Cal2K Operating Manual: Dds Calorimeters

DDS CALORIMETERS
www.ddscalorimeters.com
Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters
CAL2K OPERATING MANUAL
VERSION 4.8
MANUFACTURED BY DIGITAL DATA SYSTEMS (PTY) LTD.
AND PART OF THE DDS CALORIMETERS BRAND
CAL2K OPERATING MANUAL V4.8 | www.ddscalorimeters.com | calo@ddsystems.co.za

DDS CALORIMETERS
Contents
HISTORY OF DDS BOMB CALORIMETERS .................................................................................................................. 13
HOW TO USE THIS MANUAL ..................................................................................................................................... 13
WARNING SYMBOL ............................................................................................................................................... 14
INFORMATION (NOTE) SYMBOL ........................................................................................................................... 14
.............................................................................................................................................................................. 14
CALORIMETER (CAL2K-1) .......................................................................................................................................... 14
COOLER (CAL2K-2) .................................................................................................................................................... 15
FILLING STATION (CAL2K-3) ...................................................................................................................................... 15
HIGH PRESSURE OXYGEN .......................................................................................................................................... 15
VESSEL (CAL2K-4) ...................................................................................................................................................... 16
SYSTEM COMPONENTS ............................................................................................................................................. 17
THE CALORIMETER (CAL2K-1) ................................................................................................................................... 18
.................................................................................................................................................................................. 18
EXTERNAL CONNECTIONS (REAR PANEL) .............................................................................................................. 19
CALORIMETER COMPONENTS............................................................................................................................... 19
.................................................................................................................................................................................. 20
KEYPADS/KEYBOARDS........................................................................................................................................... 20
.................................................................................................................................................................................. 20
LCD DISPLAY .......................................................................................................................................................... 20
INDICATOR LAMP.................................................................................................................................................. 20
BEEPER (SITUATED BEHIND KEYBOARD) ............................................................................................................... 20
DOOR LATCH AND LID SWITCH ............................................................................................................................. 20
VESSEL CONNECTIONS .......................................................................................................................................... 21
THE COOLER CAL2K-2 ............................................................................................................................................... 21
.................................................................................................................................................................................. 21
COOLER SYSTEM COMPONENTS ........................................................................................................................... 22
COOLER INSTALLATION ......................................................................................................................................... 22
COOLER PERFORMANCE TESTING ......................................................................................................................... 22
COOLER NORMAL OPERATION ............................................................................................................................. 23
COOLER DISPLAY PANEL........................................................................................................................................ 23

DDS CALORIMETERS
VESSEL LED LIST .................................................................................................................................................... 23

ELEMENTS LED LIST ............................................................................................................................................... 24
STATUS LED LIST ................................................................................................................................................... 24
PUSH BUTTON LIST ............................................................................................................................................... 24
THE FILLING STATION CAL2K-3 ................................................................................................................................. 25
.................................................................................................................................................................................. 25
FILLING STATION SYSTEM COMPONENTS ............................................................................................................. 25
FILLING STATION INSTALLATION ........................................................................................................................... 26
ADJUSTMENTS ...................................................................................................................................................... 26
THE VESSEL CAL2K-4 ................................................................................................................................................. 28
.................................................................................................................................................................................. 28
VESSEL BACKGROUND .......................................................................................................................................... 29
MICROPROCESSOR................................................................................................................................................ 29
PERMANENT FIRING WIRE .................................................................................................................................... 29
VESSEL BASE CONTACTS ....................................................................................................................................... 29
THEORY OF “ISOTHERMAL” CV DETERMINATIONS : CONVENTIONAL WAY.............................................................. 30
MODIFIED CONVENTIONAL WAY .............................................................................................................................. 30
DRY METHOD ............................................................................................................................................................ 30
CAL2K VESSEL IMPROVEMENTS ................................................................................................................................ 31
.................................................................................................................................................................................. 31
SYSTEM CONFIGURATIONS FOR NETWORKING ........................................................................................................ 31
CHOICE 1 – OPERATE THE SYSTEM WITH OR WITHOUT A PC ............................................................................... 31
CHOICE 2 – IS A BALANCE CONNECTED, AND IF SO WHERE? ................................................................................ 31
.............................................................................................................................................................................. 32
CALORIMETER KEYBOARD MENU ACCESS ............................................................................................................ 32
BALANCE CONNECTION CHOICE ........................................................................................................................... 33
CONNECTING THE CAL2K SYSTEM ............................................................................................................................ 33
THE COOLER CONNECTION ................................................................................................................................... 33
THE BALANCE CONNECTION ................................................................................................................................. 33
THE CALORIMETER CONNECTION ......................................................................................................................... 33
.............................................................................................................................................................................. 34

DDS CALORIMETERS
CALORIFIC VALUE MEASUREMENT ........................................................................................................................... 34

TEMPERATURE MEASUREMENT ............................................................................................................................... 34
SAMPLE IDENTIFICATION (SID) ................................................................................................................................. 34
GROUP IDENTIFICATION (GID) .................................................................................................................................. 34
VESSEL IDENTIFICATION............................................................................................................................................ 35
SAMPLE MASS ENTRY ............................................................................................................................................... 35
AUTOMATIC MASS ENTRY .................................................................................................................................... 35
MANUAL MASS ENTRY .......................................................................................................................................... 35
VESSEL CALIBRATION ................................................................................................................................................ 35
CV DETERMINATION CYCLE ...................................................................................................................................... 35
INITIAL .................................................................................................................................................................. 36
FIRING ................................................................................................................................................................... 36
FINAL..................................................................................................................................................................... 36
DONE .................................................................................................................................................................... 36
CORRECTION FACTORS ............................................................................................................................................. 36
CALORIMETER ACCESS CONTROL ............................................................................................................................. 37
MENU ACCESS ....................................................................................................................................................... 37
SYSTEM CONFIGURATION PARAMETERS .............................................................................................................. 37
MENU ACCESS RESTRICTIONS ................................................................................................................................... 38
SID AND MASS ENTRIES ............................................................................................................................................ 38
SID ENTRY ............................................................................................................................................................. 38
MASS ENTRY ......................................................................................................................................................... 39
KEYBOARD ENTRY ................................................................................................................................................. 39
BALANCE ENTRY.................................................................................................................................................... 40
SYSTEM PARAMETERS .............................................................................................................................................. 40
PRIOR TO FIRING A VESSEL ....................................................................................................................................... 40
PREPARING VESSELS ................................................................................................................................................. 41
CALIBRATION OF VESSELS ......................................................................................................................................... 42
STEP BY STEP PROCEDURE FOR CV DETERMINATIONS ............................................................................................. 43
PREPARE ............................................................................................................................................................... 43
WAIT (STABILIZE) .................................................................................................................................................. 43

DDS CALORIMETERS
SAMPLE ................................................................................................................................................................. 43
COOLING ............................................................................................................................................................... 44
EXPLANATION OF DISPLAY DURING A DETERMINATION .......................................................................................... 45
LID OPEN – NO VESSEL IN WELL ............................................................................................................................ 45
SELECT MASS & SID ............................................................................................................................................... 45
CLOSE LID .............................................................................................................................................................. 45
INITIAL .................................................................................................................................................................. 45
FIRING ................................................................................................................................................................... 46
FINAL..................................................................................................................................................................... 46
DONE .................................................................................................................................................................... 46
OPEN LID ............................................................................................................................................................... 46
DETERMINATION OF VESSEL DEVIATION FACTOR .................................................................................................... 46
DETERMINATION OF CALORIMETER DEVIATION FACTOR ......................................................................................... 46
.................................................................................................................................................................................. 47
SINGLE VESSEL SYSTEM............................................................................................................................................. 47
DUAL VESSEL SYSTEM ............................................................................................................................................... 47
TRIPLE VESSEL SYSTEM ............................................................................................................................................. 48
.................................................................................................................................................................................. 48
SAMPLE MASS ENTRY ............................................................................................................................................... 48
NORMAL DETERMINATION ....................................................................................................................................... 48
CALIBRATION ............................................................................................................................................................ 49
ENTER USER ID (NUMBER) ........................................................................................................................................ 49
RECALL DEFAULT SETUP............................................................................................................................................ 50
BA CHECK SAMPLE ON/OFF ...................................................................................................................................... 50
DISPLAY OR SET GID .................................................................................................................................................. 51
DISPLAY ACTIVE BOMB CAL. ..................................................................................................................................... 51
DISPLAY B. CAL DETAILS ............................................................................................................................................ 51
SPIKE VALUE ............................................................................................................................................................. 53
SPIKE MASS ............................................................................................................................................................... 53
SPIKING ON/OFF ....................................................................................................................................................... 53
TIME OF DAY IN HHMM ............................................................................................................................................ 54

DDS CALORIMETERS
DATE IN DDMMYY..................................................................................................................................................... 54
CLEAR HEAP .............................................................................................................................................................. 54
DISPLAY SOFTWARE VERSION ................................................................................................................................... 55
CALIBRATION VALUE OF B.A. .................................................................................................................................... 55
CALIBRATION DEVIATION ......................................................................................................................................... 55
SAVE CALIBRATION 0-9 ............................................................................................................................................. 56
RECALL CALIBRATION................................................................................................................................................ 56
INITIAL DRIFT IN DEGREE C ....................................................................................................................................... 56
INITIAL TIME IN MINUTES ......................................................................................................................................... 57
FINAL DRIFT IN CAL VALUE........................................................................................................................................ 57
FINAL DRIFT IN DEGREE C ......................................................................................................................................... 57
FINAL TIME IN MINUTES ........................................................................................................................................... 57
SET AMBIENT TEMP. OFFSET .................................................................................................................................... 57
CORRECTION #1 (SULPHUR)...................................................................................................................................... 58
CORRECTION #2 (COTTON) ....................................................................................................................................... 58
SET CALORIMETER ID 1-7 .......................................................................................................................................... 58
SET BOMB NUMBER ................................................................................................................................................. 58
SET FIRING VOLTAGE ................................................................................................................................................ 59
INITIAL COMPENS. ON/OFF ...................................................................................................................................... 59
HIGH MASS LIMIT ..................................................................................................................................................... 59
LOW MASS LIMIT ...................................................................................................................................................... 59
BALANCE MASS, PC OFF ............................................................................................................................................ 59
ENERGY UNIT : BTU, CAL, MJ .................................................................................................................................... 60
AUTOMATIC BALANCE MASS .................................................................................................................................... 60
SELECT LANGUAGE 1-4 ............................................................................................................................................. 60
LOW RISE CURVE CHANGE ........................................................................................................................................ 61
ENABLE BOMB MASS ENTRY ..................................................................................................................................... 61
RECOMMENDED VALUE FOR MJ/KG......................................................................................................................... 61
SPIKE VALUE ............................................................................................................................................................. 63
SPIKE MASS ............................................................................................................................................................... 63
STEP BY STEP ENTERING THE SPIKE VALUE ............................................................................................................... 63

DDS CALORIMETERS
SOFTWARE INTALLATION.......................................................................................................................................... 64
MINIMUM SYSTEM REQUIREMENTS .................................................................................................................... 64
STEP BY STEP INSTALLATION..................................................................................................................................... 64
INSTALLING THE CAL2K MANAGEMENT TOOL ...................................................................................................... 64
USING THE CAL2K MANAGEMENT TOOL SOFTWARE ............................................................................................... 68
FAMILIARISING THE SOFTWARE FUNCTIONS ........................................................................................................ 68
USER SECURITY MANAGER ................................................................................................................................... 70
ADMINISTRATE USERS .......................................................................................................................................... 70
AUTOMATED DOWNLOAD OF RESULTS FROM CAL2K .......................................................................................... 71
FILE MANAGEMENT .............................................................................................................................................. 71
MENU ITEMS......................................................................................................................................................... 72
DECIMAL SEPARATOR ........................................................................................................................................... 73
TOOLS ................................................................................................................................................................... 73
STATUS.................................................................................................................................................................. 73
SETUP CALORIMETER ............................................................................................................................................ 74
HELP ...................................................................................................................................................................... 74
DISPLAYED INFORMATION ITEMS ......................................................................................................................... 75
BUTTON ITEMS ..................................................................................................................................................... 75
SETTING UP THE CALORIMETER ............................................................................................................................ 76
LOADING A FILE .................................................................................................................................................... 77
UPLOADING AND RETRIEVING RESULTS ............................................................................................................... 78
VIEW VESSEL ......................................................................................................................................................... 81
TEMPERATURE GRAPH.......................................................................................................................................... 82
GRAPH EXPLANATION ........................................................................................................................................... 83
DRIFT CURVE ......................................................................................................................................................... 84
CALORIFIC CURVE ................................................................................................................................................. 84
LOAD CURVES ....................................................................................................................................................... 85
HEAP MANAGEMENT............................................................................................................................................ 86
ADVANCED CALIBRATION ..................................................................................................................................... 86
CURVES ................................................................................................................................................................. 87
SAVING OPTIONS .................................................................................................................................................. 88

DDS CALORIMETERS
METHOD FOR AVERAGE, MEAN AND COPY .......................................................................................................... 88

METHOD FOR CHANGE FACTOR ........................................................................................................................... 89
METHOD FOR SAVE TO FILE .................................................................................................................................. 89
METHOD TO LOAD SAVED FILES ........................................................................................................................... 89
STATUS.................................................................................................................................................................. 90
NETWORK OPERATIONS ....................................................................................................................................... 90
OPERATION ........................................................................................................................................................... 90
SETUP.................................................................................................................................................................... 92
INITIAL .................................................................................................................................................................. 94
FIRE ....................................................................................................................................................................... 94
MAIN..................................................................................................................................................................... 95
DETERMINATION DONE ........................................................................................................................................ 96
.............................................................................................................................................................................. 96
CALORIMETER ........................................................................................................................................................... 96
COOLER ..................................................................................................................................................................... 97
WEEKLY MAINTENANCE........................................................................................................................................ 97
FILLING STATION ....................................................................................................................................................... 97
O-RING REPLACEMENT ......................................................................................................................................... 98
HIGH PRESSURE PIPE ............................................................................................................................................ 98
NOZZLE ................................................................................................................................................................. 98
PISTON .................................................................................................................................................................. 98
NIPPLE (INSIDE THE NOZZLE) ................................................................................................................................ 99
FLOW ADJUSTOR .................................................................................................................................................. 99
FLOW ADJUSTER NIPPLE ....................................................................................................................................... 99
VESSEL .................................................................................................................................................................... 100
RECONDITIONING ............................................................................................................................................... 100
MAINTENANCE SCHEDULE .................................................................................................................................. 100
GENERAL HINTS ...................................................................................................................................................... 101
OPERATING HINTS .................................................................................................................................................. 102
................................................................................................................................................................................ 103
GENERAL MESSAGES............................................................................................................................................... 103

DDS CALORIMETERS
“NOT IN CALIBRATION”....................................................................................................................................... 103

“NO BOMB RECOGNIZED” .................................................................................................................................. 103
“BAD ENTRY, SEE MANUAL” ............................................................................................................................... 104
"ENTRY REQUIRED"............................................................................................................................................. 104
"BAD KEY SEQUENCE" ......................................................................................................................................... 104
"NO MASS + SID AVAILABLE" .............................................................................................................................. 104
"BAD MASS+SID HEAP ENTRY" ............................................................................................................................ 104
"ENTER SELECTS, S=NEXT" .................................................................................................................................. 104
"SELECTION NOT ALLOWED" .............................................................................................................................. 104
"BOMB COMMUNICATION FAULT" ..................................................................................................................... 104
"LID OPEN: RESULT ABORTED" ........................................................................................................................... 104
"MISSFIRE: RESULT ABORTED" ............................................................................................................................ 104
"TERMINATED AT 5 MINUTES" ........................................................................................................................... 105
"FORCED CALIBRATION CYCLE" ........................................................................................................................... 105
"NO CALIBRATION TO SAVE"............................................................................................................................... 105
“CALIBRATION SAVED -> C0" .............................................................................................................................. 105
"ABORTED: BOMB UNSAFE" ............................................................................................................................... 105
"BOMB RECONDITIONING REQ"; 18 ................................................................................................................... 105
"FIRING CIRCUIT FAULT"; 19 ............................................................................................................................... 105
"RESULT MEMORY FULL"; 20 .............................................................................................................................. 105
"RESULT NOT SAVED (FULL)" .............................................................................................................................. 105
"NO RESULTS IN MEMORY" ................................................................................................................................ 106
"WARNING: BOMB TOO WARM" ........................................................................................................................ 106
"WARNING: BOMB TOO COLD" .......................................................................................................................... 106
"MASS OUTSIDE LIMITS" ..................................................................................................................................... 106
"TRAY ID DIFFERS FROM GID" ............................................................................................................................. 106
"LOW RESULT, USED C1 CAL" .............................................................................................................................. 106
"FAULTS NOT RECORDED????" ........................................................................................................................... 106
"POWER UP AFTER FAILURE" .............................................................................................................................. 106
"REAL TIME CLOCK ERROR" ................................................................................................................................ 106
"TEST STARTED" .................................................................................................................................................. 106

DDS CALORIMETERS
"PARA CHANGE NOT SAVED" .............................................................................................................................. 106

"CALIBRATION CYCLE ENABLE" ........................................................................................................................... 106
"CHECK SAMPLE ENABLED" ................................................................................................................................ 107
"SPIKING ENABLED" ............................................................................................................................................ 107
"SPIKING DISABLED" ........................................................................................................................................... 107
"TIME SET PERFORMED" ..................................................................................................................................... 107
"DATE SET PERFORMED" .................................................................................................................................... 107
"MASS HEAP WAS CLEARED" .............................................................................................................................. 107
"BOMB NUMBER CHANGED!"............................................................................................................................. 107
"INITIAL COMPENSATION ON" ............................................................................................................................ 107
"INITIAL COMPENSATION OFF" ........................................................................................................................... 107
"UNIT OF MEASURE CHANGED".......................................................................................................................... 107
"LANGUAGE HAS CHANGED" .............................................................................................................................. 107
SPECIAL DISPLAYS ................................................................................................................................................... 107
DISPLAY ACTIVE BOMB CAL ................................................................................................................................ 107
BOMB DETAILS .................................................................................................................................................... 108
SUB MENU ENTRY: 0-9..................................................................................................................................... 108
SUB MENU ENTRY: 10 ...................................................................................................................................... 108
SUB MENU ENTRY: 11 ...................................................................................................................................... 108
SUB MENU ENTRY: 12 ...................................................................................................................................... 108
SUB MENU ENTRY: 13 ...................................................................................................................................... 109
SUB MENU ENTRY: 14 ...................................................................................................................................... 109
RESULT DISPLAY .................................................................................................................................................. 109
LINE 1 - LCD DISPLAY ............................................................................................................................................... 109
SET UP NO BOMB SELECT MASS+SID ............................................................................................................ 109
SET UP NO BOMB (Mass)(SID) ...................................................................................................................... 109
SET UP (Temperature) (Mass)(SID) LID OPEN ............................................................................................... 109
INITIAL (Drift) (Mass)(SID) T=(Time) T or D .................................................................................................... 110
FIRING (Drift) (Mass)(SID) T=(Time)............................................................................................................... 110
FINAL (Time) (T rise) (Mass)(SID) (Result) ................................................................................................... 110
DONE (T rise) (Mass)(SID) (Result) ............................................................................................................ 110

DDS CALORIMETERS
SET UP (Temperature) SELECT MASS+SID (Result) ....................................................................................... 110

SET UP NO BOMB SELECT MASS+SID (Result).............................................................................................. 110
Returns to Step 3. ............................................................................................................................................... 110
............................................................................................................................................................................ 110
BASIC TESTS (T) - FROM T1 TO T7 ........................................................................................................................... 110
T1 : SHOW AMBIENT & BOMB TEMPERATURE: AA.A BB.BBB .......................................................................... 110
T2: FLASH LAMP and LCD: ................................................................................................................................... 110
T3: SHOW FIRE / SUPPLY VOLT: FF.F S.S .......................................................................................................... 110
T4: FIRE AT TARGET VOLTAGE:............................................................................................................................ 111
T5: SHOW LID AND WIRE SENSE: ........................................................................................................................ 111
T6: SHOW REALTIME EVERY Y SEC: DDMMYY HHMM SS ................................................................................ 111
T7: DISPLAY TEST ................................................................................................................................................ 111
CALORIMETER ......................................................................................................................................................... 111
COOLER ................................................................................................................................................................... 112
FILLING STATION ..................................................................................................................................................... 112
VESSEL .................................................................................................................................................................... 112
................................................................................................................................................................................ 112
DOCKING STATION OPERATION .............................................................................................................................. 114
DOCKING STATIONS PARTS ..................................................................................................................................... 115
DOCKING STATION MESSAGES ............................................................................................................................... 115
SETUP OF IDENTIFICATION STRING WITH EXAMPLES ............................................................................................. 116
CALIBRATION .......................................................................................................................................................... 117
................................................................................................................................................................................ 117
PARTS LIST – CAL2K-1 CALORIMETER ..................................................................................................................... 118
CAL2K-1-KT CALORIMETER INSTALLATION KIT........................................................................................................ 118
PARTS LIST – CAL2K-2 COOLER ............................................................................................................................... 119
CAL2K-2-KT COOLER INSTALLATION KIT.................................................................................................................. 119
PARTS LIST – CAL2K-3 FILLING STATION ................................................................................................................. 119
CAL2K-3-KT FILLING STATION INSTALLATION KIT.................................................................................................... 120
PARTS LIST – CAL2K-4 VESSEL ................................................................................................................................. 120
CAL2K-4-KT VESSEL INSTALLATION KIT ................................................................................................................... 121

DDS CALORIMETERS
................................................................................................................................................................................ 121
PRESSURE CONVERSIONS ....................................................................................................................................... 123
MJ / CAL / BTU ENERGY CONVERSIONS .................................................................................................................. 123
BALANCE SETTINGS FOR CAL2K BOMB CALORIMETER ........................................................................................... 123
DB25 CONNECTOR .............................................................................................................................................. 123

DDS CALORIMETERS
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 bomb calorimeter systems available today. The system is used to
measure the calorific value of both solids and liquids. dds has three different Bomb Calorimeter models in their
Scientific CAL2k range:
CAL2K ECO E2K

The CAL2k Calorimeter is aimed at The ECO Calorimeter is inexpensive The e2k Calorimeter is a middle of
the higher volume market; which and aimed at the lower volume the range product, suited to both the
requires higher quantities of CV market; which requires very small lower and higher volume markets. It
samples per day. quantities of CV samples per day. also comes with a fantastic language
compatible feature.
A determination will take A determination will take
approximately 7 minutes to run and approximately 40 minutes to run, A determination can take
depending on the number of Vessels and 1 (One) sample can be carried approximately 10 minutes using the
used, 10 samples can be carried out out every hour. CAL2K-2 Cooler and one Vessel.
every hour.
You have chosen the CAL2k Bomb Calorimeter System, which is best suited for your calorimetry requirements.
HISTORY OF DDS BOMB CALORIMETERS

In 1972, dds manufactured its first Calorimeter product the AMPC (Automatic Micro Processor Calorimeter). It was a
dual water isothermal unit controlled by a microprocessor. In 1980 a new revolutionary design of Vessel, namely the
DRY Vessel or CP510 was produced as it had no surrounding water jacket. The determination time was significantly
reduced, thus increasing the product’s efficiency by 4 times.
With the processing power of the microprocessors available at the time, the CP500 Calorimeter was born with its
striking “buttercup yellow” colour. The CP500 proved to be a very fast and reliable system and was exported to the
USA, Europe, Scandinavia, Australasia, Africa and India.
In early 2002 work began on the new CAL2k model. The tried and tested DRY system was retained and only the very
latest electronic technology was used, including surface mount devices. The CAL2k is now in full production and is
sure to be an even bigger success than its predecessor, the CP500. In 2005, dds realized the need for a smaller, low
sample volume, and inexpensive calorimeter system with the same accuracy and reliability of the CAL2k. Based on
these requirements, the ECO was then created as an alternative system to the CAL2k. By 2007, due to customer
demands work began on the e2k model. The e2k was designed to be able to have two language options – one being
English and the other an alternative language for example French. The e2k was also designed to work faster than
the ECO but not as fast as the CAL2k with less features as the CAL2k to keep it cost-effective.
HOW TO USE THIS MANUAL

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

DDS CALORIMETERS
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.
CAL2K CALORIMETER OVERVIEW

• Manages the temperature received from a Vessel, and present it in the various measurement ranges
• Calculates CV(s)
• Provides access to the Vessel
• Restarts the temperature sampling in the Vessel every 6 seconds
• Provides access to other Calorimeters
• Provides large storage for results
• Provides interface to a balance
• Provides RS232 interface to a PC
• Manages the SAMPLE ID and MASS (HEAP)
• Provides the Cooler with the ambient temperature
• Provides firing control
• Manages calibration curves in the Vessel
• Has a Serial interface to the Vessel
• Interfaces to the display and keyboard
• Provides beeper and pilot light outputs
• Insulates the Vessel from the environment during a determination
SAFETY
CALORIMETER (CAL2K-1)
• Electrical Shock: There are NO user serviceable parts inside.
• Do not open the back panel unless the mains cable has been disconnected.
• Dangerous voltages will be present inside after the mains cable has been disconnected.

DDS CALORIMETERS
DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO THAT THE
EARTHING CAN BE CHECKED.
COOLER (CAL2K-2)
• Electrical shock: There are NO user serviceable parts inside.
• Do not open with the water hoses connected.
• Disconnect from Mains before opening the Cooler (CAL2K-2).
• Dangerous voltages will be present inside after the mains cable has been disconnected.
DO NOT TAMPER WITH THE EARTHING - CONSULT A QUALIFIED ELECTRICIAN SO THAT THE
EARTHING CAN BE CHECKED.
FILLING STATION (CAL2K-3)

• Secure the Filling Station to the table.
• Install the flexible nylon pressure pipe without any sharp bends.
• Check the nylon pressure pipe for 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 pressure regulator must be supplied by your agent, or sourced locally.
• The oxygen bottle should be secured according to regulations.
DO NOT USE ANY OTHER PIPE OTHER THAN THE HIGH PRESSURE PIPE SUPPLIED.
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.

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

• Secure the bottle against a wall.
NEVER use oil or oil based grease on any part of the gauge assembly or any part of the Filling Station
and Vessel for SAFETY reasons!
DO NOT use a hammer to free a jammed valve.
• Use only an approved pressure reduction valve with a safety blow valve.
• Consult your safety engineer when in doubt.
VESSEL (CAL2K-4)
• The Vessel has been pressure tested (certificate will be provided if required), at 3000 KPa according to
international standards.
• The Vessel and its Cap’s thread is subject to wear and tear, and it must be inspected regularly. Check for
excessive play.
• A Vessel with “loose” or worn threads is dangerous, and it must be repaired (reconditioned) by the dds
Factory.
• A Vessel with worn threads may cause the lid to blow off during a determination, which is extremely
dangerous and may cause injury to the operator. Vessels with worn threads which cannot be reconditioned
will be deemed unsafe and a condemnation certificate will be issued.
• Vessels should be returned to dds every 6 months for reconditioning, checking and subsequent pressure
tests. A Vessel will require reconditioning after 5000 firings; however it is this quantity could be significantly
reduced depending on the type of samples analysed. Therefore it is advisable to have your Vessel(s)
checked regularly. Vessels will need to be returned to dds for reconditioning, an agent is not authorised to
recondition a Vessel and therefore it must be sent to dds for this procedure.
• Do not extend any part of your body over the CAL2K-1 Calorimeter during the initial period.
• Consult your safety engineer or your mechanical engineer for guidelines, when in doubt.
NEVER OPERATE ANY UNSAFE VESSEL.
NEVER IMMERSE THE VESSEL INTO COLD WATER WHEN COOLING. USE THE CAL2K-2 COOLER OR
ALLOW THE VESSEL TO COOL DOWN NATURALLY.
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 CAL2K SYSTEM REGULARLY.
UNPACKING THE CAL2K SYSTEM

Please retain all the packaging boxes and material once you have received the Bomb Calorimeter System for the first
year (Warranty Period).

DDS CALORIMETERS
There are no special precautions to be taken during unpacking, other than retaining all the packaging material.
Other information and instructions when unpacking the Bomb Calorimeter System, can be found in the printed
CAL2k Handbook.
GETTING STARTED
SYSTEM COMPONENTS
Congratulations on purchasing your new CAL2k Bomb Calorimeter System!
The CAL2k System is the most advanced Calorimeter system available today and if treated with the care and respect
it deserves, it will give you years of service and satisfaction. No other calorimeter operates quite like the CAL2k and
for this reason, we ask you to spend some time learning and discovering its qualities and idiosyncrasies. The time
invested in studying this manual will provide you, the User, with the maximum usage of the machine.
The CAL2k Calorimeter Full System comprises of the following products:
Calorimeter, Cooler, Filling Station and a minimum of two Vessels.
PRODUCT PART NUMBER DESCRIPTION

CAL2K-1 The Calorimeter
This conducts the calorific value
determination.
CAL2K-2 The Cooler

This cools the Vessel to the required
temperature.

DDS CALORIMETERS
CAL2K-3 The Filling Station

This fills the Vessel with oxygen.
CAL2K-4 The Vessel

This holds the sample and gets fired
in the Calorimeter while under
pressure with oxygen.
THE CALORIMETER (CAL2K-1)

Below is an external picture of the Calorimeter CAL2K-1 showing the major components that make up the
Calorimeter. Locate and identify each component to facilitate the understanding of reference to these parts in
subsequent sections.
Door Knob (Lid Lock)

Pull to Open
LCD
Display
Numerical
Keypad/Keyboard
Indicator
Pilot Light
Operating
Keypad/Keyboard
FIGURE 1. : CALORIMETER – EXTERNAL FRONT VIEW

DDS CALORIMETERS
EXTERNAL CONNECTIONS (REAR PANEL)
Sensor Balance: D25

Ambient sensor Input on D25 for
connection to connection to the Balance
CAL2K-2 Cooler PC: D9 (RS232)
Earth Lug
Connection to PC
Interconnection: 2 x D15 9 Volt DC Power Supply

Interconnecting the CAL2K-1 External Connection
FIGURE 2. : CALORIMETER – EXTERNAL REAR PANEL
CALORIMETER COMPONENTS
The Calorimeter comprises of the following components:
1 x CAL2K-1 Complete Calorimeter

1 x CAL2K-1-KT Calorimeter Installation Kit
An Installation Kit is supplied with necessary accessories and spare parts. Please refer to the section on the CAL2K-1
Calorimeter Installation Kit at the back of this manual, for a list of which items are included in this kit.

DDS CALORIMETERS
KEYPADS/KEYBOARDS Clears keyboard

entries or returns
(HEAP) through the MENU
File steps/options
SAMPLE BACK
SPECIAL
FUNCTION RESULT CLEAR ID ENTER
(History) Clear Screen Entry Accepts a
File or Exit from Keyboard
present Entry
operation
FIGURE 3. : CALORIMETER NUMERICAL AND OPERATING KEYPADS
LCD DISPLAY
The display consists of 4 lines (rows), each has a maximum of 40 characters:
• Line #1: Calorimeter Operations
• Line #2: Result and Mass Selection
• Line #3: Faults, Warnings, Key Entry
• Line #4: Menu, Parameter Display
INDICATOR LAMP
This lamp indicates the status of the Calorimeter unit:
OFF : The unit is OFF or the Lid is OPEN.
ON : The Lid is CLOSED and a determination is IN PROGRESS.
FLASHING : The determination is COMPLETE and the Lid is CLOSED or an ERROR OCCURED during the
determination and the Lid is CLOSED.
BEEPER (SITUATED BEHIND KEYBOARD)

This is used as an audible indication that an error or warning has occurred. The error or warning may also be
displayed on the screen.
DOOR LATCH AND LID SWITCH

The Lid closure switch is incorporated in the Door Latch, so as to ensure that the lid is securely closed before a
determination is started. This is for safety purposes.

DDS CALORIMETERS
VESSEL CONNECTIONS
These are situated inside the Vessel Well, inside the Calorimeter. There are four (4) connections between the
Calorimeter and the Vessel. Three connections are in the Base of the Well and the fourth connection is at the top of
the Vessel where the Vessel connects to the Lid Contact inside the Calorimeter’s Lid.
The ground contact is incorporated in the 3 Vessel supports. Communication with the Vessel is via the two spring-
loaded contacts in the centre of the Base board. The firing contact is in the centre of the Lid and again is a spring
contact, which only makes contact when the Lid is closed.
THE COOLER CAL2K-2
LED Display Control Buttons
Door Lock
Well
Door
FIGURE 4. : COOLER – external FRONT VIEW
Water Out Computer Ambient Mains Water In

Connection Sensor
FIGURE 5. : COOLER – EXTERNAL REAR VIEW

DDS CALORIMETERS
COOLER SYSTEM COMPONENTS

The Cooler should comprise of the following components:
1 x CAL2K-2 Complete Cooler
1 x CAL2K-2-KT Cooler Installation Kit
An Installation Kit with Accessories and Spare Parts is supplied with the Cooler. Please see the Section of CAL2K-2
Cooler Installation Kit at the back of this manual, for a list of which items are included.
COOLER INSTALLATION
• A stable, balanced workbench, near water and mains power supply is required.
• The power requirements (Mains supply) need to be the following:
o Voltage: 90 – 260 VAC, 50/60Hz
o Consumption: 150 Watts Maximum
• The CAL2K-2 needs to be positioned in a convenient place where it has access to both a mains supply and a
main water supply (please note that only a TRICKLE of water flow is required).
• Water may also be circulated through a tank system.
• Connect the water supply to the CAL2K-2 pipe marked IN using the plastic water pipe and fittings supplied.
The pipe marked OUT is to be taken to a draining point such as a sink or sump. Connect the ambient cable
between the CAL2K-1 and the CAL2K-2 to the respective plugs marked AMBIENT SENSOR. This is for the
remote temperature sensor for the Cooler. The Ambient Sensor cable is reversible.
• Plug in the Mains cable.
COOLER PERFORMANCE TESTING

• Plug the Cooler into mains and observe that the POWER LED is ON. An auxiliary LED will flash every 6
seconds.
• Press the LED test switch – all 11 other LEDs should be illuminated while the switch is held down.
• Ensure that there is a flow of water in order not to overheat the pads. If there is no water flow, the LEFT or
RIGHT OVER TEMP LEDs will switch on.
• The LEFT and RIGHT ON LEDs should come on initially and then go off once the pads have cooled down. They
will then come on and go off periodically.
• Without a Vessel in the Cooler, no orange or red LEDs should be on. If there are any on, you should refer to
the section on Troubleshooting.
• After a few minutes, touch both the left and right pads. They should feel cold.
• Place the warm Vessel in the Cooler’s well. The “VESSEL IN WELL” LED should be on as well as the “CLOSE
DOORS” LED after 6 seconds.
• Close the doors by holding both the Left and Right Doors in your hand and bringing them together until they
lock into place. The Doors should stay closed and the “VESSEL COOLING“ LED will come on.
• Once the doors latch, test the “OPEN DOORS” function by pressing the “OPEN DOORS” button on the list of
switches. The doors should open immediately. Close the doors again.
• Once the Vessel has cooled to ambient temperature, the doors will open automatically and the “CLOSE
DOORS” and “VESSEL COOLING” LEDs will switch off.
• Remove the Vessel and the “VESSEL IN WELL” LED will switch off.
• To test idle, press the “IDLE” button on the switch list. The “IDLE” LED should come on. Now press the
“WAKE-UP” button and the “IDLE” LED should switch off.

DDS CALORIMETERS
• Remove ambient cable and check that “AMBIENT FAULT” LED comes on. Re-insert ambient cable, and
observe that the LED switches off again.
COOLER NORMAL OPERATION

1. Connect the water supply, ambient sensor cable and Mains power cable.
2. Wait for a few minutes for the Cooler to cool down.
3. Load hot Vessel in Cooler and close the doors. The indicators can be observed during this time.
4. When the doors open (release) the Vessel will be at the correct temperature, ready for further use.
This Cooler is designed to reduce the temperature of a recently fired Vessel to ambient temperature. The ambient
temperature reference is plugged into the CAL2K-1 Calorimeter ambient sensor. Solid state cooling is used and the
hot junction of the Peltier elements is cooled by a continuous trickle from the mains water supply.
After installation and an initial warm-up or cool-down period, the unit is designed to operate continually and will
reduce the average hot Vessel to ambient in approximately 2 minutes. This unit is suitable for high volume workload
applications.
For a small volume workload the Cooler can be set in idle mode, when it is not required.
If 0,5 grams of average coal is burnt in the CAL2K-4 Vessel, the temperature will rise by approximately 9 degrees C,
however this is not fixed and may rise above or below 9 degrees C. The energy released is approx. 220 Watt min.
This heat has to be dissipated before a new determination can be started, otherwise the Vessel would get warmer
with every determination.
WARNING: NEVER immerse the Vessel in water to cool it down!
The Cooler, with an effective cooling capacity of 200 Watt can cool the Vessel to its starting temperature within 2
minutes. The Vessel needs to be at ambient temperature prior to a determination.
This "cooling to ambient" is done to allow the Vessel enough time to stabilise (equalise) when it is being reloaded
and handled.
COOLER DISPLAY PANEL

The display consists of 12 coloured LEDs and 4 push buttons. There are four (4) LEDs for the VESSEL, four (4) LEDs for
the ELEMENTS and four (4) LEDs for the STATUS.
• Green LEDs indicate that the Cooler is functioning correctly
• Orange LEDs are informative and indicate the status of the Cooler
• Red LEDs indicate fault conditions and require attention
VESSEL LED LIST

The far left column of Four (4) LEDs indicates the VESSEL status as follows:

DDS CALORIMETERS
VESSEL IN WELL
This LED will be green when the Cooler recognizes that a Vessel has been inserted into the well. The LED will go off
once the Vessel has been removed.
CLOSE DOORS
This LED will be orange if the Vessel is warm, indicating that the doors need to be closed.
VESSEL COOLING
This LED will be orange if the Vessel is cooling. Once the Vessel has reached ambient temperature, the LED will go
off.
VESSEL TOO COLD

This LED will be red if the Vessel has significantly over cooled, indicating that the doors have stuck onto the Vessel.
The centre column of 4 LED’s indicates the status of the Peltier elements. The elements are referenced as left and
right when the unit is viewed from the front.
ELEMENTS LED LIST

These four (4) Green LEDs are in the Middle Column of the Panel and indicate the ELEMENTS status as follows:
LEFT ON AND RIGHT ON

These are green LEDs and indicate when the elements are actually switched on. The elements work independently of
each other and consequently both LEDs may not be on at the same time.
LEFT OVER TEMP AND RIGHT OVER TEMP

These are red LEDs and indicate that the hot side of the elements has become too hot. This is usually caused by
insufficient water flow or the incoming water is too hot.
STATUS LED LIST

The far right column of 4 LEDs indicates the STATUS of the Cooler as follows:
POWER
This is a green LED and will be ON continuously as long as mains power is applied to the unit.
IDLE
This is an orange LED and will be ON if the unit has gone into IDLE mode.
AMBIENT FAULT
This is a red LED and will be ON if the ambient sensor is not detected. This occurs if the ambient cable is faulty or not
plugged into both the Cooler and the Calorimeter.
AUXILIARY
This LED has not been assigned to any function.
PUSH BUTTON LIST

The four (4) push button switches are momentary and need to be pressed in order for them to operate. When these
buttons are pressed, their functions will be as follows:

DDS CALORIMETERS
OPEN DOORS
This will open the doors before the ambient temperature has been reached.
IDLE
This will force the Cooler to go into Idle mode. The idle LED will then be switched ON (green).
WAKE-UP
This will take the Cooler out of idle mode and return it to normal operation.
LED TEST
This will illuminate all the 12 LEDs thus confirming that they are working. The test is only operative while the button
is being held down.
THE FILLING STATION CAL2K-3
Vessel pressure Gauge
Bottle Pressure Gauge
Lever
Nozzle
Lid Holder or
Defiller Cap or
Handling Hook
Holder
Base
FIGURE 6. : FILLING STATION – MAIN PARTS (EXTERNAL)
FILLING STATION SYSTEM COMPONENTS

The Filling Station should comprise of the following components:
1 x CAL2K-3 Complete Filling Station
1 x CAL2K-3-KT Filling Station Installation Kit

DDS CALORIMETERS
A Filling Station Installation Kit is supplied. Please see the CAL2K-3 Filling Station Installation Kit at the back of this
manual for a list of the contents.
FILLING STATION INSTALLATION

Prior to installation please make sure you have a suitable oxygen high pressure regulator. The regulator should be a
high pressure regulator, capable of filling a Vessel to a pressure of 3000Kpa.
The Filling Station is packed in its own box along with the other components and Vessels, which are in their own
plastic bag. Remove the foam, which holds the Filling Station in place. Before proceeding any further, inspect the
Filling Station for any possible damages during transportation. If you find it to be damaged in any way, contact your
Agent immediately. Also, check the packing list and confirm all the contents.
The type of oxygen to be used is normal Industrial Oxygen, used for welding. A purity of 99.5% is suitable. The
oxygen bottle should be firmly secured to a wall or pillar. Using the pressure pipe and connectors supplied, connect
the Filling Station to the oxygen bottle. Slowly increase the pressure and check all connections for any possible leaks.
If a connection is leaking, turn the oxygen off and disassemble the connection to ensure that the ferrule is sealing.
Once the Filling Station is installed and ready to use, place the Vessel on the base and lower the arm, ensuring that
the Filling Station nozzle fits directly and cleanly over the Vessel’s valve. Once the arm is fully down it will latch in this
position and the Vessel will then fill, unattended. When the Vessel reaches the required pressure the arm can be
lifted and the Vessel removed.
There are 2 pressure gauges on the Filling Station. The right hand gauge indicates the bottle or incoming pressure,
and this should always be 3000Kpa. The gauge on the left indicates the Vessel or filling pressure. The rate of the
filling is clearly visible on this gauge. One can fill the Vessel to less than 3000Kpa (never more), however this will only
be applicable when one is analysing samples which are highly combustible (e.g. Wood samples) and need less
oxygen to burn. For samples such as these we recommend filling the Vessel to 1500Kpa.
During normal operation the Filling Station requires very little maintenance. However it is suggested that the ex-
centre and piston be lightly silicone greased (NOT oiled) so as to minimize wear. (See the parts detail further on in
this manual). Also, the O-ring in the nozzle should be lightly smeared with silicon grease daily, to avoid the Vessel
from sticking to the nozzle when filling. Incorporated with the Filling Station are two holders on either side – one can
be used for holding the handling hook and defiler cap, while the other is to hold the Vessel’s lid assembly.
WARNING: NEVER use any oil or oil based lubricant on the Filling Station and Vessel. A light (small)
amount of special silicone grease can be used on the Filling Station Nozzle O-Ring, Lever, Piston and
Ex-Centre. DO NOT use silicone grease on any part of the VESSEL.
ADJUSTMENTS
The Filling Station was designed to be as simple as possible to use by the Operator and to have as few adjustments
as possible. Please refer to the diagrams on the Filling Station parts under the section on “Maintenance” further on
in this Manual. There are only two adjustments which may be required on the Filling Station:
Firstly, the plastic base is adjusted so that the Vessel valve is directly under the Filling Station’s nozzle. This is
adjusted in the Factory and should not require adjustment again. However, if an adjustment is necessary, the
following procedure should be followed:

DDS CALORIMETERS
a) If the Filling Station is bolted to the table, remove the bolts.

b) Loosen the screw, which holds the plastic base to the base of the Filling Station.
c) Place a Vessel in the disc and lower the arm of the Filling Station, ensuring that the nozzle fits cleanly onto
the Vessel’s valve, until the arm latches down all the way.
d) Now tighten the plastic base’s screw from underneath.
e) Check the alignment and if correct, bolt the Filling Station back to the table.
Secondly, adjustment to the rate of filling the Vessel may be needed. This is adjusted by the Flow Adjustor screw on
the right hand side of the gauge block holder, next to the bottle pressure gauge. (See the parts detail further on in
this Manual). This screw is already adjusted at the dds Factory so that a Vessel will fill up to 3000Kpa in about 20
seconds. Turning the screw inwards (clockwise) will reduce the flow and thus the Vessel will take longer to fill.
Turning the screw outwards (counter clockwise) will increase the flow enabling the Vessel to fill faster. When
turning the screw inwards, do not over tighten, as this will damage the plastic nipple inside.
When turning the screw outwards great care must be taken. The screw must NOT be turned more than 2 turns from
its original position.
WARNING: Over turning can cause the screw to be blown out of the threads by the pressure. This
can result in damage or cause injury to the Operator.
The filling time should be varied between 30 - 60 seconds only. The actual time being chosen should be in
accordance with the operator’s experience and speed.
One more adjustment which could be required is that of the Bottle Pressure. This should always be set to 3000Kpa
to allow the Vessel to fill unattended. If the pressure is set correctly the Vessel will not overfill. Please remember
that with high combustible samples which require less oxygen to burn, it is advisable to fill the Vessel to 1500Kpa.
The absolute maximum pressure to which the incoming pressure can be set is 4000Kpa.
WARNING: Any additional pressure can cause damage to the Filling Station or even injury to the
Operator. If a Vessel is filled to below 3000Kpa, and the sample being analysed does not have a high
combustion, there is a chance you will receive a misfire error as there is not enough oxygen in the
Vessel to burn the sample. However, as mentioned already this may not happen if the sample you
are analysing is highly combustible and needs less oxygen to ignite.

DDS CALORIMETERS
THE VESSEL CAL2K-4
Cap
Lid Assembly
Vessel FIGURE 7. : VESSEL – BASE VIEW
FIGURE 8. : VESSEL - MAIN COMPONENTS
Lid
Centre Electrode
Top O-Ring
Lid O-Ring Bottom O-Ring
Valve Screw
Outside
Electrode
Sleeve
Deflector Plate
FIGURE 9. : VESSEL - LID ASSEMBLY PARTS

DDS CALORIMETERS
VESSEL BACKGROUND
The CAL2K-4 Vessel is smaller than a conventional Vessel, which results in a smaller heat capacity. Special attention
was given to a thermally balanced Vessel design that was achieved with computer aided design (CAD) and computer
simulation of heat transfer characteristics.
The Vessel has an oxygen volume of 0.2 Litre, which allows for a 0.5g sample of Coal with approx. 30MJ/Kg. The
temperature sensors are located cylindrically within the Vessel’s walls at four places and terminate on the bottom of
the Vessel PCB and subsequently onto the contact base rings.
The approx. temperature rise of the CAL2K-4 Vessel after the burning of 0.5g benzoic acid is 9 Degrees Celsius.
Practical tests have shown that up to 0.8g of benzoic acid can be burnt without affecting the accuracy. Oxygen
starvation affects the results with higher charges.
The Vessel must be cooled after a determination. This can be achieved by conventional means such as making use of
a fan or simply leaving it on the table to cool down naturally. To speed up the cooling down process, a CAL2K-2
Solid-State Cooler is recommended, and a necessity should more than 6 determinations be required in one hour. The
Cooler reduces the temperature of the warm Vessel to the starting temperature, which is also the room (or ambient)
temperature. The absolute ambient temperature is not important.
Another design feature is the “firing through the valve” concept, which is of the utmost importance for the thermal
balanced heat conductivity.
MICROPROCESSOR
The Vessel is “smart” with a microprocessor built into its base. The sensors plug directly into the microprocessor
board. All the information pertinent to a Vessel is stored permanently inside the Vessel i.e. Vessel number,
calibration curve, number of firings, date of last reconditioning, etc.
The Vessel PCB is only powered up when it is placed in the Calorimeter or the Cooler. The consequence of the Vessel
memory is that any Vessel can run in any Calorimeter without a new calibration. The Vessel’s memory can only be
accessed from the Calorimeter’s Keyboard or the PC. The electronics and sensors are fully vacuum epoxy
impregnated to prevent physical damage as well as moisture from entering the electronics.
PERMANENT FIRING WIRE

The Firing Wire (CAL2K-4-FW) is semi-permanent and only needs to be replaced when it is damaged or burnt. Only
firing wire, which is pre-cut and supplied by DDS or its agents must be used.
For firing, a length of pure cotton thread (CAL2K-4-FC) is tied to the firing wire with its “tail” touching the sample.
The Firing Cotton must be pure cotton, not any blend with synthetic fibres and must be of a standard length. It is
recommended that only firing cotton supplied by DDS or its Agents should be used.
VESSEL BASE CONTACTS

There is digital communication between the Vessel and either the Calorimeter or Cooler.

DDS CALORIMETERS
Only three connections are required: positive, ground and signal. The connections are made via slip rings between
the base of the Vessel and the base connection holders in the CAL2K-1 Calorimeter and the CAL2K-2 Cooler. Always
ensure these slip rings are clean.
THE PRINCIPLE OF CALORIFIC MEASUREMENT

Studying this section is not essential to successfully operate the CAL2K-1 Calorimeter. It is intended for the
laboratory technician or chemist who wants to know "how and why” things happen.
THEORY OF “ISOTHERMAL” CV DETERMINATIONS : CONVENTIONAL WAY

The CV (Calorific Value) of a substance is measured by burning it in a controlled environment. The resulting heat
released by this combustion i.e. the net temperature rise, is proportional to the calorific value.
A problem, however, occurs in that during the determination period (±10min) some energy may be gained from or
lost to the environment.
In the adiabatic system, the environment is controlled so that no energy is lost or gained. To achieve this state, the
calorimeter’s Vessel (bomb) and bucket are surrounded by a water jacket which is strictly temperature controlled by
a system of circulators, heaters and Coolers, so that it has the same temperature as the inner bucket.
An Isothermal calorimeter measures the effect that the environment has on the bucket before and after the
determination and corrects the result accordingly. This implies that the environment is stable during the
determination. To achieve stability a large body of water surrounds the Vessel and bucket assembly, which is
thermally stable.
MODIFIED CONVENTIONAL WAY

Prior to development of the CP500, over a 5-year period, it was demonstrated by "dds" that a polystyrene jacket,
which has very little thermal mass and negligible heat conductivity, could replace the water jacket. This system was
used in dds’s first calorimeter product the AMPC.
DRY METHOD
In the conventional way a Vessel is placed in a water container and the water temperature is measured. Since the
water quantity and container are part of the effective heat capacity, great care must be taken not to change the
capacity. Equally important is that the water acts as a heat sink and a temperature transfer medium to the sensor.
In the dry way, the Vessel, water and container are replaced by a highly temperature conductive aluminium jacket
which is shrunk over the stainless steel body at a very high pressure and forms an integral part of the Vessel. The
temperature sensors are equally spaced around the Vessel body in between the aluminium jacket and the stainless
steel body. This method eliminates all the problems with water and results in very fast temperature equilibrium,
with a fixed heat capacity.
Since the Vessel became that much faster, the environment could affect the measurement 5 times less than with the
conventional use of a water jacket.

DDS CALORIMETERS
Also, a warm Vessel is not placed in cold water to achieve equilibrium. The solid-state CAL2K-2 Cooler reduces the
temperature from warm to ambient, after which the Vessel would be ready for firing once again.
The Vessel design was the result of a computer aided process and extensive computer simulations to predict its
temperature behaviour. The Vessel is tested and certified to international material and test requirements.
From the operator’s point of view, the Vessel is lighter, easier to handle and plated on the exterior, for easy cleaning.
CAL2K VESSEL IMPROVEMENTS

The CP500 had the sensors inside the Vessel, and the measuring electronics inside the CP500 Calorimeter. The
CAL2k has the electronics and sensors inside the Vessel (bomb). Effectively the “whole” calorimeter is placed inside
the Vessel, and the Vessel is “docked” in the CAL2k Calorimeter for supervision. The result is a faster and more
stable temperature reading. Most important, a calibrated Vessel can be used in any CAL2k Calorimeter and the
calibration curves (of which there are 10) are contained in the Vessel.
The Vessel’s temperature is measured with 8 sensors and a 25% redundancy (software). The Vessel’s electronics are
vacuum epoxy sealed, and require no adjustment or maintenance.
The Vessel can be operated over a wide temperature range (+10 to +50 degrees C), but it is advised that the Vessel’s
starting temperature is the ambient (room) temperature. The “intelligent-SMART” Vessel brings other
improvements such as: firing counts, identification, history of use and reconditioning data.
CONNECTION
SYSTEM CONFIGURATIONS FOR NETWORKING
The CAL2k Calorimeter full system is ideally suited for single systems and high volume, multiple Calorimeter
networked systems. However, two basic choices must be made regardless of the number of systems in the setup.
Either use the Calorimeter with or without a PC, or make use of a Balance connection
The system configuration follows the “plug-and-play” idea and can be setup by anyone.
CHOICE 1 – OPERATE THE SYSTEM WITH OR WITHOUT A PC

The Calorimeter can operate without a PC, but a PC facilitates some functions better, such as the retrieval of result
data.
The Calorimeter has no printer output and if a hardcopy of the data is required, a PC should be used (at least once a
week) to retrieve and print the results.
CHOICE 2 – IS A BALANCE CONNECTED, AND IF SO WHERE?

The number of systems in the setup will influence this choice.

DDS CALORIMETERS
The following configurations are possible:
a) The MASS is manually entered (typed in) via the Calorimeter’s Keypad.
b) A balance is connected to any CAL2K-1 Calorimeter and the mass and sample identification (SID) is
distributed to all Calorimeters within the Network.
NOTE: Tray identification is not possible.
The CAL2k is very versatile in catering for your requirements and expansions. The following maximum system
configuration shows that although it is not practical, it is still possible:
Balance
(Up to 7)
CAL2K-1 CAL2K-2
PC (Max 7)
(Max 7)
(Max 7)
Optional:
Network ……………………..
nodes Up to 255 Vessels CAL2K-4
(Max 7)
FIGURE 10. : MAXIMUM cal2K SYSTEM CONFIGURATION FOR NETWORKING
CALORIMETER KEYBOARD MENU ACCESS

The Keyboard Menu on the Calorimeter itself, consists of three sections:
1. Always needed, basic commands

2. Seldom needed
3. Only needed to change system configurations
With a PC connected, Menu items 2 and 3 can be locked. For details see the section on Menu Access further on in
this Manual. Some parameters require a “once only” setting from the PC.

DDS CALORIMETERS
BALANCE CONNECTION CHOICE

Wherever you would like to connect a balance, it will work. However, the distribution of the mass and the sample
identification (SID) can be changed to the following choices:
• A MASS and SID entry is distributed throughout the CAL2k system. That means you can see it on any
Calorimeter, and do a determination on any Calorimeter. The MASS and SID entry can come from a PC or
from a Balance connected to one of the Calorimeters.
• A Balance can be connected to a “CAL2k Docking Station”, which allows entering the MASS, SID, GID into the
bomb Vessel. See the Section: System with Docking Station at the end of this Manual.
CONNECTING THE CAL2K SYSTEM

Once the system configuration has been chosen, the following connections need to be made:
THE COOLER CONNECTION

The Cooler needs to be connected to:
• A clean water supply
WARNING: Just a trickle of water is required for the Cooler. Too much pressure with a full open tap
will cause leakages. The Cooler has been designed for LOW pressure!
• Mains power supply

• The ambient sensor to the CAL2K-1 Calorimeter via the supplied cable – CAL2K-2-AS (round connectors)
THE BALANCE CONNECTION

• D25 Connector on the Calorimeter
• Mains Power supply
NOTE: dds supplies a Balance Cable with a D25 connector. This Balance Cable has been
manufactured for use and compatibility with a Sartorius Balance. However, should you wish to
connect to another brand of Balance all you need to do is ensure that it has the correct connector to
the CAL2K-1 Calorimeter.
THE CALORIMETER CONNECTION

The CAL2K-1 Calorimeter should be connected to:
• A PC (if one is being used)
• Any other CAL2K-1 Calorimeter (if more than one in the networked system) via a D15 to D15 cable
(Calorimeter Interconnection Cable – CAL2K-CIC). This cable can be ordered from dds if you are the Agent or
from your local Agent if you are the end-customer.
• A Balance (if preferred)
• Mains Power
• CAL2K-2 Cooler

DDS CALORIMETERS
GENERAL OPERATION
Calorimeter Lid
Calorimeter Lid
Lid Contact
Door Knob Lid Poly
Well
Calorimeter
Keyboards
Microswitch
Display
FIGURE 11. : CALORIMETER CAL2K-1 - MAIN PARTS (EXTERNAL)
CALORIFIC VALUE MEASUREMENT

In essence, the CAL2K-1 Calorimeter measures the temperature rise of a Vessel with constant mass, volume, and
pressure in an isothermal environment. The temperature rise is proportional to the energy released, which will yield
the specific energy if the weight is known. The gross calorific value obtained is then related to the calibration and a
gross sample CV is obtained. The corrections are applied and the corrected CV is displayed and stored in memory.
TEMPERATURE MEASUREMENT
8 Calibrated sensors are embedded within the Vessel’s wall. These are averaged to determine a single temperature.
The temperature resolution on the display of the Calorimeter is limited (only shows a certain amount of characters),
so on the display it will read as 0,0001Cº. But the actual Temperature resolution of the Calorimeter is 0,000006Cº.
The temperature measuring range is from 0Cº to 65Cº. However, the actual temperature rise of a burned sample
should be in the 4 – 12Cº range, which can be anywhere in the total measuring range of 0 to 65Cº.
SAMPLE IDENTIFICATION (SID)

A label identifies a particular sample. This label is called the SID and is entered via the Calorimeter’s keyboard or
automatically via a PC. The SID is an 8-character number only entered via the Calorimeter’s keyboard or a 4-
character alphanumeric text plus 4-character number which may only be entered via the PC.
GROUP IDENTIFICATION (GID)

The Group Identification (GID), sometimes called Tray ID, is an 8 character label, which can be used from the front
panel (as a number) or from the PC as alphanumeric text.

DDS CALORIMETERS
VESSEL IDENTIFICATION
Each Vessel has a unique number so that the Calorimeter can identify which Vessel is being used. Vessel
identification can be set by specialised PC software or from the keyboard and will be a number from 1 to 255.
NOTE: The number from 1 to 255 is NOT a serial number!
SAMPLE MASS ENTRY

The CAL2K-1 Calorimeter utilises a sample mass of approximately 0.5g. The actual mass of the sample can be
entered in the CAL2K-1 Calorimeter in one of two ways:
AUTOMATIC MASS ENTRY

This method is most effective for high throughput rates by using batch weighing or the sample tray system and the
samples are numbered consecutively within the batch or tray. It requires the connection of an electronic balance
either directly to the CAL2K-1 or to a PC with an RS232 communication connection. One balance can serve a network
(up to 7 in total) of CAL2k Calorimeters directly.
MANUAL MASS ENTRY

With the Manual Mass Entry Method, the sample MASS and SID are entered into the Calorimeter via the
Calorimeter’s Keyboard prior to the determination.
VESSEL CALIBRATION
The method of determining a single Vessel factor, in the conventional sense, is not utilised by the CAL2k. It is
replaced by a "Vessel Curve" determined by many "parameters” to achieve higher accuracy and data security.
Generation and storage of these "Vessel Curves” is automatically performed during calibration runs against standard
CV values (e.g.: Benzoic Acid, Coal Standard, etc.). The CAL2k will not allow access to the calibration parameters, but
using a PC can manage the calibration.
The Vessel can retain 10 curves, made up of one “prime operating” curve and 9 “reserve” curves. The calibration
curves can be managed from a PC.
CV DETERMINATION CYCLE
When a Vessel is inserted into the measuring chamber of the Calorimeter (Well) and the Lid is closed, the following
checks are performed:
• There is communication to the Vessel

• A SID and MASS have been entered
• There is continuity between the Vessel’s electrodes (the Firing Wire is present)
• A calibration curve is available for the particular Vessel
• The firing voltage (in the Calorimeter) is present
• The Vessel is safe to operate (within the required firing count)

DDS CALORIMETERS
Assuming that the above checks are satisfactory, the determination cycle will automatically start and will proceed
through the following four phases:
INITIAL
A temperature stabilisation phase will be carried out. The duration of this phase is dependent on the preset initial
parameters and the stability of the Vessel prior to insertion into the CAL2K-1 Calorimeter.
FIRING
When the preset initial conditions have been met, the Vessel is automatically fired. This means that the preset firing
voltage is applied to the Firing Wire.
FINAL
This is initiated immediately after a successful firing phase. During this phase, a CV figure is calculated every 6
seconds taking into account the calibration curve, CV corrections and sample mass. The duration of this phase is
dependent on the preset final parameters. An unsuccessful firing (i.e. sample not ignited or absent) will be reported
as a “MISFIRE” fault and the determination aborted. Sometimes, a “MISFIRE” can also mean that the Lid Assembly is
at fault.
DONE
On successful completion of the FINAL phase, a final CV result is displayed and stored. The MASS and SAMPLE ID are
deleted from the heap.
WARNING – COOLING: DO NOT IMMERSE THE VESSEL INTO COLD WATER WHEN COOLING. Use the
CAL2K-2 Cooler or allow the Vessel to cool naturally.
CORRECTION FACTORS
Two corrections are possible within the operating procedure of the CAL2K-1 Calorimeter. The CAL2K-1 calculates (in
principle) the following:
( BURNT ENERGY − CORR2) − CORR1= RESULT

MASS
Correction 2 (CORR2) is a constant for cotton, wire and nitric acid; Correction 1 (CORR1) is a constant for sulphur, or
the like.
Correction 1 is assumed to be zero during calibration. The corrections can be changed at any time without affecting
the calibration.

DDS CALORIMETERS
NOTE: Correction 2 is independent of the sample mass. Correction 1 is dependant on the sample
mass.
CALORIMETER ACCESS CONTROL

The CAL2k Calorimeter has 3 stages of menu access via its keyboard:
1. Always allowed, basic access

2. Seldom used access
3. Setting parameters access (restricted use)
The access level can be changed by a keyboard operation and by a PC entry. A change or setting made using the PC
entry (setting) dominates i.e. it locks. That is to say if Menu Access 2 and 3 are enabled by the PC, the key access can
be set from the keyboard to 1, 1 and 2 or 1, 2 and 3. A PC = 1 only access, does not allow any change from the
keyboard.
NOTE: Only “MENU” operations are access controlled.
MENU ACCESS
The Equals Sign key accesses the Menu.
The Equals Sign key pressed repeatedly, scrolls through the available Menu Options.
The Back Arrow key will return one Menu Option.
The Square key will exit from the Menu Option and clear the screen.
The Menu is always displayed on line 4 of the Calorimeter’s LCD Display, while value entries are made in the Key field
of line 3.
SYSTEM CONFIGURATION PARAMETERS

Upon delivery of a new CAL2K Calorimeter unit, the system parameters must be checked and if necessary be set to
the desired values. The system will be delivered with default values. The PC software has a recommended “default”
setting, which was loaded before delivery.

DDS CALORIMETERS
Press to view the present value. The first Menu item will be displayed.
Press each time in order to view the next Menu item, description and value.
Press to return to the start of the Menu list.
Press to return one Menu Option.
To change a value:
Press or until the required Menu Option and value are displayed. Type in the complete value,
followed by (ENTER) observe that the new value is displayed. It is then automatically stored.
The new value can be entered in the Keyboard entry field, then press . The new value is now displayed in the
original position and stored. The changed value is recorded in the “result memory” for further reference. Some
values are entered with the “double-confirm” feature.
MENU ACCESS RESTRICTIONS

To restrict the access one level down (3 to 2, 2 to 1), press the following:
, ,
To lift access restrictions one level up, provided the level is “enabled” by a PC operation, press the following:
, ,
SID AND MASS ENTRIES

The SID and MASS entries have dedicated front panel Keys for speed of entry.
SID and MASS entries must be done one after another as they form a single record in the HEAP. Entries can be made
at any time, even while a determination is in progress.
SID ENTRY
SID is up to 8 characters – 4 alpha followed by 4 numeric. Last 4 characters must be numeric to allow for auto
incrimination of the SID. Alpha characters can only be entered via a PC.
Press to CLEAR the screen.

DDS CALORIMETERS
Press Key and the following will happen:
Line 3 will display: SID # →
Line 4 will display: ENTER 1-8 SID NUMBERS XXXXXXXX

Where XXXXXXXX is the next available automatically incremented number.
To change this number: Using the Keyboard, enter an 8 digit number. This will be displayed on line 3, next to SID #
→.
Press to accept. (Screen will clear)
To confirm, press – A new SID will be displayed on line 4.
MASS ENTRY
Press and the following will happen:
Line 3 will display: MASS:
Line 4 will display: MASS ENTRY, confirm ID = XXXXXXXX.

Where XXXXXXXX is the SID entered via the Keyboard or the last SID incremented by 1. (If this SID is not correct, go
to SID entry).
KEYBOARD ENTRY
Enter the Mass via the Keyboard, this entry will be displayed next to MASS: on line 3. To accept this entry press
, and the screen will be cleared. Mass & SID are now added to HEAP and available for use.

DDS CALORIMETERS
BALANCE ENTRY
If a balance is connected and set up correctly, any stable mass will be displayed on line 4. The mass is checked
against preset limits and if it is outside of these limits, the mass is displayed with a “?” at the end.
If the mass is correct, press , and the screen will clear. MASS & SID are now added to the HEAP and available
for use.
NOTE: A Keyboard entry takes precedence over a balance entry. That is, if a balance entry is
displayed on line 4 and Keyboard entries are entered on line 3 and “enter” is pressed on the
Keyboard, then the Keyboard entry will be saved.
SYSTEM PARAMETERS
The CAL2K Calorimeter system can be setup from the Keyboard or from a PC. The PC allows editing, saving and
printing of the parameters.
The CAL2K-1 Calorimeter stores two sets of parameters:

1. Operational parameters : These are visible through the Menu
2. Default parameters : These are settable from the PC only. The default parameters can be viewed only after
they are invoked (loaded into the operational parameters).
PRIOR TO FIRING A VESSEL

Prior to using the CAL2K system for routine CV determinations (or bomb Vessel calibration) the following checklist
must be verified:
1. All equipment is switched ON. Warm-up time for the Cooler is approx. 5 minutes. Oxygen pressure checked
and regulator adjusted if necessary. Cooler water flow checked and adjusted if necessary.
2. System Tests carried out.
3. Configuration parameters entered and/or checked.
4. All Vessels cleaned and O-rings checked for any damage, if damaged please change the o-rings.
5. All Vessels calibrated.
6. All Vessels checked against known CV standards and re-calibrated if necessary.
7. All Vessels checked for accurate Vessel correction factors.
8. Determine new correction factors if necessary.
Verification of the above checklist before starting a new batch of samples or after prolonged non-usage of the
Calorimeter will ensure trouble-free operation with minimum downtime.

DDS CALORIMETERS
PREPARING VESSELS
NOTE: This section MUST be read as it provides valuable information for achieving accurate results.
The art of producing highly reproducible results revolves around establishing a constant work cycle with the
minimum of interruptions. Adherence to the following Vessel preparation sequence will ensure that unexpected
breaks in routine operation will be kept to the absolute minimum.
• Depressurise the Vessel if it has just been fired using the Defiller Cap (CAL2K-4-DC).
• Place Vessel in the Cooler if it has just been fired.
• Remove Vessel from the Cooler when the Cooler doors open. (If Vessel has been standing for a while, check
that it is at ambient temperature by placing it in the Cooler.
• Open the Vessel, clean the inside of the chamber using paper towel, and ensure no fibres are left inside
the chamber. The Vessel should always be cleaned after every determination.
• Remove and clean the Crucible (CAL2K-4-CB) with a Wire Brush (CAL2K-4-WB). Old or damaged crucibles
should be discarded as they can cause damage to the Vessel during firing.
• Clean the Vessel and Vessel Cap threads with a Wire Brush.
• Remove any old Firing Cotton (CAL2K-4-FC) from the firing wire (if the Vessel was not fired recently). If the
Vessel has been fired the cotton would have burnt away with the sample so there should be no firing cotton
left on the firing wire.
• Inspect the Firing Wire (CAL2K-4-FW) and replace if necessary. Only use the dds supplied pre-cut Firing Wire.
• Insert the pre-cut length of Firing Cotton (CAL2K-4-FC) by looping it over the firing wire and then twisting the
ends together.
• Weigh the sample using a balance. Make sure you place the empty crucible on the balance weigh plate first,
then press “Tare”. Once this has been done then you may place the sample inside the crucible and weigh the
sample. By following this procedure you will cancel out the weight of the crucible and this will give you an
accurate sample mass.
• Insert weighed crucible and sample into the outside electrode’s crucible holder, ensuring that the firing
cotton touches the sample.
• Be careful as not to “flick” any sample out of the crucible with the cotton. Experience and technique practice
helps.
• Insert the electrode assembly (Lid Assembly) into the Vessel body.
• Screw the cap down until it touches the top of the lid. Tighten with quarter to half a turn. Do not over
tighten, as it will be difficult to open later. Also make sure the cap does not screw all the way down.
• Place the Vessel under the Filling Station, keeping it upright. Fill it with 3000KPA oxygen. The right hand
gauge should read 3000KPA.
• Remove from the Filling Station with the Handling Hook (CAL2K-4-HH) and let the Vessel stabilize for approx.
1 minute before inserting it into the Calorimeter.

DDS CALORIMETERS
CALIBRATION OF VESSELS
Each Vessel is calibrated before delivery and the calibration is stored in C0 and C1. C0 is the “working” calibration
curve, and C1 is one of nine additional curves available for storage.
Should it become necessary to perform a calibration, then follow the steps below:
1. Weigh a tablet of Benzoic Acid and enter the mass into the Calorimeter
2. Prepare a Vessel as per the procedure above (and place it in the Calorimeter’s Well).
3. Do not close the Calorimeter’s lid.
4. Confirm (if this is the first ever calibration) the following parameters, this can be done very conveniently from a
PC, but here the Menu Options that are used:
Press repeatedly until the required Menu Option is displayed:
Calibration : ON 1
Enter user ID : Any number (001.001)
Spiking : OFF 0
Time : Check
Date : Check
Energy unit : Select required unit of measure 1-3
(1 = BTU, 2 = CAL, 3 = MJ/Kg)
Calibration value of BA : Enter in units of measure e.g. 26.454MJ/Kg
Calibration deviation : 1.000
Initial drift : 0.002 (or as required)
Initial time : 1.0
Correction #1 : Enter cotton correction in units of measure.
5. Enter SID (if not done already).
Press , enter 8 digit number, press .
6. Enter MASS.

DDS CALORIMETERS
Press , observe correct SID, enter Mass, press .
7. Enter Sample in Process.
Press until SID and Mass are displayed, press .
8. Close the Calorimeter’s lid. Observe that the CAL2k goes through Initial, Fire, Final and Done stages (5 minutes
in total).
9. If you open the lid, then the calibration is saved C0 (the working curve!).
STEP BY STEP PROCEDURE FOR CV DETERMINATIONS

Before starting any batch of CV determinations, ensure that the prerequisites have been carried out.
During a complete determination, each Vessel has to go through 4 distinct cycles as shown in the following
sequence. Note that the WAIT cycle does not require any work:
CYCLE OPERATION PERFORMED TIME (MIN)

PREPARE Prepare the vessel 1.0 to 3.0
WAIT Wait for stabilization 0.5 to 1.0
SAMPLE (INITIAL, FINAL) Actual Determination 2.0 to 3.5
COOL Cool the Vessel – DO NOT immerse 3.0 to 5.0
vessel in water to cool. Use the
CAL2K-2 Cooler.
Total 4.5 to 9.5 per sample, per vessel
The above cycle sequence must be adhered to for best results. Total throughput time is improved by the use of more
Vessels. The following describes the various operational cycles in detail.
NOTE: For maximum throughput, the sample should be weighed in batches.
PREPARE
Prepare a Vessel as in the section Preparing Vessels.
WAIT (STABILIZE)
During this time (0.5 to 1.0 minute), the Vessel can equalize outside the CAL2K-1. If placed directly into the CAL2K-1
and the lid is closed, an erroneous firing could take place with a slightly high result. (A side effect of pressurizing is to
raise the internal Vessel temperature).
SAMPLE
1. Open the Calorimeter’s lid (if not open already).

DDS CALORIMETERS
2. Insert a prepared Vessel using the Handling Hook. It is preferable not to insert the Vessel with your hand as
you may affect the temperature of the Vessel.
3. Press and scroll through the HEAP records until the required record, i.e. MASS & SID, is located. Press
until required Mass and SID are displayed.
4. Press ENTER and the selected record will be transferred to line 1 of the display, only if the Vessel is in the
well.
5. If the MASS & SID have not been entered, then do so now.
6. If the HEAP is empty, then enter the MASS & SID now.
7. Close the Calorimeter’s lid.
8. If a fault occurs now or at any stage during the determination then refer to the section on Troubleshooting
for full details. The pilot light will flash until the lid is opened.
9. If no fault is detected then the INITIAL status will be displayed and the pilot light will be ON.
10. Drift & time will be displayed during this period depending on the initial parameters of the Calorimeter.
11. Once the initial period criteria have been met then the Vessel will be fired.
12. The FIRE status will be briefly displayed (6 seconds).
13. Immediately after firing the FINAL status will be displayed.
14. Drift or time will be displayed during this period depending on the final parameters of the Calorimeter.
15. The result will also be displayed as it develops during the final period.
16. Once the final period criteria have been met then the determination will end.
17. The DONE status will be displayed and the pilot light will flash until the lid is opened.
NOTE: If the pilot light is flashing then the Calorimeter needs attention.
1. The result that is displayed is the final result with -> inserted before the result.
2. Open the lid and the pilot light will go OFF.
3. Remove the Vessel.
4. The information contained in line 1 will be transferred to the result memory and stored.
5. Line 1 will be cleared ready for the next determination.
NOTE: The sample record, i.e. MASS and SID, is removed from the HEAP.
COOLING
• De-fill the Vessel using the Defiller Cap
• Place the Vessel in the Cooler

DDS CALORIMETERS
WARNING: DO NOT COOL VESSEL IN COLD WATER. USE THE CAL2K-2 COOLER UNIT TO COOL THE
VESSEL.
• Observe the Cooler’s display indications

• Close doors
• Wait
• Remove the Vessel from the Cooler when the doors open
Repeat the cycle sequence above for all samples in batch using the next available Vessel.
EXPLANATION OF DISPLAY DURING A DETERMINATION

The top line of the display is reserved for the analysis data of the determination that is being done by the
Calorimeter at any given time. For times and drifts refer to Recommended Setup.
LID OPEN – NO VESSEL IN WELL

You will notice on the screen “SETUP…NO BOMB”
SELECT MASS & SID
Please note the MASS and SID will be blank until the Vessel is inserted. Once inserted you will see the following:
Temperature of Vessel
CLOSE LID
If no errors are detected the following will be displayed. The indicator lamp will go ON.
INITIAL
Initial Drift Timer
The initial drift is the rate in degrees C at which the Vessel temp. is drifting up or down. The timer will not start until
the drift conditions have been met.
“D” indicates the initial drift is outside limits.
“T” indicates that the timer has started.

DDS CALORIMETERS
The timer will then run for the preset initial time as long as the drift is within the preset limits. If the drift goes out of
these limits, then the timer will reset.
FIRING
Once the initial conditions have been met then the Vessel will fire.
FINAL
After firing the final phase will commence.
Timer Temperature Rise Dynamic Result
The timer will run for the preset final time. The temperature rise and result will be displayed dynamically.
DONE
At the end of the preset final time “DONE” will be displayed. The indicator lamp will start flashing.
Final Temperature Final Result
OPEN LID
The lid of the Calorimeter can now be opened. The Vessel can also be removed and the next determination started.
DETERMINATION OF VESSEL DEVIATION FACTOR

Each curve (C0 to C9) has a Vessel deviation factor, sometimes called a “Vessel fiddle factor”. This feature is not
really necessary, but some customers require it to be in the specifications.
The fiddle factor is multiplied with the calibration to affect the result. Normal entry is 1.0000. If calibration is low or
high, then the fiddle factor can be used to adjust the result.
This Vessel deviation factor can only be set by a PC. It is set to 1.0000 during the calibration.
DETERMINATION OF CALORIMETER DEVIATION FACTOR

This factor, visible from the Menu, adjusts the result. The result can be adjusted if it is found that the laboratory is
producing different results as compared to other laboratories, despite repeated calibration. Reasons for this could
be the following:

DDS CALORIMETERS
• Balance offset.
• Moisture offset.
• Calorimeter offset (could result from a poor installation).
• Sample preparation offset.
With offset, we don’t mean a mathematical offset but rather a “constant difference”.
The deviation factor can be adjusted while the CAL2k is in “DONE” mode, and the effect of the adjustment is visible.
Otherwise the deviation can be adjusted whenever it is suitable. Normal entry is 1.0000.
OPERATING CYCLES
As explained in the previous section, a complete CV determination goes through four distinct cycles:
• Preparation
• Wait
• Sample
• Cool
The CAL2k system has been designed to operate with multiple Vessels with each Vessel in one of the above cycles
for maximum throughput. The following timing examples show the effect that the number of Vessels in the system
has on throughput:
SINGLE VESSEL SYSTEM

In this case, batch weighing does not result in a throughput advantage and sample weighing can be done during the
sequence. Achieved times range from 7 to 10 minutes.
DUAL VESSEL SYSTEM

Weighing of samples can be done during the sequence although batch weighing may be recommended.
VESSEL 1 VESSEL 2 TIME

PREPARE SAMPLE 3
WAIT COOL 2
SAMPLE PREPARE 3
COOL WAIT 2
10 MINUTES FOR 2 DETERMINATIONS

DDS CALORIMETERS
NOTE: The Calorimeter is only 60% occupied and the Cooler 40%.
TRIPLE VESSEL SYSTEM

Batch weighing is recommended
VESSEL 1 VESSEL 2 VESSEL 3 TIME

PREPARE SAMPLE COOL 3
WAIT COOL PREPARE 2
SAMPLE PREPARE WAIT 3
COOL WAIT SAMPLE 3
11 MINUTES FOR 3 DETERMINATIONS
This method is somewhat difficult due to the different times, but the CAL2K-1 is almost 100% utilized.
QUICK GUIDE
This section is intended as a quick reference guide to the Operating Instructions and Menu Options:
SAMPLE MASS ENTRY
• Press : Confirm NEXT Sample ID.
• Press : Enter MASS.
• Press : Enter next MASS …
The SID is auto-incrementing, so a new SID does not need to be entered.
NORMAL DETERMINATION
• Press : Until required Sample ID is displayed.
• Press : Uses the selected MASS and SID.

DDS CALORIMETERS
• Put a prepared Vessel into Well.

• Close Lid.
• Observe that the PILOT LIGHT is continuously ON.
• Wait until the PILOT LIGHT flashes = DONE.
• Open lid and remove Vessel for cooling.
CALIBRATION
• Press to clear display and reset MENU.
• Press : Until “Calibration ON/OFF” is displayed.
• Press : Calibration is ON.

• Proceed with NORMAL DETERMINATION.
• Press : Calibration is OFF.
NOTE: Calibration will only stay ON for one sample so after a calibration it is not necessary to turn
calibration OFF.
ENTER USER ID (NUMBER)

The “User ID” is always 3 numbers, if only one or two numbers are required then the number must have leading
zeros e.g.: 033 or 004 or 567.
To change the “User ID” – select the relevant Menu Option.
To enter a new “User ID” – enter new “User ID” then press enter e.g.: 123.123 . The new “User ID” will now
be displayed.

DDS CALORIMETERS
RECALL DEFAULT SETUP

To “Recall default setup” select the relevant Menu Option, then enter the following:
USER ID. USER ID ENTER
E.g.: 123.123
DONE will be displayed if the operation was successful.
BA CHECK SAMPLE ON/OFF

When running benzoic acid as a check sample (not calibration) the sulphur correction factor, if entered, must be set
to zero. By setting this Menu Option ON the sulphur correction factor is ignored.
Select the relevant Menu Option:
1 is = ON
0 is = OFF
NOTE: This function only stays ON for one determination and then reverts to OFF.

DDS CALORIMETERS
DISPLAY OR SET GID

To set the “Display or set GID” (GID = Group Identification).
Select the relevant Menu Option. Enter numerals (characters can only be entered via PC)
Press
DISPLAY ACTIVE BOMB CAL.

This displays which calibration curves are active for the Vessel that is inserted into the Calorimeter.
Active bomb
calibration
DISPLAY B. CAL DETAILS

This displays the Vessel (bomb) calibration details plus other information relating to the Vessel. Select the relevant
Menu Option and type:
0 displays the data for calibration curve 0.
1 displays the data for calibration curve 1. (and continue this way from 1 to 9 to view all calibration curves
and their details).
9 displays the data for calibration curve 9.
Display format is as follows:
Curve No. Date Time Sample ID Result
Vessel No.
Above is an example and is showing the data for curve 0.

DDS CALORIMETERS
10 displays the Vessel’s Manufacturing information and Serial Number.
Date of Manufacture Serial Number
11 displays the Firing Count and Status
Firing Count Status
12 displays the Date of the First Reconditioning of the Vessel
Date of First Reconditioning
13 displays the Date of the Second Reconditioning of the Vessel
Date of Second Reconditioning

DDS CALORIMETERS
NOTE: The 3rd reconditioning of the Vessel will overwrite the first reconditioning and so on.
14 displays the Customer Name
Customer Name
SPIKE VALUE
This is the known calorific value of the substance to be used for spiking, usually benzoic acid of approx. 26.454MJ/Kg.
On some occasions, the use of a Gelatine Capsule (CAL2K-4-GC) or Crucible Cover Disc (CAL2K-FLDS) needs to be
used with a solid sample or a volatile liquid sample respectively. When using these items, you will first need to
determine the energy value of the item in question. You will need to use Benzoic Acid as the substance for spiking,
as the Gelatine Capsule of Cover Disc becomes the “sample”. Once you have determined this value, you will then
have the “Spike Value” for your determination.
SPIKE MASS
This is the mass of the substance to be used for spiking. The procedure to follow, is to place the crucible on the
balance and press TARE. Then add the substance to be used for spiking to the crucible. This Mass value is the “Spike
Mass” and must be entered manually into the Calorimeter. Then add the sample. This mass is the spike item’s mass
plus the sample’s mass and must be entered in as the Mass. This can be read directly from the balance if a balance is
connected.
SPIKING ON/OFF
1 Spiking is ON

DDS CALORIMETERS
0 Spiking is OFF
NOTE: Unlike some of the other features, Spiking will stay ON until it is turned OFF.
TIME OF DAY IN HHMM

This Menu Option allows you to change the time (also available via the PC Software).
Enter a new time in the format HHMM and then press . The new time will be displayed.
DATE IN DDMMYY
This is the same as time but displays the date in DDMMYY format.
CLEAR HEAP
HEAP is the term given for the combination of MASS and SID. To clear these entries, select the relevant Menu Option
and then enter USER ID. USER ID
USER ID MUST be 3 digits. E.g.: 033.033
The word “Done” will be displayed if the operation is successful.

DDS CALORIMETERS
NOTE: Entries in the HEAP will be deleted.
DISPLAY SOFTWARE VERSION

This Menu Option displays the software version of the Calorimeter (Firmware Version).
CALIBRATION VALUE OF B.A.

This Menu Option displays the entered value of benzoic acid, which is used during calibration usually 26.454 MJ/Kg.
To change the value, select the relevant Menu Option. Enter the new value, then press . The new value will
now be displayed.
CALIBRATION DEVIATION
This is the Calorimeter factor and is usually set at a factor of 1,0000. All results are multiplied by this factor. It allows
an entire Calorimeter to be adjusted up or down. To calculate a new factor:
Factor = required value

obtained value

DDS CALORIMETERS
SAVE CALIBRATION 0-9

The calibration curve must be saved at the end of a calibration run. If this Menu option is not selected, then the
calibration is saved in C0 automatically.
To save the calibration curve under another number or position e.g. C1 or C2, first select the “Save calibration 09-“
Menu option.
For example, enter 1.1 to save in C1. The new calibration curve will now be saved.
NOTE: The calibration can only be saved to one curve.
RECALL CALIBRATION
This will show which calibration curve is being used.
Curve No. Date Time
Vessel No.
The calibration curve being used can be changed as follows:
1 - changes to curve number 1
NOTE: If “AV” appears in the curve number place and “?” in time or date, then there is no date for
that particular curve number.
INITIAL DRIFT IN DEGREE C

The initial drift must be below this value for the initial time counter to start. To change this value, select the relevant
Menu Option. Enter new value e.g.: 0.0030, then press . The new value will now be displayed.

DDS CALORIMETERS
INITIAL TIME IN MINUTES

This is the period for which the initial drift conditions must be met.
To change this time, select this Menu Option and then enter a new value e.g. 1.5. Now press , and the new
value will be displayed.
FINAL DRIFT IN CAL VALUE

The difference between 2 consecutive result values must be less than this for the determination to finish. To change
this value, select this Menu Option. Enter a new value e.g. 1.0, then press . The new value will now be
displayed.
FINAL DRIFT IN DEGREE C

Same as for “Final Drift CAL Value” but result must be within the temperature tolerance. The default is 2 degrees C.
FINAL TIME IN MINUTES

This is the time that the final period will run for as long as the CAL VALUE ans TEMP DRIFT is within the required
tolerance. Maximum final time is 5 minutes. The time can run between 2 and 5 minutes, the ideal being 3 minutes.
The system’s default is set at 3 minutes.
SET AMBIENT TEMP. OFFSET

This is used to calibrate the ambient sensor of the Calorimeter so that the Vessel and the ambient sensor both read
the same temperature.

DDS CALORIMETERS
CORRECTION #1 (SULPHUR)
This is the correction for sulphur (mass related). To change the value, select this Menu option. Enter the new value,
then press . The new value will now be displayed
CORRECTION #2 (COTTON)
This is the correction for cotton and firing wire (not mass related). Change the value the same way as for Correction
# 1.
SET CALORIMETER ID 1-7

Each Calorimeter on a network must have a different Calorimeter ID.. There can only be a maximum of 7
Calorimeters on a network. If the Calorimeter is not on a network, then the Calorimeter ID is usually 1. To change
the Calorimeter ID, select this Menu option. Enter the new number in the format #.# e.g. to change the Calorimeter
ID 2 enter 2.2. Then press , and the new number is now displayed.
SET BOMB NUMBER

This sets the bomb number for a particular Vessel. (This is NOT related to the Vessel’s serial number, which is
stamped on the Vessel’s body and Vessel Cap). The Vessel number must be in the range of 1>255. To change the
number, insert the Vessel into the Calorimeter. Select this Menu option and the existing Vessel number will be
displayed. Enter a new number which must be 3 digits in the format ###.### e.g.: 002.002 (zeros must be entered).
Then press . The new number will now be displayed.

DDS CALORIMETERS
SET FIRING VOLTAGE

This option allows the firing voltage to be changed. The Firing Voltage must be in the range of 25 to 30 volts. To
change the voltage, select this Menu option. Enter a new voltage e.g. 25 (the default is 25, and this is the
recommended value). Now press . The new value will now be displayed.
INITIAL COMPENS. ON/OFF
1 is ON
0 is OFF
This feature is not operational, however the Menu option has been retained. This Menu option can be ignored.
HIGH MASS LIMIT

This option is to set the maximum allowable sample mass (lab dependant). To change the value, select this Menu
option. The existing value will be displayed. Enter a new value, then press . The new value will now be
displayed.
LOW MASS LIMIT

This is similar to the “High Mass Limit” but this sets the lowest allowable sample mass. To change the value, follow
the same steps as for the “High Mass Limit”.
BALANCE MASS, PC OFF
This turns the balance communication ON or OFF.
0 is Off
1 is ON
Setting this Menu Option to “OFF” allows for Tray ID entries. This option should normally be left “ON”.

DDS CALORIMETERS
ENERGY UNIT : BTU, CAL, MJ

This option changes the units of measure in which the display functions. The Calorimeter always calculates in BTU
but converts the result to display in the chosen unit of measurement for the display.
1 = BTU/lb
2 = CAL/g
3 = MJ/Kg
To change the unit of Measurement setting, select this Menu Option. The existing units will be displayed. Enter the
new number e.g.: 3, then press . The new unit of measure of the display will now be reflected.
AUTOMATIC BALANCE MASS

This option allows for automatic balance entries.
0 is OFF
1 is ON
SELECT LANGUAGE 1-4

English is the only language option available on the CAL2k Calorimeter, irrespective of the number selection choice.
Should you wish to have a Calorimeter system which is language compatible and wish to have the display in different
languages, please speak to your Agent about the e2k Calorimeter system or visit our website
www.ddscalorimeters.com for more information on a Calorimeter product that is language compatible.

DDS CALORIMETERS
LOW RISE CURVE CHANGE
1 is ON
0 is OFF
This function is used when the temperature rise of the sample is less than 4 degrees C. When the temp. rise is low
then calibration curve C1 is used instead of C0 and the error “Misfire” is ignored.
ENABLE BOMB MASS ENTRY

If a Docking Station is in use, then this Menu option must be “ON”.
0 is OFF
1 is ON.
RECOMMENDED VALUE FOR MJ/KG
MENU OPTION SETTING

Calibration ON/OFF -

DDS CALORIMETERS
Enter User ID Select

Recall default set up -
B.A. check sample ON/OFF Select
Display or set GID -
Display active bomb CAL -
Display B. CAL Details -
Spike Value 0
Spike Mass 0
Spiking OFF
Time of day -
Date -
Clear Heap -
Display Software Versions -
Calibration value of B.A. 26.454
Calibration deviation 1.0000
Save Calibration -
Recall Calibration 0
Initial Drift degree C 0.0020
Initial time in minutes 1.0
Final drift in CAL value 2.0
Final drift in degree C 2.0
Final time in minutes 3.0
Set ambient temp. offset 0.0000
Correction #1 0
Correction #2 0
Set calorimeter ID 1
Set bomb number Select
Set firing voltage 25
Initial compensation OFF
High mass limit 1.0
Low mass limit 0.1
Balance mass, PC ON
Energy Unit MJ/Kg
Automatic baance mass OFF
Select language 1
Low rise curve change OFF
Enable Bomb mass entry OFF

DDS CALORIMETERS
USING THE SPIKING TECHNIQUE

SPIKE VALUE
This is the known calorific value of the substance to be used for spiking, usually benzoic acid of approx. 26.454MJ/Kg.
On some occasions, the use of a Gelatine Capsule (CAL2K-4-GC) or Crucible Cover Disc (CAL2K-FLDS) needs to be
used with a solid sample or a volatile liquid sample respectively. When using these items, you will first need to
determine the energy value of the item in question. You will need to use Benzoic Acid as the substance for spiking,
as the Gelatine Capsule of Cover Disc becomes the “sample”. Once you have determined this value, you will then
have the “Spike Value” for your determination.
SPIKE MASS
This is the mass of the substance to be used for spiking. The procedure to follow, is to place the crucible on the
balance and press TARE. Then add the substance to be used for spiking to the crucible. This Mass value is the “Spike
Mass” and must be entered manually into the Calorimeter. Then add the sample. This mass is the spike item’s mass
plus the sample’s mass and must be entered in as the Mass. This can be read directly from the Balance if a Balance is
connected.
STEP BY STEP ENTERING THE SPIKE VALUE

• Place the crucible on the Balance.
• Press “Tare” to clear the weight of the crucible and get to 0.000g
• Place one Benzoic Acid tablet and note the Mass.
• Add the crucible cover disc and note the new total Mass.
• Remember to place the prepared crucible (benzoic acid tablet with cover disc) in the lid assembly, inside the
Vessel, close the Vessel and fill with the required 3000Kpa of oxygen.
• On the Keyboard, go through the Menu options until you get to “Spike Mass”. Here type in the Benzoic Acid
mass e.g. 0.4787g, press the enter key.
• On the Keyboard, go to the next item “Spike Value CV”. Here enter the energy value of the Benzoic Acid
tablet that you are using. This can be found on each bottle of dds Certified Benzoic Acid bottle of tablets,
e.g. 26.454 (MJ/g). YOU MUST ENTER THIS VALUE EACH TIME YOU RUN A DETERMINATION WITH A COVER
DISC OR GELATINE CAPSULE.
• Continue through the Menu items, until you get to “Enter MASS, SID”.
• Enter the Sample Mass, e.g. 0.5565g
• Enter the SID, e.g. 001
• Close the Lid of the Calorimeter
• The CAL2k Calorimeter will now perform some standard checks and if all is okay, it will begin with the “Initial
Phase”, “Fire”, “Main” phase and then indicate that the determination has been completed.
Once the determination is complete, the result will display the calculated calorific value of the sample. The
calorimeter will automatically take the end result, minus the spike energy and present your final result of your
sample.

DDS CALORIMETERS
OPERATING WITH THE CAL2K MANAGEMENT TOOL SOFTWARE

SOFTWARE INTALLATION
MINIMUM SYSTEM REQUIREMENTS
The minimum system requirements for the CAL2k software are as follows:
• 100Mz Processor
• 128MB RAM
• Microsoft® Windows® 98/2000/XP/NT4.0 ENGLISH VERSION ONLY
• 100MB Hard disk space
NOTE: Before you begin please make sure your screen layout settings on the PC are set correctly.
The DPI setting must be set to 96dpi and not 120dpi.
NOTE: If you are using a laptop which has this software loaded, please make sure you have the
correct USB adaptor which allows you to connect to an RS232 port. Not all USB adaptors/converters
work the same way.
STEP BY STEP INSTALLATION

INSTALLING THE CAL2K MANAGEMENT TOOL
Insert the CD supplied with the Calorimeter System, into your computer’s CD-Rom Drive. In “My Network Places” or
“Windows Explorer”, double click on “Setup”.
The following screen will appear, select “OK” to continue:
The Microsoft. NET Framework package will need to be installed. Select “Yes”.

DDS CALORIMETERS
The Microsoft. NET Framework license agreement screen will appear, select “I Agree” and click on “ Install”. The
package will begin to install.
Once the package is finished installing the following screen will appear:
Click on “OK”
The CAL2k Management Tool Setup Wizard will begin immediately afterwards. Click on “Next”:

DDS CALORIMETERS
You can select whether you are loading the software for yourself or everyone who is using the computer by selecting
the appropriate radio button, shown below. You can also change the folder where the software will be saved. It is
recommended that you keep to the default settings. Always save software programs under “Program Files” when
using Microsoft Windows.
Click on “Next” once you have made your selection/changes (It is recommended to leave these options on their
Default choices):
The Installer will request that you confirm the installation, click “Next” to continue:
Wait until all the components have been installed:

DDS CALORIMETERS
Once the CAL2k software has been completely installed, you will see the following screen and you can now click on
“Close”.
The following screen confirms that the installation was successful:
Exit from the CD Drive and remove the CD.

Return to your Desktop screen.
A shortcut icon “CAL2k” will appear on your desktop:

DDS CALORIMETERS
The CAL2k software has been successfully installed. You can double click on the icon to run the software. Before you
run the software make sure your display settings on your PC are set to Windows Standard. To change the settings go
to Windows “Control Panel”, click on “Display”. This will bring up your Display properties. Click on the Appearance
Tab, under “Schemes” select Windows Standard, then click Apply.
USING THE CAL2K MANAGEMENT TOOL SOFTWARE

FAMILIARISING THE SOFTWARE FUNCTIONS
Double click on the CAL2k shortcut icon. The following dialog box will appear. You can either click on “Continue” or
wait, as the software will automatically take you to the login screen.
The login screen will now appear. Click OK to access the software. IT IS NOT NECESSARY TO ENTER A USERNAME
AND PASSWORD. THIS OPTION IS NOT ACTIVATED, CLICK ON OK TO GO TO NEXT SCREEN. NO USERNAME AND
PASSWORD IS REQUIRED.
Once you have accessed the software you will see the following status screen:

DDS CALORIMETERS
In order to setup your security feature you will need to access the User Security Manager. Click on .
The following screen will appear:
Enter this user name and password.
Username: LabMan3
Password: cal2kAdminUser

DDS CALORIMETERS
You will now return to the Main Screen however you will now have access to the User Security Manager by clicking
on the button.
After clicking on the Admin button you will see the following screen:
USER SECURITY MANAGER
ADMINISTRATE USERS
There are four (4) options available. The Lab Manager or Agent will need to select the one which is most suitable:
• None – this simply means the software is not locked or secured and anyone can use the software
• Edit and Existing User – if the Lab Manager or Agent has already set up a user this can be edited

DDS CALORIMETERS
• Create a New User – the Lab Manager or Agent can create a new user
• Delete a User – the Lab Manager or Agent can delete an existing user
You will note that for creating a new user, there is a block called “User Info”. This is where details for the new user
must be entered.
After each selection, you must select “Saves User Changes” to activate the changes made.
AUTOMATED DOWNLOAD OF RESULTS FROM CAL2K

This is the same as a LIMS interface. If you wish to receive the results automatically from the CAL2k you must tick
“Enable Automatic Result Retrieval”. You also have options here of locking the software on start-up or enabling the
software to be locked. You can also select the time in which results should be downloaded by checking the CAL2k
machines every so many seconds for results. The range for results checking is 30 seconds to 86400 seconds (24
hours). You can also select more than one Calorimeter, up to a maximum of 7 in a networked system.
Remember once changes have been made, click on “Save Changes” to effect those changes.
FILE MANAGEMENT
Here you can select your operating director and file name. Please note that the file will be saved with a CSV
extension. You also have the option of formatting the CSV file which will affect the data sequence and contents.
Select “Format file contents”.
Once you have selected the contents and sequence of the data you want, select “OK”.
Remember before closing to save any changes that have been made to the Security Manager, once you select
“close” you will return to the main status screen:

DDS CALORIMETERS
A destination number must be displayed, i.e. a number between 1 and 7, as there can be only 7 systems networked
together. If the destination number is 0 then there is a problem (your Calorimeter is not being picked up) and you
must check the connection between the PC and Calorimeter.
ITEM DESCRIPTION SOFTWARE IMAGE

Communication Select the next available
Comms port and click on
“Refresh”.
Click on the “Status” button to acquire the latest data from the network. While the PC loads the connected
Calorimeter, the following dialog box will appear:
All Menu Items, Displayed Information and Buttons will now be described.
MENU ITEMS
The Menu Items can now be located under the main screen under “Tools”:

DDS CALORIMETERS
DECIMAL SEPARATOR
Please note the Decimal separator must be set prior to printing or downloading results. The decimal separator
applies to the entire setup of the Calorimeter, as well as the results. In Europe they use the comma to separate the
Decimal, in South Africa we use the decimal point (period), so therefore please make sure you set the decimal
separator according to your requirements.
TOOLS
Set Time Click on “Set Time” if you want the
time of the Calorimeter to be the
same as that on your PC.
Display Data in You can select the unit of
measurement that you would like
your results or parameters to be
displayed in, by selecting the
relevant unit of measurement under
“Display Data in”. You have the
option of selecting: BTU/MJ/CAL.
Clear Memory Click on “Clear Memory” to clear the
result memory of the CAL2k.
Reset Calorimeter Click on “Reset Calorimeter” to reset
(clear) the station you have selected.
This destroys all HEAP information.
This function is helpful if a “fresh
starting point” is required.
The following screen will appear after selecting to Reset the Calorimeter. Select “Yes”, if you are completely certain
you are happy to lose all data in memory.
STATUS

Status Click on “Status” if you want to
connect to a different Calorimeter on
your network.

DDS CALORIMETERS
Upload Data This uploads data from the CAL2K-1

Calorimeter and displays it in the
software.
SETUP CALORIMETER
When you initially select this button, four options will be available: ”Upload from file”, “Upload from CAL2k”,
“Download to CAL2k” and “Download to Default”. In order to have all the items available, you will need to click on
“Upload from CAL2k”. Please read the details in the section “Setting up a Calorimeter” before clicking on this option.

Upload from File
Save File
Upload from CAL2k
Download to CAL2k
Download to Default
HELP

Handbook Click on “Help” on the menu bar
Operating Manual then select either Handbook or
Operating Manual.

DDS CALORIMETERS
DISPLAYED INFORMATION ITEMS

The main screen has a number of displayed information items under the Menu Bar. These are described as follows:

CAL2K No. Indicates the Calorimeter number
assigned to the particular
Calorimeter.
Destination Indicates which unit is being

interrogated.
Number of Records Indicates the number of results and

parameter changes in the unit’s
memory
Status of CAL2K Indicates whether the lid of the
Calorimeter is open or closed, i.e.
whether the unit is idle or doing a
determination.
PC Host Indicates to which Calorimeter the
PC is connected.
Version Displays the software version of the
Calorimeter’s firmware.
BUTTON ITEMS
There are Buttons on the Main Screen, which are described as follows:

Status This allows you to connect to the
Calorimeter. It also indicates the
Calorimeter number assigned to
each unit and uploads the latest
data.
Operation This displays the Operation Setup
screen. This screen displays all the
operational features such as Mass,
SID, GID, etc.
Lock Screen This enables the administrator to
lock the software. Only a user with
the username and password can
unlock the software.
Upload Data To get the data from the
Calorimeter. The memory of the

DDS CALORIMETERS
destination unit will now be

displayed.
Setup Calorimeter Brings up the screen where all your
settings are entered.
Refresh Re-loads the information from the
connected Calorimeter.
View Vessel Shows the information from a Vessel
that is inserted into the Calorimeter.
Temperature Graph View the temperature graph during a
determination.
Heap Management Manage the information in the HEAP
stack.
Calibration Curves Load the calibration curves from the
Vessel.
SETTING UP THE CALORIMETER
To set up the Calorimeter, click on the button. The following screen will appear:
The parameters for the destination Calorimeter are immediately displayed. Any of the parameters in the boxes can
now be changed. Once changes have been made, you can save the new parameters. To save a set of parameters
onto a file, click the button and select another folder on your C Drive or Network Drive or create a new
folder. Re-name your file and then click on “Save”.

DDS CALORIMETERS
Change folder
or directory
Change
filename
LOADING A FILE
To load a file, click the button, then select . All previously saved set up
files will be displayed, as indicated in the screen print below:
Select the required file by clicking inside the check box under “File Name” so that a tick mark appears, as shown
above.
Once you have selected a file, click on the button. The loaded file will now be displayed on the screen.
To download a parameter file to the Calorimeter, ensure that the required file is displayed on the screen. Then click
on “Download to CAL2k”. The file will now be downloaded onto the Calorimeter. The displayed file can also be
downloaded to the default values in the Calorimeter in a similar way by clicking on “Download to Default”.

DDS CALORIMETERS
Download to
CAL2k
Download to
Default
To delete a saved file from the list of saved setup files, select the file by ticking the box next to the file name. Then
click on the “Delete” button. A window will appear which will read “Are you sure you want to delete”. If you want to
delete click on “Yes”. That file will now be deleted. Only one file can be deleted at a time.
Delete button
Return to status screen by clicking on the button.
UPLOADING AND RETRIEVING RESULTS
To view the uploaded results click on the button. The following dialog box will be displayed:

DDS CALORIMETERS
Click the “Start Upload” button to upload the data. The records will now be sorted into new “duplicates” as well as
results, parameter changes and errors (as above). “Duplicates” in this case are records that have been previously
uploaded.
Click on the button. The result history database will now be displayed:
All = displays all results

Today = displays the results for today only
Yesterday = displays the results for yesterday only
Last 7 days = displays the results from the previous 7 days
Get the data by selecting the relevant date and then click on the button. This will customise your view
and will display the five columns as indicated below:

DDS CALORIMETERS
The “Indicators Name” is a fixed column and cannot by changed. It indicates the parameters that are stored in a
result.
Under the column called “Header”, the indicator’s name can be changed.
In the column called “Screen Display”, this is the sequence in which the parameters will be displayed on the screen
and can be changed. “POSI” indicates in which column the parameter will appear. For example,
0 = will not be displayed at all
1 = will appear in column one, etc.
Clicking on the “POSI” drop down arrow, will indicate which columns can still be used (i.e. are still available). The
“Field Size” indicates the width of the column.
The “Print Position” and “Export Format” columns set the format for printing and exporting data respectively.
Once the columns have been set up, click then click on to exit the “Format View”
screen. Then click on the “Result Display” screen and click on . The
results will now be displayed in the new format. While in the Result History screen you can also Print Data and
Export Data.
To print data click the button and then follow the prompts in your print dialog screen.

DDS CALORIMETERS
To export data click the button. Select where the data must be exported to and the file name, then
click “Save”. The exported data will be in Microsoft Excel format and can then be changed, plotted or manipulated.
VIEW VESSEL
Click on the button, and a screen with general/default data will be displayed. Ensure that the Vessel is
inserted into the Calorimeter. To load the data click on the button. The actual data from the
Vessel will now be displayed against a grey background, indicating that the data can only be viewed and not
changed.

DDS CALORIMETERS
Serial Number This is the number stamped onto the Vessel.

Manufacture This is the date of manufacture.
Status 1 indicates that Firing Count is <4352 (less than)
5 indicates that Firing Count is >4352 (greater than)
13 Indicates that Firing Count is >5000 (greater than)
5000+ Vessel is unsafe for use. Reconditioning is required.
Firing Count This is the number of firings performed by the Vessel since the last reconditioning.
Reconditioning # 1 # 2 Displays the last two reconditioning dates.
Vessel Owner Displays the company name of whom the Vessel was sold to.
Vessel Number Indicates the Vessel number assigned to this Vessel.
Unlinear Value Value as set by the dds Factory.
TEMPERATURE GRAPH
Click on the button, to display the temperature curves during a determination. This is opened as
a separate screen.

DDS CALORIMETERS
Temperature curve is the default screen. There are two options: a) Show all 8 Sensors or b) Show the average temp.
Ticking the box as shown in the diagram above can activate both or either of these options.
The following information is displayed numerically:
Sensors 1 – 8 Temperature of each sensor.

Average Temp Average temperature of all 8 sensors.
Drift The drift in average temperature for one reading to the next.
CAL2K Status Displays the state the Calorimeter is in.
Calorific value Displays the calorific value during the “Final” phase and also the result at “Done”.
GRAPH EXPLANATION
The temperature scale is auto ranging and the firing point is fixed. Only the last two minutes of the initial period are
shown. The graph is refreshed automatically every 6 seconds.
At the end of a determination a window will appear on the screen indicated as “Temperature Curve”, and it will
need a description. Enter a description for this determination e.g.: sample ID number and press enter. The data is
now stored and can be recalled later for comparison purposes. The graph stays on the screen until the next
determination is started. Clicking on the “Refresh” button will clear the screen. You are able to recall the saved
curves by selecting the button. The following screen will then appear:

DDS CALORIMETERS
Select the curve you wish to load and click on the “Load >>” button.
DRIFT CURVE
To show the Drift Curve click on the button. This curve shows the difference between two
consecutive average temperature readings. I.e. how the average temperature of the Vessel is drifting.
CALORIFIC CURVE
To show the calorific value curve click on the button. This curve shows the calorific value of the
sample after firing. Before firing the value is zero.

DDS CALORIMETERS
LOAD CURVES
This same procedure applies to “Temperature Curve”, “Drift Curve” and “Calorific Curve”.
To load a saved curve click on the button. A list of saved temperature curves will then be
displayed. Tick the box next to the file you wish to select; you can load up to 4 curves at one time. Once all the
curves have been selected click on “Load>>”.
All loaded curves are displayed in pink to highlight a curve. Click on the relevant curve from the list displayed on the
left side of the screen.
List on left
hand side

DDS CALORIMETERS
A real time determination can be displayed at the same time as a loaded curve. This allows for comparisons between
determinations and also for comparisons between different Vessels.
To exit the “Temperature Curves” click on the exit button on the Windows bar.
HEAP MANAGEMENT
To view the HEAP records click on . The HEAP consists of a mass attached to a sample ID (SID) that has
been entered into the Calorimeter but has not yet been analysed. Click on to upload the contents
of the HEAP. The contents are now displayed on the screen.
To delete records, select the record by ticking the box next to the HEAP in the Status column. Multiple records can
be selected. Click on “Delete Items from Heap” a window will appear “Are you sure you want to delete”. Click “Yes”
to continue or “No” to abort.
ADVANCED CALIBRATION
To enter this option, click on the button. A screen without any data will be displayed.

DDS CALORIMETERS
To load the calibration curves from a Vessel, insert the Vessel into the Calorimeter and click on
. The curves are then uploaded and displayed on the screen. The curves can now be
manipulated, copied and saved.
CURVES
The value stored in the calibration curve can be displayed at anytime by clicking on the pointer next to the “Final
time” text and holding the mouse button down and then dragging the pointer to the left or right as desired. The
value at a specific time is now displayed in the column.

DDS CALORIMETERS
Drag Pointer
The Deviation, Average, Standard Deviation and Mean of any selected curve are displayed for the selected time, at
the bottom right of the screen.
SAVING OPTIONS
Average Takes the average of the selected curves (more than one curve must be selected).
Mean Takes the mean of the selected curves (more than one curve must be selected).
Copy Allows the selected curve to be copied to another destination (curve position) (only one curve
can be selected).
Change factor Allows the entire curve to multiply by a factor (only one curve can be selected).
Save to File Allows a curve to be saved as a file, which can be recalled later (only one curve can be selected).
METHOD FOR AVERAGE, MEAN AND COPY

• Select the saving option required – either “Average” or “Mean”.
• Select the file or files C0 to C9 (far right hand column check boxes).
• Select the determination from “Save To” (C0 – C9) (far left hand column in yellow).
• Click on “Save”.
NOTE: The saved curve will not be displayed until “Load from Vessel” is selected. Once “Load from
Vessel” has been selected you will see the saved curve displayed.

DDS CALORIMETERS
METHOD FOR CHANGE FACTOR

• Select “Change Factor”.
• Select the curve (only one) (far right hand column check boxes)
• Enter the new factor..
• Select the destination from “Save to” (C0-C9) (far left hand column in yellow).
• Click on “Save”.
METHOD FOR SAVE TO FILE

• Select “Save to File”.
• Select the curve to be saved (only one) (far right hand column check boxes).
• Click “Save”.
The file has now been saved.
METHOD TO LOAD SAVED FILES
• Click on the button. A list of saved calibration curves will now be displayed.
• Select the file to be loaded (only one), by ticking the box next to the file name.
• Select the destination curve (only one) (far right hand column C0-C9).
• Click on the “Load>>” button.
• The loaded curve will not be displayed until “Load from Vessel” has been selected.

DDS CALORIMETERS
STATUS
Whenever a calibration curve has been manipulated then the status is changed.
Original calibration CAL2k (OK)

Average of several curves P.AVE (PA)
Mean of several curves P.MEAN (PM)
Copy of a curve P.COPY (PC)
Change of a factor P.FIDDLE (PF)
The symbols in brackets are the codes displayed on the screen of the Calorimeter when the “Vessel Data” is
displayed.
NETWORK OPERATIONS
The PC software supports CAL2k Network Operations. The only difference is that when the status is acquired then
multiple units are displayed on the screen.
NOTE: Each unit connected to the networked system must have a different Calorimeter number
from 1 to 7, as only a maximum of 7 systems can be networked.
The units that have not been integrated will have a “talk to me” button. To change the Calorimeter that is being
integrated press “STATUS” and then “Talk to me” of the required unit. The procedure is now the same as for a single
unit. This is only applicable if 1 or more systems are connected (networked).
OPERATION
Operation is designed so that the Calorimeter can still be operated via the PC even if a display or Keyboard fault
occurs on the Calorimeter unit itself.

DDS CALORIMETERS
NOTE: The “Operation” feature will only work on the host Calorimeter. That means the PC must be
connected directly to the CAL2k Calorimeter, which is to be used via the Operation Software.
Click on the button. The Operation Setup screen will be displayed.
The screen above indicates the “User Controlled” option.
Two Methods of Operation are available:
1. where the CAL2k is still operational and the PC screen displays the status of the Calorimeter.
2. where the Calorimeter is controlled from the PC screen.
In order to switch between the two methods of operation, simply click on either “User Controlled” or “PC
Controlled” button once.
Click here to change

between User control
and PC control.
The screen above indicates the “PC Controlled” option.
NOTE: Once in PC Control the Calorimeter is LOCKED OUT and can only be returned to User Control
by clicking on PC Control – escaping out of the screen or closing the program or switching off the PC
will leave the Calorimeter in PC Control. EXPLANATION OF SCREEN

DDS CALORIMETERS
Setup Enter Mass, SID and GID for a sample.

Initial Once the lid is closed, CAL2k will go through an initial stage of approximately 1 minute depending if
the drift of the Vessel is within the drift limit. The Drift not the Drift Limit can be viewed in Section
D below.
Fire The Vessel is fired.
Main The final time is counted until the final reaches its set value
Done The CV is displayed.
SETUP
A C
B D
F
E
A These five fields on the left indicate the status of the Calorimeter.
In the above Setup screen you need to enter the information in the area indicated by B.
B This section displays the Mass and SID setup for the Calorimeter.
B Mass: Displays the mass transmitted from the balance (if a balance is connected to the Calorimeter). To
accept this mass click on Once the balance Mass is accepted, the Balance
Mass is transferred to the Mass field. The accepted mass is already transferred to the CAL2k.
Mass: Allows for manual mass entry. Enter the mass and then press “enter”. Mass block will turn red if the
mass is outside of the preset limits.
SID: Sample ID. First 4 characters are alpha numeric, last 4 are numeric only. This automatically
increments in PC controlled mode.
GID: Group ID. Can be alpha numeric. This is not a required field
C This section displays the calibration information presently used by the Vessel.

DDS CALORIMETERS
Run a Calibration Click this box to perform a calibration. A Check mark (√) will appear in the box (this is
automatically reset once the calibration is complete i.e. only stays on for one
determination).
Calibration #: Displays the present calibration curve being used. It will always be curve “0”.
Cali Details: Displays the manipulated status of the calibration curve in position “0”.
Date: Displays the date and time of when the calibration curve “0” was
done.
D This section displays the Temp, Drift and Time of the determination. The only two fields with numbers in at
the Setup stage are Temp and Drift Limit.
Temp: Continuously displays the temperature of the Vessel when it is in the Calorimeter’s Well.
Drift Limit: This is the drift limit during the initial phase, which is preset via the setup menu.
E Displays messages similar to those on the CAL2k screen.
Below is the list of messages which could appear in the message box:
Vessel Missing Vessel not inside the Calorimeter’s Well

Vessel Mass Mass entered via the Docking Station
Upload Repeat Data not downloaded from the Vessel
Forced Calibration No calibration curve in Vessel
Calibration On Calibration set to “ON”
Vessel Disabled Vessel not allowed in this Calorimeter
Fire Voltage Firing voltage not at pre-set level
Vessel Unsafe Vessel needs reconditioning and will not operate
Vessel Near Recon Vessel will need reconditioning soon
No Wire No firing wire present
Temp Warning Vessel temperature too hot or too cold
MISS FIRE Misfire occurred and the result was aborted
Bomb Ini Fault Vessel initialisation fault
NO SID No sample ID entered
NO Mass No Mass entered
The above messages will be appended to one another should there be more than one fault. The message display will
show the state of the CAL2k, regardless in which Operational mode the screen is being used.

DDS CALORIMETERS
F This button indicates if the Lid of the Calorimeter is open or closed.
INITIAL
In the “User Controlled” mode, this field automatically changes to “Lid Closed” when you close the lid of the
Calorimeter.
In “PC Controlled” mode, “Lid Open” needs to be clicked once to change it to “Lid Closed”. The physical lid of the
Calorimeter also needs to be closed for the Initial phase to start.
The screen now changes to the Initial screen.
Once in the Initial phase, the numbers in Temp, Drift and Initial Time start to change.
Drift Displays the actual temperature drift of the Vessel during the Initial phase. The Drift needs to be
lower than the Drift Limit for a certain time before the Vessel can be fired.
Initial Time This displays the time of the initial phase. This time continuously increments until firing when the
counter stops and the total initial time is displayed. The Initial Time is displayed in 6 second
intervals e.g. 1.5 = 1 minute 30 seconds.
All other information remains the same.
FIRE
This mode cannot be changed. The Fire mode is automated and will sometimes not even be seen by the operator of
the CAL2k.

DDS CALORIMETERS
The Calorimeter then fires the Vessel. The screen above appears only for a short moment. The “Temp Fire” now
reflects the temperature at which the Vessel has been fired. .
Temp Fire: Displays the temperature of the Vessel at firing.
At the Fire phase, the sample mass and the SID are used and removed from the HEAP. Also, the “PC Controlled/User
Controlled” button is disabled so that the determination can complete its course. Should a misfire occur, the button
will be enabled again.
MAIN
The screen then changes to the “Operation – Main” screen.
Once in the Main phase, the numbers in Temp Rise, Temp, Drift and Final Time change.
Temp Rise: Displays the temperature rise of the Vessel from the firing during the final phase (no temperature
deployed during calibration).
Final Time: Displays the time taken for the final CV value to be allocated. The Final Time can be changed in the
Setup window. The Final Time is displayed in 6 second intervals. E.g. 3.1 is 3 minutes and 6 seconds.

DDS CALORIMETERS
G Amount now starts reflecting in the CV field. The value in the CV field is a pre calculated value based on the
present temperature rise in the calibration curve.
DETERMINATION DONE
Once the “Final Time” has been completed, the screen moves to the “Determination Done” phase. The screen now
changes to the final “Determination Done” screen, as indicated above.
In this screen all the figures in D and G are final.
The CV button now turns to green and the result is reflected in the units of measurement as selected.
The determination of this sample is now fully complete. The lid can now be opened.
In the “User Controlled” mode, the field automatically changes to , when the lid of the
Calorimeter is opened. Once the lid is opened, the Done phase is complete and the screen will indicate Setup phase;
the beginning of the next determination.
In the “PC Controlled” mode, the physical lid of the Calorimeter needs to be opened and in the software select
to open the Lid on the Done screen. will now reflect and the screen now changes back
to Setup and you can commence with your next determination.
MAINTENANCE
CALORIMETER
The Calorimeter needs very little maintenance. The Calorimeter should never be opened, as there are no serviceable
parts inside.
• Always keep the Calorimeter clean.

DDS CALORIMETERS
• Ensure that the Vessel Well is clean – blow out any dirt with compressed air if necessary.
• Ensure that both connections to the Vessel (one in the lid and one in the base) are clean and that they do
not stick down when depressed.
• If the Vessel Well or Lid Polystyrene is damaged, call a service technician or your local Agent to replace them.
• If the Keyboard or the display fails, call a service technician or your local Agent.
• Always ensure that the Door Knob of the Lid latches correctly, as this incorporates the lid microswitch and is
also a safety device to prevent the Lid from lifting in case of a Vessel failure.
COOLER
WEEKLY MAINTENANCE
• Clean Vessel base to ensure that the Vessel sits neatly and central and that the contacts meet successfully
with the base of the Vessel and its contact rings.
• Ensure the base contact operates freely.
• The contacts are spring loaded and when pressed down and released they should return to their original
position.
FILLING STATION
Arm
Knob
Holder
Ex Centre
Shaft
Piston O-ring
Piston
Spring
Nipple O-Ring
Nozzle Nozzle Body

Pressure Pipe
Connections
Nozzle O-ring
Knurled Nut
FIGURE 12. : FILLING STATION - MAIN INTERNAL PARTS

DDS CALORIMETERS
O-RING REPLACEMENT
It is strongly suggested the following checks be made every 3 months or sooner depending on the number of firings
you perform per day, as well as the type of sample you are analyzing (for the Vessel). A sample which ignites easily
(highly combustible) will cause the Vessel o-rings to perish a lot faster than a substance which is less combustible.
• Verify the oxygen flow rate and re-adjust the Flow Adjustor if necessary. The rate of flow should be adjusted
to fill a Vessel in approx.45 seconds. Replace the O-ring if necessary.
WARNING: DO NOT over tighten the Flow Adjustor – it should be tightened by hand and as soon as
any resistance is felt stop tightening!
• Check all pressure pipe connections for leaks.

• Check the Nozzle O-ring and replace if worn. Apply a light film of Silicon grease, to ensure it does not stick to
the Vessel.
• The Piston O-Ring is the same part as that for the Nozzle O-Ring, but it does not get worn down as frequently
as the Nozzle O-Ring. Check the Piston O-Ring at least once a year and replace if worn.
WARNING: Please DO NOT apply any OIL in any form to any o-rings on the Vessel. You may apply a
light film of silicon grease on the nozzle o-ring of the Filling Station ONLY, however it is advised not
to apply grease to any other o-rings.
Before an O-ring is replaced, turn the oxygen supply OFF at the bottle and release the pressure in the pipes by filling
a Vessel until both gauges on the Filling Station read zero.
HIGH PRESSURE PIPE

A brass Ferrule is supplied inside the nut where the High Pressure Pipe (CAL2K-3-OP) needs to be attached to the
Gauge Block. Place this Ferrule inside the High Pressure Pipe and tighten it to the nut on the Gauge Block. The other
end of the High Pressure Pipe will need to be attached to the High Pressure Oxygen Regulator. dds provides an
Oxygen Regulator Connection with the Filling Station Installation Kit, but this is not a universal connection and may
not work for some oxygen regulators. If the oxygen regulator is purchased from dds, the oxygen regulator gets a
special fitting on it in order for it to be attached to our Filling Station.
NOZZLE
The O-ring in the Nozzle, which seals onto the Vessel’s lid valve, is replaced by unscrewing the cover (knurled nut)at
the end of the Nozzle. (A pair of round jaw pliers may be required to grip the nut, but generally it should be hand
tight and can be opened by hand). Once the knurled nut has been removed the o-ring can be replaced. Lubricate the
new o-ring with a very SMALL amount of silicon grease before use. The knurled nut can now be replaced onto the
nozzle.
PISTON
There is an O-ring between the Nozzle and the Piston. To replace this O-ring the two pressure pipe connections to
the Nozzle must be removed FIRST. The Nozzle can now be unscrewed from the Piston. To stop the Piston from
turning when the Nozzle is unscrewed, we suggest that the arm be put down in the latched position. The O-ring can
now be changed. The O-ring on the Piston is the same as the Nozzle O-ring. Before re-assembly, ensure that the

DDS CALORIMETERS
nipple inside the Nozzle is in place. Screw the Nozzle back onto the Piston and then re-attach the two pressure pipe
connections.
NIPPLE (INSIDE THE NOZZLE)

To replace the O-ring on the nipple proceed as in the “Piston” O-ring above until the Nozzle and Piston are
separated. Now remove the Nipple from the Nozzle, replace the O-ring on the Nipple and re-assemble as above. Use
the same Viton O-ring which is used on the Vessel’s Centre Electrode for the Nipple’s O-ring.
FLOW ADJUSTOR
To replace the O-ring on the screw Flow Adjustor, unscrew the adjustor completely and remove it. The O-ring must
now be cut off the Adjustor and a new one put on. The Adjustor can now be screwed back in completely using your
hand to tighten.
WARNING: DO NOT over tighten as this can damage the plastic seal (Nipple).
Now un-screw the Adjustor about 1/4 to 1/2 a turn outwards. The filling flow must now be adjusted by trial error as
explained in the section about Adjustments for the Filling Station above.
FLOW ADJUSTER NIPPLE

To replace the plastic seal (Nipple) inside the Flow Adjustor, proceed as in the Flow Adjustor procedure above BUT
with exception. When the Adjustor is removed, apply high pressure oxygen to the oxygen pipe in order to “blow out”
the nipple from the Flow Adjustor hole. Take the new Nipple and place a small amount of glue on it and place it
onto the end of the Adjustor. The glue is required to hold the Nipple in place so that you can replace the Adjustor
into its hole for tightening.
FIGURE 13. : FILLING STATION - GAUGE BLOCK PARTS

DDS CALORIMETERS
FIGURE 14. : FILLING STATION - NOZZLE PARTS
VESSEL
RECONDITIONING
Every 6 months a service engineer or your Agent, must inspect the threads of the Vessel for excessive wear and tear.
If the wear is excessive the Vessel must be returned to dds for reconditioning. Irrespective of time, the Vessel must
be returned to dds for inspection and possible reconditioning after 5000 firings. The built in counter will prevent the
Vessel from operating after 5000 firings.
MAINTENANCE SCHEDULE
The Vessel design incorporates several O-rings and other consumable items and parts, which require checking,
cleaning and/or replacing on a regular basis. Please remember that the frequency of replacement of consumables is
a function of usage, quality and type of sample and Vessel cleaning techniques. The following Vessel maintenance
schedule provides a guideline.

DDS CALORIMETERS
NOTE: This is A GENERAL GUIDELINE and depending on the quality of the sample, the maintenance
schedule may need to be followed more regularly. i.e. With a substance which ignites easily (highly
flammable) the o-rings may only last 5-10 firings (sometimes less) and therefore it may be necessary
to change the o-rings more often. Please do take note of this and use this maintenance schedule as a
GUIDELINE only.
ITEM & PART NUMBER CLEANING & REPLACEMENT METHOD

FREQUENCY
VESSEL BODY Clean every 10 to 50 firings Scrub with water and detergent. Use wire brush
CAL2K-4-BD on threads.
DO NOT immerse the Vessel in water.
DO NOT wet the Vessel contact PCB
when cleaning or cooling.
VESSEL CAP Clean every 10 to 50 firings Scrub with water and detergent. Use the
CAL2K-4-CP supplied wire brush on threads.
LID ASSEMBLY Clean residue after each CV. Clean Dismantle and scrub all parts with water and
(ELECTRODE ASSEMBLY) fully every 10 to 50 firings. detergent. Use wire brush to remove deposits.
CAL2K-4-CL Dry and reassemble, change o-rings if necessary.
TOP ELECTRODE Replace every 5 to 50 firings. Check Remove deflector plate from lid. Unscrew
O-RING after every 5 firings to confirm. centre electrode remove old o-ring and replace.
CAL2K-4-CR
BOTTOM ELECTRODE Replace every 5 to 50 firings. Check Follow the steps as above and remove old o-ring
O-RING CAL2K-4-CR after every 5 firings to confirm. and replace.
LID O-RING Replace every 20 to 50 firings. Remove deflector plate from lid. Remove old o-
CAL2K-4-LR Check after every 20 firings to ring and replace with a new one. Ensure the
confirm. new o-ring fits snug in the o-ring cavity.
DEFLECTOR PLATE Replace when heavily corroded and Remove and replace.
CAL2K-4-DP cannot be cleaned.
CENTRE ELECTRODE Replace whenever necessary. Remove deflector plate. Unscrew valve screw.
CAL2K-4-CE Change electrode and o-rings. Reassemble.
OUTSIDE ELECTRODE Replace whenever necessary. Remove deflector plate. Unscrew the electrode
CAL2K-4-OE and change with a new one. Reassemble.
After every determination clean the inside of the Vessel with a paper towel to remove any residue or moisture.
Clean the threads on both the Vessel body and Vessel Cap using the Wire Brush.
HINTS AND TIPS

GENERAL HINTS
• The use of 10ml sodium carbonate solution (1 litre water and 100g sodium carbonate) is recommended if
Vessel washings are not examined. It neutralises the sulphuric acid and prolongs the life of the Vessel parts.

DDS CALORIMETERS
REMEMBER – DO NOT immerse the Vessel in water!
• For additional accuracy, place the sample on the bottom of the crucible in a spread out form. This prevents
clogging and oxygen starvation.
• Spiking. In certain cases it is necessary to know the calorific value of a substances whose combustibility is too
low for self-ignition. In such cases the technique of “spiking” is used. A known amount of a more
combustible substance of known calorific value is mixed with the sample, thus allowing the composite
material to ignite. Provided the total calorific value of the “spike” is entered in the CAL2K-1 Calorimeter,
automatic compensation is made, and the true Calorific value of the sample is displayed.
• Sample preparation: a 200-mesh sample size is sufficient. Please note this refers to coal samples only.
• An easy way to check for leaking Vessel lid o-rings, is to fill the top of the Vessel cap with water (lid assembly
must be inside the Vessel, the Vessel cap screwed down and the Vessel filled with oxygen (under pressure)).
If bubbles are seen in the water then it is clear that one or more of the o-rings are leaking and should be
replaced. Remember only to fill the lid cap (lid assembly inside Vessel) with a little water – DO NOT immerse
the entire Vessel in water!
OPERATING HINTS
• Benzoic acid fires easily with wire and cotton.

• Do not change the method between calibration and samples.
• Develop a technique for inserting the crucible into the holder without “Flicking” the sample out of the
crucible.
• Discard sample after a misfire
• Do not leave the Vessel with sample, filled with oxygen (pressurized) for more than 15 minutes before firing.
• Do not leave the Vessel pressurized (filled with oxygen) over night.
• Check the Vessels once a day for leaks and replace, if necessary, the respective O-ring. The lifetime of the
large Lid O-ring is estimated to be one month. The small electrode top O-ring can fail within a day,
depending on use, delta temperatures achieved and bad-luck. (Refer to Vessel maintenance schedule).
Remember the easy way of checking for leaking o-rings refer to General Hints above.
• The CAL2K-1 Calorimeter is the most accurate if the temperature rise is the same as that of the calibration
e.g. Approximately 9 degrees Celsius. Please note the temperature rise is not fixed, the ideal rise is 9 degrees
C but this can be more or less.
• Use only the recommended firing wire and firing cotton supplied.
• Re-calibrate the Vessel if the electrodes or deflector plate have been damaged and replaced.
NEVER operate the Vessel without the Deflector Plate.
• Remember to use the correct firing wire and firing cotton when running a normal determination with
oxygen. DO NOT use the demo firing wire when running a normal determination with oxygen.

DDS CALORIMETERS
• Fill the Vessel with oxygen to 3000Kpa to avoid a misfire. Please note it is important to fill the Vessel to this
pressure, however with some samples (highly combustible, easily ignitable samples) the pressure can be
less. Please note the Vessel pressure must NEVER be more than 3000Kpa.
DO NOT COOL VESSEL IN WATER, RATHER USE CAL2K-2 COOLER TO COOL THE VESSEL.
DO NOT SUBMERGE THE VESSEL IN WATER FOR CHECKING FOR LEAKS, CLEANING OR COOLING.
DO NOT APPLY GREASE OR ANY OTHER FORM OF LUBRICANT TO THE O-RINGS ON THE LID
ASSEMBLY OR VESSEL.
• Store the Vessels cleaned and open over night.

• Use only the crucibles supplied. Burn in new crucibles in a furnace at 800 degrees C for 10 minutes to burn
any excess oil away.
• Keep crucibles clean with a wire brush. Heavy deposits can be burnt off in a furnace.
• Do not touch the Vessel unnecessarily during preparation. Wipe the outside if it is wet from the Cooler.
• Clean Cooler brackets if excessive condensation collects.
• Switch the Cooler OFF over night, but leave the CAL2K-1 running. The Cooler CAL2K-2 consumes up to 150
watts, the CAL2K-1 only 15 watts of power.
• Do not place the Vessel on a surface or area where the surface can touch the contact base rings.
• The electrodes must be replaced if they are damaged. Always keep spares of the electrodes, crucibles, o-
rings, deflector plates, firing wire and firing cotton.
MESSAGES ON THE DISPLAY

GENERAL MESSAGES
• The following messages are displayed in the 3rd display line on the Calorimeter.
• The messages range from informative, to warning, to error.
• The printout is of the “ENGLISH” Version.
“NOT IN CALIBRATION”
You have tried to save a calibration curve, but the CAL2K-1 is not in calibration mode.
“NO BOMB RECOGNIZED”

You have tried to save a calibration curve, or set the Vessel number, but the VESSEL is not in the well, or it is not
recognized.

DDS CALORIMETERS
“BAD ENTRY, SEE MANUAL”
The entry required is the "security" type, which requires a double entry, separated by a decimal point.
"ENTRY REQUIRED"
The RECALL CALIBRATION requires a Keyboard entry. The purpose of the RECALL... command is to take a calibration
curve from 1-9 to slot 0, which is the slot used for all determinations.
"BAD KEY SEQUENCE"

The RECALL CALIBRATION function can be performed by specifying more than one curve, which instructs the Vessel
to place the AVERAGE of the specified curves into slot C0. If the Key sequence is not understood by the CAL2K-1,
then this message appears and the function is terminated.
"NO MASS + SID AVAILABLE"

The HEAP is empty. Fill the HEAP by setting a correct SID and entering a MASS. The MASS entry can be done
manually, or semi-automatic from a connected balance, or fully automatic from the balance, or from a PC.
"BAD MASS+SID HEAP ENTRY"

The HEAP, which stores the MASS and the associated SID, has a corrupt entry. It is advisable to scroll through the
HEAP and use all good entries before CLEARING the HEAP via the Menu.
"ENTER SELECTS, S=NEXT"

This message is displayed when you have pressed the "S" Sample Key, and a HEAP (SID+MASS) is displayed. Press "S"
again to scroll through the HEAP, or {CLEAR} and {S} to start from the beginning (oldest entry). Press {Enter} to
SELECT this MASS and SID for the determination.
"SELECTION NOT ALLOWED"

The Lid of the Calorimeter is closed, and you can't change the MASS+SID entry.
"BOMB COMMUNICATION FAULT"

A communications fault was detected! If this happens often, then a technician or your local Agent must check the
Vessel and CAL2K-1 Calorimeter, or the Calorimeter must be sent to the dds Factory for inspection and repair.
"LID OPEN: RESULT ABORTED"

You have opened the Lid PREMATURELY, and the determination was aborted. This can happen if the lid contact is
marginal, or makes a bad contact. Have a technician or your local Agent to look at the Lid Contact.
"MISSFIRE: RESULT ABORTED"

The sample has not ignited, or it has not raised the Vessel temperature sufficiently. The following reasons can cause
a MISSFIRE:

DDS CALORIMETERS
• Vessel was not filled with oxygen or not filled to 3000KPA. Filling the Vessel with less than 3000KPa may
cause a misfire. Bear in mind that some sample types require less oxygen pressure.
• Firing voltage is set too low. Must be set to 25.0
• Firing Cotton was not attached correctly to the firing wire
• Sample too low in calories: use SPIKING. This is useful when the sample does not ignite easily however it is
important to follow the steps and understand the steps of spiking.
• Maybe using the incorrect firing wire, make sure you are not using the demo firing wire.
"TERMINATED AT 5 MINUTES"
For some unknown reasons the FINAL drift is wrong. The CAL2K-1 Calorimeter has terminated the determination.
"FORCED CALIBRATION CYCLE"

The Vessel has no calibration curve in C0. The CAL2K-1 Calorimeter will perform a forced calibration cycle, which will
take 5 minutes.
"NO CALIBRATION TO SAVE"

You have attempted to save a calibration curve without performing a calibration. Calibration (curves) must be saved
after the final phase (5 minutes) and before the lid is opened.
“CALIBRATION SAVED -> C0"

You have performed a calibration WITHOUT saving the calibration curve. The CAL2K-1 Calorimeter has saved the
curve automatically to the C0 slot ready for the next determination.
"ABORTED: BOMB UNSAFE"

The determination cycle has been terminated due to the Vessel exceeding the maximum amount of firings allowed.
The Vessel cannot be used anymore and must be sent to dds for checking and reconditioning. The maximum
number of firings allowed per Vessel is 5000.
"BOMB RECONDITIONING REQ"; 18

The amount of firings performed by this Vessel requires reconditioning soon. Check the Vessel for wear and tear on
the threads, and prepare to send the Vessel for reconditioning or checking to the dds Factory. The Vessel may still
operate for some time. This is a warning message only.
"FIRING CIRCUIT FAULT"; 19

The firing circuit has a fault, which must be fixed by a technician before proceeding. It may be that the FIRING WIRE
from the control card to the lid is shorted to ground.
"RESULT MEMORY FULL"; 20

The result memory is full (2048 results) or the result memory (pointer) must be initialised.
"RESULT NOT SAVED (FULL)"

The result of the determination was not saved, because the memory is full.

DDS CALORIMETERS
"NO RESULTS IN MEMORY"

The result memory is empty.
"WARNING: BOMB TOO WARM"

This is a warning message only. If the Vessel temperature is more than one degree C above the ambient
temperature, then this warning is displayed. Ideally, the Vessel should be at the ambient temperature before firing.
"WARNING: BOMB TOO COLD"

This is a warning message only. If the Vessel is more than 1 degree C cooler than the ambient temperature, then this
message will be displayed. Ideally, the Vessel should be at ambient temperature before firing. The CAL2K-2 Cooler
will return the Vessel to ambient temperature.
"MASS OUTSIDE LIMITS"

The sample mass is outside the high or low limits, which can be set from the Calorimeter’s Keyboard.
"TRAY ID DIFFERS FROM GID"

In the BALANCE_MASS=0 mode, where the PC can send a group of samples (tray) to the Calorimeter, the Tray ID
must be identified, and entered in the GID field.
Only mass + SID (HEAP) entries which gave a matching TRAY_ID and GID are allowed to be used.
"LOW RESULT, USED C1 CAL"

Once the CALIBRATION_CHANGE=1 (enabled) the CAL2k will select the C1 curve for a determination which results in
a temperature rise of less than 5 degree C.
This message informs that the change has taken place. The calibration curve change takes place at the end of the
determination.
"FAULTS NOT RECORDED????"

If the result memory is full, then the faults can't be recorded. Re-initialise the memory, or upload the result with a
PC.
"POWER UP AFTER FAILURE"

This message indicates that the CAL2k has performed a power-up operation.
"REAL TIME CLOCK ERROR"

The time and date have been lost. This can happen if the CAL2k has lost power for more than a week (possibly during
shipment). Re-enter the time and date from the Keyboard menu, or from the PC.
"TEST STARTED"
This message informs that the test function was activated from the Calorimeter Keyboard.
"PARA CHANGE NOT SAVED"

Every setup parameter, which is changed from the Calorimeter Keyboard, is recorded.
"CALIBRATION CYCLE ENABLE"

This message informs the operator that the next sample will be a calibration.

DDS CALORIMETERS
"CHECK SAMPLE ENABLED"

A check sample must be specified when B.A. is used as a sample, to verify (check) a calibration. During a check
sample the Correction #2 (SULPHUR) is ignored.
"SPIKING ENABLED"
This indicates that SPIKING has been enabled. The calorific calculation will use the spike mass and spike value.
"SPIKING DISABLED"
Spiking is disabled. Spike mass and Spike value are ignored.
"TIME SET PERFORMED"

The time was set from the Calorimeter Keyboard.
"DATE SET PERFORMED"

The date was set from the Calorimeter Keyboard.
"MASS HEAP WAS CLEARED"

The MASS+SID HEAP was cleared from the Calorimeter Keyboard.
"BOMB NUMBER CHANGED!"

The Vessel number in the range from 1-255 was changed. This is not to be confused with the Vessel’s serial number!
"INITIAL COMPENSATION ON"

The initial temperature drift compensation was enabled from the Calorimeter Keyboard. The two parameters
compensation GAIN and FACTOR are now active. Both factors can only be set from the PC.
"INITIAL COMPENSATION OFF"

The initial drift compensation has been disabled.
"UNIT OF MEASURE CHANGED"

The unit of measure was changed between BTU, CaLories, or MJ. The CAL2k Calorimeter always works in BTU, but
the display of calorific value is changed.
"LANGUAGE HAS CHANGED"

The language has been changed from the Calorimeter Keyboard. The CAL2k has 4 preset languages, however only
English is available at present. “0” is always English. There are no other languages available on the CAL2k model. The
new e2k Model is language compatible.
SPECIAL DISPLAYS
Some display functions are special, and the details are explained below.
DISPLAY ACTIVE BOMB CAL

The active calibration curves C0 to C9 are displayed for the Vessel in the well.
0xx 1xx 2xx 3xx 4xx 5xx 6xx 7xx 8xx 9xx

DDS CALORIMETERS
Where xx: OK, Normal Calibration

AV, Average Performed
PC, Standard deviation performed by PC
BOMB DETAILS
Details of the Vessel in the well can be displayed by typing a SUBMENU entry from 0-14, to identify specific
information.
SUB MENU ENTRY: 0-9

The details of each calibration curve C0-C9 are displayed in the form:
CAL.No: N_C_DDMMYY_HHMM_AAAAiiii_VVVVVVV
Where: N = Calibration curve 0-9
C = Calorimeter number 1-7 which was used
DD = Day
MM = Month
YY = Last two digits of year
HH = Hour
MM = Minute
AAAAiiii = Sample identification
VVVVVVV = Standard value
SUB MENU ENTRY: 10

The Vessel manufacturing information is displayed in the form of:
BOMB MANUF AAAAAAAAAAAAAAAA sn: SSSSSSSS

Where: AAAA = Manufacturing information
SSSS = Serial number
SUB MENU ENTRY: 11

The Vessel use is displayed in the form:
FIRING COUNT: xxxx Status: iiiiiiii

Where: xxxx = Firing count
iiiiiiii = Status
1 = Calibrated
1 = Sensor fault
1 = Near reconditioning
1 = Reconditioning required
SUB MENU ENTRY: 12

The reconditioning #1 information is displayed in the form:
RECON #1: AAAAAAAAAAAAAAAA

Where: AAA = Text describing the reconditioning date, other.

DDS CALORIMETERS
SUB MENU ENTRY: 13

The reconditioning #2 information is displayed in the form:
RECON #2: AAAAAAAAAAAAAAAA

Where: AAA = Text describing the reconditioning date, other.
SUB MENU ENTRY: 14

The customer information is displayed in the form:
CUST: AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
Where: AAA = Customer related text.
RESULT DISPLAY
The last result can be displayed by pressing the {R} Key in the form:
ddmmyyhhmm_Bnn_S_M.MMMM_IIIIIIII_RR.RRRR
Where: dd = Day
mm = Month
yy = Last two digits of year
hh = Hours
mm = Minutes
Bnn = Bomb number
S = Status
M.MM = Mass
IIII = Sample identification SID
RR.R = Result in chosen unit of measure.
LINE 1 - LCD DISPLAY

The following information (IN BOLD) is the reading, which will be displayed on the first line of the LCD display screen
during a determination. Below this, you will find a brief explanation as to what the reading means or next action that
needs to be taken.
A description of the (BRACKETED) words can be found after the table of LCD readings below.
SET UP NO BOMB SELECT MASS+SID

Select MASS and SID.
SET UP NO BOMB (MASS)(SID)

Insert bomb (Vessel). MASS SID will only be displayed if Vessel is inserted.
SET UP (TEMPERATURE) (MASS)(SID) LID OPEN

Close lid. If no errors occur, the determination will start. If errors do occur, a message will be displayed on line 3.

DDS CALORIMETERS
INITIAL (DRIFT) (MASS)(SID) T=(TIME) T OR D

“D” indicates the drift conditions are not being met. T indicates the time conditions apply – once the time conditions
are met, the Calorimeter will fire the Vessel.
FIRING (DRIFT) (MASS)(SID) T=(TIME)

This display stays for 6 seconds
FINAL (TIME) (T RISE) (MASS)(SID) (RESULT)

Final drift and time conditions are now observed and once met, the Calorimeter proceeds to DONE.
DONE (T RISE) (MASS)(SID) (RESULT)

-> indicates final result
SET UP (TEMPERATURE) SELECT MASS+SID (RESULT)

(Result) is the last result
Remove the Vessel.
SET UP NO BOMB SELECT MASS+SID (RESULT)

Insert the Vessel
RETURNS TO STEP 3.
(Drift) – Drift in degrees Celsius per 6 seconds.
(Mass) – Mass in grams.
(Result) – Calorific Value as it develops.
(SID) – Sample ID.
(Temperature) – Temperature of Vessel.
(Time) – Time in decimal minutes.
(T rise) – At firing, the temperature is set to zero and the ‘Temperature rise’ is displayed.
CALORIMETER BASIC TESTS

BASIC TESTS (T) - FROM T1 TO T7
T1 : SHOW AMBIENT & BOMB TEMPERATURE: AA.A BB.BBB

Ambient Temperature = AA.A
Bomb Temperature = BB.BBB (if the Bomb is inserted in the Well (it will be 00.0000 if no Bomb is inserted.)
T2: FLASH LAMP AND LCD:

The lamp on the Front Panel and the LCD back light will flash alternatively.
T3: SHOW FIRE / SUPPLY VOLT: FF.F S.S

FIRING VOLTAGE: FF.F = Firing voltage (this should be 25 +/- 0.2 Volts. (Check the firing voltage in the setup
program, it should be 25V)

DDS CALORIMETERS
SUPPLY VOLT: S.S = Supply Voltage (this should be 9.0 +/- 0.1 Volts
T4: FIRE AT TARGET VOLTAGE:

This will only operate if a Vessel with Firing Wire is inserted into the Well and the Lid is closed. The Vessel will fire
and then the voltage will build up back to its setting at which stage the Vessel will fire again. Open the Lid and
remove the Vessel from the Well.
T5: SHOW LID AND WIRE SENSE:

Starts off as: OPEN OPEN
Close the Well Lid:

Display will now be: CLOSED OPEN
Open the Calorimeter’s Lid, insert the Vessel with Firing Wire and Close the Lid:
Display will now be: CLOSED CLOSED
T6: SHOW REALTIME EVERY Y SEC: DDMMYY HHMM SS

The Display will increment every second:
DD = Day
MM = Month
YY = Year
HH = Hour
MM = Minute
SS = Second
T7: DISPLAY TEST

All segments of the LCD Display go dark
TROUBLE SHOOTING AND SOLUTIONS

CALORIMETER
a) “No Wire” – clean base and lid connections and then check Vessel. Make sure you are using the correct
firing wire and not demo firing wire.
b) “No Bomb” – clean base connections and check Vessel. Make sure the PCB contact is not wet.
c) Pilot lightdoes not illuminate when lid is closed. Check lid switch operation and lamp inside the light.
d) Keys stick down – blow out slots with compressed air. If symptom persists, call a Service Technician.
e) Polystyrene deteriorates – call a Service Technician or your local Agent to replace all polystyrene inserts.
f) MASS does not transfer from the Balance – check interconnection cable, balance cable and balance set-up.

DDS CALORIMETERS
COOLER
This section is intended to coincide with the section “Cooler : Performance Testing”. If any problems are
encountered, please return to the section “Getting Started” and see the subsection “The CAL2K-2 Cooler –
Performance Testing”, to refer to the following diagnoses:
a) If no POWER LED – check that mains is connected to the unit.

b) If all or some of the LED’s do not work – refer to the Maintenance Manual.
c) With no water flow, the LEFT and RIGHT OVER TEMPERATURE LED’S will come on after a while. DO NOT run
the Cooler in this condition continuously. Once water is flowing, they should switch off.
d) If the LEFT and RIGHT ON LED never come ON – refer to the Maintenance Manual.
e) If any orange or red LEDs are ON, then refer to that specific condition.
f) If either pad is NOT cold – refer to the Maintenance Manual.
g) If the “VESSEL IN WELL” LED does not come ON -check the seating of the Vessel and the Vessel contacts. If
the “CLOSE DOOR” or “VESSEL LOADING” LEDs come ON, check that the Vessel is warmer than ambient
temperature. The “VESSEL TOO COLD” LED will come ON if the Vessel is colder then the ambient
temperature.
h) If the “CLOSE DOOR” LED is ON and the doors will not stay latched – refer to the Maintenance Manual.
i) If the doors do not open when the “DOORS OPEN” switch is pressed - ensure that the doors are not
mechanically jamming on the Vessel. If the doors are free and this still occurs, refer to the Maintenance
Manual.
j) If the doors do not automatically open - refer to i) above.
k) If the VESSEL LED doesn’t go OFF – refer to the Maintenance Manual.
l) If the IDLE LED on and then OFF – refer to the Maintenance Manual.
FILLING STATION
a) Bottle pressure gauge does not indicate – check the regulator on the oxygen bottle. Check the connection
between regulator and Filling Station.
b) Vessel does not fill – check the setting of the Flow Adjustor, check Lid Assembly of the Vessel.
c) Nozzle leaks while Vessel is filling – replace the Nozzle O-ring.
d) Nozzle leaks even with no Vessel inserted – replace Valve O-ring (Nipple) inside Nozzle assembly.
VESSEL
a) “No Wire” – check that the Firing Wire is present and securely clamped by the sleeves. Make sure you are
using the correct Firing Wire and not “Demo” Firing Wire.
b) Oxygen leaks – replace all Lid Assembly O-rings. Make sure the Vessel is filled to 3000Kpa. If under filled it
could cause leaking. Remember however, that high combustion samples require less oxygen.
c) Cap is difficult to turn – clean threads on both the Vessel Cap and Vessel Body with a wire brush.
d) Display shows “No Bomb” when Vessel is in the Well – clean the base of the Vessel and contacts in the
Well. Give the Vessel a twist to ensure a better contact. Make sure that the Vessel’s base is NOT wet!
e) Centre elEctrode does not move freely – strip and clean the Lid Assembly.

DDS CALORIMETERS
SYSTEM WITH THE DOCKING STATION (CAL2K-5)

The purpose of the Docking Station is to allow the orderly preparation of Vessels in a high production environment
with multiple Calorimeters, multiple Vessels and multiple Operators. It is not required by all laboratories but is highly
recommended when samples are mixed up in a high volume operation. The Vessel is “CHARGED” as always with the
sample and the oxygen. The Docking Station “charges” or loads the Vessel with the MASS, SAMPLE ID, GROUP ID,
and other items such as DATE and TIME.
The Docking Station allows the alpha-numeric entry of:
• Sample mass
• Sample identification
• Sample group identification (tray)
• Other
WARNING: The GID can ONLY be in alpha (letters of the alphabet) or numerical (numbers/digits)
format. NO special characters can be interpreted (e.g. dash, slash, full stop, bracket, etc.). The SID
can ONLY be in numerical format (NO Special Characters) as it is a number which gets incremented.
From the Docking Station, the prepared Vessel can then be inserted into any Calorimeter without further action. For
this to happen automatically, two conditions must be met:
A. A MASS and SID must be present in the Vessel. Only a Docking Station can perform this task.
B. The “BOMB MASS” operation must be enabled in the CAL2k via the Keyboard commands or via the PC
Interface. This operation needs to be performed once only.
The Docking Station can connect to the following peripherals:

1) Balance
2) PC Keyboard:
a. Keyboard entry
b. Barcode scanner
c. Both of the above
3) (PC) via RS232 interface, for in-house operations

DDS CALORIMETERS
Vessel Loaded with:

Group ID, Sample ID, MASS
Calorimeter (CAL2K-1)
Operation:
Balance
Vessel Mass Enabled
Docking Station
(CAL2K-5)
Vessel
Barcode (CAL2K-4)
Scanner 0-9 Normal
numerical value
Return (Back Space)
Enter
Optional External
Keyboard
Result includes: Group ID, Sample ID,
MASS from Vessel
FIGURE 15. : DOCKING STATION CONNECTIONS
The barcode scanner port is shared with the external Keyboard. Either or both can be used. The Docking Station has
some of its own pushbutton Keys as follows:
Keypad (Keyboard):
Numerical Keys 1
to 0
Back Space Key

Clears entry
Enter Key
Confirms entry
DOCKING STATION OPERATION

1) Place the cleaned Vessel inside the docking receptacle. The Vessel verification will be indicated on the
Display.

DDS CALORIMETERS
2) Enter (as an example) – No: = 1 Use: = 83 – where “No: “ is the Vessel number e.g.: 1 and “Use:” is the
firing count of the Vessel e.g.: 83. Then enter the Sample ID. The Sample ID needs to be numerical ONLY
as it is incremented automatically.
3) Scan the barcode or enter the Sample ID from the Keypad. The sample ID will be indicated on the
display. If a change (edit) or a re-scan is required, then this can be done at this time.
4) Weigh the sample. Once the weight is indicated press the ENTER Key on the Keypad. An error message
may be displayed (see errors), otherwise the confirmed message “DONE REMOVE VESSEL” will be
displayed. This concludes the operation and the MASS, SID and GIDhave now been entered in the Vessel.
5) Remove the Vessel from the Docking Station and place the Crucible into the Vessel.
6) Fill the Vessel with oxygen.
7) The Vessel is now ready to be inserted (after a 1 minute stabilization period) into any CAL2k Calorimeter.
8) The CAL2k will recognize the charged (loaded) MASS, SID and GID if: “ENABLE BOMB MASS ENTRY/ON” is
set on the CAL2k. This can be confirmed through the CAL2k Keyboard MENU function. The “ENABLE
BOMB MASS ENTRY” needs to be set once only.
DOCKING STATIONS PARTS

Ordering number: CAL2K-5
Complete Docking Station
(Includes power supply and mains cable)
Spare parts: None
DOCKING STATION MESSAGES

No Bomb - No Vessel inserted into Vessel Holder.
Bomb full - Vessel already has SID and MASS in its memory – to overwrite this, press Enter.
Done Remove Vessel - SID and MASS successfully entered into Vessel
Bomb FLT (Bomb Faulty) - Vessel is in Holder but it is not communicating with the Docking Station.
Remove the Vessel and re-insert it. If it is still faulty, try another Vessel.

DDS CALORIMETERS
S = SID
M = MASS
NO = Vessel Number
VSE = Firing Count
SETUP OF IDENTIFICATION STRING WITH EXAMPLES

The sample identification string consists of 3 parts:
GID - Group Identification

SID - Sample Identification
IGN - Ignore Characters
F = GID + SID + IGN
To change the set up proceed as follows:

Use PC Keyboard plugged into the Docking Station
Type F followed by number of GID characters (only alpha or numerical or a combo of both), then number of SID
characters (only alpha or numerical or a combo of both) and finally number of ignore characters, then press Enter.
E.g.: F541
GID No. of Characters = 5

SID No. of Characters = 4
IGN No. of Characters = 1
So 5531210628
55312 = GID
1062 = SID
8 = IGN
E.g.: F260

Entry of Data: ABCDEFG1

Docking SID: __CDEFG1
CAL2k GID: AB
CAL2k SID: CDEF0001
Note the missing letter “G”. If the missing letter(s) are important in the case that the numerical content is LESS than
4 digits, then the Fxxx (Format) must be changed to shift the missing digits to the GID, as follows:
E.g. F710

DDS CALORIMETERS

Entry of Data: ABCDEFG1

Docking SID: _______1
CAL2k GID: ABCDEFG
CAL2k SID: ____0001
NOTE: The SID display shows the “formatted” SID BEFORE conversion to the CAL2k format.
RULE: The numerical portion of the SID must be more than 4 digits without any character other than
numbers! If this is not possible, then the Docking Station will ignore the “non-numerical” characters,
unless they are shifted to the GID with the format setup (Fxxx) as shown above.
NOTE: In manual SID entry if the SID is set to 4 characters then 4 characters must be entered e.g.: a
SID of 10 must be entered as 0010 (leading zeros must be entered). NO Special Characters are to be
entered, only numerical characters.
To clear the screen and start again during an entry type “x”.
CALIBRATION
A sample can be set as a calibration sample at the Docking Station as follows:
1) Insert the Vessel into the well

2) Press “X”, then press “Enter”
3) Type CAL, then press enter – the sample is now a calibration
4) Proceed as normal to enter SID and MASS and transfer to the Vessel
CAL2K SYSTEM TECHNICAL SPECIFICATIONS

DESCRIPTION UM CAL2K-1 CAL2K-2 CAL2K-3 CAL2K-4
Dimensions: mm 280 x 290 x 400 280 x 250 x 320 220 x 450 x 300 82 mm Diameter
(Width, Height, 150 mm Height
Depth)
Weight: Kg 10 10 5.5 2.5
Power : 90 – 260 VAC 90 – 260 VAC - -
50/60Hz 50/60Hz
Operating 0 – 60°C 0 – 60°C
Temperature:

DDS CALORIMETERS
Repeatability: 0.1 (%RSD – Relative Standard Deviation)

Energy Resolution: 0.001 (MJ/Kg)
Temperature Resolution: 0.000001°C
Calibration: Calibration Details per Calibration Curve
10 Stored Calibration and Deviation Curves
Automatic Standard Deviation Calculations
Determinations: 10 per Vessel, per Calorimeter per Hour
Results in Memory: 2048
PARTS AND INSTALLATION KITS

PARTS LIST – CAL2K-1 CALORIMETER
PART DESCRIPTION
CAL2K-1 Calorimeter
CAL2K-1-AS Ambient Sensor
CAL2K-1-BB Capacitor Bus Bar
CAL2K-1-BC Base Contact PCB with Supports and Contact
CAL2K-1-CS Case Set
CAL2K-1-DC Display Cover
CAL2K-1-DK Door Knob
CAL2K-1-DL Door Latch and Switch
CAL2K-1-DS Display
CAL2K-1-KB Keyboard
CAL2K-1-LC Lid Contact
CAL2K-1-NC M3 Nut Cover
CAL2K-1-PC Protective Cover
CAL2K-1-PL Pilot Light
CAL2K-1-PS Display Power Supply
CAL2K-1-PY Polystyrene Set with Lid Contact
CAL2K-1-RP Rear Panel Assembly and Wiring
CAL2K-1-SO Stand Off
CAL2K-1-KT CALORIMETER INSTALLATION KIT

QTY PART NUMBER DESCRIPTION
5 CAL2K-4-CB Crucible
1 CAL2K-4-PS Preparation Stand
1 CAL2K-4-WB Wire Brush
1 CAL2K-HB Printed Handbook
1 CAL2K-OM Operating Manual
1 CAL2K-4-FC Firing Cotton
2 CAL2K-4-BA Certified Benzoic Acid
1 CAL2K-MC Mains Cable

DDS CALORIMETERS
1 CAL2K-1-SM Power Supply
PARTS LIST – CAL2K-2 COOLER

PART DESCRIPTION
CAL2K-2 Cooler
CAL2K-2-AC Ambient Cable
CAL2K-2-BC Base Connection
CAL2K-2-CB Cast Cold Block
CAL2K-2-CN Hot Block Connections – Straight
CAL2K-2-CR Hot Block Connections - 90°
CAL2K-2-CS Case Set
CAL2K-2-DL Door Lock Mechanism
CAL2K-2-DS Door Support
CAL2K-2-FR Ferrule
CAL2K-2-HB Hot Block
CAL2K-2-HC Hose Clamp
CAL2K-2-NC M3 Nut Cover
CAL2K-2-PN Pipe Nut
CAL2K-2-SD Studs for Hot Block
CAL2K-2-SM Switch Mode Power Supply
CAL2K-2-SO Power Supply Stand Offs
CAL2K-2-TS Temperature Sensor
CAL2K-2-VH Vessel Holder
CAL2K-2-WC Water In/Outlet Connection
CAL2K-2-WN Water In/Outlet Nut
CAL2K-2-WP 1m Water Piping
CAL2K-2-WR Wiring and Connectors
CAL2K-2-KT COOLER INSTALLATION KIT

3 CAL2K-2-HC Water Pipe Hose Clamp
1 CAL2K-2-AC Ambient Cable
1 CAL2K-2-WP 10m Water Pipe
1 CAL2K-MC Mains Cable
PARTS LIST – CAL2K-3 FILLING STATION

PART DESCRIPTION
CAL2K-3 Filling Station
CAL2K-3–AM Arm and Knob
CAL2K-3–BN Gauge Block Nipples
CAL2K-3–EC Ex Centre
CAL2K-3–FA Flow Adjustor

DDS CALORIMETERS
CAL2K-3–FN Flow Adjustor Nipple

CAL2K-3–FR Flow Adjustor O-Ring (4.42 mm x 2.62mm)
CAL2K-3 –FS Frame plus 2 Plates
CAL2K-3–HR Gauge Holder
CAL2K-3–HR Holder
CAL2K-3–KN Knurled Nut
CAL2K-3–NP Nipple
CAL2K-3–NR Nozzle O-Ring (8mm x 2.62mm)
CAL2K-3–NZ Nozzle Body
CAL2K-3-OP 2m 1/8 Inch High Pressure Oxygen Pipe
FERRULE High Pressure Oxygen Pipe Ferrule
CAL2K-3–PG Pressure Gauges
CAL2K-3–PH Pipe Holder
CAL2K-3–PN Pipe Nuts
CAL2K-3–PR Piston O-Ring (8mm x 2.62mm)
CAL2K-3–PS Piston
CAL2K-3–SG Spring
CAL2K-3–ST Shaft
CAL2K-3–VH Vessel Holder
CAL2K-3–WR Washer
CAL2K-3-KT FILLING STATION INSTALLATION KIT

2 CAL2K-3-FR Flow Adjustor O-Rings
5 CAL2K-3-NR Nozzle O-Rings
1 CAL2K-3-OP High Pressure Pipe 2m
1 CAL2K-3-RC Oxygen Regulator Connection
1 CAL2K-4-DC Defiller Cap
1 CAL2K-4-HH Handling Hook
PARTS LIST – CAL2K-4 VESSEL

PART DESCRIPTION
CAL2K-4 Vessel Complete
CAL2K-4-BD Body with Sleeve
CAL2K-4-BR Body Ring
CAL2K-4-CE Centre Electrode, Top and Bottom, and Sleeve
CAL2K-4-CP Cap – with Thread Cut
CAL2K-4–CR Top and Bottom O-Ring (3.1mm x 1.6mm Viton)
CAL2K-4-DP Deflector Plate
CAL2K-4-LD Lid – Without Electrodes
CAL2K-4-LR Lid O-Ring (46.0mm x 3.53mm)
CAL2K-4-OE Outside Electrode - with Sleeve
CAL2K-4-PT Pressure Test

DDS CALORIMETERS
CAL2K-4-SN Temperature Sensor

CAL2K-4-SV Valve Screw
CAL2K-4-VS Vessel PCB
CAL2K-4-KT VESSEL INSTALLATION KIT

1 CAL2K-4-CE Centre Electrode
10 CAL2K-4-CR Top & Bottom O-Rings
5 CAL2K-4-LR Lid O-Rings
1 CAL2K-4-OE Outside Electrode
5 CAL2K-4-FW Firing Wire
1 CAL2K-4-DP Deflector Plate

DDS CALORIMETERS
CERTIFICATIONS

DDS CALORIMETERS
APPENDIX 1
PRESSURE CONVERSIONS
3000KPa = 3 MPa
= 30 Bar
= 30 Atmospheres
= 435 PSI
APPENDIX 2
MJ / CAL / BTU ENERGY CONVERSIONS
1 MJ/Kg = 429.9 BTU/Lb
1 MJ/Kg = 238.85 Calories/gm
APPENDIX 3
BALANCE SETTINGS FOR CAL2K BOMB CALORIMETER
Data Output: Automatic output synchronous readout at stability
Characters: 7 Bit
Baud Rate: 2400
Synchronisation: 1 start bit, 1 stop bit
Parity Bit: Odd
DB25 CONNECTOR
Pin 1: Ground
Pin 2: Balance transmit (output)/input to CAL2k or ECO

Cal2K Operating Manual: Dds Calorimeters

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Manufacturers of CAL2K/CAL3K Oxygen Bomb Calorimeters