OPERATING INSTRUCTIONS FOR MAX 5 Portable Combustion Efficiency Monitor DANGER HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM. PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM. HAZARDOUS VOLTAGES EXIST 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.
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.
TABLE OF CONTENTS MAX 5 PORTABLE COMBUSTIBLE EFFICIENCY MONITOR GENERAL DESCRIPTION Introduction Main Features 1 1 OPERATION OF CONTROLS, DISPLAYS, & INDICATIONS Front Panel Controls Back Panel Controls 3 4 PRINCIPLE OF OPERATION Sensor Description Temperature & Calculated Values Sampling System Description 4 5 6 INSTALLATION AND START UP PROCEDURES Precautions Electronic Zeroing of Oxygen Section Sensor Installation and Replacement 9 10 11 INSTRUMENT OPERATING PROCEDURE Installation of Thermocouple
TABLE OF CONTENTS (continued) ROUTINE MAINTENANCE Scrubber Battery Recharging Battery Replacement Sensor Replacement 19 20 20 21 OPERATOR’S CHECKS & ADJUSTMENTS Messages Failure Warning Signs 22 23 APPENDIX To Print Stored Readings Material Safety Data Sheets (MSDS) 24a 24b-g LIST OF SPARE PARTS DRAWINGS LIST OF FIGURES Figure 1 2 3 4 5 Display Panel Membrane Keyboard Back Panel Location of Sensors (Top View) Sample Probe With Built-In Thermocouple 2 2 3 11 12 LIST OF TABLES Tables 1 Detector Respo
MAX5 PORTABLE COMBUSTION EFFICIENCY MONITOR GENERAL DESCRIPTION INTRODUCTION The MAX 5 Portable Combustion Efficiency Analyzer provides several special features and applications. It directly measures oxygen, carbon monoxide, combustibles, and temperature levels in a subject sample stream. The MAX 5 also includes microprocessor-based special functions enabling the computer to calculate levels of carbon dioxide and combustion efficiency.
MAIN FEATURES 1. Auto Zero. MAX 5 offers automatic zero calibration for carbon monoxide and combustibles and automatic span calibration for oxygen. Also, you can adjust them manually. You have to adjust the span calibration manually for carbon monoxide and combustibles. 2. Stored Readings. The computer stores up to 20 sets of readings and reports them to the LCD (Liquid Crystal Display) or to an optional serial printer. 3. Computer Memory.
Temp Key (°F or °C). This key, when pressed, determines which of the two available temperature scales (toggles between degrees Fahrenheit or degrees Centigrade) will be used to display temperature readings. See “Initial Calibration/Automatic Calibration” - “Temperature”. O2 / CO2. Because both the oxygen and carbon dioxide readings occupy the top row of the LCD, you press this key to display one or the other. To get a valid CO2 reading, you must select the proper fuel (see “FUEL” below). COMB/TEMP.
* continuous flow of all six readings F. Air Flowmeter with flow set valve to regulate air flow. G. Sample Flowmeter with flow set valve to regulate sample flow. H. Chemical Scrubber for removal of corrosive compounds, such as SO2,, H2S, and NOx. I. Sample-in Port. J. Coalescing Filter (to remove particulates and water) and filter-drop out pot. PRINCIPLE OF OPERATION SENSOR DESCRIPTION Oxygen. The oxygen section uses Teledyne’s Micro-Fuel Cell, Class B-3 oxygen sensor (U.S. Patent No. 3,429,796).
methane in nitrogen. In other cases, a hydrogen and carbon monoxide mixture might be used. In the presence of catalyst poisons, the combustibles sensor will hold its sensitivity to a hydrogen/CO mixture far longer than to methane; therefore, it is important to calibrate it with the right mixture. TEMPERATURE AND CALCULATED VALUES Temperature. The MAX 5 uses a type “K” thermocouple.
The analyzer should be inspected and calibrated each time it is used. This includes inspecting the filter/water trap and scrubber, checking the condition of the batteries, and calibrating the instrument. The sample gas and the ambient temperature must be between 32° and 122°F (0° to 50°C) for the temperature compensation to operate properly. For maximum accuracy, the analyzer should be calibrated at the same pressure, flow rate, and temperature anticipated in the sample gas.
calibrate the instrument with Methane, but make it read as if it were exposed to the gas of interest. For example, if you calibrate with Methane and the MAX 5 reads 3%, but Propane would read 4%, you calibrate with Methane and adjust the MAX 5 to read 4%. TABLE 1 DETECTOR RESPONSE TO GASES COMPOUND LEL* Methane Hydrogen Carbon Monoxide Ethane Ethylene Acetylene Propane Propylene Butane Hexane Cyclohexane Heptane Benzene Pentane Toluene Ethylene Oxide Methyl Ethyl Ketone Methyl Acrylate 5.0 4.0 12.5 3.
.32 For a mixture of 70% Hydrogen and 30% Carbon Monoxide: 0.7(2.0) + 0.3(2.0) = 3.5% .86 .32 CAUTION In most cases, the concentration of any particular compound that the sensor is exposed to should not exceed the LEL of that compound or sensor damage could occur.
water for at least 15 minutes. Call a physician. See Material Safety Data Sheets (MSDS). 3. The PURAFIL Media Scrubber contains Potassium Permanganate. PURAFIL Media is non-toxic upon oral, dermal, and inhalation exposure. Breathing of the dust may cause sneezing. Skin may feel dry after contact. PURAFIL Media is an eye irritant. In case of eye contact, immediately flush eyes with cold water for at least 15 minutes. Call a physician immediately. See Material Safety Data Sheet (MSDS). 4.
shown in Figure 4. Figure 4. Location of Sensors (Top View) CO SENSOR: (Refer to Interconnection Diagram) a. Installation: To install the F-1R sensor, remove the sensor from its protective bag and plug it into the center receptacle in the bottom of the MAX 5. Next, take the the connector from J6 on the analog board and plug it into the top of the F-1R sensor. b.
a. Remove the sensor from its protective bag. Carefully remove the shorting clip. b. Pull up on the oxygen sensor holder (on the right), place the Micro-Fuel Cell (membrane side down) onto the surface under the sensor holder, and place the sensor holder over the cell. Be sure that the sensor is connected to J5 on the analog board. COMBUSTIBLES SENSOR: (Replacement Only): (See Interconnection Diagram) a. The combustibles sensor is connected to J4 on the analog board.
If the analyzer is subject to high positive pressures, damage may occur to the pumps or other flow systems. A regulator may be necessary upstream to maintain sample pressure at or below atmospheric level, if you want to use this analyzer to measure a high pressure sample. 1. Connect the probe sample line to the inlet port of the analyzer, being sure that the exhaust port is vented to a safe area. 2. Press the PUMP ON/OFF key. 3.
CAUTION: ADJUST SPAN GAS PRESSURE REGULATOR TO MINIMUM FLOW RATE (2-3 scfh) BEFORE CONNECTING TO ANALYZER. NOTE: To perform manual spanning of the MAX 5, the Calibration Kit is required. The calibration kit consists of 3 gases; 2 calibration (CO & Combustible) and a background (nitrogen). 1. For Carbon Monoxide (CO) Span: a. Run span gas through the analyzer; adjust the span gas pressure regulator until the analyzer’s flowmeter indicates 2.0 SCFH. NOTE: This is for standard range only (0-1000 ppm).
To store reading press ENTER. The word SPAN will light up on top of the LCD. For span calibration a known higher temperature input would be required or changes to the low temperature. So if span calibration is not desired, press ENTER to return to normal operation. NOTE: Centigrade readings are automatically stored in memory. To store Fahrenheit readings, press COMB/TEMP key, then press °F/°C key.
To restore the built in temp. calibration constants press the CAL and LOGO keys simultaneously, then press °F/°C key. Press the CAL and COMB/TEMP keys simultaneously. This restores the proper values and exits the calibration mode. SPECIAL FUNCTIONS To activate the other special functions press both the arrow keys simultaneously. The LCD will show: 1 2 3 4 5 6 7 8 9 The numbers 1 through 9 represent the nine keys on the keypad.
To STORE current readings (Key 3) 1. Activate Special Functions. 2. Press key number 3; the display will read “5 0 0”. CAUTION: If you press ENTER while the display reads “0 0 0”, you will ERASE all previous readings. To abort the erasing feature, simply press the LOGO key instead of ENTER. 3. Set the display to an ID number (1 to 999 set-table) using the arrow keys. 4. Press ENTER to store the reading and the I.D. number (or Teledyne key to exit). Normal operation will resume. 5.
3. To test, press any key other than the LOGO or ENTER keys; to resume normal operation press the LOGO key. 4. To perform a total memory reset press the ENTER key twice in succession. AUTOMATIC DATA OUTPUT (Function 7) 1. Activate Special Functions. 2. Press key 7 to activate the Data Output function. 3. Press the up or down arrow as needed to cause the display to read the desired time interval (002 to 999 seconds) between reports. Press ENTER.
1. Turn power switch on (without O2 sensor installed). If a negative O2 reading is displayed, proceed to step 2. If a negative reading is not displayed, electronic zeroing is not required. 2. Press the CAL and LOGO keys simultaneously. CAL will display on the screen. 3. Press the CAL key. 4. Press the CAL, UP and DOWN keys simultaneously. A double beep will occur followed by a short interval and a second double beep. Electronic zeroing is now completed.
case, and lift the hood off the unit. BATTERY RECHARGING The rechargeable Nickel-Cadmium batteries need to be recharged after about 8 hours of use. To Recharge the Batteries: 1. Turn the back panel power switch off. 2. Plug the power cord (connector end) into the back panel AC power receptacle and plug the other end into the correct voltage outlet. 3. Allow the batteries to recharge for the required line power: 100VAC, 50/60 Hz - 24-30 hrs. 115VAC, 50/60 Hz - 14-16 hrs. 230VAC, 50/60 Hz - 14-16 hrs.
To Replace Batteries: 1. Loosen the screws indicated on the back panel of the MAX 5. 2. Remove the upper and lower screws on the outside of the MAX 5 housing and remove both panels of the MAX 5. Disconnect J2 from the analog PCB (smaller PCB assy.). 3. Remove the screw holding the battery pack in place. Carefully lift out the battery pack. 4. Remove the tape and plate holding the existing batteries in place. Replace the batteries with new Nickel-Cadmium rechargeable batteries. 5.
-0.00/-0.0 The negative sign in a reading of -0.00 or -0.0 in the CO or COMB section after auto zero is not significant. bAd Indicates a bad reading from the cell. If the cell is outside its specifications or is noisy and unstable, the computer cannot get a good reading, and the calibration adjustment required to compensate may be greater than the maximum allowable adjustment, resulting in this error message. REMEDY: Recalibrate the instrument or replace the cell.
APPENDIX TO PRINT STORED READINGS (KEY 5) - OPTIONAL 1. On the back of the instrument is a “serial output” receptacle for connection to a serial (RS-232C) printer (see Note). The RS-232C data output format is as follows: 1 start bit, 8 data bits, and 1 stop bit, at a rate of 300 baud (bits/sec.). A connecting cable is available from TBE/AI when using a standard serial printer with the analyzer.
MATERIAL SAFETY DATA SHEET Section I - Product Identification Product Name: Micro-Fuel Cells, all classes except A-2, A-3, A-5, B-2F and B-2VF. Electrochemical Oxygen Sensors, all classes except R-19. Mini Micro-Fuel Cells, all classes.
Section III - Physical Hazards Potential for Fire and Explosion: The electrolyte in micro-fuel cells is not flammable. There are no fire to explosion hazards associated with micro-fuel cells. Potential for Reactivity: The sensors are stable under normal conditions of use. Avoid contact between the sensor electrolyte and strong acids. Section IV - Health Hazard Data Primary Route(s) of Entry: Exposure Limits: Ingestion, Eye/Skin Contact OSHA PEL .05 mg/cu.m. (Pb) ACGIH TLV 2 mg/cu.m.
Section V - Emergency and First Aid Procedures Eye Contact: Flush eyes with water for at least 15 minutes and get immediate medical attention. Skin Contact: Wash affected area with plenty of water and remove contaminated clothing. If burning persists, seek medical attention. Ingestion: Give plenty of cold water. Do not induce vomiting. Get medical attention. Inhalation: Liquid inhalation is unlikely.
MATERIAL SAFETY DATA SHEET Section I - Product Identification Product Name: Carbon Monoxide Sensor, Class F-1R, F-1RH and F-2 Manufacturer: Teledyne Brown Engineering/Analytical Instruments Address: 16830 Chestnut Street, City of 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: Sulfuric Acid (H2SO4) 17% Silica (SiO2) 50% CAS
Section III - Physical Hazards Potential for Fire and Explosion: The electrolyte in carbon monoxide sensors is not flammable. There are no fire or explosion hazards associated with carbon monoxide sensors. Potential for Reactivity: The sensors are stable under normal conditions of use. Avoid contact between sensor electrolyte and strong acids, strong bases, strong oxidizers and reducers. Primary Route(s) of Entry: Exposure Limits: Ingestion, Eye/Skin Contact OSHA PEL N/A ACGIH TLV 1 mg/cu.m.
Section V - Emergency and First Aid Procedures Eye Contact: Flush eyes with water for at least 15 minutes and get immediate medical attention. Skin Contact: Wash affected area with plenty of water and remove contaminated clothing. If burning persists, seek medical attention. Ingestion: Give plenty of cold water. Do not induce vomiting. Get medical attention. Inhalation: Solid inhalation is unlikely.
RECOMMENDED SPARE PARTS LIST MAX 5 MONITOR QTY. P/N 1 1* 1 1 C-6689-B3 MICRO-FUEL CELL - OXYGEN SENSOR C-40371-F1R ELECTROCHEMICAL SENSOR - CO (01000 PPM STD.) A-39202A COMBUSTIBLE PROBE/CABLE B-39764A PROBE GUN ASSEMBLY (TYPE “K” HI TEMP. THERMOCOUPLE) B-39764B PROBE GUN ASSEMBLY (TYPE “J” LO TEMP.
SEND ORDERS TO: TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry, CA 91748 Telephone: (626) 9341500 Fax: (626) 9612538 Web: www.teledyneai.com or your local representative.
REFERENCE DRAWINGS MAX 5 MONITOR INSTALLATION DRAWINGS B-39437 B-39430 B-43108RF C-39776 OUTLINE DIAGRAM PIPING DIAGRAM (STANDARD) PIPING DIAGRAM (%CO) (OPTIONAL) CONNECTION DIAGRAM ASSEMBLY DRAWING A-40342 ASSEMBLY - PRINTER CABLE
(INSERT DRAWINGS)
