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Max 5 Combustion Efficiency Analyzer

What are the cold start procedures for this instrument?
What is the effect on the MAX 5's performance if the thermocouple is disconnected from the unit?
Can you advise components needed to do a retrofit for a special range: 0 - 2.5% CO?
The Max 5's VR2 Analog board was moved from its original location to a different spot with wires attached. Please advise why.
How frequently will we have to replace the sensors?
What is the composition of span gas to calibrate the combustible sensor?
What is the principle of operation for the CO sensor?
The fuel option is between a #2 oil and a #6 oil. What is the difference?
Can you provide the formula to calculate the CO2 level?
Can we use the MAX 5 in a positive pressure sample gas even with its internal pump?
Can we use the MAX 5 on a high temperature sample gas (more than 50 degrees C)?
If we run the Max 5 on 120v, will we damage the unit or get a faulty reading?
The CO cell has three pins to connect to. The manual calls out to connect the J6 jumper to the CO cell. The J6 jumper is a 2 pin connector. I am assuming that it does not matter what pins the J6 connector land on. Is my assumption correct?
The manual says see interconnect diagram but there does not seem to be one in the manual.
Is it true the Max 5 will not function properly unless all 3 sensors are installed?
On the CO (F1-R) sensor proper there are 3 exposed pins on the top of the sensor/cell. Do these pins occupy a connector or do they have a purpose? See verbage below taken from manual MAX 5 P/N M39218 11/13/98 ECO#98-0542. I have bolded the verbage that is confusing.

CO SENSOR: (Refer to Interconnection Diagram)

a. Installation: To install the F-1R sensor, remove the sensor from its protective bag and plug it into the center receptacle in the bottom of the MAX 5. Next, take the connector from J6 on the analog board and plug it into the top of the F-1R sensor.

b. Replacement: To replace the F-1R sensor, unplug the connector from J6 at the top of the sensor, remove the sensor by pulling up on it, and throw away the old sensor. Take a new F-1R sensor from its protective bag, insert it into the receptacle (center bottom of the MAX 5), and attach the connector from J6 to the top of the sensor
We have two Max 5 analyzers. One checked out with a bad O2 cell from the start, we replaced it witha spare cell and it's now OK. The other check out OK initially but after delivery to the client it faied with a bad )2 cell. We replaced MFC, Replaced MFC, got reading and calibrated, we observed the reading falling away gradually until 00.0, when touching the O2 MFC connector J5 reading went back to 20.9%. We checked the plug for loose connections but found none. Please advise.
How do you calculate the efficiency level on the Max 5?
Could you please provide the serial data spec. for a Max 5 efficiency analyser? I need to connect it to a data logger so I need to know what input and output strings it uses, as well as the COM port settings.
What printers work with the Max5?
Do you have any resources for serial printers?
How do I print stored readings on a Max5?
How do I print an instruction manual?
Does the Max 5 work accurately in a predominantly nitrogen atmosphere?
After receiving a bad O2 sensor message, I replaced the cell but am still receiving a bad sensor message. What is the issue?


What are the cold start procedures for this instrument?

Cold start procedures can be found by downloading this PDF file.


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What is the effect on the MAX 5's performance if the thermocouple is disconnected from the unit?

The unit will no longer read temperature, and the calculated CO2 and efficiency calculations will be incorrect. All else will function properly (combustibles reading and O2 reading).


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Can you advise components needed to do a retrofit for a special range: 0 - 2.5% CO?

The retrofit kit is p/n B43108RF. Here are the parts and procedure.


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The Max 5's VR2 Analog board was moved from its original location to a different spot with wires attached. Please advise why.

The original VR2 was obsoleted. The new VR2 works better at the new location due to the emi generated by the new VR2.
VR2:
Was: CB3802
Is: PM672


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How frequently will we have to replace the sensors?

CO sensor every 6-12 months; Combustibles sensor = 12 months; Oxygen = 12 months.


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What is the composition of span gas to calibrate the combustible sensor?

2.0% - 4.5% methane in Nitrogen


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What is the principle of operation for the CO sensor?

The F1R sensor is a solid-state electro-chemical cell, which produces a micro-amp signal proportional to the amount of CO at the sensor. It is a three-electrode sensor. This sensor requires a -75 mV bias voltage applied generate the current output signal.


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The fuel option is between a #2 oil and a #6 oil. What is the difference?

Some difference between the #2 oil and #6 oil are: the density, the BTU, the fuel factor.


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Can you provide the formula to calculate the CO2 level?

MAX5 %CO2 CALCULATION

%CO2
EXAMPLE: MAX5 READING/SET UP
2 %O2
0.1% COMB.
5.036 (SOLID) FUEL TYPE

t1= 1000-[4.78(%O2 X 10)]-%COMB. X 10
= 1000-[4.78(2 X 10)]-0.1 X 10
= 1000-[4.78(20)]-1
= [1000-95.6]-1
= 904.4-1
= 903.4

%CO2= [(t1/FUEL FACTOR) + 0.5] /10
= [(903.4/5.036) + 0.5] /10
= (179.3884 + 0.5) /10
= 179.8884/10
= 17.98884

%CO2 = 18%

FUEL FACTORS: #2 OIL= 6.396
#6 OIL= 5.981
NATURAL GAS= 8.719
SOLID (COAL)= 5.036


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Can we use the MAX 5 in a positive pressure sample gas even with its internal pump?

Yes, but the pressure must be very low (close to atmospheric). Pressure must not be high enough to effect the flowrate already set by the pump.


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Can we use the MAX 5 on a high temperature sample gas (more than 50 degrees C)?

The recommended 0-50 degrees C is the temperature range for the sample when it reaches the sensor. However the MAX5 is designed for use in much higher temperatures, like stacks and boilers. The high temperature sample will have cooled to the 0-50 degrees range by the time the it reaches the analyzer/sensors.

The metal tube of the MAX5 probe is inserted into the hot sample, and the sample is cooled as it travels through the metal probe and the 15 feet of hose that is a part of the probe/thermocouple assembly.

The standard MAX5 uses the probe with type K thermocouple which operates in temp 0-1200 deg. C. We also have the low temp. option which is built with the type J thermocouple 0-750 deg C.


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If we run the Max 5 on 120v, will we damage the unit or get a faulty reading?

Operating the MAX 5 with AC line voltage can cause damage to the analyzer.

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The CO cell has three pins to connect to. The manual calls out to connect the J6 jumper to the CO cell. The J6 jumper is a 2 pin connector. I am assuming that it does not matter what pins the J6 connector land on. Is my assumption correct?

It does matter.The connector J6 on the analog pcb is a 5-pin connection for both the 3pin connector on the CO sensor cable, and the two-pin connector for the thermistor wires from the CO sensor receptacle.

Plug the 3-pin (CO sensor cable) connector into #1, 2 , &3. of J6, and plug the 2-pin connector into #4 & 5 of the same J6 to the pcboard.

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The manual says see interconnect diagram but there does not seem to be one in the manual.

A copy of the Connection diagram is attached here.

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Is it true the Max 5 will not function properly unless all 3 sensors are installed?

Yes all sensors must be installed for proper operation of the analyzer.
1) All sensors are needed to get all the Measurements.
2) All sensors must be installed to keep the gas flow path closed between the sample input and the vent.
If the CO or Comb. sensor is not installed, the pump will be pulling in ambient air at all times through the open receptacles.

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On the CO (F1-R) sensor proper there are 3 exposed pins on the top of the sensor/cell. Do these pins occupy a connector or do they have a purpose? See verbage below taken from manual MAX 5 P/N M39218 11/13/98 ECO#98-0542. I have bolded the verbage that is confusing.

CO SENSOR: (Refer to Interconnection Diagram)

a. Installation: To install the F-1R sensor, remove the sensor from its protective bag and plug it into the center receptacle in the bottom of the MAX 5. Next, take the connector from J6 on the analog board and plug it into the top of the F-1R sensor.

b. Replacement: To replace the F-1R sensor, unplug the connector from J6 at the top of the sensor, remove the sensor by pulling up on it, and throw away the old sensor. Take a new F-1R sensor from its protective bag, insert it into the receptacle (center bottom of the MAX 5), and attach the connector from J6 to the top of the sensor


All three sensor having there individual plug-in cable. CO sensor also having plug-in cable which is terminated at J6 location.

The contents of the manual is like this;

During replacing OR removing the CO sensor from its housing, one needs to disconnect the plug-in cable from CO sensor ( from top, three pin plug-in cable is there on CO sensor). Then remove the sensor & install the new sensor properly & plug the cable. Pins should face upward direction. There is no connections needs to be removed from PCB assembly for CO sensor installation OR removal & replacement. Just un-plug the connector from sensor & plug it properly when it is replaced.

Please refer to the following documents for sensor outlines:

MAX 5 Connection Details
MAX 5 Sensor Installation
MAX 5 Sensor Outline


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We have two Max 5 analyzers. One checked out with a bad O2 cell from the start, we replaced it witha spare cell and it's now OK. The other check out OK initially but after delivery to the client it faied with a bad )2 cell. We replaced MFC, Replaced MFC, got reading and calibrated, we observed the reading falling away gradually until 00.0, when touching the O2 MFC connector J5 reading went back to 20.9%. We checked the plug for loose connections but found none. Please advise.

Please check the following: Is there a bad contact in the probe? First to check make sure the hold down bracket is installed. If the holdown bracket is installed then do a cold start. If cold start won't help then replace the O2 probe. Attached are the procedures for doing a cold start: MAX5_Keypad_Cold_Start.pdf

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How do you calculate the efficiency level on the Max 5?

Please refer to the following document:

Max5_efficiency_level.pdf

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Could you please provide the serial data spec. for a Max 5 efficiency analyser? I need to connect it to a data logger so I need to know what input and output strings it uses, as well as the COM port settings.

Please refer to the following documents:

MAX5_RS_232C.pdf

MAX5_11-16-2007_RS232_M.pdf

Additional information is available in the instruction manual pages 18 - 21 (Using the "Function keys")

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What printers work with the Max5?

Teledyne Analytical Instruments P/N P-528
Citizen #GX190
Citizen #200GX


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Do you have any resources for serial printers?

Micro Trends International (Citizen #200GX) (818)799-4556
National Parts Depot (Citizen #GX190)
http://linx.co.uk/
http://www.lb.shuttle.de/puffin/cbm4linux/
http://www.linas.org/serial/


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How do I print stored readings on a Max5?

To print stored readings:
(Key 5) (Optional - see appendix)

1) Plug the printer cable into the serial port and the printer. Turnon the p[rinter.

2) Activate Special Functions and press key #5. The printer will print the ID number and the six numerical values of each of the stored readings in chronological order.

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How do I print an instruction manual?

To print an instruction manual:
(Key 8)

1) Connect a serial printer to the instrument's serial port. Turn on the printer and switch it "on-line."

2) Activate Special Funtions, then press key 8.

3) The abridged version of the instrument's instruction manual will be printed.

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Does the Max 5 work accurately in a predominantly nitrogen atmosphere?

Yes, the MAX5 will work accurately within it's measuring ranges in a mostly Nitrogen background.

A mostly Nitrogen sample or span gas background is not a problem in the MAX5 monitor because it has an internal dual head pump to pull in enough air for the necessary air dilution.

The MAX5 Combustion Efficiency Analyzer requires a minimum of 2:1 Oxygen dilution with the combustible gas. The air pump pulls in air (20.9% O2) which is mixed with the sample before it gets to the combustibles sensor.

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After receiving a bad O2 sensor message, I replaced the cell but am still receiving a bad sensor message. What is the issue?

The previous calibration from the bad sensor is still stored in the unit's EEPROM, so is likely causing this issue. Remove the O2 sensor and perform an electronic zero of the oxygen section (see page 10 of the manual). Once complete, the displayed reading should be "-00.0". Install the sensor and proceed with initial calibration.

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