E Instruments 4400 Manual
Summary of 4400
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4400 4400 portable combustion gas analyzers.
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3 @ist01530eej 01 917 5a0 19 041 1 1.0 introduction 05 1.1 general description of the combustion analyzer 05 1.2 general features of the flue gas analyzer 05 1.3 4400 main configurations 06 2.0 technical specifications 07 2.1 technical specifications 07 2.2 overview of flue gas analyzer components 0...
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4 @ist01530eej 01 917 5a0 19 041 1 5.0 sensors 54 5.1 sensor arrangement 54 5.2 sensor types and relevant positioning 54 5.3 gas sensor life 55 5.4 gas sensor life 55 5.5 expandability to 4 sensors 56 6.0 maintenance 57 6.1 routine maintenance 57 6.2 preventive maintenance 57 6.3 cleaning the sample...
Page 5: 1.0 Introduction
5 @ist01530eej 01 917 5a0 19 041 1 1.1 general description of the combustion analyzer the design of the handheld combustion analyzer “4400” is clean and ergonomic with an extremely clear and user -friendly keypad. The “4400” immediately suggests just how even the most sophisticated engineering can g...
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6 @ist01530eej 01 917 5a0 19 041 1 4400-n cod. K9401a0004 4400-s cod. K9401a0005 o 2 sensor co+h 2 sensor no sensor no 2 sensor so 2 sensor automatic autozero co dilution calibration certificate instruction manual flue sampling probe 300mm (12”) + 10’ dual hose combustion air temperature probe conde...
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7 @ist01530eej 01 917 5a0 19 041 1 2.0 technical specifications 2.1 technical specifications autozero: automatic autozero cycle with probe inserted in the stack. Dilution: expansion system of the co sensor measuring range up to 50,000ppm (5.00%v/v) programmable as a simple protection of the co senso...
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8 @ist01530eej 01 917 5a0 19 041 1 2.2 overview of flue gas analyzer components legend a keypad b display c cover to access the impact printer d flue sampling probe e condensate separator and fine dust filter unit (water trap assembly) f compensated male connector of the fumes exhaust temperature pr...
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9 @ist01530eej 01 917 5a0 19 041 1 keypad adhesive polyester keypad with preformed keys featuring main control functions (pos. In fig. 2.2). Display backlit 128 x 64 pixel lcd display (pos. In fig. 2.2), with 8 lines x 20 characters available. Allows the user to view the measured parameters in the m...
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10 @ist01530eej 01 917 5a0 19 041 1 the cold junction is compensated by a pt 100 resistance thermometer which measures the temperature at the thermocouple connector. The type k thermocouple (nickel/nickel chromium) permits continuous measurements up to 800°c. If special- purpose probes are used, the...
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11 @ist01530eej 01 917 5a0 19 041 1 measuring ambient co probe for monitoring the concentration of co and checking safe conditions in the boiler room. An acoustic and visual warning signal is given if the thresholds are exceeded according to the osha levels. Internal gas leak detector sensor this se...
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12 @ist01530eej 01 917 5a0 19 041 1 2.3 measurement ranges and accuracies all data relative to concentration accuracies are referred to an instrument operating at a constant temperature within the correct operating range (-5°c .. +45°c), being in operation for at least 15 minutes, powered by its int...
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13 @ist01530eej 01 917 5a0 19 041 1 3.0 using the flue gas analyzer 3.1 preliminary operations remove the instrument from its packing and check it for damage. Make sure that the content corresponds to the items ordered. If signs of tampering or damage are noticed, notify the e instruments service ce...
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14 @ist01530eej 01 917 5a0 19 041 1 attention the power supply/battery charger is a switching type one. The applicable input voltage ranges between 90vac and 264vac. Input frequency: 50-60hz. The low voltage output is 12 volt wi th an output current greater than 1.5a. Low voltage supply connector: d...
Page 15: 4.0 Operation
15 @ist01530eej 01 917 5a0 19 041 1 4.1 working principle the gas sample is taken in through the sample probe, by a diaphragm suction pump inside the instrument. The measuring probe has a sliding cone that allows the probe to be inserted in holes with a diameter of 11 mm to 16 mm and to adjust the i...
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16 @ist01530eej 01 917 5a0 19 041 1 the measurement cells. This is also the reason why it is important to periodically drain the trap, anyhow at the end of each test (see chapter 'maintenance'). A replaceable low-porosity line filter is placed after the condensate trap aimed at keeping the solid par...
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17 @ist01530eej 01 917 5a0 19 041 1 4.7 keypad overview warning: to turn-on / off the instrument it is necessary to press and hold the on/off button for at least 2 seconds. 1 2 3 4 5 6 7 8 on / off select / modify confirm cancel / exit mem ory menu print menu configure menu info menu analysis menu z...
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18 @ist01530eej 01 917 5a0 19 041 1 this menu provides information regarding instrument status: battery capacity: shows the status of the internal battery. The battery charge status is shown graphically and in text as a percentage between 0 and 100%, together with the battery voltage. Configuration ...
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19 @ist01530eej 01 917 5a0 19 041 1 4.8.1 flow chart - info menu to return to the previous screen, press . Activ ates the info menu. ►battery status sensors config. Sensors diagnostic memories diagnostic info service information bat: 91 ٪ vbat:7.82 v battery status battery status ►sensors config. Se...
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20 @ist01530eej 01 917 5a0 19 041 1 4.9 configure menu this menu is used to configure the instrument’s reference parameters described below: fuel: lets the user select the type of fuel to be used during analysis. This datum can be changed either from this menu or during the analysis itself. Measurem...
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21 @ist01530eej 01 917 5a0 19 041 1 low-level alarms are triggered when the reading drops below the defined threshold, whereas high-level alarms are triggered when the reading rises above the defined threshold. When an alarm threshold is crossed, the instrument emits an intermittent audible alarm be...
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22 @ist01530eej 01 917 5a0 19 041 1 activ ates the configure menu. All selected data can be modif ied by pressing cursor keys . To cancel changes and return to the prev ious menu press . 4.9.1 flow chart - configure menu ►fuel measurement units o 2 reference display contrast autozero/pump ▼ configur...
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23 @ist01530eej 01 917 5a0 19 041 1 fuel ►measurement units o 2 reference display contrast autozero/pump ▼ configuration co no,no 2 , nox pressure temperature measurement units mg/m 3 ppm hpa °c co no,no 2 , nox pressure temperature measurement units ppm ppm hpa °f co no,no 2 , nox pressure temperat...
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24 @ist01530eej 01 917 5a0 19 041 1 autozero ►pump autozero/pump on s 15 autozero pump autozero/pump s on 15 autozero pump autozero/pump s off 15 ▲ o 2 reference display contrast autozero/pump co auto-dilution ►automatic analysis ▼ configuration ►mode automatic analysis manual mode automatic analysi...
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25 @ist01530eej 01 917 5a0 19 041 1 manual time ►date mode time/date eu / 12 / 12 12 . 12 12 time date mode time/date eu / 12 / 12 12 . 12 12 time date mode time/date eu / 12 / 12 10 . 13 12 time date mode time/date eu / 12 / 12 10 . 13 12 time date ►mode time/date eu / 12 / 12 12 . 12 12 time date ...
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26 @ist01530eej 01 917 5a0 19 041 1 number measure active limit ►unit alarms maximum co 1 1500 ppm number measure active limit unit alarms maximum co 1 1500 ppm number measure active ►limit unit alarms maximum co 1 1500 ppm number measure active limit unit alarms maximum co 1 +01500.0000 ppm the ala...
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27 @ist01530eej 01 917 5a0 19 041 1 1:e instruments ►2: 3: 4: report header philadelphia, pa_ ▲ ◄ 9:;?!“#$٪& ’)~* ► ▼ text editing 1:e instruments 2:philadelphia, pa ►3:t(215)750-1212 4: report header t(215)750-1212_ ▲ ◄ 9:;?!“#$٪& ’)~* ► ▼ text editing 1:e instruments 2:philadelphia, pa 3:t(215)750...
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28 @ist01530eej 01 917 5a0 19 041 1 4.10 memory menu this menu is used to display and print individual and average values of the analysis data stored in memory. Analysis data can be ordered either by memory position or by storage date; draft and smoke values can also be recalled. The print menu is e...
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29 @ist01530eej 01 917 5a0 19 041 1 activ ates the memory menu. This menu is used to display and print the indiv idual and av erage v alues of the analysis data stored in memory. Analysis data can be ordered either by memory position or by storage date; draft, smoke and ambient co (no) v alues can a...
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30 @ist01530eej 01 917 5a0 19 041 1 1:19/12/10 15.30 2:19/12/10 16.00 3:19/12/10 16.30 average analysis ►meas. Conditions ▼ recall memory 2:19/12/10 16.00 3:19/12/10 16.30 average analysis meas. Conditions ►draft ▼ recall memory 3:19/12/10 16.30 average analysis meas. Conditions draft ►smoke ▼ recal...
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31 @ist01530eej 01 917 5a0 19 041 1 4.11 print menu this menu is used to access the following print and check configurations: print analysis report: shows the details of the selected ticket type and allows to start printing. Configure print: allows to set the number of printed copies and layout of t...
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32 @ist01530eej 01 917 5a0 19 041 1 4.11.1 flow chart - print menu enables the print menu. Allows to print the combustion analysis data on a paper ticket which reports the measurement v alues. The printed v alues are those shown on the display when the menu is enabled. This menu can be used f or com...
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33 @ist01530eej 01 917 5a0 19 041 1 4.12 analysis menu through this key the analysis results are displayed. Moreover the operator is allowed, once this key is further depressed, to display and possibly modify the analysis parameters before proceeding with the measurements. Measured v alues are: o 2 ...
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34 @ist01530eej 01 917 5a0 19 041 1 4.12.2 flow chart - analysis menu (zoom) ►refo 2 auto:001 ▼ o 2 4.2٪ co 2 9.3٪ xair 1.25 tf 190.1c ta 15.4c ∆t 74.7c eff 83.4٪ loss16.6٪ co 146p no 40p so 2 41p no x 51p ►refo 2 auto:001 ▼ o 2 4.2٪ co 2 9.3٪ xair 1.25 co 146p no 40p so 2 41p nox 40p o o o o 2 2 2 ...
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35 @ist01530eej 01 917 5a0 19 041 1 select the analysis mode - automatic or manual. If automatic mode is selected, def ine the test time and print mode - automatic or manual. Select the test operator. Setup the report printing, selecting the number of copies and the type of report to print. Activ at...
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36 @ist01530eej 01 917 5a0 19 041 1 4.13 draft menu the draft menu gives access to the stack draft measurement. The user to input the external air temperature as required by the standard. Afterwards the measurement screen is reached: here the user can acquire the value displayed in order to add it t...
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37 @ist01530eej 01 917 5a0 19 041 1 4.14 measurements menu this menu is used to access the following readings: smoke: it is possible to enter the data for up to three (3) separate smoke test measurements taken by means of an optional device (smoke pump); see the relevant instructions. The method con...
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38 @ist01530eej 01 917 5a0 19 041 1 p: actual pressure measured by the instrument, in the selected measurement unit. ∆p 1 ': pressure variation in the last minute, updated every 10 seconds. This value gives a rough indication about the stabilization level reached in the piping system. Wait time: rem...
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39 @ist01530eej 01 917 5a0 19 041 1 when the 'volume measurement' option is selected instead, the procedure, described also in the flow charts of the tightness test according to uni 11137-1, is described in the following steps: • close both faucets in the kit assembly supplied for the test execution...
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40 @ist01530eej 01 917 5a0 19 041 1 4.14.1 flow chart - readings menu activ ates the smoke menu. See the ‘tightness test’ f low-chart , next page. In the smoke menu the user can input the smoke v alue. The values entered with the arrow keys can be associated with the ongoing analysis through the ' '...
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41 @ist01530eej 01 917 5a0 19 041 1 tightness test flow -chart according to standards uni 7129 and uni 11137-1. Pressurize the piping and select test with the ' ' key. Automatically after a f ew seconds. Automatically, after 15 minutes. During stabilization the pipe pressure p is displayed and also ...
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42 @ist01530eej 01 917 5a0 19 041 1 select the f igure to be modif ied with the key s . Mo d ify the v alu e of t he hi gh li ght ed f ig ur e with keys . New piping ►existing piping tightness test ►start test stabilization combustible gas test gas existing piping start test ►stabilization piping vo...
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43 @ist01530eej 01 917 5a0 19 041 1 vtot volume measure ►add tube subtract tube zero volume piping volume 25.0 dm 3 vtub 0.0 dm 3 ►material copper diameter 20 mm length 0.0 m add tube vtub 0.0 dm 3 material copper ►diameter 20 mm length 0.0 m add tube vtub 0.0 dm 3 material copper diameter 20 mm ►le...
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44 @ist01530eej 01 917 5a0 19 041 1 city gas natural gas ►l.P.G. Air existing piping city gas ►natural gas l.P.G. Existing piping city gas natural gas ►l.P.G. Existing piping start test stabilization piping volume combustible gas ►test gas existing piping city gas ►natural gas l.P.G. Air existing pi...
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45 @ist01530eej 01 917 5a0 19 041 1 pressurize the piping and select test with the ' ' key. Automatically, after 1 minute. During stabilization the pressure p in the piping is shown, together with the v ariation ∆p1’ in the last minute. The waiting time is set in the test conf iguration menu. The st...
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46 @ist01530eej 01 917 5a0 19 041 1 4.15 flow chart - configure analysis menu in the select menus the cursor indicates the activ e v alue. In this phase one can either select the test operator and/or change the name displayed (ref er to configure menu). At this point the user can select the analysis...
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47 @ist01530eej 01 917 5a0 19 041 1 4.16 flue gas analysis to perform complete flue gas analysis, follow the instructions below. 4.16.1 switching on the instrument and auto-calibration press the on/off key to switch on the instrument - an introductory screen will appear. After a couple of moments th...
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48 @ist01530eej 01 917 5a0 19 041 1 the following data must be configured: memory: use this submenu to define the memory in which the test data and client details are to be stored. Fuel: the user will be asked to define the type of fuel used by the plant. Operator: this is where the name of the test...
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49 @ist01530eej 01 917 5a0 19 041 1 4.16.5 flow chart - flue gas analysis select the fuel of the plant being tested. Select the memory position under which the data will be sav ed. Select the test operator. Select analysis mode. Record the draft v alue. Enter the smoke values. Setup the printing opt...
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50 @ist01530eej 01 917 5a0 19 041 1 how to proceed in manual mode (standard sequence). Save test 3. Save test 1. Save test 2. Recall the average test values. If desired, set the preferred number of copies and analysis report format. Print the analysis report. ►save analysis display average select me...
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51 @ist01530eej 01 917 5a0 19 041 1 ►print report print setup paper feed print test print print report ►print setup paper feed print test print ►copies model print setup full full full full 1 ►print report print setup paper feed print test print memory analysis model print report print quit full 1 0...
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52 @ist01530eej 01 917 5a0 19 041 1 how to proceed in automatic mode. Automatic, when the def ined time elapses. Automatic, when the def ined time elapses. Automatic, when the def ined time elapses. If , when configuring test parameters, manual printing has been selected (see example), the average v...
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53 @ist01530eej 01 917 5a0 19 041 1 4.17 measuring the differential pressure (optional hose kit) (part # aackp01) the instrument is fitted with an internal temperature-compensated piezoresistive transducer to measure positive and negative pressures. This sensor, which is mounted on the instrument, i...
Page 54: 5.0 Sensors
54 @ist01530eej 01 917 5a0 19 041 1 5.0 sensors 5.1 sensors arrangement 5.2 sensor types and relevant positioning s1 s2 s3 s4 flex-sensor o 2 cod. Aaa32-240 flex-sensor co+h 2 cod. Aacse05 flex-sensor no cod. Aacse06 flex-sensor no 2 cod. Ag526-w00 flex-sensor so 2 cod. Ad527-w04 flex-sensor co 100....
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55 @ist01530eej 01 917 5a0 19 041 1 5.3 gas sensor life the gas sensors used in this instrument are electrochemical: thus, when the relative gas is detected, a chemical reaction takes place inside them that generates an electrical current. The electrical current acquired by the instrument is then co...
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56 @ist01530eej 01 917 5a0 19 041 1 5.5 expandability to 4 sensors in the 4400 instrument range, two are the versions which can be expanded: the upgrading of the number of sensors can be easily done by the user by performing the following directions: - both the expandable instruments are arranged in...
Page 57: 6.0 Maintenance
57 @ist01530eej 01 917 5a0 19 041 1 6.0 maintenance 6.1 routine maintenance this instrument was designed and manufactured using top-quality components. Proper and sy stematic maintenance will prevent the onset of malfunctions and will increase instrument life altogether. The following basic requisit...
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58 @ist01530eej 01 917 5a0 19 041 1 6.5 replacing the particulate filter if the particulate filter appears black, especially on the inner surface (see adjacent example), it has to be replaced immediately. In this way gas flow is not obstructed. 6.6 replacing the gas sensors the gas sensors of the in...
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59 @ist01530eej 01 917 5a0 19 041 1 electrical connection 3 locate the sensor to be replaced; here is an example of a connected sensor to be replaced. 4 disconnect the sensor to be replaced; here is an example of a disconnected sensor to be replaced. 1 2 3 4 5 6 7 8.
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60 @ist01530eej 01 917 5a0 19 041 1 7 fit the sensor again taking care the electric connection is turned outside the instrument, not inside (see point 5). 5 the sensor is bayonet-connected to its socket; rotate it counter-clockwise to remove it. Here is an example of a rotated sensor. Attention whil...
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61 @ist01530eej 01 917 5a0 19 041 1 turn on the instrument to check the new sensor works correctly through the menu “sensor troubleshooting”. It is normal if a newly installed sensor gives a 'current error': it is necessary to wait some time, so that the sensor polarization can settle. The table her...
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62 @ist01530eej 01 917 5a0 19 041 1 6.7 on-site recalibration it is possible to make a recalibration of the instrument’s gas sensors with known concentration gas cylinders. Recalibration of oxygen (o 2 ) sensor is not available since it is already recalibrated during every autozero cycle. The access...
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63 @ist01530eej 01 917 5a0 19 041 1 choose the sensor to be recalibrated and proceed as described (co sensor is shown in this example): • connect the known concentration gas cylinder to the instrument as shown in the following scheme: ▲ operator report header setup micromanometer language ►calibrati...
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64 @ist01530eej 01 917 5a0 19 041 1 • apply the gas to the instrument and regulate the cylinder output pressure so that the flow meter shows a minimum flow (0.5 l/m) to ensure that the instrument is getting exactly the gas needed by its internal pump. • the instrument measures the concentration of t...
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65 @ist01530eej 01 917 5a0 19 041 1 6.8 replacing the battery pack follow these instructions to replace the battery pack: 1 2 3 4 5 6 7 8 1 undo the fixing screw on the battery compartment cover, and remove it . 2 remove the battery pack. Battery pack connector 3 remove the battery pack connector, a...
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66 @ist01530eej 01 917 5a0 19 041 1 6.9 replacing the printer paper follow these instructions to change the paper roll in the printer. 3 fit the paper roll as shown in the figure. 5 now, let the report paper move forward through the print menu - paper feed, while accompanying the printing report by ...
Page 67: 7.0 Troubleshooting
67 @ist01530eej 01 917 5a0 19 041 1 7.0 troubleshooting 7.1 troubleshooting guide symptom probable causes and remedies the instrument does not work at all. When the on/off pushbutton is pressed the instrument does not come on. A. Keep the on/off key depressed for at least 2 seconds. B. The battery i...
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68 @ist01530eej 01 917 5a0 19 041 1 troubleshooting guide symptom probable causes and remedies the rear lighting of the display is not on. The backlighting led’s are faulty. Contact the nearest service center to replace the display. The batteries last less than 9 hours. A. Battery capacity is limite...
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69 @ist01530eej 01 917 5a0 19 041 1 8.0 spare parts and technical 8.1 spare parts aac bf01: sensor junction block aac fa01: particulate filter aac ni01: ink ribbon for printer aac pb02: battery pack - 5 x 6v 1800 mah elements aac rc01: paper roll for printer, h=57 mm, diam.= 40 mm aac se11:flex-sens...