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
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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.
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