Instruction Manual 924-2 11/1/03 EGA4 Combustion Analyzer
Instruction Manual MM850481 ed.01 INTRODUCTORY NOTE NOTE: THIS MANUAL IS VALID FOR INSTRUMENTS WITH SERIAL NUMBER 25865 AND FIRMWARE REV. 2.001 OR HIGHER This manual has all the information you need to install, operate and maintain the flue gas analyzers EGA4 and its accessories. Eclipse has used the best care and efforts in preparing this book and believes the information in this publication are accurate.
Instruction Manual MM850481 ed.01 TABLE OF CONTENTS 1 GENERAL DESCRIPTION .................................................................................................................. 5 1.1 1.2 2 Specifications........................................................................................................................................................ 6 Accuracies and ranges ....................................................................................................................
Instruction Manual MM850481 ed.01 7.10.1 7.11 7.12 8 CO probe operations...................................................................................................................................... 29 Natural gas leak checker (option)................................................................................................................... 30 Temperature & Humidity probe (option) .........................................................................................................
Instruction Manual MM850481 ed.01 1 GENERAL DESCRIPTION EGA4 is designed to satisfy the market needs; but they are the result of the advanced research and experience of Eclipse. EGA4 is a multigas compact palm-top multifunction instrument. The micro-processor based instrument includes a flue gas analyzer, an emissions monitor and an ambient parameters indicator. Two internal electrochemical sensors read the Oxygen (O2) and carbonic monoxide (CO) gas concentration.
Instruction Manual MM850481 ed.01 1.1 Specifications Type: 2, 3 or 4 cells palm-top flue gas analyzer. Calibration: automatic calibration procedure at instrument switching-on. Self-diagnosis: Sensors efficiency test with anomalous status announcement. Fuel types: Up to 10 totally programmable. Pump: rate of flow 0.8 lit / head –230mbar All data measured using 3 meters long probe and line filter connected.
Instruction Manual MM850481 ed.01 1.2 Accuracies and ranges Parameter Sensor type Electrochemical O2 CO H2 compensated up Electrochemical to 1000ppm Range Resol. from 0 to 25.0% 0.1% Max response 20 sec. from 0 to 8000 ppm 1 ppm 50 sec. CO Electrochemical from 0 to 20000 ppm 1 ppm 40 sec. NO Electrochemical from 0 to 4000 ppm 1 ppm 40 sec. NO2 Electrochemical from 0 to 1000 ppm 1 ppm 50 sec.
Instruction Manual MM850481 ed.01 2 2.1 GENERAL Keypad & Display The tactile keyboard allows the operator to enter the main operative mode and all other complementary or auxiliary modes following the menu driven instructions. The high contrast graphic LCD (40x56 mm), equipped with an automatic back-light device, displays the measured and/or calculated parameters in the preferred format (Zoom function). The above parameters can be also displayed in a graphic mode. 2.
Instruction Manual MM850481 ed.01 2.8 Smoke measurement Smoke index measurement is done by using a hand pump (supplied as an accessory), the results cam be memory stored and printed in the report. 2.9 Remote temperature probe A remote Pt100 probe is available for combustion air temperature measurement from –10°C to 100°C. This probe is strongly recommended mainly in forced air boiler to obtain an accurate calculation of the efficiency. 2.
Instruction Manual MM850481 ed.01 3 PHYSICAL DESCRIPTION The EGA4 portable analyzer consists of a rugged and compact case, a mother board with all base function circuits, 2, 3 or 4 electrochemical cells, a gas pump, a keyboard, an LCD backlighted display, a Ni-MH rechargeable battery pack and, optionally an impact printer. The 2 pieces of the case are jointed by 8 screws. The batteries, the pneumatic circuit and the cells are positioned in the rear of the analyzer and 2 screws locked the lid.
Instruction Manual MM850481 ed.01 4 PRINCIPLE OF OPERATION The EGA4 analyzer is based on the following functional blocks: 2° Sensor CO Gas outlet Water trap Line filter Pump 1° Sensoe O2 Gas input INLET P2 - ∆P 4° Sensor 3° Sensor Differential pressure sensor Pt100 Tair input External probe input P1 – Draft/Pressure MicroController TcK Tgas input 250 memory IR serial port Display Battery charger input Power supply Keyboard Ni-MH battery Impact printer 4.
Instruction Manual MM850481 ed.01 4.1.2 Water trap & line filter The gas flows through an external combined water trap and line filter to avoid the presence of condensation and suspended solid particles in the analysis section of the instrument. A cylinder is positioned at 15 cm from the instrument gas inlet it is divided into two parts: the water trap and the line filter.
Instruction Manual MM850481 ed.01 NOTE: TO OBTAIN AN ACCURATE MEASURE IT IS RECOMMENDED TO WAIT 3/5 MINUTES. Toxic gas sensor can be present a ±2% drift and a long resuming time it an excessive (>150% of F.S.) gas concentration is applied. In that case it is recommended to wait for a measured value lower than 20ppm, by sucking fresh air before switch the analyzer off.
Instruction Manual MM850481 ed.01 The color of the spot on the filter is compared with a graduated (from 0 to 9) reference scale and it is called “smoke index”. You can type in the instrument up to 3 smoke index values; the analyzer calculate the average value and can print these values on the report. Normative and laws about the air pollution, describe the procedure: DIN51402, 2116, 2117 and 2297 VDI directives, ASTM D 2156-63 T, etc. 4.2.3.1 1. 2. 3.
Instruction Manual MM850481 ed.01 5 RECOMMENDATIONS The analyzer should be used in environments where the temperature is between -5°C and +45°C. When the analysis are completed, before switch the instrument off, remove the probe from the gas pathway and wait about 30 seconds cleaning the pneumatic circuit from gas. Do not use the analyzer with clogged filters or filled with humidity. Before placing the probe in the case, be sure that the probe, the water trap and the hose are clean and cold.
Instruction Manual MM850481 ed.01 6 6.1 CONNECTIONS Electro-pneumatic connections To prepare the instrument for operation connect the sampling probe to the instrument: • Plug the pneumatic connector of the probe to the GAS INLET connector. If you are using the gas sampling probe with Draft option, connect also its connector to the instrument Pressure/Draft inlet. • Plug the probe temperature sensor plug to the pertinent connector.
Instruction Manual MM850481 ed.01 Tair probe CAUTION FOR A CORRECT GAS ANALYSIS, NO AIR MUST REACH THE FLUE GAS AS A RESULT OF NON-GAS-TIGHT CONNECTION POINTS BETWEEN THE HEAT PRODUCER AND THE MEASUREMENT SITE (PROBE). THE FLUE GAS AND EXHAUST GAS PATHWAYS MUST BE CHECKED FOR GAS-TIGHTNESS BEFORE CARRYING OUT A MEASUREMENT, AND IF NECESSARY NON-GAS-TIGHT POINTS SHOULD BE SEALED.
Instruction Manual MM850481 ed.01 7 OPERATIONS 7.1 Basic operation All the procedures and programming operations on the EGA4, can be made using the keyboard and the display. NOTE: ALL NUMERIC VALUES SHOWN IN THE FIGURES OF THIS MANUAL ARE INDICATIVE AND LISTED AS AN EXAMPLE. The analyzer should be used in environments where the temperature does not exceed the specified limits (from -5°C to +45°C) and where the relative humidity is lower than 95% non-condensing. 7.1.
Instruction Manual MM850481 ed.01 Menu&Measure area O2 : CO : Ta : Tg : η : NOx: 20.9 % 2000ppm 20 °C 400 °C 95.7 % 500ppm Status bar SO2 : CxHy: Lam : NO2 : CO2 : Per : 1000 5.00 0.99 100 10.2 10.5 – GRAPH Ref O2 Function box The Menu and Measure area displays the analysis data, the menu and all messages for the operator. The measured and calculated parameters are displayed in different pages of 6 parameters each. Using the [S] and [T] keys you can change page, changing the displayed parameters.
Instruction Manual MM850481 ed.01 The “S” symbol below the first digit is the cursor. You can move the cursor between the digit using the [W] and [X] keys. You can change the selected digit using [S] and [T]. If “9” or “0” values are exceeded, the left digit is increased or decrease. Press [ENTER] to memory store the value and return to the previous page. Press [ESCAPE] (F1) to return to the previous page without save the changes. 7.1.4 Text input If you have to set a text parameter (e.g.
Instruction Manual MM850481 ed.01 7.2 Flue gas analysis Connect the gas probe to the analyzer as shown in chapter 7. DO NOT INSERT THE PROBE IN THE CHIMNEY. Switch the analyzer on pressing the [ON] key. The display will show the following page: EcoLine 4000 Num. Serie: Versione: GreenLine 4000 1257 1.000 Num. Serie: Versione: UniGas 3000+ 1257 1.000 Num. Serie: Versione: 1257 1.
Instruction Manual MM850481 ed.01 Pressing the [W] and [X] keys, it is possible to zoom-in and zoom-out increasing or decreasing the number of displayed parameters. O2 CO2 CO 20.9% 0.0% 1ppm Ref O2 GRAPHIC O2 20.9% Ta 20.2C Tf 400.3C 95.7% η CO2 10.2p NOx 500p : : : : : : CO Eff NO2 2000p 0.99 100p – – Ref O2 GRAPHIC Pressing the [S] and [T] you can change page for others parameters. Pressing the [REF. O2] key the measured parameters will be referred to the programmed oxygen value.
Instruction Manual MM850481 ed.01 CAUTION IF A SINGLE TUBE GAS SAMPLING PROBE (TG MODEL) IS USED FOR PRESSURE/DRAFT MEASUREMENTS, BE SURE THAT PROBE AND HOSE ARE CLEAN AND DRY BEFORE CONNECTION TO THE PRESSURE INPUT. Special draft probe (TGD models): This special probe model has a double gas collector: one for the flue gas analysis and one for the draft measurement. When you connect the probe to the analyzer you have to insert both gas inlet and pressure inlet connectors.
Instruction Manual MM850481 ed.01 7.4.1 Input of the smoke index Before input the data, you have to execute the smoke index measurements. You can input up to 3 values; the analyzer will do the average calculus. The smoke measurement requires the instrument in normal operating conditions indicating one of the measured or calculated parameters. Press [SMOKE] on the keyboard. The following page will be shown: SMOKE Meas. 1: Meas. 2: Meas. 3: - AVG - Oil.Der.
Instruction Manual MM850481 ed.01 On the “Measure” field, the instrument will display the current temperature value measured using the connected thermocouple. The error message “Tc open” will be displayed if the thermocouple is not connected or broken. Positioning the thermocouple on the flow pipe. Use the [S] and [T] to move the cursor symbol to “T. Flow” field. Press [COPY] to copy the current temperature as T. Flow value.
Instruction Manual MM850481 ed.01 7.8 Analysis data print An internal impact printer can be installed as an option in the instrument. Read paragraph 8.10 for header report changing. To print the report (ticket) of the analysis use the following procedure: Before make all measurements you need: Smoke index, pressure and draught, T. flow, etc. After make the gas analysis measurements and wait same seconds for measurement stabilizing. Press the [PRINT] key.
Instruction Manual MM850481 ed.01 Switch the analyzer on. Keeping the [HELP] key down; press the [X] key to bypass the autozero procedure. Press [PRINT] then press the [FEED] key for paper feed. Press the [ESCAPE] key when the paper will came out for same centimeters. Close the cover inserting the paper end in its slot. Pressure decay procedure (option) 7.9 This optional operative mode allows to find pipes leakage. To set and run leak test, press the [MENU] key from measuring page.
Instruction Manual MM850481 ed.01 Use the [S] and [T] keys to move the cursor symbol to the value to be changed. Press the [ENTER] key to store the new selection. Select “TEST RESULT” option for results viewing and press the [ENTER] key. Now you can connect the instrument Pressure inlet (INP) connector to the gas circuit. CAUTION BE SURE FOR EMPTY AND CLEAN CIRCUIT: OVERPRESSURE, DUST, LIQUID AND CONDENSING MAY DAMAGE THE INSTRUMENT INTERNAL CIRCUITS. With circuit depressurized, press the [TEST] key.
Instruction Manual MM850481 ed.01 Ambient CO probe (option) 7.10 This optional external probe allows ambient CO monitoring for personnel safety. When connected to the analyzer, it monitor continuously CO concentration and it signal when the Long-term Exposure (TWA) limits are reached. An acoustic and visible signals are emitted by unit. The following page show the current exposure limits for CO gas. This table is a guidance only, and figures must be checked before being used.
Instruction Manual MM850481 ed.01 7.11 Natural gas leak checker (option) To enable natural gas monitoring press the [MENU] key from measuring page. The following page will be displayed: MENU MEASURE RECALL MEMORY FLOW/RETURN TEMP AMBIENT ANALYSIS – ESCAPE Use the [S] and [T] keys to move the cursor symbol to “MEASURE” option. Press the [ENTER] key to select the option. Press [ESCAPE] (F2) to return to the previous menu. MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBIENT CO ENVIRON.
Instruction Manual MM850481 ed.01 MENU MEASURE RECALL MEMORY FLOW/RETURN TEMP AMBIENT ANALYSIS – ESCAPE Use the [S] and [T] keys to move the cursor symbol to “MEASURE” option. Press the [ENTER] key to select the option. Press [ESCAPE] (F2) to return to the previous menu. MEASURE P DECAY LEAK TEST GAS LEAK TEST AMBIENT CO ENVIRON. TEMP/HUM – ESCAPE Use the [S] and [T] keys to move the cursor symbol to “ENVIRON. TEMP/HUM” option. Press the [ENTER] key to select the option.
Instruction Manual MM850481 ed.01 8 MEMORY MANAGEMENT The standard configuration include an internal memory to store up to 250 complete gas analysis divided by Tags (max. 40 tags). Each analysis includes 10 gas concentration values, data and time. Each Tag includes one or more analysis data, 16 characters ID, 3 rows for the Customer data, Draught and smoke index values, Water temperatures, etc. An optional PC compatible PCMCIA internal adapter can be installed for memory extension.
Instruction Manual MM850481 ed.01 RECALL MEMORY TAG SELECTION MEMORY DATE MODE – VIS.MEM NOTE: ESCAPE BEFORE RECALL THE MEMORY YOU MUST SELECT THE TAG IF IT IS DIFFERENT FROM THE CURRENT, SELECT THE READING MODE: SINGLE OR AVERAGE AND SELECT THE STORED DATA. Press [VIS.MEM] (F1) to visualize the analysis data: the selected memory data or the average values of the selected Tag. Press [PRINT] (F2) to print the report for the displayed data.
Instruction Manual MM850481 ed.01 When database is complete, you can select up to 40 boilers on the table for data transfer by selecting the “Select for data transfer” column. Pressing the “Select to Do Analysis”, you can select in automatic mode all analysis made by more than “XX” months. Pressing the “Show selected” button, the program will show all boiler selected for data transfer. You can exclude manually one or more boiler from the list.
Instruction Manual MM850481 ed.01 8.4.2 Analysis menu This option is the main part of the program. You can transfer the analysis data from the analyzer to the PC, save and TM manage it using a database structure, display and export the data in Microsoft Excel compatible format. The analysis window is made by 3 tables: plant and customer information, boiler information for the selected plant and analysis groups data for the selected boiler.
Instruction Manual MM850481 ed.01 The operator can change the measuring units, the fuel type, etc. The program will made the conversion in real time and will display the new values. A set of 4 buttons allows you to set the printer, to print measures, export measures using an Excel compatible format, show or hide the columns. A fifth button is normally disabled and it allows to display graphics. To display graph, you have to select one or more columns for graphics.
Instruction Manual MM850481 ed.01 NOTE: THE FUEL DATA TRANSFER FROM ANALYZER SHOULD BE MADE AFTER THE PROGRAM INSTALLATION OR IF THE FUEL DATA CHANGES ON THE ANALYZER. IMPORTANT TO CHANGE OR ADD NEW FUELS DATA, YOU HAVE TO USE GASCONFIG SOFTWARE. THE INSTRUCTIONS ARE SHOWN ON 9.2 PARAGRAPH. 8.4.4 DBGas 2000 Installation DBGas 2000 runs on IBM PC under WINDOWS 95/98/NT.
Instruction Manual MM850481 ed.01 8.5 Configuration Software GasConfig software is a PC windows compatible program for configuring the EGA4 flue gas analyzers. You can change all memory settings: displayed measurements pages, printed measurements layout, Alarms, Fuels coefficients, measuring technical units, etc. 8.5.1 How operate using GasConfig When you run GasConfig a 2 independent windows system will be displayed on the PC monitor. The window on the left is a parameter icon list.
Instruction Manual MM850481 ed.01 Alarms Aux Inputs Analog Output Timer Fuels Bar graphs Service 8.5.2 You can enable, disable, and program up to 4 different acoustic and visible alarms for critical measurements. Not available for software version 1.001 Not available for software version 1.001 You can change the autozero time and the leak decay time. Up to 10 different fuels coefficient tables can be programmed. You can set up to 6 different bargraph (parameter and range).
Instruction Manual MM850481 ed.01 9 CONFIGURATION Many parameters can be modified using the instrument keyboard. Pressing the [SETUP] key, you can change the current fuel, include or exclude the CO cell, change the technical unit, set the alarms, etc. The CONFIGURATION P1 --- FUEL --> LPG CO SENS. Includ.
Instruction Manual MM850481 ed.01 When you select the Alarms option, the following page will be displayed: ALARMS Alarm 1: O2 Enabled : Thresh. : Type : Yes 5.00 Min – NEXT ESCAPE Use the [S] and [T] keys to move the cursor symbol to the desired option. Press the [ENTER] key to change the value. Press [ESCAPE] (F1) to return to the previous menu. Press [NEXT] (F1) to display the next alarm page. Up to 4 alarms can be set for different gas type and levels.
Instruction Manual MM850481 ed.01 SENSOR DIAGNOSTIC O2 CO NO 428.46 uA 0.34 uA 1.09 uA – ESCAPE Press [ESCAPE] (F2) to return to the previous page. 9.3.3 Service Data The “SERVICE” option, allows you to read the information to contact us for service assistance and the information that we wont to know for identify your instrument configurations: instrument configuration code and serial number, firmware version, etc. Press the [SERVICE] (F1) to display the following page: Eurotron Srl Tel.
Instruction Manual MM850481 ed.01 10 MAINTENANCE The EGA4 analyzer has been developed and manufactured using high quality components. A correct, systematic maintenance will prevent damage and will increase substantially the life of the instrument, giving excellent results. Anomalous conditions that require extraordinary maintenance interventions are promptly displayed, either clearly or with an information code. 10.1 Error messages The instrument performs the autodiagnostic procedure when switched on.
Instruction Manual MM850481 ed.01 Press and maintain the [SETUP] key down; press the [ON/OFF] key. The analyzer will switch on. A password input page will displayed. Insert the password code “0011” and press the [ENTER] key. The following page will displayed: SET-UP Pag.1 CLOCK SERIAL PORT ANALYSIS PAR. P DECAY TIME – ESCAPE NEXT Press the [NEXT] (F1) key to change menu page. SET-UP Pag.
Instruction Manual MM850481 ed.01 SERIAL Address Baud-rate : 0 : 9600 – ESCAPE Use the [S] and [T] keys to move the cursor symbol to the desired option. Press the [ENTER] key to set a new ID number or baud rate. Press [ESCAPE] (F2) to return to the previous menu. 10.2.3 Analysis Selecting this option you can change the analyzer auto-zeroing time and CH4 & Natural gas heating probe time (we suggest to use the pre-set values of 180 sec for autozero time and 60 sec for CH4 heating time).
Instruction Manual MM850481 ed.01 10.3 Firmware Upgrade In order to upgrade the firmware of the instrument proceed as follows: 1 - Install the ST167Flash program from the CD. 2 - Connect the infrared interface adapter to the serial port of the PC with the supplied cable (note back the serial port used: COM1 , COM2 or other). 3 - Position the interface near the right side of the instrument. 4 - Run the ST167Flash program you have installed. 5 - Select the same serial port that you noted back.
Instruction Manual MM850481 ed.01 11 11.1 CERTIFICATES Warranty terms Each instrument is shipped with a Warranty Certificate that indicates the validity conditions of the warranty itself. Eclipse warrants its products against defects in materials and workmanship. If the unit should malfunction, it must be returned during the warranty period, transportation prepaid, to Eclipse for evaluation. Upon examination, if the unit is found to be defective it will be repaired or replaced at no charge.
Instruction Manual MM850481 ed.01 APPENDIX A1 Example The following steps show how you can make a quick measurement using the EGA4 portable analyzer. 1. Switch EGA4 on. It will begin the autozero and the autodiagnostic procedure. System error and trouble will be displayed if encountered. EcoLine 4000 Serial Num: Version : 1257 1.001 ! ! Don t insert probe in chimney ! ! Op.: Antonio Bat: 5.2V (23.5°C) Autozero: 180 sec – MEASURE MENU 2. Select the combustible used by burner.
Instruction Manual MM850481 ed.
Instruction Manual MM850481 ed.
