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CA-CALC™ THREE GAS COMBUSTION ANALYZERS
TSI's CA-6203 CA-CALC Combustion Analyzer is a practical tool for boiler maintenance professionals who measure flue gases to tune standard burners and low NOx burners for safe, efficient operation. Real-time data easily viewed on the extra-large 3-line LCD display. Factory-set fuels and user-defined fuels provide fast setup and flexibility for use with common fuels like natural gas to bio-fuels.
The CA-6203 leads the industry in low cost operation with its field serviceable design. It provides for easy replacement of consumable components, such as batteries and the gas sensors, to ensure that the analyzer readily available for use.
The analyzer is an excellent preventative maintenance tool to supplement boiler room logs by monitoring stack gases and temperatures from a printout, data download or from data saved in the on-board memory. Limits can be set to trigger a scheduled maintenance request that can provide operational savings.
The CA-6203 provides O2, CO, CO2, NO, NOx, combustion temperatures, and flue draft pressure.
Features and Benefits
- Models available that provide O2, CO, NO, NOx, SO2, ambient temperature, stack temperature, differential temperature, draft pressure, efficiency, excess air and lambda
- Replacement sensors are shipped pre-calibrated for field installation
- Automatic baseline calibration
- Message indication when sensors need replacing due to calibration drift
- Operates on C-cell batteries (24 Hours) or AC power
Applications
- HVAC service and repair
- Plant maintenance
- School maintenance
- Hospital maintenance
- Monitoring boiler and furnace performance
- Boiler emissions monitoring
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TSI Model CA-6203 CA-CALC 3-Gas Combustion Analyzer O2, CO, NO, NOX, (H2 compensated), flue temperature, air temperature & draft pressure
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SERVICE INFORMATION
APPLICATION NOTESHANDBOOKSMANUALSQUICK GUIDESFREQUENTLY ASKED QUESTIONSshow/hide all answers
- Are different lengths of sampling probes or sampling hose available?
12-inch and 24-inch sampling probe lengths, with 9-foot or 25-foot sample hose lengths, are standard optional configurations. Custom sizes are available. Contact the factory for an authorized distributor for specific sizes, configurations, prices and delivery lead times.
- Can the Series CA-6203 Combustion Analyzer measure combustion gases on systems that have unique fuels, like wood pellets?
Yes. The Series CA-6203 is designed with seven (7) factory set fuels with adjustable fuel parameters and one (1) user defined fuel. The manufacturer of the fuel can provide you with the fuel parameters to enter into the analyzer under the fuel parameters menu option. The new fuel will be saved in memory for future use. The user-defined fuel should be used for unique fuels, while the fuel parameters for the seven (7) factory fuels can be adjusted for regional variations in composition. The instrument will use those parameters when that fuel type is selected as the current fuel.
- Do the CA CALC Series CA-6100 and CA-6200 Combustion Analyzers measure NOx?
The Series CA-6100 Combustion Analyzers do not have options to measure NO nor NO2 so therefore cannot measure NOx. The CA-6000 Single Gas Monitors and the Series CA-6200 Combustion Analyzers have options for the measurement of NOx.
- Does the CA-6203 Combustion Analyzer have Data Logging?
The CA-6203 has memory capacity to store and retrieve 100 discreet sample sets. The data can be printed or downloaded into a computer for end of the day or service reports. The data can be output as individual sample sets, as sets of measured data per customer or per individual equipment serviced. Data can also be output directly from the current data displayed on the screen when an immediate hard copy is preferred.
- Does the CA-6203 Combustion Analyzers require factory service when sensors need recalibration or replacement?
No. That is one of the exceptional features of the CA-CALC. All new sensors are shipped calibrated from the factory for easy field installation and minimized instrument downtime.
- Does the CA-CALC™ have UL or CSA approval? If not why do we not have these approvals?
In general, CSA and UL are not required for the combustion analysis products currently offered by TSI. The instruments do not have intrinsic safety requirements or other safety requirements for which UL or CSA would be required. The power adaptor, which plugs directly into the wall outlet, is UL listed, and has CSA approval as required.
- How does the emissions probe improve SO2 and NO2 measurement accuracies?
The emissions probe is effective for measuring NO2 and SO2 because it minimizes the conditions that could cause SO2 or NO2 to be scrubbed out of a sample. This is accomplished by the advanced design which includes a non wetting probe hose lining which provides an internal diameter to increase the velocity the gas sample, plus a sintered metal filter on the probe tip to prevent soot from entering the probe and collecting on the tubing walls. This special emissions probe is both accurate and cost effective. If moisture content or local regulating authorities require heated lines and/or a complex moisture removal gas preparation system, the CA-6200 would be set up to take the sample after the moisture removal device.
- How durable is the CA-CALC™ Combustion Analyzer? In particular, will the hose fittings withstand being dropped? Will it stand up to water spray? Oil spray? How do you clean it if you get oil or grease on it?
The CA-CALC™ is a very durable instrument. It has been drop tested, it has a splash resistant design and it can be cleaned with a dry or slightly damp cloth and a small amount of a mild soap or isopropyl alcohol. Its total design is rugged to withstand the harsh environments of some mechanical rooms and test locations. Care should be taken to avoid placing the instrument in puddles, as the sensor and battery compartment covers are not watertight.
- How often do the CA-CALC™ Combustion Test Instruments need recalibration?
A baseline calibration is performed during the warm up cycle each time the instrument is powered up if the warm up is not bypasses by the operator. This baseline calibration recalibrates the zero point for most sensors and the span of oxygen to 20.9%. TSI recommends annual full recalibration of the sensors as a minimum. Recalibration services are available through TSI, through a local calibration facility or by anyone with a calibration kit. If recalibration is done at the factory, the instrument is cleaned and inspected in addition to the full instrument calibration. Heavy use of the instrument would warrant more frequent recalibration.
- Is the CA-6203 Combustion Analyzer able to run on battery power. If so, how long will operate on battery power?
An AC power supply is a standard accessory for these instruments but the instruments can be operated from standard ‘C’ Cell batteries. The batteries provide continuous operation for 24+ hours, with the pump on. Battery life of the CA-CALC™ is increased significantly when the pump is switched off between measurements, and the backlight is turned off. Competitive combustion analyzers typically operate for 8 hours or less on battery power when new and this decreases over time since they generally use expensive rechargeable batteries. The heavy battery-packs of some of the competitive models make them less portable than the lightweight CA-CALC.
- What are the units #/MBtu used for?
These units indicate the amount of each gas generated per unit of fuel burned or energy produced. CA-6203 Combustion Analyzers have the capability to calculate Emission Rates directly from the measured data for fast easy comparison to the limits set by the local regulating agencies or the EPA.
- What certifications does the CA-CALC™ Series CA-6203 Combustion Analyzer have?
It has passed CE testing as required by European Regulations and has will have TUV approval soon. CE testing verifies that the instrument is not a source of, nor affected by, particular electromagnetic frequencies and intensities. TUV tests are aligned with the preliminary EC guidelines.
- What does the CA-CALC™ CA-6203 measure? What does it calculate?
The CA-6203 measure O2, CO (H2 compensated), NO, ambient temperature, stack temperature and draft pressure as standard. An optional accessory provides measured combustion air inlet temperatures. Efficiency, loss, excess air, lambda and NOX are calculated form the measured data. Air free (undiluted) NOX and air free CO are calculated and displayed with the measured NO and CO. Unique for this class of portable combustion analyzer, the CA-6203 provides the option to display the data as emission rates for easy comparison to regulated site and equipment limit information.
- What happens if the CO sensor becomes saturated by high CO concentration exposure? Does it require re-calibration if this happens? How long does it take to recover?
Sensors exposed to high concentrations of a gas can take up to several hours to recover to zero. In most cases the reading will return to acceptable baseline in less than 15 minutes. For faster recovery, run the instrument in clean air with the probe hose detached from the instrument until it recovers. Recalibration of sensors is not needed but a baseline calibration is recommended to correct for any drift that has occurred.
- What is NOx? Why is it measured? Does the CA-CALC CA-6203 measure NOx?
NOx is a term used to describe the total oxides of nitrogen. NOx is commonly estimated from the measured NO, based on the assumption that total NOx is 5% NO2 and 95% NO. This assumption is generally acceptable when combustion exhaust gases are measured at the outlet of the combustion system, and the oxygen concentration is low. If the measurement is made at the exhaust outlet or in the atmosphere, the NO2 is likely much higher than 5% of the total NOx. Measurement of NO and NO2 is recommended for accurate total NOx information. The CA-6203 estimates total NOx. NOx is important to measure because reactions involving volatile organic compounds (VOCs) with nitrogen oxides (NOx) in the presence of sunlight form ozone in the atmosphere. Ground-level ozone causes throat irritation, congestion, chest pains, nausea and labored breathing. It aggravates respiratory conditions like chronic lung and heart diseases, allergies and asthma. Ozone ages the lung and may contribute to lung disease.
- What is the best calibration gas package for a customer who buys the Model CA-6203?
Outside North America, gasses can be purchased locally and setup for recalibration as diagramed in the Operation and Service Manual. Copies are available from the web site. If you are in the US or Canada, as a minimum O2 and CO KIT NUMBER 802003. is recommended. It includes a 500 PPM CO cylinder, an N2 cylinder for zeroing the O2 sensor, a demand flow regulator, probe adaptor kit and a carrying case. KITs for O2 or CO individually include the appropriate calibration gas cylinder, a demand flow regulator, probe adaptor kit and a carrying case. To perform a CO-H2 cross sensitivity recalibration on these instruments: CO-H2 cylinder P/N 801942. is recommended and carrying case P/N 800676 is recommended for the additional cylinder. To recalibrate the NO sensor: NO2 cylinder P/N 801921 is recommended and carrying case P/N 800676 is recommended or the additional cylinders as needed.
- What is TUV?
TUV testing involves rigorous testing of the applications for which the instrument is designed. It includes verification that the device satisfies the strictest European regulations for the industry and ensures the instrument specifications are stating correctly. Periodic retesting of the equipment is required to maintain TUV approval. TUV is probably the most comprehensive testing any instrument of this type will undergo.
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