down arrows select the memory location of the readings you want to display 4 Press the Scroll Enter key once The 717 will display a page of t...

Page 29: ...nt Mode If Stor mode is selected Addr will be displayed on the top line along with SA and a location number from 0 to 49 will be flashing on the screen Select the required address location that you wish to print data from by pressing the Up and Down Arrow Keys and press the Scroll Enter Key The analyzer will display Wait out and bars will change position on the LCD until printing is complete CAL P...

Page 30: ...uipment Circle one to indicate the result of a smoke test performed using the optional A788 smoke test pump Date and time of combustion test Fuel type selected during test Customer information and signed confirma tion of test Fill in this data and have the customer sign for confirmation 28 www com information itm com 1 800 561 8187 ...

Page 31: ... 500g Casing Rubber Boot as Standard Switch Off Failsafe Exhaust Safety Spigot Conforms to BS7927 and the draft BS7967 Flue Temperature Probe Construction Pistol Grip with Stainless Steel Shaft Hose Length 2500mm Insertion Length 200mm K Type Thermocouple Accuracy 0 3 1 C Maximum Temperature 1472 F 800 C Gases Range Resolution Accuracy Oxygen 0 25 0 1 0 3 Carbon Monoxide 0 10 000 ppm 1 ppm 5 ppm o...

Page 32: ...racy 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 The 712 accepts industry standard K type thermocouple probes with sub mini connectors 30 www com information itm com 1 800 561 8187 ...

Page 33: ...ble A760 Sensor replacement requires calibration gas Sensors for the 717 can be replaced in the field Please see appendix for the replacement procedure WARRANTY Your TPI 717 Flue Gas Analyzer is guaranteed free from defects in materials and workmanship for 3 Years from the date of purchase This guarantee does not affect your statuary rights For additional information please refer to the included w...

Page 34: ...e used in oil fired Thermocouple Probe Check applications Water Trap Check Visually check the water trap for 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 connecte...

Page 35: ...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...

Page 36: ... 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 FLO ERR 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 FLO ERR this is an indication of a possible leak somewhere in the flue probe and you may proc...

Page 37: ...ter 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 2 Remove the water trap from the flue probe hose See picture below 3 Insert the A773 sulfur filter flue probe tube where the water trap was removed 35 www com infor...

Page 38: ...f the A773 sul fur filter See picture below 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 A773 SULFUR FILTER MAINTENANCE The A773 should be replaced when most of the pellets become discolored usual ly white or black If the A773 begins to trap condensate and fi...

Page 39: ... shut off This can trap CO in the internal manifold When returning to analyzer mode this error will display if the trapped CO is 15ppm or more Allow the analyzer to run until the error is cleared Lo bat Low battery Batteries needs to be changed Charge batteries See Appendix J oFL Overflow indication The pressure being measured is outside the maximum mea surement capability Pressure being measured ...

Page 40: ...re the optional oil fil ter A773 is installed See Appendix B One or all of the following parameters Ratio CO air free excess air and efficien cy read and print dashes Measured values are such that the calculated values of these parameters are out of range Redo combustion test Since these are calculated values the measure values must be within certain levels for these to display If the measured oxy...

Page 41: ...ement before using your analzyer Follow these steps to replace the sensors 1 Remove the protective rubber boot by using your hands to pry the boot from the bottom of the analyzer first Once the bottom is free the boot can be removed 2 Locate the screw that secures the sensor access panel to the back of the ana lyzer The screw is located just above the battery access screw see picture below 3 Loose...

Page 42: ...full access to the CO and O2 sensors see picture below 5 To remove a sensor pull the rubber hose off each side of the sensor see below 40 Oxygen O2 sensor Sensor color is white Carbon Monoxide CO sensor Sensor color is red Hoses removed from smart sensor www com information itm com 1 800 561 8187 ...

Page 43: ...er by orienting the flat corner of the sen sor with the flat corner of the sensor holder Align the socket of the sensor with the pins on the main board and press the sensor down onto the pins and into the holder 41 Smart Sensor Sensor connector after removal Flat corner of the sensor holder Pins on main board Flat corner on sensor www com information itm com 1 800 561 8187 ...

Page 44: ...is time the 717 sensor calibration data will be transferred and the sensor will have power applied to enable it to acclimate NOTE YOU MUST WAIT 24 HOURS AFTER SENSOR INSTALLATION BEFORE TURNING YOUR ANALYZER ON AND USING IT FOR THE FIRST TIME FAILURE TO DO SO WILL RESULT IN AN ERROR CODE DISPLAYED AND THE ANALYZER WILL NOT FUNCTION PROPERLY NOTE FACTORY CALIBRATION ONCE PER YEAR IS STILL RECOMMEND...

Page 45: ...reducing efficiency Obstructions in the flue block exhaust gases and alter the air mixture in the combustion chamber which reduces efficiency Air leaks in the combustion chamber also alter the mixture causing decreased efficiency Note 3 The primary way to affect change in combustion efficiency when work ing with modern gas fired equipment is through gas manifold pressure adjust ment Confirm manifo...

Page 46: ...hen performing this test Please see below The middle display shows the carbon monoxide level For this test ignore the top display oxygen 3 Connect the Mini Pump Protection filter to the analyzer See picture below 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 part of the dis play 5 If necessary the flue probe...

Page 47: ... Slight headache fatigue dizziness and nausea after 2 to 3 hours expo sure 400ppm Frontal headaches and other symptoms inten sify after 1 to 2 hours exposure Life threaten ing after 3 hours Maximum allowable limit in flue gas according to EPA and AGA 800ppm Headache dizziness nausea and convul sions within 45 minutes of exposure Unconscious within 2 hours Death within 2 to 3 hours 1 600ppm Headach...

Page 48: ... 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 symptoms mimic other illnesses P...

Page 49: ...urn the analyzer over and locate the phillips head battery cover screw See picture below 2 Loosen the screw Pull out on the screw to remove the battery cover 3 Remove the old batteries and observing the polartiy markings in the battery compartment install the new batteries 4 Re install the battery cover by fitting the bottom part in first 5 Tighten the battery cover screw Battery Cover Battery Cov...

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