ENERAC POCKET 60 User manual

ENERAC POCKET 60

CARBON MONOXIDE ANALYZER

INSTRUCTION MANUAL

Rev.2

October 1996

1. UNPACKING

Unpack the instrument carefully and inspect it for any visible signs of damage. The

Model 60 includes the following:

a. One Model 60 carbon monoxide analyzer.

b. One stack probe equipped with a desiccant filled water trap and disposable

filter.

c. One battery charger.

d. One small screwdriver.

e. One instruction manual.

f. One carrying case.

2. DESCRIPTION

a. PURPOSE AND FUNCTION.

The Model 60 carbon monoxide analyzer is a light weight hand-held meter

that can measure the concentration of toxic carbon monoxide gas with

greataccuracy over the range from zero parts per million (ppm) to 20,000

ppm (2.0%). The instrument has been designed so that it can be used for a

number of different applications. Three of the most significant applications

are listed below:

i. FLUE STACK MONITOR

When the stack probe is connected to the analyzer the instrument

becomes an excellent continuous real time monitor of carbon

monoxide emission in the stacks of boilers, furnaces and the exhaust of

engines. The significance of measuring carbon monoxide

concentrations as a means for tuning boilers for maximum efficiency is

well known. Maintaining a certain very small amount of carbon

monoxide in the stack is the best way to ascertain that a boiler is

operating at its peak efficiency.

ii. AREA SAFETY MONITOR

Carbon monoxide gas is present in many work areas. It is a highly

toxic, odorless and colorless gas and exposure to high concentrations

can be lethal. The analyzer operating on the diffusion mode is an

excellent monitor against build up of carbon monoxide gas. A dual

audiovisual alarm warns people when concentrations excced a preset

limit.

iii. DUAL PURPOSE METER

When a hose is connected to the analyzer input, the instrument can pull

gas samples from any closed or difficult to get compartment. If the

analyzer is switched to its cycling mode, the instrument can

"simultaneously" monitor gas concentrations in remote compartments

such as a stack and also in the area where the analyzer is located.

b. OPERATING PRINCIPLES

i. POWER REQUIREMENTS

The instrument is powered by six "AA" rechargeable Nickel Cadmium

batteries. Battery life is 10 hours of continuous operation with the

pump running, or 30 hours of continuous operation with the pump off.

The rechargeable batteries can be recharged by plugging the AC

charger to an suitable 115 VAC, 60 HZ outlet (220-240 VAC for

export units) and letting the batteries charge overnight. The battery

charger may also be used to run the Instrument continuously from an

AC source without depleting the batteries. When the battery is

discharged (i.e., the voltage drops below 5.5 volts) the display will

blank. This is an indication that the batteries need recharging.

ii. GAS FLOW DESCRIPTION

The instrument houses an electrochemical sensor which converts the

concentration of carbon monoxide to a millivolt signal. The relation

between concentration and voltage is linear. The sensor is highly

specific to carbon monoxide. Hydrogren and hyrogen sulfide are the

only two common gases that interfere (i.e., the sensor will respond to).

It is not affected by relative humidity and its sensitivity to temperature

variations is minimal over the range from zero degrees celcius to 40

degrees celcius. It's expected life is 1-2 years. The sensor is mounted

on a thin aluminum housing that has two openings, one to the pump

and the other to the diffusion input on the side of the instrument. If the

sensor is exposed to a large concentration of carbon monoxide gas

(exceeding 20,000 ppm or 2.0%) it will saturate. The display will

indicate overrange. If the source of carbon monoxide is then removed,

the display will still indicate overrange for a few minutes depending on

the concentration of CO gas and duration of exposure. Once the excess

CO has been consumed by the sensor, the display will give normal

readings. The sensor will be not be permanently damaged by high

concentrations of CO.

iii. SAMPLING MODE (PUMP ON).

With the stack probe (or any other hose) connected to the stack input of

the instrument, a gas sample of approximately 1000 cc/min is drawn by

the pump through the probe which includes the fiber filter and water

trap, whose respective functions are to trap soot particles and remove

condensed water and water vapor. The gas sample is drawn by one

small rugged gas pump that is operated by a high quality motor. It is

then introduced into the housing that contains the carbon monoxide

sensor and exhausted through the diffusion port on the side of the

instrument.

iv. DIFFUSION MODE

When the pump is not operating, gas simply diffuses past the stainless

steel screen of the diffusion input and into the housing where the

sensor is located. The length of the diffusion path is only about 1/4

inch.

v. CYCLING MODE (PUMP CYCLES ON AND OFF)

In the cycling mode, gas enters the sensor cavity alternatively from the

stack input (when the pump is operating) and from the diffusion input

(when the pump is not operating).

3. OPERATING CONTROLS

a. ON - OFF SWITCH

This is a two position slide switch that must be pushed upward to operate

the instrument. When charging, the batteries this switch must remain in the

OFF position.

b. PUMP MODE SELECTOR SWITCH

This is a three position slide switch that controls the operation of the pump.

When the switch is in the uppermost position the pump will run

continuously and gas flow takes place from the stack input toward the

diffusion port. When the switch is in the bottom position, the pump is not

operating and the gas enters the sensor housing only from the diffusion

input. When the switch is in the middle position the pump will operate

intermittently as follows:

It will run for approximately 2 minutes (with the exception that the pump

will operate for 4 minutes during the first cycle), then it will turn off for

approximately 25-30 minutes, it will then run again for 2 minutes, shut off

for 30 minutes and so on.

c. ALARM LEVEL SWITCH

This is a three position slide switch that allows setting of the audio & visual

alarm to one of three different levels. When the switch is in the bottom

position, the alarm will turn on when the carbon monoxide level detected by

the sensor exceeds 50 ppm. (It will turn off when the level drops below 42

ppm). This alarm position should be used for safety purposes.

When the switch is in the middle position the alarm will turn on when the

CO concentration exceeds 200 ppm. (It will turn off when the level drops to

190 ppm). A Carbon Monoxide level of 150-200 ppm is usually considered

the point where efficiency of a boiler is maximum.

The top position of the switch sets the alarm at 400 ppm. This is the

maximum level allowed by certain regulatory agencies.

d. BUZZER SWITCH

This is a tiny slide switch that turns on or off the sound alarm. It is

convenient to use when testing the instrument or when the sound of the

buzzer is not necessary.

e. THE DUAL RANGE SWITCH

This switch selects the operating range of the analyzer. There are two

ranges: 0-2000 PPM and 0-20,000 PPM. If you are not sure of the carbon

mopnoxide concentration of your source, always turn the analyzer on with

the range switch set in its upper (20K PPM) position. For accurate low

concventration readings set the range switch to the lower (2K PPM)

position.

NOTE: We strongly recommend that the analyzer not be exposed to

concentrations exceeding 5000 PPM for more than a few minutes to prevent

gradual sensor saturation.

4. INSTRUMENT OUTPUTS

a. DISPLAY

This is a 3-1/2 digit, 0.5 inch high liquid crystal display that indicates the

concentration of carbon monoxide in parts per million (ppm). When the

range switch is in the lower position, resolution is 1 PPM. When the range

switch is in the upper position, the display reads in thousands PPM and its

resolution is 10 PPM(0.01%). If the display’s range is exceeded, a one

followed by blanks will be displayed. A blank display functions as a low

battery indicator.

b. OUTPUT JACK

This is a convenient miniature jack output for use with a recorder or for

remote measurements of carbon monoxide concentration. Output is linear

and corresponds to 1 volt per 1000 ppm of carbon monoxide (range switch

in the lower 2K position) and 1 volt per 10,000 PPM (range switch in the

upper 20K position).. It can be connected to any instrument with an

impedence of 100 ohms or higher.

c. ALARMS

There is one audio and one visual alarm. The audio alarm is a continuous 2

KHZ tone. The visual alarm is a flashing red light located on the face of the

casing. The alarm will turn on at the level selected by the alarm switch.

5. OPERATION

a. START UP PROCEDURE

Remove the instrument from its case. If the unit is to be used for stack

measurements, take the probe and make sure that there is no liquid water in

the water trap, that the desiccant is blue in color, and the disposable filter is

clean. Connect the probe to the instrument. Set the pump mode selector

switch to the desired position. Turn the instrument on. The display will

come on and you will notice a quick increase in the display reading followed

by a gradual drop to zero in about 30 seconds. If the display reading does not

go back to exactly zero and you are in clean atmosphere, the small

screwdriver can be used to make the necessary adjustment by rotating the

zero adjustment potentiometers. There are two separate zero adjustments.

Set the range switch to the upper position and zero the display using the

20K zero adjust potentiometer. Next set the range switch to its lower

position and zero again the display using the 2K adjust potentiometer.

Now the instrument is ready to take measurements.

b. STACK MEASUREMENTS

To measure the carbon monoxide concentration in the flue stack, set the

pump switch to the ON position. You should hear the pump running.

If you don’t know the approximate CO concentration, or if you are

measuring engine exhaust set the range potentiometer to its upper (20K

PPM) position.

Insert the stack probe into a 5/16 inch diameter hole in the stack and push

the probe so that its tip is as near as possible to the center of the stack. The

instrument can be held in the hand, or if it is desired to make adjustments to

the furnace or boiler, use the instrument handle to hang it from any nearby

convenient protrusion that is not hot to the touch, or to decrease the viewing

angle when the instrument is placed on a flat surface. MAKE SURE THE

INSTRUMENT OR HOSE IS NOT IN CONTACT WITH A HOT

SURFACE! (A surface that is too hot to touch).

To monitor the carbon monoxide in the stack on a 24 hour basis, set the

pump switch to the cycle position. Keep in mind that the water trap may

become filled up and the disposable filter may require replacement after 4-5

hours of continuous operation in the stack. Consequently, if the instrument

is operated in the cycling mode, the filter and water trap must be checked

once each day. In addition, the instrument will have to operate with the

battery charger connected to a 110 volt AC source after the first day of

operation.

c. AREA MONITORING

NOTE: The instrument is not designed to be intrinsically safe and

should not be used in explosive atmospheres!!!

The instrument may be used as a safety device for the detection of

hazardous carbon monoxide gas for work areas. Do not connect the probe to

the instrument. Set the pump switch to the OFF position. Set the range

switch to its lower (2K PPM) position. Set the alarm switch to the 50 ppm

position. You may hang the instrument from any convenient place or carry it

with you. If you wish to take a quick "sniff" of a suspected area, turn on the

pump, wait 30 seconds. If the instrument is operated on a 24 hour

continuous basis, the pump may wear out after 4-6 months.

d. SHUT DOWN PROCEDURE

When you are finished using the instrument, make sure the power switch is

turned off. If you have used the stack probe, do not touch the metal tubing

until it is cool.

Remove any water from the water trap, turn the probe upside down and

shake it well and get rid of the condensed water.

Give the instrument batteries a fresh charge.

6. MAINTENANCE

a. CLEANING THE WATER TRAP

The water trap is made of two compartments. The first compartment is

intended to catch all moisture that has condensed in the probe. The second

compartment is filled with a dessicant material (#44 silica gel) that will

adsorb the remaining water vapor in the stack gas. The dessicant is colored

deep blue when dry. As it absorbs moisture its color changes progressively

to dark pink and eventually to pale pink when it is completely used up.

There is sufficient desiccant material in the trap for approximately four

hours of continuous operation. When the desiccant is used up it must be

replaced, otherwise moisture will eventually penetrate through the filter and

will be deposited on the surface of the sensor. This may cause erratic or low

readings.

Used up desiccant material can be reactivated by heating at 300-400 degrees

Fahrenheit in a clean atmosphere for about one hour until it becomes blue

again. Because of possible soot collection, however, it may be impractical to

reactivate the dessicant more than two or three times.

Extra desiccant material is available from the factory. It is supplied in one

pound containers.

To replace the desiccant material, simply pull out the plastic plug (caplug).

Fill the silica gel compartment with new material and force the plastic plug

back over the clear tube until an airtight seal is obtained. Liquid water which

has accumulated in the first compartment can be removed by simply pulling

out the caplug at the other end of the water trap, pouring out the liquid and

replacing the plug.

b. CHANGING THE DISPOSABLE FILTER

The disposable filter needs periodic replacement. It must be replaced it is is

noticeably discolored, or if the pump fails to operate, indicating a blockage

in the line. The disposable filter must always be connected so that the

direction of flow is radially inwards (towards the center). This allows the

operator to more eaily notice discoloration of the filter and any moisture that

penetrates through the water trap. To replace the filter, simply loosen the

two clamps that secure it to the hose. Take a new filter and connect the two

ends of the tubing to it, observing the correct direction of flow. Fasten the

clamps.

c. REPLACING THE CARBON MONOXIDE SENSOR

This is a very infrequent procedure since the carbon monoxide sensor has an

expected life of 1-2 years. The CO sensor needs replacement when it is no

longer possible to calibrate the instrument using calibrated gas.

To replace the sensor, remove the four screws that secure the base and

expose the interior to the instrument. The sensor is the 1-1/2 inch round

plastic disk that is attached to the back of the aluminum housing. Remove

the screws that hold the sensor (the CO sensor contains sulfuric acid,

exercise caution). Attach a new sensor to the housing. Remove the short

between the sensor terminals and connect the wires to the sensor, observing

the correct color code. Carefully, close the case, making sure that no wires

or tubing are being pinched. Secure the case with the four screws.

7. INSTRUMENT CALIBRATION

The Model 60 Carbon Monoxide Analyzer has been calibrated at the factory by using

a calibrated gas that contains 200 ppm carbon monoxide in air (range switch in the

lower position). (However, any other calibration gas in the range of 50-2000 ppm CO

in air or nitrogen can be used, if available. Higher concentration may be used with the

range switch set in its upper position ). The sensor possesses good stability and does

not require frequent calibration.

A tentative recommended calibration schedule is as follows:

If the unit is used in engine exhausts, calibrate after 10- 20 hours of use. If the unit is

used in boilers calibrate every one or two weeks. If the unit is used for area

monitoring (safety) calibrate every 3-4 months.

If it is desired to check the calibration of the instrument, connect the probe to the

instrument and turn on the instrument. Turn on the pump. Wait two minutes and

carefully zero the instrument, making sure the air the instrument draws is clean and

free of any smoke or exhausts.

If you are using the ENERAC calibration kit follow the directions in the calibration

kit manual.

If you are using your own span gas, feed the calibrated gas to the stack probe at a rate

of approximately 1000-1500 cc/min. Use a flow meter to observe the flow into the

instrument. Listen to the sound of the pump. Adjust the flow rate between 1000-1500

cc/min. so that the sound of the pump appears normal as when it was aspirating air.

Wait till the CO reading of the display has stabilized. If you are using high

concentration span gas, make sure the area is well ventilated, or carry out the

calibration under a fume hood, since carbon monoxide gas is highly toxic. Remove the

small round black plastic cap that covers the span adjustment potentiometer. With a

small screwdriver, rotate the span adjustment potentiometer until the display indicates

the correct reading. Replace the black plastic cap. Shut off the gas, disconnect the

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