Kane KANE451, 451 Plus User Manual

KANE451

Flue Gas Analyser

with direct CO2 measurement

Stock No: 19116 July 2012

© Kane International Ltd

Page 2

CONTENTS

Page No:

KANE451 Overview 4

ANALYSER LAYOUT & FEATURES 5-6

1. BATTERIES 7

2. BEFORE USING THE ANALYSER EVERY TIME 8-9

2.1 FRESH AIR PURGE 8

2.2 STATUS DISPLAY 9

3. USING THE FOUR FUNCTION BUTTONS 10-12

4. USING THE ANALYSER 13-24

4.1 COMBUSTION TESTS ........................................13-14

4.2 PRESSURE TEST ............................................... 15-16

4.3 LET-BY & TIGHTNESS TESTING....................... 17-18

4.4 DIFFERENTIAL TEMPERATURE ............................ 19

4.5 ROOM CO TESTING................................................ 20

4.6 KANE451 PRINTOUTS ............................................ 24

5. USING THE MENU 25-26

6. USING THE KANE451 AS A THERMOMETER 27-28
OR PRESSURE METER

7. MEASURING FLUE GASES 29

8. ANALYSER PROBLEM SOLVING 30-31

9. ANALYSER SPECIFICATION 32

10. ELECTROMAGNETIC COMPATIBILITY 34

Page 3

11. EN50379 REGULATED INSTRUCTIONS 35-37

12. CLEANING 38

13. ANALYSER ANNUAL RECALIBRATION
AND SERVICE 38

14. RETURNING YOUR ANALYSER TO KANE 39

15. SERVICE RETURNS 40

APPENDIX 1 – MAIN PARAMETERS 42-43

ADDENDUM

OPTIONAL NITRIC OXIDE (NO) SENSOR 44-47

Page 4

KANE451 Overview

The KANE451 Combustion Analyser measures carbon dioxide (CO2), carbon
monoxide (CO) to 10,000ppm, differential temperature and differential pressure. The
direct measurement of CO2 is achieved using a Kane designed infra-red sensing
system.

CO2 is set to zero in fresh air automatically after the initial countdown.

If “RESET GAS ZERO” is indicated ensure that the unit is in fresh air before pressing
the button with an “Enter” symbol.

It calculates oxygen (O2), CO/CO2 ratio, losses, combustion efficiency (Nett, Gross or
Condensing) & excess air.

The KANE451 Combustion Analyser can also measure CO levels in ambient air ­useful when a CO Alarm is triggered. It can also perform a Room CO Test for up to 30
minutes duration.

The analyser has a protective rubber cover with a magnet for “hands–free” operation
and is supplied with a flue probe with integral temperature sensor.

The large display shows 4 readings at a time and all data can be printed via an
optional infrared printer. The printed data can be 'live' data or ‘stored’ data.

The memory can store up to:
99 combustion tests
20 pressure tests
20 let-by/tightness tests
20 temperature tests
30 room CO tests

Two lines of 20 characters can be added to the header of printouts.

The analyser is controlled using 4 function buttons and a rotary dial.

The four buttons (from left to right) switch on and off the analyser, switch on and off
the backlight and task light, switch on and off the pump and send data to a printer or to
the memory. The buttons with UP, DOWN and ENTER arrows also change settings
such as date, time, fuel, etc. when in MENU mode.

Page 5

ANALYSER LAYOUT & FEATURES

Rotary Switch

Function

buttons x 4

“Battery Charging”

indicator

Water Trap

Particle Filter

Enter

Menu controls

Scroll up/down

Tasklight and infra-red emitter

Flue Gas Inlet

Temp and pressure

connections

Battery Compartment

(behind rubber sleeve)

Page 6

Page 7

1. BATTERIES

Battery Type

This analyser has been designed for use with disposable alkaline batteries or
rechargeable Nickel Metal Hydride (NiMH) batteries. No other battery types are
recommended.

WARNING

The battery charger unit must only be used when NiMH batteries are fitted.

Replacing Batteries

Turn over the analyser, remove its protective rubber sleeve and fit 4 “AA” batteries in
the battery compartment. Take great care to ensure they are fitted with the correct
battery polarity. Replace the battery cover and protective rubber sleeve.

Switch the analyser on and check that the analyser’s time and date are correct. To
reset see USING THE MENU, Section 5.

Charging NiMH Batteries

Ensure that you use the correct charger. The part number is KMCU250/UK.

To fully charge NiMH batteries:

Switch the KANE451 on.
The charger must then be connected and switched on.
When charging, the red Battery Charging Indicator will illuminate.

Now switch the KANE451 off. The display will show “BATTERY CHARGING”

The first charge should be for 12 hours continuously. NiMH batteries are suitable for
top up charging at any time, even for short periods.

An in-vehicle charger can be used to top up the analyser's batteries from a 12 volt
vehicle battery. The part number is KMCU450/12

Battery Disposal

Always dispose of depleted batteries using approved disposal methods that protect the
environment

Page 8

2. BEFORE USING THE ANALYSER EVERY TIME:

Check the water trap is empty and the particle filter is not dirty:

- To empty water trap, unscrew the red drain plug and re-plug once it is empty.

- To change the particle filter, remove protective rubber sleeve, slide the water
trap unit from the analyser, remove the particle filter from its spigot and replace.
Reconnect the water trap unit and rubber protective sleeve.

Connect the flue probe hose to the analyser’s flue gas inlet and connect the flue
probe’s temperature plug to the T1 socket – check the plug’s orientation is correct ­see Page 6.

2.1 FRESH AIR PURGE

Position the flue probe in fresh air, then press / . The analyser’s pump
starts and the analyser auto-calibrates for approximately 90 seconds. When complete:

Select “Ratio” on the dial. In fresh air the CO reading should be zero.
Select “O2/Eff” on the dial. In fresh air the O2 reading should be 20.9% ± 0.1%.

RESET

GAS ZERO

IN FRESH

AIR

Ð

This message indicates that the analyser needs to be reset in fresh air. To do so,

ensure that the analyser is in fresh air and press / .

To perform a manual ‘Gas Zero’, select ‘Ratio’ on the dial, hold down the

key and you will see the message above.

Page 9

2.2 STATUS DISPLAY

Select “Status” on the dial to view the following:

BAT 39

→

Replace alkaline batteries if less than 10.
Recharge NiMH batteries if less than 30.

14:56:29

→

Current time. Can be re-set via the “Menu”.

11/03/06

→

Current date. Can be re-set via the “Menu”.

CAL 283

→

Shows number of days until next calibration is
due.

NOTE: The BAT status number for fully charged NiMH batteries or

new professional alkaline batteries is typically 99.

SAFETY 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

analyser must only be used in well-ventilated locations by trained and
competent persons after due consideration of all the potential hazards.

Users of portable gas detectors are recommended to conduct a “bump” check before
relying on the unit to verify an atmosphere is free from hazard.

A “bump” test is a means of verifying that an instrument is working within acceptable
limits by briefly exposing to a known gas mixture formulated to change the output of all
the sensors present. (This is different from a calibration where the instrument is also
exposed to a known gas mixture but is allowed to settle to a steady figure and the
reading adjusted to the stated gas concentration of the test gas).

Page 10

3. USING THE FOUR FUNCTION BUTTONS:

Switching ON
the Analyser

Press / button to switch the unit ON. This must be
done in fresh air to ensure that the analyser auto calibrates its
sensors properly.

When switched on, the analyser beeps and briefly displays battery
%, fuel and pressure units. Its bottom line counts down from 90
until the sensors are ready to use. If the analyser will not auto
calibrate, its sensors need to be replaced or recalibrated by an
authorised repair centre.

If an inlet temperature probe (optional) is connected into the T2
socket during its countdown, the measured temperature from the
inlet probe will be used as the inlet temperature.

If an inlet temperature probe is not connected to the analyser
during countdown the measured temperature from the flue probe
will be used as the inlet temperature.

If neither probe is connected during countdown the analyser’s
internal ambient temperature will be used as the inlet temperature.

Switching OFF
the Analyser

Press / button to switch the analyser OFF. The
display counts down from 30 with the pump on to clear the sensors
with fresh air – If the probe is still connected, make sure analyser
and probe are in fresh air.

Press / if you want to stop the countdown and return
to making measurements.

Note: The analyser will not switch off unless the CO
reading is below 20ppm.

Page 11

Backlight &
Tasklight

Press / to switch the display's backlight and
tasklight on and off.

NOTE: Use of the backlight/tasklight significantly increases
the current drain on the batteries.

Switching
PUMP on / off

The analyser normally operates with the pump on.

Press / to switch the pump off and on.

When the pump is switched off “-PO-" is displayed instead of the
O2, CO & CO2 readings. The analyser also displays "PUMP OFF"
on the top line approx every 20 seconds.

NOTES:

1) The pump will not switch off if the CO reading is above
20ppm . This helps to protect the CO sensor from damage.

2) The pump will automatically switch itself off when the
rotary switch is set to Menu, Status, Pressure, Tightness or
Differential Temperature.

Zeroing the
pressure
sensor

To re-zero the pressure sensor when “Prs” is selected on the dial,

press and hold / until the top line display shows
CAL ZERO.

Printing Data

Press and quickly release

/ to start the analyser
printing. The analyser displays a series of bars until this is
completed. Press and release the key again to abort printing.

Make sure the printer is switched on, ready to accept data and its
infrared receiver is in line with the analyser’s emitter (on top of the
analyser).

Page 12

Storing a set
of readings

Press and hold / for approx. 2 seconds.

The top line briefly displays the log number.

Note: This STORE function is inhibited in normal operation if
the pump is switched off.

Using /

/

Buttons

The function buttons below the symbols / / are used
to navigate through the menu when the rotary switch is set to
MENU – See USING THE MENU, Section 5.

Page 13

4. USING THE ANALYSER:

4.1 COMBUSTION TESTS:

Insert the tip of the flue probe into the centre of the flue. The readings will stabilise
within 60 seconds assuming the boiler conditions are stable.

The rotary switch can be used to display the following information:

RATIO Display

NAT GAS

→

Fuel type can be changed via “Menu”.

R 0.0008

→

CO/CO2 ratio.

COp 52

→

Carbon monoxide (ppm).

CO2% 6.3

→

Carbon dioxide (%).

Press / to print a full combustion test, (or send to PC via optional
Bluetooth).

Hold

/ for 2+ seconds to log a full combustion report.

O2/EFF display

O2% 9.8

→

Oxygen (%) left after combustion. Should be

20.9% ± 0.1% in fresh air.

TFc 145.1

→

Flue temperature (oC).

TIc 5.4

→

Inlet temperature (oC). Normally set by flue
probe during fresh air purge.

EfC 91.3

→

‘Net’, ‘Gross’ or ‘Condensing’ efficiency (%)
can be selected via “Menu”.

Page 14

Press / to print a full combustion test, (or send to PC via optional
Bluetooth).

Hold / for 2+ seconds to log a full combustion report.

AUX display

P 0.00

→

The AUX (auxillary) display can be
customised via MENU / SCREEN / AUX.

R 0.0008

The parameters displayed on lines 1, 2, 3 and
4 can be set by the user.

COp 52

They remain the AUX parameters until
changed by the user.

CO2% 6.3

Press / to print a full combustion test, (or send to PC via optional
Bluetooth).

Hold / for 2+ seconds to log a full combustion report.

Viewing / printing a logged combustion test

Select MENU / REPORT / COMB’N / VIEW

Use

, and to select the log number to be viewed.

Use and to scroll through the individual readings on lines 2 & 3.

Hold or for 2+ seconds to scroll to the next / previous log number.

Press / to print the test, (or send to PC via optional Bluetooth).

Page 15

4.2 PRESSURE TEST

Select “Prs”. The pump stops automatically. Press / to auto-zero the
pressure sensor. Using the black connectors and manometer hose, connect to P1 for
single pressure or P1 and P2 for differential pressure.

PRS display

PRESSURE

→

Normal response or smoothed (damped)
response can be selected via “Menu”.

P 0.01

→

‘High’ or ‘Low’ resolution readings can be
selected via “Menu”.

mbar

→

Pressure units can be selected via “Menu”.

14:56:29

→

Displays time to enable manually timed tests.

Press / to print a full pressure test, (or send to PC via optional
Bluetooth).

Hold / for 2+ seconds to log a pressure report.

Viewing / printing a logged pressure test

Select MENU / REPORT / PRESSURE / VIEW

Use or to select the log number to be printed.

Press / to print the test, (or send to PC via optional Bluetooth).

WARNING

Before using the KANE451 to measure the pressure of a gas/air ratio valve, read the
boiler manufacturer’s instructions thoroughly. If in doubt contact the boiler
manufacturer.

After adjusting a gas/air ratio valve it is essential that the CO, CO2 and CO/CO2 ratio
readings are within the boiler manufacturer’s specified limits.

Page 16

If using larger bore tubing when performing pressure tests:

;

Push ‘orange’ tube over the rim of the spigot to ensure a gas tight seal.

:

This may not produce a gas tight seal.

Page 17

4.3 LET-BY & TIGHTNESS TESTING

Select “Tightness”. The pump stops automatically. Press / to auto­zero the pressure sensor. Connect from the test point to P1 using a black connector
and manometer hose.

The display shows “LET BY?”. Use , and to select YES or NO.

If YES is selected set the let-by pressure then press to start the let-by test. The
display shows:

LET BY

→

The let-by test is automatically stored in the
memory.

P1 10.15

→

Pressure at start of let-by test.

P2 10.15

→

Real time pressure reading.

TIME 59

→

Let-by default time is 1 minute. Can be
changed via “Menu”.

If the let-by test fails simply move the rotary switch to any position other than
“tightness” to abort the test.

If the let-by test passes adjust the gas pressure for the tightness test and press to
start the stabilisation test. The display shows:

STABIL’N

P1 20.01

→

Real time pressure reading.

mbar

→

Pressure units.

TIME 59

→

Stabilisation default time is 1 minute. Can be
changed via “Menu”.

Page 18

When complete readjust the gas pressure if necessary then press to start the
tightness test:

TIGHTN’S

P1 20.01

→

Pressure at start of tightness test.

P2 20.01

→

Real time pressure reading.

TIME 119

→

Tightness default time is 2 minutes. Can be
changed via “Menu”.

When complete the display will show:

LOG 01

→

The tightness test is automatically stored in
the memory. See Note: below

P1 20.01

→

Pressure at start of tightness test.

P2 19.98

→

Pressure at end of tightness test.

PRINT Ð

→

Press to print the complete test.

Viewing / printing a logged Let-by and Tightness test

Select MENU / REPORT / TIGHTN’S / VIEW

Use or to select the log number to be printed.

Press / to print the test, (or send to PC via optional Bluetooth).

Note:

The analyser’s memory can store up to 20 tightness tests. Tightness tests are logged
automatically therefore the tightness section of the memory will be full after the 20th
tightness test is complete. Before the 21st tightness test can be performed the
tightness section of the memory must be cleared. To do this select MENU / REPORT

/ TIGHTN’S / DEL ALL / YES then press .

Page 19

4.4 DIFFERENTIAL TEMPERATURE

Select “Diff Temp” to measure flow, return and differential temperatures

DIFF TEMP display

TEMP

→

Pump stops automatically when dial is moved
to Diff Temp.

T1c 60.4

→

Use the T1 connection for the flow
temperature sensor.

T2c 55.2

→

Use the T2 connection for the return
temperature sensor.

∆Tc 5.2

→

Real time temperature difference.

Press / to print a differential temperature test, (or send to PC via
optional Bluetooth).

Hold / for 2+ seconds to log a differential temperature report.

Viewing / printing a differential temperature test

Select MENU / REPORT / TEMP / VIEW

Use or to select the log number to be printed.

Press

/ to print the test, (or send to PC via optional Bluetooth).

Page 20

4.5 ROOM CO TESTING

Select “Room CO” to measure and record CO readings. Up to 30 CO tests can be
stored in each Log.

i) Interval and Start Screen

INTERVAL

5 MIN?

→

The test interval can be set to 1, 5 or 10
minutes

+ -

→

↓ ↓

Use the and buttons to select the
required test interval then press

to start

measuring and recording.

ii) Measure and Record Screen

10:24:49

→

The clock is displayed

COp 00

→

Real time CO reading (ppm)

TEST 00

→

Test 00 = initial CO test in series.
Up to 30 tests can be stored in each Log.

LOG 01

→

The CO test series is automatically stored in
the memory as a log number. The analyser’s
memory can store 30 Logs.

If or are pressed the ‘Pause / Stop Screen’ will be displayed.

If not stopped earlier, the Room CO test will automatically end after the 30th test. The
display will change to the ‘View and Print Screen’.

Page 21

iii) Pause / Stop Screen

PAUSE?

→

Press to PAUSE recording

STOP?

→

Press to STOP recording

P S

↓ ↓

If PAUSE is selected the display will change to ‘Paused Screen’. In paused mode the
‘live’ CO readings are displayed but not recorded.

If STOP is selected the CO test series is ended. The display changes to the ‘View and
Print Screen’.

iv) Paused Screen

10:33:59

→

The clock is displayed

Cop 00

→

Real time CO reading (ppm)

TEST

Recordings of the CO test series is paused
until the user restarts it.

PAUSED

If or are pressed the ‘Restart / Stop Screen’ will be displayed.

Page 22

v) Restart / Stop Screen

RESTART?

→

Press to RESTART recording

STOP?

→

Press to STOP recording

R S

↓ ↓

If RESTART is selected the display recerts to the ‘Measure and Record Screen’. CO
readings are displayed and recorded at the interval originally selected.

If STOP is selected the CO test series is ended. The display changes to the ‘View and
Print Screen’.

vi) View and Print Screen

LOG 01

The CO test readings were automatically
stored in the memory as this Log number.

TEST 09

→

To scroll through the CO reading for each test
in this LOG press quickly.

Cop 28

→

This is the CO reading for test 09.

PRINT

↓

When completed the log can be printed immediately by pressing / for
2 seconds.

Viewing / printing a logged Room CO test

Select MENU / REPORT / ROOM CO / VIEW

Use or to select the log number to be printed.

Page 23

Press / to print the test, (or send to PC via optional Bluetooth).

NOTE: The analyser’s memory can store up to 30 Room CO Logs. Room CO tests
are logged automatically, therefore the Room CO section of the memory will be full
after the 30th Room CO Log is complete. Before the 31st Room CO Log can be
performed the Room CO section of the memory must be cleared. To do this select

MENU / REPORT / ROOM CO / DEL ALL / YES then press .

Page 24

4.6 KANE451 PRINTOUTS

KANE451 v 1.04B KANE451 v 1.04B KANE451 v 1.04B

YOUR COMPANY NAME &
PHONE NUMBER HERE

YOUR COMPANY NAME &
PHONE NUMBER HERE

YOUR COMPANY NAME &
PHONE NUMBER HERE

SERIAL NO. 123456789 SERIAL NO. 123456789 SERIAL NO. 123456789

DATE 31/01/11 PRESSURE DIFF TEMP
TIME 12:00:08
TIME 12:56 31/01/11 TIME 12:10 31/01/11
COMBUSTION
………………………………………. PRS mbar -0.037 T1 oC 60.1
T2 oC 47.0
FUEL NAT ……………………………………………. ∆T

o

C 13.1
O2 % 5.4 Customer …………………………………………….
CO2 % 8.8 Customer
CO ppm 12 …………………………………………….
FLUE

o

C 55.1 Appliance …………………………………………….

INLT

o

C 17.2 Appliance

NETT

o

C 37.9 …………………………………………….
Ref. …………………………………………….
EFF (C) 98.3 Ref.
LOSSES 1.7
XAIR % 34.8

CO/CO2 0.0001

PRS mbar 0.00

KANE451 v 1.04B

YOUR COMPANY NAME &
PHONE NUMBER HERE

…………….…………………………….

KANE451 v 1.04B

YOUR COMPANY NAME &
PHONE NUMBER HERE

Customer SERIAL NO. 123456789
SERIAL NO. 123456789
…………….……………………………. ROOM CO TEST
Appliance LOG 04
LOG 01 TIME 11:53 31/01/11
………….………………………………. DATE 31/01/11
Ref. Let By Test
TIME COppm …………………………………………….
…………….……………………………. 10:22:08 00

10:27:08

00 PRS-1 mbar 10.12

10:32:08

00 PRS-2 mbar 10.11

Gap = readings paused

LET-BY MINS 1:00

10:42:08

05

10:47:08

08 Tightness Test

10:52:08

13 …………………………………………….

10:57:08

28
11:02:08 47 PRS-1 mbar 20.12
11:07:08 88 PRS-2 mbar 20.10
11:12:08 152 ∆PRS mbar -0.02

Up to 30 tests per Log

STABIL’N MINS 1:00

…………………………………………….. TIGHTN’S MINS 2:00
COppm MAXIMUM 152
…………………………………………….
…………………………………………….. Customer
Customer
…………………………………………….
…………………………………………….. Appliance
Appliance
…………………………………………….
…………………………………………….. Ref.
Ref. …………………………………………….

Page 25

5. USING THE MENU

Select “Menu” on the rotary switch and navigate using the function buttons:

U

= Scroll up

V

= Scroll down

= Enter

MAIN
MENU

SUB
MENU

OPTIONS / COMMENTS

SETUP SET FUEL

NAT GAS, L OIL, PROPANE, BUTANE, LPG,
PELLETS (wood)

N Å C Æ G

Ef(C) = condensing boiler nett efficiency
Ef(N) = nett efficiency, Ef(G) = gross efficiency

SET TIME

HH:MM:SS format
e.g. 7 am = 07:00:00, 7pm = 19:00:00

SET DATE DD/MM/YY format

EXIT

PRESSURE SMOOTH

OFF = normal response.
ON = slower (damped) response

RESOLVE

LOW = e.g. 0.01mBar resolution.
HIGH = displays to an extra decimal place

PS UNITS

mBar, mmH2O, Pa, kPa, PSI, mmHg, hPa, InH2O

TIME

LET BY = Set duration of let-by test in minutes.
Default = 1 minute
STABIL’N = Set duration of stabilisation in minutes.
Default = 1 minute
TIGHTN’S = Set duration of tightness test in
minutes. Default = 2 minute

EXIT

Page 26

MAIN MENU SUB MENU OPTIONS / COMMENTS

REPORT COMB’N

Stored combustion tests:
VIEW, DEL ALL, EXIT

PRESSURE

Stored pressure tests:
VIEW, DEL ALL, EXIT

TIGHTN’S

Stored tightness tests:
VIEW, DEL ALL, EXIT

TEMP

Stored differential temperature tests:
VIEW, DEL ALL, EXIT

ROOM CO

Stored room CO tests:
VIEW, DEL ALL, EXIT

EXIT

SCREEN

CONTRAST Factory setting is 04

AUX

Enables users to customise the parameters on the
AUX display: LINE 1, LINE 2, LINE 3, LINE 4, EXIT

HEADER

Printout header, 2 lines, 20 characters per line:
HEADER 1, HEADER 2, EXIT

EXIT

SERVICE CODE

Password protected for authorised service agents
only. Leave set to 0000.

BLUE COM*

* Bluetooth is a factory fitted optional extra.

NOTE: To EXIT the MENU at any time simply move the rotary switch to any

position other than “Menu”. Any changes that have not been
“entered” will be ignored.

Page 27

6. USING THE KANE451 AS A THERMOMETER OR

PRESSURE METER

With the KANE451 switched off, press and hold down the / button and

then press and release / . Release / after MANO_MOD
is displayed on top line.

The KANE451 will now operate as a fixed display thermometer/pressure meter with
the pump off and inhibited. The readings can be printed but not stored.

The display will show:

P 0.00

→

Real time pressure reading.

T1 21.3

→

Use the T1 connection for the flow
temperature sensor.

T2 21.3

→

Use the T2 connection for the return
temperature sensor.

∆T 0.0

→

Real time temperature difference.

The standard printout for this mode is as follows:

K451 1.0

YOUR COMPANY NAME &
PHONE NUMBER HERE

DATE 15/05/07
TIME 13:00:47

…………….…………………………

T1

o

C 21.3

T2

o

C 21.3

∆T

o

C 0.0

PRS mbar 0.00
………………………………………
Ref.

………………………………………

Exit ‘Mano-Mod’ by switching the KANE451 off.
The ‘Menu’ and ‘Tighness’ positions still operate normally in ‘Mano-Mod’

Page 28

If using larger bore tubing when performing pressure tests:

;

Push ‘orange’ tube over the rim of the spigot to ensure a gas tight seal.

:

This may not produce a gas tight seal.

Page 29

7. MEASURING FLUE GASES

After the countdown is finished and the analyser is correctly set up, put its flue probe
into the appliance’s sampling point. The tip of the probe should be at the centre of the
flue. Use the flue probe’s depth stop cone to set the position.

With balanced flues, make sure the probe is positioned far enough into the flue so no
air can ‘back flush’ into the probe.

NOTE: Ensure that the flue probe handle does not get hot!

Make sure you do not exceed the analyser’s operating specifications. In particular:

• Do not exceed the flue probe’s maximum temperature (600oC)

• Do not exceed the analyser’s internal temperature operating range

• Do not put the analyser on a hot surface

• Do not exceed the water trap’s levels

• Do not let the analyser’s particle filter become dirty and blocked

View the displayed data to ensure that stable operating conditions have been achieved
and the readings are within the expected range.

Press and quickly release

/ to start the analyser printing. The analyser
displays a series of bars until this is completed. Press and release the key again to
abort printing.

Make sure the printer is switched on, ready to accept data and its infrared receiver is
in line with the analyser’s emitter (on top of the analyser).

Page 30

8. ANALYSER PROBLEM SOLVING

If any problems are not solved with these solutions, contact us or an authorized repair
center.

Fault symptom Causes / Solutions

• Oxygen too high

• CO2 too low

• Air leaking into probe, tubing, water trap,

connectors or internal to analyser.

• CO reading (- - - -) • Analyser was stored in a cold environment

and is not at normal working temperature.

• CO sensor needs replacing.

• Batteries not holding charge

• Analyser not running on mains

adapter.

• Batteries exhausted.

• AC charger not giving correct output.

• Fuse blown in charger plug.

• Analyser 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 nett displays (-OC-) • Probe not connected.

• Faulty connection or break in cable or

plug.

• Ratio, EFF, X-Air all display (- - - -) • CO2 reading is below 2%.

Page 31

Fault symptom Causes / Solutions

• Analyser just continually
beeps

• Turn dial back to MENU and press ENTER

• Turn dial back to Tightness and press ENTER

• BAT only shows 65 with

fully charged NiMH
batteries fitted

• This is not a problem and is to be expected.
NiMH batteries only deliver 1.25 V per cell
whereas Alkalines deliver 1.5 V per cell. Fresh
alkalines give a BAT value of 90 or so.

Page 32

9. ANALYSER SPECIFICATION

(NOTE: MAY BE SUBJECT TO CHANGE)

Parameter

Range

Resolution

Accuracy

Temp Measurement

Flue Temperature

Inlet Temperature
(Internal sensor)

Inlet Temperature
(External sensor)

0-600oC

0-50oC

0-600oC

0.1oC

0.1oC

0.1oC

+2.0oC

+0.3% reading

+1.0oC

+0.3% reading

+2.0oC

+0.3% reading

Gas Measurement

Oxygen*2

Carbon monoxide

Carbon dioxide
Efficiency (Net or Gross)

*2

Efficiency High (C) *2
Excess Air *2
CO/CO2 ratio *2

0-21%

0-5,000ppm nom

10,000ppm max

0-20%

0-99.9%

0-119.9%

0-250%
0-0.999

0.1%

1ppm

0.1%

0.1%

0.1%

0.1%

0.0001

+0.2%*1

+10ppm*1

or +5% reading

whichever is greater

+0.2% reading
+1.0% reading
+1.0% reading
+0.2% reading

+5% reading

Pressure (differential)

Nominal range +80mBar
Maximum over range
without damage to sensor is
+400mBar

+0.2 mBar

+

1 mBar

+80 mBar

0.001 mBar

+

0.005 mBar

+

0.03 mBar

+3% of reading

Pre-programmed Fuels

Natural gas, Propane, Butane, LPG, Light Oils (28/35
sec), Wood Pellets

Storage Capacity

99 Combustion tests
20 Pressure tests
20 Tightness tests
20 Temperature tests
20 Room CO tests

*1

Using dry gases at STP

*2

Calculated

Page 33

Ambient Operating Range

0oC to +40oC 10% to 90% RH non-condensing

Battery Type / Life

4 AA cells
>8 hours using Alkaline AA cells

Chargers (optional)

220v charger, for NiMH batteries only
12v in vehicle charger, for NiMH batteries only

Dimensions

Weight:
Handset:
Probe:

0.8kg handset with protective cover
200 x 45 x 90mm
300mm long including handle.
6mm diameter x 240mm long stainless steel shaft with
3m long neoprene hose. Type K thermocouple

Page 34

10. ELECTROMAGNETIC COMPATIBILITY

European Council Directive 89/336/EEC requires electronic equipment not to generate
electromagnetic disturbances exceeding defined levels and have adequate immunity
levels for normal operation. Specific standards applicable to this analyser are stated
below.

As there are electrical products in use pre-dating this Directive, they may emit excess
electromagnetic radiation levels and, occasionally, it may be appropriate to check the
analyser before use by:

Use the normal start up sequence in the location where the analyser will be
used.

Switch on all localized electrical equipment capable of causing interference.

Check all readings are as expected. A level of disturbance is acceptable.

If not acceptable, adjust the analyser’s position to minimize interference or
switch off, if possible, the offending equipment during your test.

At the time of writing this manual (October 2011) Kane International Ltd are not aware
of any field based situation where such interference has occurred and this advice is
only given to satisfy the requirements of the Directive.

This product has been tested for compliance
with the following generic standards:

EN 61000-6-3 : 2001
EN 61000-6-1 : 2001

and is certified to be compliant

Specification EC/EMC/KI/K451 details the
specific test configuration, performance and
conditions of use.

Please Note:

Batteries used in this instrument should be disposed of in accordance with current
legislation and local guidelines.

At the end of the product's life it should be re-cycled in accordance with current
legislation and local guidelines.

Page 35

11. EN 50379 REGULATED INSTRUCTIONS

EN 50379 Section 4.3.2 “Instructions” defines a number of specific points that must be
included in the relevant instruction manuals. The paragraph numbering below relates
to that section of EN 50379.

a) The KANE451 is designed to be compliant with EN 50379 Part 2 and Part 3.

b) The KANE451 is intended to be used with the following fuels:
Natural gas
Light oil (28/35 sec)
Propane
LPG
Wood pellets
Butane

c) The KANE451 is designed for use the either non-rechargeable alkaline AA cells

or rechargeable NiMh AA cells. Four cells are needed. Types cannot be mixed.
Under no circumstances should any attempt be made to recharge alkaline cells.

The battery charger supplied with the KANE451 is rated for indoor use only. Its

voltage input must be in the range 100 – 240 V ac at 50 – 60 Hz with a current
capability of 0.3 A. The chargers output voltage is 9 V dc at a maximum of 0.66A.

The charger has no user serviceable components.

Only a correctly specified and rated charger must be used with the KANE451.

d) The KANE451 is not designed for continuous use and is not suitable for use as a

fixed safety alarm.

e) An explanation of all the symbols used on the analyser’s display is given in

Appendix 1 of this manual.

f) The recommended minimum time required to perform one complete

measurement cycle and achieve correct indication of the measured values in EN
50379 Part 2 is 110 seconds. This is based on the T90 times defined in the
standard, always assuming that parameters being measured have reached
stability. This time is the summation of the times for a draught test (10 secs) and
a combustion test (90 secs) plus the time to move the hose connection from the
pressure input to the water trap (10 secs)

g) The recommended minimum time required to perform one checking procedure in

EN 50379 Part 3 is 110 seconds as described in section f) above.

Page 36

h) Some commonly occurring materials, vapour or gases may affect the operation of

the KANE451 in the long or the short term though in normal use Kane
International Ltd is not aware of any specific issues that have affected the
product. The following list is included to satisfy the stated requirements of
EN 50379:

Solvents
Cleaning fluids
Polishes
Paints
Petrochemicals
Corrosive gases

i) The KANE451 is fitted with an electrochemical CO sensor and an infra-red CO2

sensor which have an expected life of more than 2 years and 5 years
respectively. The calibration of these sensors must be confirmed on an annual
basis.

The batteries have an expected operational life of more than 500 re-charge

cycles.

j) The KANE451 is designed to operate at ambient temperatures in the range 0oC

to +45oC with relative humidity of 10% to 90% non-condensing. Whilst it is
recommended that the analyser is given the protection of a carry case during
transportation it is not required for normal operation.

k) The KANE451 has an initial start up delay following switch on of approx. 90

seconds. There is no additional delay after battery replacement.

l) Most sensors used in combustion analysers give a zero output when they fail and

it is widely recommended that analysers are regularly checked (also known as a
bump test) using either a can of test gas or a known source of combustion
products.

The KANE451 must have its calibration checked on an annual basis and be

issued with a traceable Certificate of Calibration.

The sensors within the KANE451 can only be replaced by Kane International Ltd

or one of its trained and approved service partners.

The water trap should be checked on a regular basis whilst the analyser is in use

(every few minutes) as the amount of condensate generated varies with the fuel
type, atmospheric conditions and the appliances operating characteristics.

Page 37

The particle filter should be checked at least on a daily basis when using ‘clean’

fuels and more often when using liquid or solid fuels.

Detailed instructions regarding the changing of the filter and the emptying of the

water trap are given in Section 2 of this manual.

m) WARNING!
When using a KANE451 to test an appliance a full visual inspection of the

appliance, in accordance with its manufacturer’s instructions, must also be
carried out.

Page 38

12. CLEANING

This product can be cleaned using a damp lint free cloth and a small amount of non­abrasive detergent. Take care to avoid moisture entering the sensor’s grill and after
cleaning leave the product in a warm dry place to allow any surface dampness to
evaporate. Under no circumstance should any solvent cleaner be used as this may
cause damage to the plastic case, display and sensor.

13. ANALYSER ANNUAL RECALIBRATION AND
SERVICE

The analyser should be re-calibrated and serviced annually to counter any long-term
sensor or electronics drift or accidental damage.

Local regulations may require more frequent re-calibration.

In the UK Kane International has service facilities at Atherton near Manchester (Tel:
01942-873434), the primary service centre for UK customers and at Welwyn Garden
City in Hertfordshire (Tel: [phone]), the primary service centre for non-UK
customers.

By sending your analyser back to Kane for an annual fixed price service (check
www.kane.co.uk for details) you have the opportunity to extend the warranty on your
analyser to 5 years.

Page 39

14. RETURNING YOUR ANALYSER TO KANE

When returning your KANE451, please always ensure that you enclose:

9 Your full contact details
9 A daytime telephone number
9 Details of faults you might have experienced
9 Any relevant accessories (eg. Probe, printer, adaptor and leak detectors). Any

accessories that are returned will be checked. If an accessory has failed then we
will quote you for a repair or a replacement.

Packing your analyser

When returning an analyser with its probe, please send them back in their carry bag.
The bag should be put into a suitable sized box (approx 45cm x 20cm x 23cm).

When returning just an anlyser, use a container the size of a shoe box and ensure that
you pack out the empty space (newspaper will do for this).

Before sealing your package, please ensure that you have enclosed the items listed
above and that it is clearly marked for the attention of:

Northern Service Centre
Kane International Ltd
Gibfield Park Avenue
Atherton
Manchester
M46 0SY

Sending your analyser

Once the analyser has been securely packed then your package is ready for shipment
back to Kane. If you do not have an account with a courier company you can take
your package to your local Post Office. It is advisable to send the package by Special
Delivery so that it is insured and traceable while in transit.

When we receive your analyser

On receipt of your package, our Service Engineers will inspect the analyser and any
accessories and confirm to you the total service cost. Once you have accepted this
the work will be carried out, and upon completion the analyser returned to you by Fed
Ex “Next Day Service”.

If you have any questions that we haven’t answered, please feel free to contact our
Northern Service Centre:

Tel: [phone]
Fax: [phone]
Email: [e-mail]

Page 40

Service Returns (Simply cut out and attach to your package)

Northern Service Department

Kane International Ltd

Gibfield Park Avenue

Atherton

Manchester

M46 0SY

Northern Service Department

Kane International Ltd

Gibfield Park Avenue

Atherton

Manchester

M46 0SY

Northern Service Department

Kane International Ltd

Gibfield Park Avenue

Atherton

Manchester

M46 0SY

Page 41

Page 42

Appendix 1 - Main Parameter:

Here are the legends used and what they mean:

O2 : Oxygen (Calculated) reading in percentage (%)

CO : Carbon monoxide (Measured) reading displayed in ppm (parts per

million). If ‘- - - -’ is displayed there is a fault with the CO sensor or the
instrument has not set to zero correctly. Switch off instrument and try
again.

CO2 : Carbon dioxide (Measured) reading in percentage (%).

TF : Temperature measured by the flue gas probe in centigrade (oC). It

displays ‘- OC -’ if the flue probe is disconnected or faulty.

TI : If an inlet temperature probe (optional) is connected into the T2 socket

during its countdown, the measured temperature from the inlet probe
will be used as the inlet temperature.

If an inlet temperature probe is not connected to the analyser during

countdown the measured temperature from the flue probe will be used
as the inlet temperature.

If neither probe is connected during countdown the analyser’s internal

ambient temperature will be used as the inlet temperature.

T Nett : Nett temperature calculated by deducting the INLET temperature from

the measured FLUE temperature. It displays ‘- OC -’ if the flue probe
is not connected or broken.

EFF : Combustion efficiency calculation displayed in percentage either as

Gross Ef(G) or Nett Ef(N) or Condensing Nett Ef(C) - Use MENU to
change. The calculation is determined by fuel type and uses the
calculation in British Standard BS845. The efficiency is displayed
during a combustion test, ‘- - - -’ is displayed while in fresh air.

Loss : Losses calculated from oxygen and type of fuel. Displays reading

during a combustion test. ‘- - - -’ is displayed while in fresh air.

X - AIR : Excess air calculated from the calculated oxygen and type of fuel.

Displays reading during a combustion test. ‘- - - -’ is displayed while in
fresh air.

CO/CO2: CO/CO2 Ratio: measured CO (ppm) divided by (CO2 (%) x 10,000).

PRS : Pressure reading, either single point or differential.

Page 43

BAT : Displays the Battery power available.

Replace alkaline batteries if reading is less than 10
Recharge NiMH batteries if reading is less than 20
Readings may be affected if used with low power batteries.

DATE : Date shown as day, month and year, DD/MM/YY. Date is recorded

when each combustion test is printed or stored.

TIME : The time shown is expressed in “Military” time HH:MM:SS. Time is

recorded when each test is printed or stored.

Note! When changing the batteries on the instrument the memory
will store the date and time for up to one minute, if outside this
time it may be necessary to re-enter the details.
Date and time may also need to be reset if re-chargeable batteries
are allowed to totally discharge.

FULL : The maximum number of tests have been stored in the memory. To

delete the stored memory, Select Reports then select the tests to be
deleted (see Page 23).

SYMBOLS used on the display

P Pressure

R CO/CO2

λ Excess Air

Loss %: 100% minus loss % = efficiency %

TF Flue temperature

TI Inlet temperature

∆T Nett temperature

EfG Gross efficiency

EfN Nett efficiency

EfC Condensing efficiency

- PO - Pump off

‘- - - -’ Calculated oxygen greater than 18% so calculation is disabled

-OC- Open circuit temperature input

CAL Number of days left before recalibration is due

Page 44

Page 45

ADDENDUM

Instructions for

KANE451 analysers

fitted with optional

Nitric Oxide (NO) sensors

Page 46

DISPLAYING THE NO READING

Select “Menu” on the rotary switch and navigate using the function buttons:

U = Scroll up V = Scroll down

= Enter

The MENU main structure is as follows:

MAIN MENU SUB MENU OPTIONS / COMMENTS

SETUP

PRESSURE

REPORT

SCREEN

CONTRAST

AUX

Enables users to customise the parameters on the
AUX display:
LINE 1, LINE 2, LINE 3, LINE 4, EXIT

HEADER

EXIT

SERVICE

BLUE COM*

* Bluetooth is a factory fitted optional extra.

NOTE: To EXIT the MENU at any time simply move the rotary switch to any

position other than MENU. Any changes that have not been “entered” will
be ignored.

Page 47

Use or to navigate to the main menu option SCREEN.

Press .

Use or to navigate to the sub menu option AUX.

Press .

The display will show

AUX

LINE 1

Press and a third line will appear.

Use or to navigate to the desired parameter to be displayed on line 1.

Press to select the parameter for Line 1 and repeat the process to select the
display parameter for all four lines and then EXIT

Rotate the dial from MENU to AUX to display all your chosen settings.

PRINTING and STORING

The NO reading are printed and stored in the same way as the other combustion gas
readings. On the printouts the NO readings appear directly below the flue CO
readings.

Note the rotor needs to be in the AUX, O

2

/Eff or Ratio positions to print or store flue

combustion readings

Page 48

NITRIC OXIDE SENSOR SPECIFICATION

Gas Measurement

Nitric Oxide (NO)
(low range)

Nitric Oxide (NO)
(high range)

Resolution

1 ppm

1ppm

Accuracy

+ 2ppm <30ppm*1

+5 ppm > 30ppm

+5ppm <100ppm*1

+5% reading

>100ppm

Range

0 to 100 ppm

0 to 1000 ppm

*1 Using dry gases at STP

Page 49

Product Registration

Please complete, detach and return to: Kane International Ltd,

Kane House, Swallowfield, Welwyn Garden City, Hertfordshire, AL7 1JG

Your Details

Name:

Job Title:

Company Name:

Company Address 1:

Address 2:

Town/City:

County:

Postcode:

Country:

Phone Number:

Fax Number:

Mobile Number:

Email Address:

Product Details

Note: Proof of Purchase may be required for warranty claims.

Date Purchased as numbers

(05.01.10):

Purchased From:

Model Number:

KANE451

Product Serial Number:

Page 50

Why did you buy a Kane Product?



Dealer Recommendation



Other Recommendation



Value for Money



Our Fixed Price Servicing Programme



Kane



Previous Owner



Not your Decision



Other:

What brand was your previous analyser?

How did you hear about Kane?



Magazine Advert



Trade Counter Literature



Personal Recommendation



Internet



Exhibition



Other:

Which do you read most often?

Often

Sometimes

Hardly Ever

Registered Gas Engineer

  

Gas Installer

  

P.H.P.I.

  

P.H.A.M. News

  

Heating Ventilating & Plumbing

  

Heating & Plumbing Monthly

  

Thank you for completing this survey.

All the information we have collected is confidential.

We do not sell or share data with any other company or organisation.

Page 51

Page 52

Thank you for buying this

analyser.

Before use, please register

on our website

www.kane.co.uk

or complete, detach

and return the

Product Registration page.