. ANALYSER LAYOUT AND FEATURES 1.
1.2 Analyser Layout Oxygen Sensor Connection lead for Oxygen sensor Filter Bridge or Sulphur Filter Particle Filter Battery enclosure Dual pressure ports Water trap connection Water trap located on side of instrument Printer unit Handset (stored in pocket) Accessory storage space (leads/water trap etc.
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2. SAFETY WARNING This analyser extracts combustion gases that may be toxic in relatively low concentrations. These gases are exhausted from the bottom of the instrument. This instrument must only be used in well ventilated locations. It must only be used by trained and competent persons after due consideration of all the potential hazards. 3. FIRST TIME USE Charge the battery for 12 hours, following this an overnight charge should be sufficient for an average 8 hour day.
Printed header name and telephone number 6 KM9106 Operators Manual 7.
4. NORMAL START UP SEQUENCE 4.
And show the countdown screen :- -- -- -- -- -- -- -- -- -- -- -- -- -9 CALIBRATING 9 9 300 -- -- -- -- -- -- -- -- -- -- -- -- -- The display will countdown from 300 to zero in one second steps. If the analyser has been used recently it may complete automatic calibration in less than 300 seconds otherwise it will count to zero.
4.3 Main Displays The main display can be changed to show the following :• • Page Mode displays 4 lines of data in set format, each page is predefined. Line scroll mode allows you to customise the display with the data you require. To change between the different modes :Press SET/CAL followed by PAGE MODE SET The and keys change between Page and Line Scroll Modes Press 4.3.1 ENTER LINE SCROLL MODE SET to select Page Mode Use the and keys to change the information displayed on the screen.
4.3.2Line Scroll Mode Line scroll mode allows you to customise the display. Use the key to change the bottom line of the display. Once the correct line is displayed press to confirm and move the line up. Select the next parameter and repeat until all lines display the desired parameters. 10 Change bottom line using NETT O2 CO CO2 C ... 0.0 % . . . 20.9 ppm . . 0000 % ... 0.0 to select and move parameter up O2 CO CO2 CO2 % . . . 20.9 ppm . . 0000 % ... 0.0 % ... 0.0 Select next parameter.
4.4 Sampling the Flue Gas Once the automatic calibration procedure has been completed and the specific fuel has been selected the probe can be inserted into the desired sampling point. It is recommended that the sampling point be located at least two flue diameters downstream of any bend and that the probe tip is in the centre of the flue (this is normally the point of the hottest temperature).
4.5 Taking a Pressure Reading With the optional pressure module fitted a flue draught measurement can be made at any time. Connect the standard probe to the appropriate pressure sensor inlet and place the probe in the flue. The pressure reading will be displayed :- CO/CO2 R . . 0.0001 P INDEX % . . . 0.01 XAIR % ... 0.0 Prs mbar 0.00 NOTE: Care must be taken to connect the probe to the correct port as the pressure will be displayed in reverse i.e. a positive pressure rather than negative draught.
4.7 Normal Shutdown Sequence DO THIS EVERY TIME YOU USE THE ANALYSER. Remove the probe from the flue - TAKE CARE ! THE PROBE WILL BE HOT and allow it to cool naturally. Do not immerse the probe in water as this will be drawn into the analyser and damage the pump and sensors. Once the probe is removed from the flue, the oxygen reading 20.9% and the CO reading is zero press and the analyser will switch off. OFF Check the water trap and probe tubes for water before packing away. 4.
5. USING THE KEYPAD 5.1 Basic Operation Basic operation of the keypad to change the display in PAGE and LINE SCROLL mode is detailed section 4.3. These modes give you the facility to perform the following :• Page Mode displays 4 lines of data in set format, each page is predefined. • Line scroll mode allows you to customise the display with the data you require. 5.2 QUICK key operation To allow parameters to be viewed quickly Quintox has a number of QUICK keys. Many of these keys have two functions.
UPPER PARAMETER KEYS ALWAYS Press UPPER FUNCTION first then SCALE AMBIENT SO2 NO2 NO NOX PRESSURE LOSSES λ to display Scaling setup parameters to display ambient temperature plus sensor, Flue and Inlet to display Sulphur Dioxide reading plus Nett, O2 and CO to display Nitrogen Dioxide reading plus NO, Nett and CO to display Nitric Oxide reading plus NOx, Nett and CO to display the Oxides of Nitrogen reading plus NO, CO and Nett to display the pressure reading plus Flue, Nett and O2 to display all four l
5.4 DISPLAY BACKLIGHT AND CONTRAST The display contrast can be adjusted to suit different lighting conditions and the backlight can be switched on or off. TO TOGGLE THE BACKLIGHT ON /OFF Press UPPER FUNCTION followed by CONTRAST TO SET THE CONTRAST Press the SET/CAL followed by UPPER FUNCTION key Pressing the CONTRAST -- -- -- -- -- -- -- -- -- -- -- -- -UPPER FUNCTION SET -- -- -- -- -- -- -- -- -- -- -- -- -- key displays SET CONTRAST Hold down either the set.
6. USER SELECTABLE SETTING The following features are under your control at any time and can be changed as detailed later in this section. Time and date Day/ Month order is selectable and the real time clock and calendar are fully adjustable. Fuel type Standard pre-programmed fuels can be selected or users can define their own fuel characteristics. Efficiency Efficiency readings can be selected to be based on Gross or Nett values. Language The analyser is programmed with ten languages.
they drift. This may happen if the sensor is taken to very high concentrations for long periods of time or over-ranged. 6.1 Time and Date (Setting numbers) This section gives details on setting the time and date and also the general principle of setting a number from 0-9 used in other functions.
To Set The Time: TIME 16-01-12 SET As with the date each number in the time is to be set. Parameter Controls Options TIME: Select each number using and or 0-9 key ENTER Once the last number has been set the screen will show the main display last shown before entering the set time routine. 6.2 Changing a fuel This section gives details on changing a standard fuel and entering a user fuel.
To Set A Standard Fuel: There are over 70 standard fuels programmed into Quintox. The fuels are arranged into tables for each country and the table should be selected for the origin of the fuel used in your boiler. Each table contains different fuel types, choose the fuel that is closest to the fuel used in your boiler.
To Set A User Fuel: If one of the standard fuels does not approximate to the one you are using in your boiler then it is possible to set the Quintox up for a USER FUEL. The information required to be able to set this are the Chemical Breakdown of the fuel and the Gross and Nett calorific value. Details of the calculation are shown in the Appendix. K1g K2 K4 Parameter Controls USER FUEL: Set each number as date using key and SET 0.350 K1n 11.89 K3 32 O2r 0.393 9.83 3.
TO SET GROSS OR NETT EFFICIENCY Press the SET/CAL -- -- -- -- -- -- -- -- -- -- -- -- -SET -- -- -- -- -- -- -- -- -- -- -- -- -- Pressing the key displays EFF Parameter Controls EFF Select using SET EFFICIENCY GROSS Options or key and ENTER GROSS NET 6.
Parameter Controls SELECT LANGUAGE Select using Options or key and ENGLISH SPANISH NETHERLANDS FRENCH ITALIAN GERMAN SWEDISH FINNISH ENTER SET LINE REJECTION 50 Hz Parameter Controls LINE REJECTION Select using Options or key and ENTER 50 Hz - UK 60 Hz - USA ppm(n) or mg/m3(n) Parameter Controls GAS UNITS ppm(n) or mg/m3(n) Select using NOTE: Options or key and ENTER ppm ppmn mg/m3 mg/m3n ppm = parts per million mg/m3 = milligrams per cubic meter n denotes the reading is normalised
Parameter Controls Options COMPENSATION Select using or key and OFF ON ENTER SET TEMPERATURE CELSIUS Parameter Controls Options TEMPERATURE Select using or key and ENTER CELSIUS FAHRENHEIT SET PRESSURE ppm Parameter Controls PRESSURE Select using NOTE: mbar inWG = = Options or key and ENTER mbar inWG millibar inches of water gauge SET REFERENCE O2 NO Parameter Controls REFERENCE O2 Select using 24 Options or key and KM9106 Operators Manual ENTER NO YES
Selecting YES allows you to set an oxygen reference value different to that shown in the fuel constants. For example 3% is set in the Natural Gas constants, to reference the toxic gas values to a different value select using the screen below (Use the number setting sequence as detailed in Setting Time) :- SET REFERENCE O2 REF. %O2 . . 03.0 This may need setting if a local authority require gas readings to be referenced to a certain oxygen value.
Parameter Controls REF NOx Select using Options or key and ENTER NOx = SUM NOx = NO NOx = NO2 There are three ways of displaying the value of NOx when the values are converted to mg/m3. Local authorities may require a certain calculation. The options are as follows: • • • NOx = SUM calculates the mg/m3 figure individually from the NO and NO2 values and then adds them together. NOx = NO adds the ppm values together and then converts to NO equivalent.
6.5 Inlet Temperature The Quintox uses as default the internal ambient sensor when calculating the Net temperature. If an optional inlet probe is fitted then INLET is used in the calculation. As an alternative to both of the above, the inlet air entering the boiler can be measured using the flue probe. NOTE: The probe must not be inserted into the flue until the INLET temperature has been set.
6.6 Oxygen Calibration If used over long periods the Oxygen sensor may drift slightly and for maximum accuracy may require resetting. TO RESET OXYGEN SENSOR With the flue probe sampling fresh air and the flue temperature reading less than 50°C/122°F, or the temperature plug disconnected from the instrument. Press the -- -- -- -- -- -- -- -- -- -- -- -- -- SET/CAL SET -- -- -- -- -- -- -- -- -- -- -- -- -Pressing the O2 key displays SET O2 = 20.9% NO Change to YES Press to set 20.9% Oxygen.
CALIBRATE SENSOR Select using or key and YES NO ENTER Select YES SET ZERO ? NO Parameter Controls SET ZERO Select using Options or key and ENTER YES NO Select YES SELECT SENSOR CO -------- . . -17 Parameter Controls SELECT SENSOR Select using Options or key and ENTER LIST OF FITTED SENSORS DISPLAYED In this example we have selected the CO sensor. The pump will now run if it has been turned off, this is to draw fresh air through the instrument to allow the sensors to be zeroed.
6.8 CO Alarm It is possible to set a point in the range of the sensor so that it alarms and warns the user of a dangerous level of Carbon Monoxide. The default level is set at 400 ppm. This should be used when there is a local limit on the level of CO that should not be emitted from a boiler.
7. PRINTING INFORMATION While in any of the main displays a manual print can be obtained by pressing The display will show the printout as it is printing :- PRINT 7 7 7 PRINTING 7 7 7 -- -- -- -- -- -- -- -- -- -- -- -- -7 7 KANE-MAY 7 7 -- -- -- -- -- -- -- -- -- -- -- -- -- Standard Printout -- -- -- -- -- -- -- -- -- -- -- The standard printout is shown below :- 777 KANE-MAY 777 77 KM QUINTOX 77 DATE TIME 02-01-97 18:14:35 NATURAL GAS O2 CO Prs EFF % .... 20.9 ppm . . . . . 0 mbar 0.
The remainder of this section explains the following :Setting auto-timed printing or logging Allows information to be printed or logged automatically at set time intervals (from 10 seconds to 90 minutes). Care must be taken in setting the interval time; a standard Quintox printout will take 30 seconds to print, it is advisable to set the interval at 2 minutes or greater if a print is requested. Turn off the printer if less than 2 minutes is set.
The next screen enables or disables the integral printer. Default is ON. Use or PRINTER ? ON key to select ON or OFF and press ENTER To edit the printout header select YES. SET HEADER ? NO Use or keys to select YES or NO and press The cursor _ will be positioned under the first 7. ENTER EDIT HEADER 777 KANE-MAY 777 77 KM QUINTOX 77 ENTER & EFF=BACK Use or to select the alpha/numeric character required. Press ENTER when the character is correct.
7.2 User Defined Printouts General Principle: A user defined printout can have a maximum of 40 lines. The contents of each line can be defined by the user from the master list of parameters detailed later in this section. The standard printout with line numbers and parameter numbers is given later in this section as an example. To define a printout you must allocate a parameter number to each line. The printout must be terminated with a line of hashes. Select YES to configure your own printout.
The above example will send the Time and Oxygen reading to the printout every two minutes. To stop the Quintox Auto printing or logging, select Auto print OFF above and return to the main displays. 7.2.1 Standard Printout - Parameter Options Used: LINE NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PARAMETER USED: -----------***KANE-MAY*** **KM QUINTOX** DATE 02-01-97 TIME 18 :14:35 NATURAL GAS 02 % ......20.9 CO ppm .....0.0 Prs mbar ....0.05 EFF %.....
7.2.2 Master List of Printed Parameters The following list is a master list of printed parameters. Details of the measured and calculated variables are given in the Appendix.
8. QUINTOX LOGGING AND PC DOWNLOAD 8.1 Overview 8.1.1 Description Data is sent to the handset through the connection lead and can be stored if required. All information logged can be displayed on the hand-set, down-loaded to a computer or output directly to a printer. The hand-set will store up to a maximum of 1926 pages (standard Quintox output). Information is stored each time the key is manually pressed or an autoPRINT timed print is requested.
8.1.3 Logging Data Data logging is done with the handset operating in 2. QUINTOX CONTROL and by either pressing the PRINT key or requesting an auto print, information will be captured by the logger and stored. The display will show the following screen to confirm information has been stored correctly. DATA LOGGED 0123 In the display shown above the data has been stored in location 123. Make a note of this on any paperwork you are using for that job so that the information can be retreived later. 8.
8.3 Logger Control This facility allows access to all of the information stored in the handset; data can be cleared, viewed on the display or output to a printer or PC. The logger records each page of Quintox information and gives it a unique log number; as additional logs are sent to the handset the log number is increased by 1 until a maximum of 1926 pages is reached. Once the memory is full, data will STOP logging. To select 1. LOGGER CONTROL position the cursor on the 1 in the MENU using and and press .
LOG DATA ? NO ENTER YES to tell the logger to store data in memory and NO to disable the logging function. DOWNLOAD MEMORY NO Download Memory allows you to output the stored information to a PC, output is in our own format and requires a special program to extract the data. Contact Kane International or Distributor for information on the ‘Fireworks’ range of software. Selecting YES will set the handset in READY mode, this allows the PC software to access the data stored.
ENTER the desired location to display the memory FROM. Entering numbers is detailed in section 6. LOG NO. DATE TIME BATTERY % 0100 23/10/96 10:32:36 54 To scroll through data, use and , note the log starts with the Log Number followed by Quintox data. Note also that once at the top of a log the will take you to the top of the previous log i.e. LOG NO. DATE TIME BATTERY % Using the 0099 23/10/96 10:31:36 54 will scroll through that particular log moving one line at a time.
8.4.1 Setting Up Your PC A standard communications package will be able to collect the data from the Quintox. Windows Terminal software is a suitable package.
8.4.2 Capturing Data From Quintox To capture data direct from the Quintox into a PC the RS232 port on the Quintox has to be connected to the serial port on your PC. Using the standard RS232 lead, and IBM/AT lead if you serial port is a 9 pin D type, connect the Quintox to the PC. The RS232 can output in two formats, Comma Separated variable (CSV) and Binary (for the logger). The standard default setting is binary and will always be set if the instrument is switched off and on.
9. CONTINUOUS MONITORING The Quintox is designed primarily as a portable emissions monitoring analyser. It can however be used for longer periods if the gas is treated correctly before being supplied to the analyser. The main problem with continuous monitoring is the build-up of water in the water trap. There are two methods available for extracting the water. Both are optional extras available :• Pump drained water trap with built-in level sensor.
10. Main Purge The main purge facility for Quintox is used where longer sampling of flue gas is required. It should be used with the KM9008 gas conditioning unit or in conjunction with any other water removal system. If dry gas is supplied to the Quintox for a long period of time the operating cells will dry out and stop working. Supplying fresh ambient air to the sensors on a periodic basis will prevent or reduce the drying effect and prolong sensor life.
To access timed purge enter the following :SET/CAL ENTER SET/CAL ENTER Enter the code 0000 at the following display :- ENTER SERVICE CODE -- -- -- -- > 0 0 0 0 < -- -- --The following screens will be displayed, enter NO to both :- CALIBRATE SENSOR NO PRINT MEMORY ? NO The purge sequence now begins, by using the arrow keys select YES to ‘SET PURGE ?’ and press . ENTER SET PURGE ? YES Enter the purge duration and similarly the purge interval by changing each character.
Set YES or NO depending on whether auto zero is required or not. AUTO ZERO ? NO Note: During both Manual and Timed purge operation the following screen will be displayed for approximately one second every 3 seconds. -------------------------------------PURGE ON -------------------------------------Recommended Operation Each monitoring situation will be different and a degree of user judgement will apply.
11. MAINTENANCE 11.1 Emptying and Cleaning the In-line Water Trap The water trap should be checked and emptied on a regular basis. Water vapour will condense and gather in the probe line this may move suddenly to the trap when the probe is moved. Care should be taken at all time. Emptying of the water trap is detailed below :- Carefully remove the end cap from the in-line housing. Dispose of the condensate in a suitable drain, care must be taken as it could be acidic.
11.3 Charging the Battery It is important that the battery is charged on a regular basis. The instrument constantly powers the internal sensors and may flatten the battery if left unattended for some months. Connect the charger supplied with the instrument to the correct mains supply. Note: The correct charger type is required for your local voltage i.e. 110 or 220 volts AC Insert the plug in the socket marked CHARGER INPUT SOCKET as detailed in section 1.4.
11.5 Changing the Printer Ribbon The printer ribbon cartridge will last for approximately two rolls of paper. Remove the printer cover as detailed above. Marked on one end of the cartridge is PUSH. Gently press down on this end and the ribbon cartridge will pop up at the other end. Remove the cartridge and dispose of. Fit a new ribbon guiding the paper roll between the exposed ribbon and cartridge body. Refit printer cover.
12. PROBLEM SOLVING The following is a list of problems that may occur on the instrument through its operating life. If the cause of the fault is not easy to identify then we advise you to contact the Kane International Service Department or an International Distributor for expert advice.
13. ANNUAL RE-CALIBRATION Whilst the sensors have an expected life of more than two years in normal use it is recommended that the analyser is re-calibrated at least annually. This is so that long term drift on the sensors and electronics can be eliminated. Local regulation may require more frequent re-calibration and users should check with appropriate authorities to ensure they comply with relevant guidelines.
14. HOW TO GET EXPERT HELP There will be occasions when despite having read the manual there will be problems that you cannot resolve and so you need external help. Before calling Kane International or one of its International Distributors please first check the following: Find the serial number of the instrument. It is located on the label close to where the charger and handset leads plug into the analyser. Also make a note of which sensor are fitted by observing the tick boxes on the same label.
15. PRODUCT SPECIFICATION INSTRUMENT Parameter Temp Measurement Flue Temperature Resolution Accuracy Range 0.1o (C/F) 1.O o C +/-0.3% of reading Inlet Temperature 0.1o (C/F) 1.O o C +/-0.3% of reading 0 - 1100°C, 32 - 2140°F * Use high temperature probe for gases > 600°C/1112°F 0 - 600°C 0-999°F Gas Measurement Oxygen (02): Carbon Monoxide (CO): 0.1% 1ppm 0.
HANDSET Dimensions Keypad Display 220 mm long 120 mm high 50 mm wide 16 tactile keys with sounder 4 line LCD with backlight and contrast control EXTENSION CABLE Specification: Cable lengths: 8 pin DIN to 15 pin ‘D’ screened cable 5m Standard 10-20m-Optional PROBE Choose from a range of probe options. See probe leaflet. BATTERY Type: Life: Charge time: Lead acid rechargeable (12V, 2 AH) 8 hours from full charge 12 hours BATTERY CHARGER Input: Output: 110-120V AC/220-240V AC.
AMBIENT OPERATING RANGE 0 - 40°C (+32°F to 104°F) 20 - 80% RH non condensing Storage: 0-50°C Maximum gas temperature at sensors: 56 Continuous +40°C Intermittent +55°C KM9106 Operators Manual
APPENDICES A - Parameter Meanings The parameters and their meanings are detailed as follows : DATE : Analyser date. See Section 6.1 to change. TIME : Analyser time. Use Section 6.1 to change. INSTABILITY : This is an indication of how stable the signals are from all the sensors. 0 = high stability, 10 = high instability. When measuring flue gases, pressure and temperature this number will rise as the sensed inputs varies. At start up when sampling fresh air this number is invariably 0.
NETT : Nett temperature calculated by deducting the internal AMBIENT temperature from the measured FLUE temperature. Displays in either Centigrade C or Fahrenheit F and will display NOT FITTED if flue probe not connected. If an external INLET probe is used then INLET is deducted from FLUE. O2 : Oxygen reading in percentage %. CO : Carbon Monoxide reading indicated in ppm or mg/m3. If the figures are referenced to oxygen then the display will show ppmn or mg/m3n. See Section 6.4 for oxygen reference.
CO/CO2 R : The CO/CO2 ratio, is the ratio of measured CO divided by CO2. It gives an indication of the following :• • How good a gas sample the instrument is reading. How clean the boiler is running. For example : A new or clean domestic boiler will display a ratio of less than 0.004, a unit in need of cleaning 0.004-0.008 and a unit in need of major overhaul will show greater than 0.008. This only shows a reading when a combustion test is being carried out. 0.0000 is displayed while in fresh air.
CxHy : Unburnt HydroCarbon reading in % of LEL of Methane, the sensor is calibrated with Methane. Displayed when a HydroCarbon sensor fitted. LEL is the Lower Explosive Limit of a gas when mixed with air, for Methane this has the ratio of 19:1 Air:Methane. Below the LEL the mixture can not ignite and burn. In the Flue an unburnt HydroCarbons should be well below this level or there is the potential for an explosion. LOSS : Total losses calculated from Combustion Theory.
B. NOx CALCULATIONS ONLY an NO Sensor fitted.
NOx referenced to NO2 NOx in mg/m3 = NO in ppm multiplied by 2.05 multiplied by (1 + assumed NO2 percentage) or NOx in mg/m3 = NO in mg/m3 divided by 1.34, multiplied by 2.
ONLY an NO2 sensor fitted When there is only an NO2 sensor fitted the NOx function is disabled NO2 in mg/m3 = NO2 in ppm multiplied by 2.
C. COMBUSTION EFFICIENCY CALCULATION The efficiency calculation is based upon British Standard BS845.
Calculated data: Tnet = Net Temperature % CO2 content in flue gas % Dry Flue Gas losses % Wet losses % Unburned carbon loss % Efficiency %CO2 = (20.9 - %O2m) x K2 / 20.9 Tnet = Flue Temperature - Inlet Temperature Dry flue gas loss = 20.9 x K1n x (Tnet) / K2 x (20.9 - %O2m) Wet loss simplified = 9 x %H2 + %H2O / Qgr x [2488 + 2.1Tf - 4.2 Ti] = [(9 x %H2 + %H2O) / Qgr] x 2425 x [1 + 0.001 Tnet] Wet loss = K3(1+0.
D. CALCULATION OF FUEL DATA For any fuel not specified by Kane International the net calorific value, gross calorific value and composition should be obtained from the fuel supplier. The following fuel data has been calculated with reference to the efficiency calculation. Example 1: Chemical composition: C H2 H2O Qnet Qg Max CO2 25% 3% 50% 8.35 MJ/kg 9.3 MJ/kg 20.4% * K1n = (255 x % carbon in fuel) / Qnet (kJ/Kg) = (255 x 25) / 8350 = 0.
E. ELECTROMAGNETIC COMPATABILITY (CE) STATEMENT This product has been tested for compliance with the following generic standards: EN 50081-1 EN 50082-1 and is certified to be compliant Specification EC/EMC/KI/KM9106 details the specific test configuration, performance and conditions of use.
