Kane KANE504 Leitfaden

KANE504

Combustion Analyser

Stock No: 19101-2 April 2012

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CONTENTS

Page No:

OWNERS MANUAL & MAINTENANCE 3

1. GETTING STARTED 4

1.1 SAFETY NOTES 4

1.2 PRE-TEST CHECKLIST 4

1.3 STORING INLET TEMPERATURE 4

1.4 SELECTING FUEL 5

1.5 ANALYSER CONNECTIONS 5

1.6 POST TEST 6

2. MAINTENANCE 6

2.1 GENERAL MAINTENANCE 6

2.2 PERIODIC SERVICE 6

2.3 ANNUAL RE-CALIBRATION 6

2.4 CLEANING 7

2.5 EMPTYING AND CLEANING THE IN-LINE WATER TRAP 7

2.6 CHANGING THE PARTICLE FILTER 7

2.7 BATTERIES REPLACEMENT 8

3. METER PROBLEM SOLVING 9

4. METER SPECIFICATION 10

5. ELECTROMAGNETIC COMPATIBILITY 11

6. GLOSSARY 12

6.1 SELECTOR AND DISPLAY PARAMETERS 12

6.2 FUELS AVAILABLE 13

7. CLEANING 13

8. ANNUAL RECALIBRATION AND SERVICE 13

8.1 RETURNING YOUR ANALYSER TO KANE 14

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OWNERS MANUAL & MAINTENANCE

The KANE504 Flue Gas Analyser tests heating appliances for carbon

dioxide (CO

), carbon monoxide (CO), Flue Temperature and

Combustion Efficiency.

It is suitable for use with all common ‘domestic’ fuels including Natural

Gas, Propane, Heavy Oil, LPG and Light Oil. (When used with oil

burning appliances the flue gases should only be sampled after the

smoke level has been measured and has been confirmed to be a very

low smoke number.)

It uses a bespoke Non-Dispersive InfraRed (NDIR) sensor to directly

measure CO

and a long life electrochemical sensor to measure CO.

The meter is controlled using a rotary dial.

The dial positions are:

OFF

STANDBY Pump off

CO ppm carbon monoxide

% carbon dioxide

% Oxygen

RATIO CO/CO2

T FLUE Flue temperature

EFF Combustion Efficiency

Note: Ratio is shown to 4 decimal places, but without a decimal point. So

0001 on the display is equivalent to 0.0001

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1. GETTING STARTED

1.1 SAFETY NOTES

Before using this meter, read all safety information carefully. In this

manual the word “WARNING” is used to indicate conditions or actions

that may pose physical hazards to the user. The word “CAUTION” is

used to indicate conditions or actions that may damage this instrument.

WARNING!

This analyser extracts combustion gases that may be toxic in relatively

low concentrations. These gases are exhausted from the back of the

instrument. This instrument must only be used in well-ventilated

locations. It must only be used by trained and competent persons after

due considerations of all the potential hazards.

1.2 PRE-TEST CHECKLIST

Clean particle filter

Water trap and probe line are empty of water

Power on and zero

All hose and thermocouple connections are properly secured

Flue gas probe is sampling ambient FRESH air

Water trap is fitted correctly to the instrument

Flue temperature plug is connected

Inlet temperature probe is connected if required

1.3 STORING INLET TEMPERATURE

To correctly calculate net temperature and combustion efficiency it is

important to have the correct inlet temperature set. Two methods are

available to properly establish the inlet temperature.

Non-ducted Systems. If the KANE504 is being used on a system that

uses combustion air from the space near the appliance, simply turn the

analyser on without the flue probe connected. The KANE504 will use an

ambient sensor inside the handset as the inlet temperature to determine

net temperature.

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Ducted Systems. If the KANE504 is being used on a system that brings

in outside air for combustion air it is important to set up the inlet

temperature prior to taking flue gas readings. To properly set inlet

perform the following steps during start-up of the KANE504:

Connect the flue temperature connector only to the KANE504.

Place the flue probe in the combustion air inlet system

Turn on and allow to complete the zero process.

Connect the flue gas connector and proceed to combustion

measurements.

The temperature measured during the zero countdown has now been

stored, and will be used to determine the net temperature.

1.4 SELECTING FUEL

When powering on, simply rotate the selector to the desired fuel. The

display will show this, and then it will complete the zero process.

NOTE: If you wish to use the same fuel as previously selected rotate the

selector to “Stand By” at power on. The fuel in use will be displayed and

then blink. If the fuel is not correct rotate the selector to the proper choice

before the zero countdown starts.

1.5 ANALYSER CONNECTIONS

NOTE: Take care when inserting the temperature probes as the pins are

polarized. Insert with the smaller pin into input marked positive. (+)

CAUTION!

Turning the pump off while the probe is in the flue will leave toxic gases

inside the analyser. Once data has been read, it is advisable to purge the

unit with fresh air as soon as possible. To do this, with the probe

removed from the flue, turn ON the pump. Always allow the readings to

return to zero (0.0 for CO2) prior to shutting the unit off.

CAUTION!

The probe will be hot from flue gases. Remove the probe from the flue

and allow it to cool naturally. Do not immerse the probe in water, as this

will be drawn into the analyser and damage the pump and sensors. Once

the probe is removed from the flue and the readings have returned to

ambient levels rotate the selector to “OFF” and switch off the analyser.

The instrument will count down from 10 to switch off.

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1.6 POST TEST

Remove the probe from the flue and allow the analyser to purge with

fresh air until the CO and the CO2 readings return to zero. (Be careful as

the probe tip will be HOT)

Drain water trap.

Check particle filter.

2. MAINTENANCE

2.1 GENERAL MAINTENANCE

Check calibration of your instrument annually to ensure it meets original

performance specifications.

Keep your instrument dry. If it gets wet, wipe dry immediately. Liquids

can degrade electronic circuits.

Whenever practical, keep the instrument away from dust and dirt that

can cause premature wear.

Although your instrument is built to withstand the rigours of daily use, it

can be damaged by severe impacts. Use reasonable caution when using

and storing the meter.

2.2 PERIODIC SERVICE

CAUTION!

Repair and service of this instrument is to be performed by qualified

personnel only. Improper repair or service could result in physical

degradation of the instrument. This could alter the protection from

personal injury this meter provides to the operator. Perform only those

maintenance tasks that you are qualified to do.

2.3 ANNUAL RE-CALIBRATION

While the sensor has an expected life of more than five years in normal

use it is recommended that the analyser is re-calibrated at least annually,

this is so that long-term drift on the electronics can be eliminated. Local

regulations may require more frequent re-calibration and users should

check with appropriate authorities to ensure they comply with relevant

guidelines.

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2.4 CLEANING

Periodically clean your instrument case using a damp cloth. DO NOT use

abrasive, flammable liquids, cleaning solvents, or strong detergents as

they may damage the finish, impair safety, or affect the reliability of the

structural components.

2.5 EMPTYING AND CLEANING THE IN-LINE WATER TRAP

The integral water trap should be checked and emptied on a regular

basis. Water vapour will condense in the probe line, which may cause

the water trap to fill suddenly if the probe is moved. Care should be taken

at all times.

Carefully unscrew the plug from the

bottom of the water trap housing.

Dispose of the condensate in a suitable

drain, care must be taken as it could be

acidic. If condensate spills onto the skin

or clothing, clean off immediately using

fresh water, seek medical advice of

problems occur. Ensure plug is

replaced before performing combustion

tests.

NOTE: CO2 reading will be low if the Water Trap Plug is not in place.

2.6 CHANGING THE PARTICLE FILTER

This is a very important part of the analyser and should be changed

regularly. It prevents dust and dirt particles from entering pump and

sensors that will cause damage. The filter MUST be changed when it

appears discoloured.

Remove water-trap assembly from the

analyser as shown above. Remove the

filter and plastic holder from the

housing. Discard the filter element but

keep the holder to fit to the new filter.

Clean the inside of the filter housing

with a suitable soft cloth. Fit the holder

onto the new filter element and then

insert into the housing. Refit the

housing onto the analyser.

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2.7 BATTERIES REPLACEMENT

This meter has been designed for use

with alkaline batteries. No other types

are recommended. The analyser is

supplied with 4 “AA” size alkaline

batteries.

These should be installed into the

instrument as shown in the diagram to

the right and indicated on the back of

the unit.

CAUTION!

Take great care when installing the batteries to observe the correct

polarity. Always check the meter for operation immediately after installing

new batteries.

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3. METER PROBLEM SOLVING

If any problems are not solved with these solutions, contact us or an

authorised repair centre.

Fault Symptom Causes / Solutions

too low Air leaking into probe, tubing, water trap

or connectors.

Meter does not respond to flue

gas

Particle filter blocked.

Probe or tubing blocked.

Pump not working or damaged with

contaminants.

Net temperature or Efficiency

calculation incorrect

Ambient temperature set wrong during

Automatic Calibration.

Flue temperature readings

erratic

Temperature plug reversed in socket.

Faulty connection or break in cable or

plug.

T flue or T net displays (----) Probe not connected or faulty.

EFF display (----) CO

reading is too low. No temperature

measurement available

CO reading too low

Air leaking into probe, tubing, water

trap or connectors.

Sensor may be depleted: check against

a known concentration

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4. METER SPECIFICATION

(NOTE MAY BE SUBJECT TO CHANGE)

Parameter

Resolution

Accuracy

Range

Flue Temperature

Carbon Dioxide

Oxygen

Carbon Monoxide

Efficiency

0.1 °C

0.1%

1 ppm

0.1%

± 2°C + 0.3% Reading

+0.2%

+/- 5ppm <100 ppm

+/-5% of reading >100

ppm

n/a

0-600°C

0 - 21%

0 to 1999 ppm

0-110%

Dimensions

(approximate)

Weight

Handset

Probe

0.5 Kg

180mm x 85mm x 50mm

250mm x 6mm stainless steel shaft

nominal 0.9m neoprene hose.

Ambient Operating

Range

C to 45°C

10% to 90% RH non- condensing

850 to 1100 mbar atmospheric pressure

Battery Life

4 AA cells

>8 hours using Alkaline AA cells

Using dry gases at STP

Calculated assuming Fuel Lean Combustion for.

Calculated

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