DDS Calorimeters CAL3K-A Manual de usuario

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected].za

CAL3K-A INSTALLATION GUIDE

VERSION 1.1

MANUFACTURED BY DIGITAL DATA SYSTEMS (PTY) LTD.

AND PART OF THE DDS CALORIMETERS BRAND

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected].za

Contents

PURPOSE OF THIS MANUAL........................................................................................................................................ 4

HOW TO USE THIS MANUAL ....................................................................................................................................... 4

WARNING SYMBOL ................................................................................................................................................. 4

INFORMATION (NOTE) SYMBOL ............................................................................................................................. 4

................................................................................................................................................................................ 4

THE CAL3K-A System CHECK LIST ................................................................................................................................ 5

THE 3K-A CALORIMETER WITH EXTERNAL oxygen filling ............................................................................................ 6

THE 3K-2 AIR COOLER ................................................................................................................................................. 6

THE 3K-5 BAYONET VESSEL......................................................................................................................................... 7

THE CAL2K-3 OXYGEN FILLING STATION ..................................................................................................................... 7

.................................................................................................................................................................................... 7

UNPACKING AND INSPECTION.................................................................................................................................... 7

SETTING UP................................................................................................................................................................. 8

PREREQUISITES ....................................................................................................................................................... 8

SITE SELECTION....................................................................................................................................................... 8

................................................................................................................................................................................ 9

CALORIMETER (3K-1_A) .............................................................................................................................................. 9

FILLING STATION (CAL2K-3) ........................................................................................................................................ 9

HIGH PRESSURE OXYGEN ...................................................................................................................................... 10

COOLER (3K-2) .......................................................................................................................................................... 10

VESSEL (3K-5)............................................................................................................................................................ 10

HOW TO TEST CAL3K-A HARDWARE......................................................................................................................... 12

HOW TO TEST THE VESSEL ........................................................................................................................................ 12

3K-5 SELF DIAGNOSTIC TEST ................................................................................................................................. 12

3K-5 VESSEL TEST .................................................................................................................................................. 13

KEYBOARD COMMANDS........................................................................................................................................... 13

MASS ENTRY ......................................................................................................................................................... 14

SAMPLE IDENTIFICATION...................................................................................................................................... 15

GROUP IDENTIFICATION ....................................................................................................................................... 15

SPIKE MASS........................................................................................................................................................... 15

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected].za

BALANCE MASS..................................................................................................................................................... 15

OPEN LID............................................................................................................................................................... 15

VESSEL USER TEST................................................................................................................................................. 15

TERMINATE USER TEST ......................................................................................................................................... 16

.............................................................................................................................................................................. 16

CAL3K-A USER TEST............................................................................................................................................... 16

.............................................................................................................................................................................. 16

SUBJECT HELP ....................................................................................................................................................... 16

OTHER KEYBOARD COMMANDS ............................................................................................................................... 16

ABORT................................................................................................................................................................... 16

FIRE MANUAL ....................................................................................................................................................... 16

CALIBRATION ........................................................................................................................................................ 16

READ RESULT ........................................................................................................................................................ 17

CONNECTING TO A BALANCE.................................................................................................................................... 17

.................................................................................................................................................................................. 17

CALIBRATION ............................................................................................................................................................ 18

INTELCAL CALIBRATION ............................................................................................................................................ 18

VESSEL CALIBRATION WITH MORE THAN ONE CALORIMETER ................................................................................. 18

ROUTINE CALIBRATION............................................................................................................................................. 19

PURPOSE OF PRODUCT WARRANTY ......................................................................................................................... 20

OWNER’S WARRANTY............................................................................................................................................... 20

EXCLUDED (NON-WARRANTY) PARTS....................................................................................................................... 20

WARRANTY – REPAIRED products ............................................................................................................................ 21

GENERAL – WARRANTY VOID ................................................................................................................................... 21

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected].za

INTRODUCTION

Digital Data Systems (Pty) Ltd (dds) specializes in the design and manufacture of scientific bomb calorimeter systems

for various types of industries and applications from the coal mining industry to educational institutes. dds bomb

calorimeter systems are the most advanced combustion calorimeter systems available today. The system is used to

measure the calorific value of both solids and liquids. dds has a wide range of systems to suit different applications

and sample requirements. Please visit our website: www.ddscalorimeters.com to find out more

You have chosen the CAL3K-A Bomb Combustion Calorimeter System, which is best suited for fast and accurate

calorimetry operations.

PURPOSE OF THIS MANUAL

It serves as a short introduction to the CAL3K-A system and the various components. It explains the very basics of

operation and guides you to perform hardware tests and do the first determination. It relies on the DEFAULT setting

and the factory calibration.

But there is more: Information and capability! This is not explained here but in an ON-LINE version. It is safe to say

that you need a PC or laptop to change from the basic operation to a more sophisticated or suitable one.

HOW TO USE THIS MANUAL

This Manual makes use of some informative symbols or icons, in order to bring your attention to the text.

WARNING SYMBOL

This yellow triangle with an exclamation mark inside it, indicates a WARNING message or a message

that is instructing you NOT to do something. Please take note of this message, because if you ignore it

you could damage the Calorimeter equipment.

INFORMATION (NOTE) SYMBOL

This white hand with a finger pointing, indicates a NOTE or INFORMATIVE message. It indicates

something that you need to pay attention to. Please take note of this message, as it provides special

or detailed information about a particular item.

USER INFORMATION AND HELP AIDS

Included in your shipment is this printed Installation Guide.

The on-line Help Guide for basic system operations, trouble-shooting and solutions, application notes as well as how

everything functions is available on-line and can be found at www.ddscalorimeters.com. Please note the CAL3K-A

Windows Software can be downloaded from the following link: www.ddscalorimeters.com/software/cal3k

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected].za

SYSTEM COMPONENTS

THE CAL3K-A SYSTEM CHECK LIST

The system consists of the following:

3K-A

CAL3K-A Calorimeter with Manual Oxygen Filling

Received

3K-A-KT

CAL3K-A Calorimeter Installation Kit

Included in Kit:

3K-SM

Power Supply

KETTLECORD

Mains Cable 220V

3K-BC

Balance Cable D9

USBCABAB

PC Cable (USB)

CAL2K-KB

PC Keyboard (PS2)

3K-4-PS

Preparation Stand

TWEEZERS/S/S

Stainless Steel Tweezers

CAL2K-4-BA

Certified Benzoic Acid Tablets (50 x 0.5g Tablets per Bottle)

3K-A-INST

CAL3K-A Installation Guide Printed

3K-2

CAL3K Air Cooler

3K-2-KT

CAL3K Air Cooler Installation Kit

Included in Kit:

3K-SM

Power Supply

KETTLECORD

Mains Cable 220 V

CAL2K-3

CAL3K Filling Station

CAL2K-3-KT

CAL3K Filling Station Installation Kit

Included in Kit:

CAL2K-3-FR

Flow Adjustor O-Rings

CAL2K-3-NR

Nozzle O-Rings

CAL2K-3-OP

High Pressure Pipe 4mm (2m) (Clear)

CAL2K-3-RC

Oxygen Regulator Connection

CAL2K-3-DC

Defiller Cap

3K-5

CAL3K-A Bayonet Vessel

3K-5-KT

CAL3K-A Bayonet Vessel Installation Kit

Included in Kit:

3K-5-CE

Centre Electrode

3K-5-NR

Vessel Nozzle O-Ring

3K-5-OE

Outside Electrode

CAL2K-4-CB-

SINGLE

Crucibles

3K-5-DP

Deflector Plate

3K-5-FW

Firing Wire (1 packet of 5 wires)

3K-5-FC

Firing Cotton Packet (1 Packet of 200 Threads)

3K-5-LR-5

Lid O-Rings (1 packet of 5)

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected]

THE 3K-A CALORIMETER WITH EXTERNAL OXYGEN FILLING

The CAL3K-A uses the Dynamic method (Isiperibol) of determination while

still using the DRY method. The prepared vessel is filled with oxygen in the

external filling station and placed in the calorimeter and the lid is closed.

The rest is automatic!

Width - 270mm

Height - 200mm

Depth - 380mm

Weight - 8kg

Power - 220-240V / 12W

THE 3K-2 AIR COOLER

The air cooler requires no water, piping or other resources. The Air Cooler

is supplied with an external 12V power supply and a suitable mains cable.

The air cooler will cool the vessel in approximately 6-8 minutes to the

specified setting. The operation of the cooler can be set via the USB port

and the CAL3K-A application software or from the CAL3K-A The cooler is

factory configured before shipment.

Width - 155mm

Height - 235mm

Depth - 285mm

Weight - 3 to 4kg

Power - 12VDC

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected]

THE 3K-5 BAYONET VESSEL

The ignition and burning process is contained within a chamber so that

the energy released can be measured in the form of heat. The Vessel has

temperature sensors built into it, so that the temperature rise can be

measured.

Because of the high pressure of oxygen required for combustion, the

Vessel is classified as a “Pressure Vessel” and is consequently tested by an

inspection authority to 10 times its normal pressure.

Diameter - 63mm

Height - 150mm

Weight - 1.9kg

THE CAL2K-3 OXYGEN FILLING STATION

The oxygen filling station is connected to the oxygen bottle via a regulator.

The regulator reduces the bottle pressure to 30bar, which is adjustable.

The regulated pressure is then supplied to the filling station, which shows

the supply pressure. Once a vessel is placed in the filling station and the

lever is lowered the vessel pressure is indicated and the actual filling

progress can be observed. The filling speed is adjustable to suit the sample

material.

Width - 220mm

Height - 450mm

Depth - 300mm

Weight - 4.5Kg

INSTALLATION

UNPACKING AND INSPECTION

There are no special precautions to be taken when unpacking your system. The following check list is for your

convenience:

1. Locate and tick-off the various system components as indicated on the CAL3K-A Check List as per above

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected]

2. Unpack and inspect all the system components such as the 3K-1_A Calorimeter, 3K-2 Air Cooler, CAL2K-3

Filling Station and the 3K-5 Bayonet Vessels according to the instructions in the relevant sections in this

document.

3. Inspect everything for any physical damage during transit. If damaged, consult your Agent immediately.

4. The Calorimeter has a GROUND (SAFETY EARTH) lug at the rear panel. This lug MUST be connected to the

EARTH supply to insure operating personal safety in case the power supply fails.

5. Verify the earth connection of the mains outlet, which you intend to use. Ask a qualified electrician to check

it.

6. Connect the power supply to the mains power and to the Calorimeter. Any power supply with 12V output,

3000mA capacity, centre pin POS, can be used.

7. Do the same for the COOLER.

8. Observe that the Display on the Calorimeter comes ON. If not, check the mains connections or consult your

Agent immediately.

9. Observe that the Display on the COOLER comes ON. If not, check the mains connection or contact your

agent.

SETTING UP

PREREQUISITES

Prior to installation of the CAL3K-A System, the User must provide the following:

1. A mains outlet for the 3K-1_A Calorimeter and a mains outlet for the 3K-2 Air Cooler power supplies.

2. A supply of oxygen at a pressure of 3.0-3.5Mpa (30-35 bars) (3000Kpa) within 4 meters of the 3K-1_A

Calorimeter. If bottled oxygen is used, a suitable high pressure oxygen regulator must be supplied. Digital

Data Systems can supply a single stage high pressure oxygen regulator; contact your agent for more

information.

3. If a balance is supplied, ensure that a sturdy, stable weighing surface is available. A mains outlet and Balance

connecting cable will also be required (balance cable supplied as part of kit).

SITE SELECTION

The 3K-1_A Calorimeter is a desktop unit, which can be installed wherever the laboratory space permits, with two

restrictions:

1. The CAL3K-A system, consisting of 3K-1_A Calorimeter, 3K-2 Air Cooler, should be connected to a mains

circuit without heavy inductive or SCR switched equipment. It is safe to have balances or other small

electronic apparatuses on the same circuit. Good installation practice would be to have a separate fused

mains circuit with separate earth leakage supply (or an earth current monitor, if applicable) for every system

component. Future computers and peripherals installed can be connected to the same circuit.

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected]

Please see above for the dimensions, weights and power requirements per unit. The BALANCE data

would be dependent on the make and model that you will be using.

SAFETY PRECAUTIONS

CALORIMETER (3K-1_A)

•Electrical Shock: There are no user serviceable parts inside.

•Do not open the bottom panel unless the supply cable has been disconnected.

•Dangerous voltages will be present inside the unit after the supply cable has been disconnected.

DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO THAT THE

EARTHING CAN BE CHECKED.

DO NOT USE ANY OTHER PIPE OTHER THAN THE HIGH PRESSURE PIPE SUPPLIED FOR OXYGEN

FILLING.

•NOTE: With some applications you may need to fill the Vessel to less than 2400KPA e.g.1500KPA (15 bar),

however this is only applicable when you have a sample which is highly combustible, for example with wood

related samples. THE FILLING PRESSURE IS ADJUSTABLE on the regulator, the filling speed is adjustable on

the filling station.

REMEMBER: You may fill the Vessel LESS than 3000KPA but NEVER more than 3000KPA.

FILLING STATION (CAL2K-3)

•Secure the Filling Station to the table.

•Install the flexible high pressure pipe supplied without any sharp bends.

•Check the nylon high pressure pipe supplied for any mechanical damage before putting it under pressure.

•Secure the pipe nuts to the pressure regulator side, then clamp the ferrule to the high pressure pipe on the

gauge block side.

•If the oxygen bottle is not situated close to the Filling Station or if it is in another room or perhaps outside,

then a solid, permanent installation of pressure piping should be installed, as well as a shut off valve and

pressure gauge within easy reach of the CAL2K-3 Filling Station.

•If bottled oxygen is used, a suitable High Pressure oxygen regulator must be supplied by your Agent, or

sourced locally. Ordering this item from the factory ensures that the necessary modifications have been

made to fit the CAL2K-3 Filling Station.

•The oxygen bottle should be secured according to regulations.

•DO NOT USE ANY OTHER PIPE OTHER THAN THE HIGH PRESSURE PIPE SUPPLIED.

DDS CALORIMETERS

www.ddscalorimeters.com

Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters

CAL3K-A INSTALLATION GUIDE V1.1 | www.ddscalorimeters.com | [email protected]

ALWAYS FILL THE VESSEL WITH OXYGEN TO A MAXIMUM PRESSURE OF 3000KPA (30 BAR).

NOTE: With some applications you may need to fill the Vessel to less than 3000KPA e.g. 1500KPA (15

bar), however this is only applicable when you have a sample which is highly combustible, for

example with wood related samples.

REMEMBER: You may fill the Vessel LESS than 3000KPA but NEVER more than 3000KPA.

HIGH PRESSURE OXYGEN

•The type of Oxygen to be used is the standard Industrial Oxygen used for welding. A purity of 99.5% will be

suitable.

•Conform to the industry standard of handling procedures for oxygen bottles.

•Secure the bottle against a wall.

•The unit has an exhaust outlet (6mm pipe). Route this pipe to the outside or any suitable scrubber to

prevent the burned gas to enter the room.

COOLER (3K-2)

•Electrical shock: There are no user serviceable parts inside.

VESSEL (3K-5)

•The Vessel has been pressure tested (certificate will be provided if required), at 30 MPA according to

international standards.

NEVER OPERATE ANY UNSAFE VESSEL.

NEVER IMMERSE THE VESSEL INTO COLD WATER WHEN COOLING. USE THE 3K-2 AIR COOLER OR

ALLOW THE VESSEL TO COOL DOWN NATURALLY.

•A SUITABLE INSPECTION WARNING PERIOD OF 2000 FIRINGS, AND A STOP OPERATING LIMIT OF 2500

FIRINGS ARE PRE-PROGRAMMED FROM THE FACTORY

THE VESSEL MUST BE INSPECTED AT REGULAR INTERVALS DEPENDING ON THE USE. A SUITABLE INSPECTION PERIOD

CAN BE SET (By your agent!) AND THE UNIT WILL ISSUE AN INSPECTION WARNING AND SOON AFTER THIS IT WILL

SHUT-DOWN THE OPERATION.

NOTE: THE MANUFACTURER (DDS) AND ITS AGENTS CANNOT BE HELD RESPONSIBLE FOR ANY LOSS

OR DAMAGE RESULTING FROM NEGLIGENCE OR INCORRECT USE OF THEIR EQUIPMENT. IT IS YOUR

DUTY AND RESPONSIBILITY TO CHECK ALL SAFETY ASPECTS OF THE CAL3K-A SYSTEM REGULARLY.

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