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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

Table of Contents:

INTRODUCTION .................................................................................................................... 1

PURPOSE OF THIS MANUAL .................................................................................................. 1

SAFETY ................................................................................................................................. 1

3.1

SAFE BURNING PROCESS ................................................................................................ 1

3.2

SAFE ELECTRICAL INSTALLATION .................................................................................... 2

3.3

SAFE HIGH PRESSURE OXYGEN ....................................................................................... 2

3.4

OVER-PRESSURE ............................................................................................................. 3

3.5

SAFE OXYGEN CONNECTIONS ........................................................................................ 3

3.6

SAFE EXHAUST GAS CONNECTION ................................................................................. 3

3.7

SAFE VESSEL HANDLING ................................................................................................. 4

BASIC KEYBOARD OPERATIONS ............................................................................................ 5

4.1

GENERAL KEYBOARD ACCESS ......................................................................................... 6

4.2

COMMAND EXECUTION ................................................................................................. 6

4.3

COMMAND NUMBER EXECUTION .................................................................................. 7

TESTING ............................................................................................................................... 7

5.1

TEST CAL3K HARDWARE ................................................................................................. 7

5.2

TEST 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

PRINCIPLE OF COMBUSTION CALORIMETER ......................................................................... 9

MODE CHANGES ................................................................................................................. 10

CONNECTING ...................................................................................................................... 11

8.1

USB PORT ..................................................................................................................... 11

8.2

PORTD1 ........................................................................................................................ 11

8.3

PORTD2 ........................................................................................................................ 11

8.4

BALANCE PORT ............................................................................................................. 11

8.5

USE OF PORT D1 ........................................................................................................... 11

8.6

CONNECTING TO A PC WITH A RS232 PORT ................................................................ 12

8.7

CONNECTING TO A PC FOR DATA COLLECTION ............................................................ 12

8.8

CONNECTING TO A BALANCE ....................................................................................... 12

OUTPUT ............................................................................................................................. 13

9.1

OUTPUT PRINTING RESULTS TO PAPER, KEYBOARD INITIATED ................................... 13

9.2

OUTPUT PRINTING, KEYBOARD INITIATED, OTHER ...................................................... 15

9.3

OUTPUT PRINTING, INTERNAL INITIATED .................................................................... 16

9.4

OUTPUT, NON-PRINTABLE ........................................................................................... 16

9.5

OUTPUT, EXTERNAL INITIATED ..................................................................................... 17

9.6

OUTPUT TO A SPEADSHEET .......................................................................................... 17

9.7

OUTPUT TO AN EXTERNAL PC ...................................................................................... 17

CYCLES ............................................................................................................................... 18

10.1

CYCLE: PREPARATION ................................................................................................... 18

10.2

CYCLE: FILLING

(CAL3K-AP ONLY)

................................................................................. 18

Содержание CAL3K Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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