Kane 9206 Quintox User Manual

1

KANE9206

Quintox Flue Gas Analyser

Stock No: 19332-5 November 2014

© Kane International Ltd

2

CONTENTS

Page No:

SAFETY WARNING 7

KANE9206 OVERVIEW 7

STANDARD FEATURES 7

HANDSET 7
MAIN ANALYSER UNIT 8

OPTIONS 9

ELECTROCHEMICAL SENSORS 9
OTHER OPTIONS 9
PROBE OPTIONS 9

SPARE PARTS LIST 9

KANE9206 WITH KANE LIVE PC SOFTWARE 10

ANALYSER LAYOUT AND FEATURES 11

HANDSET FEATURES 11
ANALYSER LAYOUT 12
ANALYSER LAYOUT WITH KMDM110/230 SAMPLE
CONDITIONING UNIT FITTED 13
TYPICAL PROBE CONFIGURATION (KMCP6) 14
ANALYSER CONNECTIONS 15

GETTING STARTED 16

BEFORE TAKING READINGS 16

MENU: ALL THE OPTIONS 17

STATUS: ESTABLISHING THE ANALYSER’S
SET-UP 18

3

SETUP: CONFIGURING THE ANALYSER’S
SET-UP 20

LANGUAGE 20
MAIN PURGE 21
PRINTER 21
AUTO SET TIME 22
SET TIME 22
SET DATE 23
HEATER STATUS 23
SELECT ANALYSER UNIT SERIAL NUMBER 23
WIRELESS SET UP 24
WIRELESS PASSKEY 24

ANALYSER UNITS: CONFIGURES ALL THE
DATA SOURCES AND SETTINGS 25

FUEL ORIGIN 25
FUEL TYPE 25
EFFICIENCY 25
GAS UNITS 26
TEMPERATURE 26
PRESSURE 26
SET PERCENTAGE REFERENCE 02 26
SET NOx CALCULATION 26
SET COMPENSATION 26
CONVERSION FACTORS 26

CO ALARM 27

CO ALARM SET 27
CO ALARM LEVEL 27

SCREEN 28

CONTRAST 28
B’LIGHT 28
MODE 28
LINES 29

4

REPORTS: CONFIGURES REPORTS 30

VIEW REPORTS 30
DELETE ALL REPORTS 31
AUTO LOG TIME 31
START AUTO LOG 31
START AUTO PRINTING 31
HEADER 1 31
HEADER 2 31
FORM FEED 31

SERVICE 32

MANUAL AIR ZERO 32

MANUAL PRESSURE ZERO 32

BEFORE USING THE ANALYSER FOR THE
FIRST TIME 33

SAFETY WARNING 33

FIRST TIME USE 33

NORMAL START UP SEQUENCE 33

EVERY TIME YOU USE THE ANALYSER 33
AUTOMATIC CALIBRATION 34

MAIN MEASUREMENT SCREEN 36

IN SMALL FONT MODE 36
IN LARGE FONT MODE 37

SAMPLING THE FLUE GAS 39

LONG TERM MONITORING 39

KMDM110/230 SAMPLE CONDITIONING UNIT 40

SETTING UP 40

5

MAINTENANCE 42

EMPTYING AND CLEANING THE IN-LINE
WATER TRAP 42
CHANGING THE PARTICLE FILTER 42
CHARGING THE BATTERY 43
CHANGING THE PAPER ROLL 43
TO START PAPER FEED 43
CHANGING THE PRINTER RIBBON 43

PROBLEM SOLVING 45

HOW TO GET EXPERT HELP 45

ANALYSER ANNUAL RECALIBRATION AND
SERVICE 46

RETURNING YOUR ANALYSER TO KANE 47

PACKING YOUR ANALYSER 47
SENDING YOUR ANALYSER 47
WHEN WE RECEIVE YOUR ANALYSER 47

SERVICE RETURNS 48

PRODUCT SPECIFICATION 50

UNIT 50
OPTIONAL IR MODULE 51
HANDSET 51
EXTENSION CABLE 52
MAIN BATTERY AND OPTIONAL HEATER BATTERY 52
BATTERY CHARGER 52
PUMP 52
INTEGRAL PRINTER 52
AMBIENT OPERATING RANGE 52
KMHL3000: HEATED SAMPLE LINE 53
KMHP1200: HEATED PROBE 53
KMDM110/230: SAMPLE CONDITIONING UNIT 53
PROBE 53
OPTIONAL PORTABLE PRINTERS 53

6

ELECTROMAGNETIC COMPATIBILITY (CE)
STATEMENT 54

END OF LIFE DISPOSAL 54
BATTERY DISPOSAL 54

EN50379 REGULATED INSTRUCTIONS 55

APPENDICES 60

A. PARAMETER MEANINGS 60

B. NOx CALCULATIONS 63

ONLY AN NO SENSOR FITTED 63

WORKING IN PPM: NOX REFERENCED TO NO 63
WORKING IN MG/M3: NOX REFERENCED TO NO OR NO2 63
WORKING IN MG/M3: REFERENCED TO NO 63
WORKING IN MG/M3: NOX REFERENCED TO NO2 64
NORMALISING READINGS 64

BOTH NO AND NO2 SENSORS FITTED 64

WORKING IN PPM: NOX = NO + NO2 64
WORKING IN MG/M3 64
NOX = SUM 64
NOX = NO 64
NOX = NO2 64
NORMALISING READINGS 65

ONLY AN NO2 SENSOR FITTED 65

NORMALISING READINGS 65

HIGH CO PURGE OPERATION 65

C. COMBUSTION EFFICIENCY CALCULATION 66

D. CALCULATION OF FUEL DATA 68

PRODUCT REGISTRATION 69

7

SAFETY WARNING

This analyser must only be used in well-ventilated locations by trained and competent
persons after due consideration of all the potential hazards and with regard to local and
National regulations and guidelines.

The analyser extracts combustion gases that may be toxic in relatively low concentrations.
These gases are exhausted from the bottom of the instrument.

Users or 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).

KANE9206 OVERVIEW

The KANE9206 is broadly based on the KM9106 and whilst retaining many of its core
features has been significantly enhanced. The most visible difference is the large
graphical display on the handset. Up to 15 lines of text/data can be displayed. The
handset links to the main analyser unit using wireless communications or the normal
cable. It also has a USB connector to link to a PC via a cable and has an infra-red output
to link to the portable Kane KMIRP-2 printer.

The main analyser unit also contains significant enhancements over the KM9106.

STANDARD FEATURES:

19301 Battery charger
18277 UK mains lead
18276 EU mains lead
18275 US mains lead
19332 Instruction manual

Kane 'LIVE' software download from Kane website

HANDSET: KBHS

Wireless and cable connectivity to analyser unit.
Wireless and USB connectivity to PC
GPS location
IR connectivity to Kane IRP portable printers
Monster data storage memory (64k records)
Graphical display with choice of large or small fonts.
Battery rechargeable via main unit or mains charger

8

MAIN ANALYSER UNIT: AS STANDARD KANE9206

Measures:

Oxygen
Carbon monoxide
Ambient temperature
Atmospheric pressure
Inlet temperature
Flue temperature
Differential pressure

Features:

Main purge
Flow control*
NiMh battery packs
Plain paper printer

*Flow control

To compensate for different suction levels in flues, hose lengths and filter contamination
levels, all of which can affect the flow of sample gases, there is an active flow control
system fitted to the KANE9206.

It operates as follows:

Every time the instrument is turned on and finishes its first fresh air purge cycle from inside
the analyser, it measures and records the pump pressure just prior to the sensor manifold
whilst the pump is at 100% flow rate. During service calibration & normal use, the pump
speed is automatically adjusted to 70% of the purge flow rate to maintain consistent flow.

The flow control can cope with typically 100 mbar suction in a flue and still maintain the
same nominal flow as that present under ambient conditions.

9

OPTIONS:

ELECTROCHEMICAL SENSORS : (UP TO 5 SENSORS)

CHOOSE FROM:

KNO1L/Q Nitric oxide (low range)
KNO1H/Q Nitric oxide (high Range)
KNO2/Q Nitrogen dioxide
KSO2L/Q Sulphur dioxide (low range)
KSO2H/Q Sulphur dioxide (high range)
KH2S/Q Hydrogen sulphide

OTHER OPTIONS:

KHSA Heater for toxic sensors
KHC/Q IR triple bench (CO, HC, CO2)
KHPUR/Q High/low CO protection (solenoid and pump)
WTS9206P Pumped water trap
KMHL3000 Heated line
KMHP1200 Heated probe
KMDM220 Gas Conditioning Module

PROBE OPTIONS:

KMCHLP6 High temperature 1 metre removable shaft
KMCHP6 High temperature 285mm removable shaft
KMCHSLP6 Smoke probe with high temperature 1 metre removable shaft
KMCHSP6 Smoke probe high temperature 285mm removable shaft
KMCSP6 Smoke probe with 285mm removable shaft
KMCLP6 1 metre removable shaft
KMCP6 285mm removable shaft

SPARE PARTS LIST:

OS11 Oxygen Sensor
KCO1/Q Carbon monoxide (H2 compensated)
IMP3R Printer ribbon
IMP10P Printer paper
SF1/5 Chemical filter
AF2 Particle filter assembly
PF2/10 Particle filter filter pack
WN8 Water trap filter pack
BP9206 Battery pack
WTS9106 Water trap assembly
19403 Peri pump tubing

10

KANE9206 WITH KANELIVE PC SOFTWARE

KANELIVE is a free download that runs on Windows based PCs and allows live display
and graphing of data. It can be downloaded from the Kane website (www.kane.co.uk)
once an analyser has been registered in the MY KANE section of the website.

In the current configuration, the handset needs to be connected to the main unit by a cable
and the wireless setting for the handset needs to be changed to TO PC using MENU,
SETUP, WIRELESS SETUP.

Once this has been selected, go to the PC and select DEVICES & PRINTERS.

Click ADD A DEVICE.

All devices within range will be displayed in icon form. The KANE9206 handset will be
displayed as:

KANE9206HS

999999107

where the 9 digit number is the serial number of the handset.

Double click on this. Now follow the instructions.

Then enter the passkey: 1111

Click on the TICK BOX and then AT SERIAL CONFIGURE and then FINISH.

Now click on KANELIVE to initiate the programme.

Select your analyser type by clicking on the analyser name displayed on the middle of the
bottom line of the screen. If more than one analyser has been enabled a drop down will
appear. Click on the analyser of your choice.

Then click CONNECT and wait for its colour to change to green.

Then click START which will change to green.

After a few seconds live data will be displayed.

11

ANALYSER LAYOUT AND FEATURES

HANDSET FEATURES

INFRA RED LED

REMOTE LEAD SOCKET
(8 PIN DIN)

PUMP ON/OFF KEY

PRINT KEY

ENTER KEY

ON/OFF KEY

MENU KEY

STORE KEY

SCROLL UP KEY

SCROLL DOWN KEY

GRAPHICAL DISPLY

PROTECTIVE COVER

BATTERY
COMPARTMENT
(BACK)

SERIAL USB CONNECTION

12

ANALYSER LAYOUT

OXYGEN SENSOR

FILTER BRIDGE OR
SULPHUR FILTER

PARTICLE FILTER

BATTERY ENCLOSURE

PRINTER UNIT

HANDSET
(STORED IN
POCKET)

CONNECTION LEAD

FOR OXYGEN SENSOR

DUAL PRESSURE

PORTS

WATERTRAP

CONNECTION

WATERTRAP
LOCATED ON SIDE
OF INSTRUMENT

ACCESSORY STORAGE SPACE
(LEADS, WATERTRAP ETC)

INSTRUMENT CASE

13

ANALYSER LAYOUT WITH KMDM110/230GAS CONDITIONING
MODULE FITTED

OXYGEN SENSOR

PARTICLE FILTER

PRINTER UNIT

HEATED LINE
CONNECTION

GAS DRYER
ASSEMBLY

INSTRUMENT CASE

WATERTRAP CONNECTION

DUAL PRESSURE PORTS

OXYGEN SENSOR

CONNECTOR

FLUE SOCKET

INLET SOCKET

AUX CONNECTOR
(25 PIN 'D')

ANALYSER 'ON' SWITCH

REMOTE HANDSET

CONNECTION

(8 PIN DIN)

RED POWER LED

CHARGER INPUT SOCKET

REMOTE HANDSET CONNECTION

(8 PIN DIN)

14

TYPICAL PROBE CONFIGURATION (KMCP6)

THERMOCOUPLE CONNECTION (FLUE)

INLET SOCKET FOR
OPTIONAL AIR
TEMPERATURE PROBE

PROBE GAS CONNECTION
TO WATERTRAP

WATERTRAP LOCATED
ON SPIGOT IN CASE

DEPTH STOP CONE

SAMPLING PROBE

15

ANALYSER CONNECTIONS

CHARGER INPUT SOCKET

DUAL PRESSURE

PORTS

(8 PIN DIN)

OXYGEN SENSOR

CONNECTOR

FLUE SOCKET

INLET SOCKET

AUX CONNECTOR(25 PIN 'D')

ANALYSER 'ON' SWITCH

REMOTE HANDSET CONNECTION
(8 PIN DIN)

RED POWER LED

16

GETTING STARTED

Check that you have all the items you have ordered.

Before attempting to use the analyser to take readings it is recommended that the
batteries are fully charged.

When the charger is connected to the analyser and powered up the red LED by the
charger socket will flash until the batteries are fully charged. Once the batteries are fully
charged the LED will no longer be illuminated.

To charge the handset; connect the handset to the main analyser unit using its cable.
Whilst switched off, but charging, the display will show the Kane logo and a battery
charging icon in the bottom right hand corner of the handset screen. Note: the handset
battery is charged via the external battery charger and not from the analyser’s internal
battery. Once the handset battery is fully charged the icon will disappear from the screen.

The handset can also be charged directly using the mains charger as used for the
analyser.

BEFORE TAKING READINGS

You need to establish the current set up of the analyser and then make the changes that
you need to suit exactly what you want to do.

So press the MENU key and then select STATUS as described below.

17

MENU: ALL THE OPTIONS

Press the MENU key.

----------------------------------MENU---------------------------------

> STATUS
SETUP
ANALYSER UNITS
CO ALARM
SCREEN
REPORTS
SERVICE
MANUAL AIR ZERO
MANUAL PRESSURE ZERO

11:33:56 23/03/13 S04

The > symbol acts as the cursor. It can be moved up or down by pressing the UP or
DOWN keys.

Having made a selection press the ENTER key.

The bottom line of this screen lists:

 the time
 the date
 the number of satellites being received
 the wireless connection status
 the estimated charge in the handset battery

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STATUS: ESTABLISHING THE ANALYSER'S SET-UP

Press MENU and then select STATUS by pressing ENTER.

----------------------------------MENU---------------------------------

HANDSET SW19170 V1.01
SERIAL NO. 999999107

ANALYSER SW19171 V1.01
SERIAL NO, 999999207

MAIN BATTERY 98%
HEATER BATTERY 100%

CAL DATE = 331

11:33:56 23/03/13 S04

This screen lists :

 the software version in the handset
 the handset serial number
 the analyser unit software version number
 the analyser unit serial number
 the estimated charge in the main battery
 the estimated charge in the heater battery (if fitted)
 the number of days before annual re-calibration is due

19

Press DOWN to move to the next screen.

----------------------------------MENU---------------------------------

REFERENCE O2 = 3.0%
NOx CALCULATION = SUM
REFERENCE NOx = 5%

EFFICIENCY = NET
FUEL = NATURAL GAS
FUEL SOURCE = UK

CO ALARM SET = NO
CO ALARM LEVEL = 400ppm

11:33:56 23/03/13 S04

Press DOWN to move to the next screen.

----------------------------------MENU--------------------------------­AUTO PURGE = YES
AUTO ZERO = NO
AUTO PUMP FLOW = NO
MAIN PURGE DURATION TIME = 2 mins
MAIN PURGE INTERVAL TIME = 30 mins

LOG 0006
AUTO LOG/PRINT TIME = 30 mins
START AUTO LOG = NO
START AUTO PRINTING = NO

11:33:56 23/03/13 S04

Press DOWN to move back to the first screen.

Press PRINT to print this status on the analyser’s printer.

Press MENU to EXIT.

20

SETUP: CONFIGURING THE ANALYSER’S SETUP

----------------------------------MENU---------------------------------

> LANGUAGE
MAIN PURGE
PRINTER
AUTO SET TIME
SET TIME
SET DATE
HEATER STATUS
SELECT ANALYSER BOX SERIAL No.
WIRELESS SETUP
WIRELESS PASS KEY
BACK

11:33:56 23/03/13 S04

LANGUAGE:

Align cursor using UP or DOWN keys, then press ENTER.

Use UP or DOWN keys to scroll through the selection.

Press ENTER to select.

21

MAIN PURGE:

----------------------------------MENU---------------------------------

> AUTO PURGE
MAIN PURGE DURATION TIME
MAIN PURGE INTERVAL TIME
AUTO ZERO CAL
AUTO PUMP FLOW
BACK

11:33:56 23/03/13 S04

AUTO PURGE: Set YES or NO

AUTO PURGE DURATION TIME: Set fresh air purge duration to between 2 and 30

minutes

MAIN PURGE INTERVAL TIME : Set the interval between fresh air purges to

between 10 and 120 minutes.

AUTO ZERO CAL: Set YES or NO to automatically re-zero sensors at

the end of a main purge cycle.

AUTO PUMP FLOW: Set YES or NO to automatically control the pump

flow. This may be required for some regulatory test
protocols

After switch on, the first purge interal is automatically set to 10 minutes if the optional IR
module is fitted. Changes in the purge interval are implemented after completion of the
next purge cycle. To implement a change immediately do a “MANUAL AIR ZERO”.

PRINTER:

This sets the destination for outputs from the handset

22

The choices of outputs are:

 KANEIRP
 KANEIRP-2
 ANALYSER PRINTER
 SERIAL
 WIRELESS

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

AUTO SET TIME:

This function is locked off if reports have been stored. To allow the function to operate,
delete the reports.

This allows the time to be set automatically from the GPS signals. Select NO to maintain
manual setting

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

SET TIME:

This function is locked off if “AUTO SET TIME” is activated or reports have been logged.
If this function is locked, delete the reports.

----------------------------------MENU---------------------------------

> SET TIME

HH:MM:SS

13:59:47

11:33:56 23/03/13 S04

If manual setting is enabled use UP or DOWN keys to change values.

Press ENTER to select.

23

SET DATE:

This function can only be set manually, not by GPS.

If this function is locked, delete the reports.

----------------------------------MENU---------------------------------

SET DATE

DD:MM:YY

26:04:13

11:33:56 23/03/13 S04

If manual setting is enabled use UP or DOWN keys to change values.

Press ENTER to select.

HEATER STATUS:

Allows the heaters to be switched off totally or to operate automatically.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

SELECT ANALYSER UNIT SERIAL NUMBER:

If more than one analyser unit is within Bluetooth range the handset needs to be set to
communicate with the correct unit,

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

24

WIRELESS SET UP:

The handset can communicate with an analyser unit or a PC. Wireless can also be
switched off and a cable can be used.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

WIRELESS PASSKEY:

This confirms the Passkey setting.

The wireless Passkey is 1111.

25

ANALYSER UNITS: CONFIGURES ALL THE DATA
SOURCES AND SETTINGS

----------------------------------MENU---------------------------------

FUEL ORIGIN
FUEL TYPE
EFFICIENCY
GAS UNITS
COMPENSATION
TEMPERATURE
PRESSURE
SET PERCENTAGE REFERENCE O2
SET NOx CALCULATION
SET COMPENSATION
CONVERSION FACTORS
BACK

11:33:56 23/03/13 S04

FUEL ORIGIN:

Select from a list of country specific fuel tables.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

FUEL TYPE:

Select from the list of fuel types associated with the chosen origin. The K values for the
selected fuel are also shown.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

There are 5 User Fuels that can be loaded from a PC. The title of these user fuels can be
edited using the keypad on the handset.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

EFFICIENCY:

Select NET or GROSS efficiency calculation

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

26

GAS UNITS:

Select ppm or ppm(n) or mg/m3 or mg/m3(n).

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

TEMPERATURE:

Allows the selection of Fahrenheit or Celsius.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

PRESSURE:

Allows the selection of pressure units.

Select from: mbar, In H2O, mm H2O, hPa, psi,.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

SET PERCENTAGE REFERENCE O2:

Can be set between 0% (equivalent to OFF) and 10%.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

SET NOX CALCULATION:

Select from: SUM, NO2 or NO

Set REFERENCE NOx to the percentage required or defined by local regulations.
Typically 5% NO2 is added to an NO reading. The value can be user set.

SUM adds the readings from an NO sensor and an NO2 sensor when fitted

NO calculates an NOx reading from the NO reading where NOx = NO x 1.1
NO2 calculates an NOx reading from the NO2 reading where NOx = NO2 x 2.05

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

SET COMPENSATION:

Select from YES or NO

CONVERSION FACTORS:

Display the Propane Equivalency Factor PEF and the Methane Equivalency Factor for the
IR module (if fitted) and the pitot factor – change from 0.10 to 1.00 as determined by the
pitot tube being used.

27

CO ALARM:

----------------------------------MENU---------------------------------

CO ALARM SET
CO ALARM LEVEL
BACK

11:33:56 23/03/13 S04

CO ALARM SET:

Switch the alarm ON or OFF.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

CO ALARM LEVEL:

Allows a specific CO level in ppm to be set as the alarm trigger point.

Use UP or DOWN keys to change the digits. Press ENTER to select and move to the next
digit.

The display will show ‘++++’ when the CO alarm is triggered.

28

SCREEN:

The screen display is fully configurable.

----------------------------------MENU---------------------------------

CONTRAST
B’LIGHT
MODE
LINES 1 - 6
LINES 7 - 12
LINES 13 - 18
LINES 19 - 24
LINES 25 - 30
BACK

11:33:56 23/03/13 S04

CONTRAST:

Allows the display to be darkened or lightened. Default value is 14.

Use UP or DOWN keys to change the digits. Press ENTER to select and move to the next
digit.

B'LIGHT:

The switch off time for the backlight can be set for between 30 and 300 seconds,

Use UP or DOWN keys to change the digits. Press ENTER to select and move to the next
digit.

During normal measurements press ENTER to switch the backlight on.

MODE:

The main display can be set for SMALL font or LARGE font.

29

LINES:

This feature allows users to customise the screen display to suit their own requirements.

Use UP or DOWN keys to change the selection. Press ENTER to select and move to the
next digit.

So for Lines 1-6, the screen shows:

----------------------------------MENU---------------------------------

LINE 1 = CO 0ppm
LINE 2 = HC 0ppm
LINE 3 = NO 0ppm
LINE 4 = NO2 0ppm
LINE 5 = SO2 0ppm
LINE 6 = NOx 0ppm
BACK

11:33:56 23/03/13 S04

The parameter to be displayed on each line can be individually selected.

Use UP or DOWN keys to change the selection. Press ENTER to select and move to the
next digit.

30

REPORTS: CONFIGURES REPORTS

----------------------------------MENU---------------------------------

VIEW REPORTS
DELETE ALL REPORTS
AUTO LOG TIME
START AUTO LOG
START AUTO PRINTING
HEADER 1
HEADER 2
FORM FEED

BACK

11:33:56 23/03/13 S04

VIEW REPORTS:

This selection displays a 'main screen' with a LOG No near the top left hand of the display.
This number can be changed using UP or DOWN and the display automatically changes.

----------------------------------MENU---------------------------------

LOG 0000
DATE 00/00/00 TIME 12:00:00AM
ORIGIN UK FUEL NATURAL GAS

O2 0.00% CO2 0.0%
CO 0ppm NO 0ppm
NO2 0ppm NOx 0ppm
SO2 0ppm H2S ----ppm
O2 19.98% FLUE 0.0deg C
INLET 0.0deg C AMBIENT 0.0deg C
NETT 0.0deg C LOSS 10
DRY 0 WET 10
11:33:56 23/03/13 S04

31

DELETE ALL REPORTS:

All reports can be deleted. A confirmation YES is required

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

AUTO LOG TIME:

Automatic logging/printing can be selected for intervals between 10 seconds and 90
minutes

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

START AUTO LOG:

Select YES or NO.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

START AUTO PRINTING:

Select YES or NO.

Use UP or DOWN keys to scroll through the selection. Press ENTER to select.

HEADER 1: 16 CHARACTERS

Allows the printed header line: YOUR COMPANY to be changed.

Use UP or DOWN keys to change the characters. Press ENTER to select and move to
the next character.

HEADER 2: 16 CHARACTERS

Allows the printed header line: NAME & PHONE No. to be changed.

Use UP or DOWN keys to change the characters. Press ENTER to select and move to
the next character.

FORM FEED:

Allows remote paper feeding on printers.

32

SERVICE:

CODE: For use by authorised service agents.

CAL DATE = number of days before annual re-calibration is due.

MANUAL AIR ZERO:

Select this and press ENTER to initiate a fresh air purge and sensor zeroing

MANUAL PRESSURE ZERO:

Select this and press ENTER to re-zero the pressure sensor

33

BEFORE USING THE ANALYSER FOR THE FIRST TIME.

SAFETY WARNING

This analyser extracts combustion gases that may be toxic in relatively low concentrations.
These gases are exhausted from the bottom 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 consideration of all the potential hazards.

FIRST TIME USE

Charge the batteries for 12 hours, following this an overnight charge should be sufficient
for an average 8 hour day. There may be three battery packs that need charging, the main
battery, the optional heater battery and the handset battery. The handset battery can use
the same charger as the analyser unit or can be charged via the main unit using a handset
lead. All batteries are NiMh.

Whilst charging the red LED will flash.

We offer a wide choice of probes which are not supplied as standard and must be ordered
as a separate item.

Take time to read this manual fully.

TIP: Take a look at the Spare Parts list and order some replacement filters and

paper rolls now.

NORMAL START UP SEQUENCE

EVERY TIME YOU USE THE ANALYSER

BEFORE SWITCH-ON CHECK THAT:

 the oxygen sensor is connected

 the particle filter is not dirty

 the sulphur filter is fitted for heavy oil or coal

 the water trap and probe line are empty of water

 all hose connections, etc, are properly made

34

 the paper roll is fitted

 the analyser unit is in fresh air

 the water trap is vertical

 the flue temperature is connected

 the instrument is placed on a clean, flat, level surface

Switch ON the analyser by pressing ON/OFF on the handset. You also need to press the
ON/OFF switch on the analyser main unit.

AUTOMATIC CALIBRATION

During this sequence the analyser pumps fresh air into the sensors to allow toxic sensors
to be set to zero and the oxygen sensor to be set to 20.9 %.

During this sequence the handset display will show the following:

KANE QUINTOX

SW 19170 v1.01

SERIAL NO. 999999107

GPS CONNECTED

WIRELESS CONNECTING ……..

Note: The software version number and serial number are examples only.

35

If there is no wireless communication between the handset and the main unit the following
will appear on the screen.

WIRELESS COMMS ERROR
TO ANALYSER UNIT

REFER TO INSTRUCTIONS

PRESS ENTER TO CONTINUE

11:33:56 23/03/13 S04

Press ENTER to continue and follow the instructions.

Once wireless communication is established the main measurement screen will appear:

36

MAIN MEASUREMENT SCREEN

IN SMALL FONT MODE

ZERO TIME 60M

CO2 ----% NETT -N\F-deg C
HC ----ppm LOSS ----­CO 0ppm DRY ----­NO 0ppm WET -N\F­NO2 0ppm CO LOSS 0%
NOx 0ppm P INDEX 0.00%
SO2 0ppm CO/CO2 R0.0000
H2S ----ppm EFF (G) ----%
O2 19.98% XAIR ----%
FLUE -N\F-deg C PRESSURE 0.00mbar
INLET 20.3 deg C ATM 986.6mbar
AMBIENT

GPS (X) -00011.458

11:33:56 23/03/13 S04

TOP LINE: shows status messages

GASES: O2 and CO2 are shown in %

other gases shown in ppm or other user selected units
CO can be shown in % if optional IR bench fitted

TEMPERATURES: displayed in C or F. N\F = not fitted

---- occurs for calculations when N\F applies

---- occurs when a calculation cannot be made due to an out of range value (Eg zero)

Atmospheric pressure (ATM) is always displayed in mbar.

37

IN LARGE FONT MODE

There are 5 screens that are accessed using the UP or DOWN keys

-----------------------------------MENU----------------------------------

> LINE 1= CO2 ----%
LINE 2= HC ----ppm
LINE 3= CO 0ppm
LINE 4= NO 0ppm
LINE 5= NO2 0ppm
LINE 6= NOx 0ppm
BACK

11:33:56 23/03/13 S04

-----------------------------------MENU----------------------------------

> LINE 7= SO2 0ppm
LINE 8= H2S ----ppm
LINE 9= O2 19.98%
LINE 10= FLUE -N\F-deg C
LINE 11= INLET -N\F-deg C
LINE 12= AMBIENT 20.3deg C
BACK

11:33:56 23/03/13 S04

38

-----------------------------------MENU----------------------------------

> LINE 13= NETT -N\F-deg C
LINE 14= LOSS ----­ LINE 15= DRY ----­ LINE 16= WET -N\F­ LINE 17= CO LOSS 0%
LINE 18= P INDEX 0.00%
BACK

11:33:56 23/03/13 S04

-----------------------------------MENU----------------------------------

> LINE 19= CO/CO2 R0.0000
LINE 20= EFF (G) ----%
LINE 21= XAIR ----%
LINE 22= PRESSURE 0.00mbar
LINE 23= ATM 986.6mbar
LINE 24= GPS (X) -00011.458
BACK

11:33:56 23/03/13 S04

-----------------------------------MENU----------------------------------

> LINE 25= GPS (Y) +5148.0957
LINE 26= MAIN BAT 24%
LINE 27= HEAT BAT 100%
LINE 28=
LINE 29=
LINE 30=
BACK

11:33:56 23/03/13 S04

39

SAMPLING THE FLUE GAS

Once the automatic calibration procedure has been completed and the specific fuel has
been selected the probe can be inserted into the desired sampling point.

It is recommended that the sampling point be located at least two flue diameters
downstream of any bend and that the probe tip is in the centre of the flue (this is normally
the point of the hottest temperature). With balanced flues and other industrial units the
probe should be positioned far enough into the flue so that no air can ‘back flush’ into the
probe.

The probe depth stop cone provided with the instrument allows the probe to be used in
holes whose diameters range from 8 mm to 21 mm (5/16 to 4/5 inch).

The standard probe is rated at 650C/1202F. Temperatures of up to 1100C/2012F can
be accommodated using an optional high temperature probe.

TIP: To conserve battery power, switch off the pump when you are not taking a

measurement. Use the pump key to turn the pump ON and OFF.

LONG TERM MONITORING

There are a number of things that need to be considered for successful long term
unattended monitoring:

 The provision of enough power for the duration of the test

 The capability to empty the water trap

 Regular fresh air purging of the sensors

 Protection from rain or water spray from the process being monitored.

If a mains power source is being used it is strongly recommended that the supply

cable is protected by a suitable Residual Current Device (RCD).

Unless the water trap is to be regularly inspected then a pumped water trap should be

40

fitted.

Electrochemical sensors need regular refreshing with fresh air, prefereably at around 50%
RH. They also need a small percentage of oxygen to be present in the sampled gas. If
there is zero oxygen the output from the sensors will decay over time (10 mins or so). In
such circumstances, fresh air purge should be programmed for a 50% duty cycle every 10
minutes.

The longest sampling time without purging should be limited to 2 hours and then purge for
30 mintues.

When the KHC infra-red module is fitted, for maximum accuracy it is recommended that
purging occurs every 30 minutes.

KMDM110/230 SAMPLE CONDITIONING UNIT

This module is fitted in the front compartment of a standard KANE9206 carry case and
comprises a Peltier fan cooled chiller assembly, a peristaltic pump to automatically remove
condensate, the control electronics and a power supply module. The module is supported
on an aluminium alloy chassis.

The chiller is connected to a flue mounted electrically heated probe (KMHP1200) by a 3
metre long heated line with automatic temperature control (KMHL3000). Because the gas
that is extracted from the flue is maintained at 120oC no condensation occurs in the probe
or the hose and so no sample gas is lost in the condensate. The chiller flash cools the
sample gas to below the ambient dewpoint and any water in the gas immediately
condenses. The condensate is then pumped away using a peristaltic pump. Because the
gas has no chance to remain in contact with the condensate, volatile sample gas is not lost
into the condensate. The chilled gas then naturally warms up as it passes through the
sampling pump to the sensors and as it does so its humidity reduces and there is no risk of
further condensation.

SETTING UP

The heated sample probe must be connected to the top of the heated line and a gas tight
connection be made without over tightening the connections. This joint must then be
thermally insulated. Both the heated probe and the heated line must be connected to a
mains power source via a suitable Residual Current Device (RCD) and be left powered up
for 20 minutes to achieve their operating temperature before attempting to extract sample
gas.

When the probe is inserted into the sampling point is must be suitably supported to
prevent bending and unnecessary strain. Likewise the heated line should be carefully
supported and never be twisted or kinked as this may damage the internal heating
elements.

The heated line is connected to the chiller by attaching the end of the line to the through
bulkhead connection in the KANE9206 carry case. A short flexible connection then links
the hose to the chiller. The chiller needs to be powered up for at least 10 minutes before it

41

is used.

The peristaltic pump operates automatically. Always check that the drain of the peristaltic
pump is clear and that there are no blockages. The peristaltic pump needs to have its
flexible rotor replaced after every 1000 hours of operation.

To operate efficiently the chiller needs to be well ventilated so the case lid must be
removed, however the unit must be protected externally to prevent ingress of water from
either the plant being tested or from rainfall.

42

MAINTENANCE

EMPTYING AND CLEANING THE IN-LINE WATER TRAP

The water trap should be checked and emptied on a regular basis. Water vapour will
condense and gather in the probe line this may move suddenly to the trap when the probe
is moved. Care should be taken at all time.

Emptying of the water trap is detailed below :-

Carefully remove the end cap from the in-line 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 if problems occur.

CHANGING THE PARTICLE FILTER

This is a very important part of the analyser and should be changed regularly. It prevents
dust and dirty particles entering the pump and sensors and hence causing damage. The
filter MUST be changed when it appears discoloured.

Remove the end cap from the filter housing. Carefully remove the paper filter element and
dispose of it. Clean the inside of the filter housing with a suitable soft cloth. Insert a new
filter element onto the spigot on the filter end cap and carefully insert it into the filter body.

43

CHARGING THE BATTERY

It is important that the battery is charged on a regular basis. The instrument constantly
powers the internal sensors and may flatten the battery if left unattended for some months.
Connect the charger supplied with the instrument to the correct mains supply.

Note: The correct charger type may be required for your local voltage i.e. 110 or 220

volts AC

Insert the plug in the socket marked CHARGER INPUT SOCKET
The CHARGER ON RED LED will flash showing the instrument is charging.

CHANGING THE PAPER ROLL

To change the paper roll remove the printer cover by loosening the two screws holding it
down. Remove the old paper roll core and insert the new roll so that it sits as follows :-

Feed the free end of paper into the printer through the metal slot beneath the printer
ribbon. Start the paper feed sequence until the paper has emerged from the top of the
printer, feed the loose end through the cover and refit.

TO START PAPER FEED

Go to MENU, REPORTS, FORM FEED

CHANGING THE PRINTER RIBBON

The printer ribbon cartridge will last for approximately two rolls of paper. Remove the
printer cover as detailed above.

Marked on one end of the cartridge is PUSH. Gently press down on this end and the
ribbon cartridge will pop up at the other end. Remove the cartridge and dispose of.

44

Fit a new ribbon guiding the paper roll between the exposed ribbon and cartridge body.

Refit printer cover.

45

PROBLEM SOLVING

The following is a list of problems that may occur on the instrument through its operating
life. If the cause of the fault is not easy to identify then we advise you to contact the Kane
International Service Department or an International Distributor for expert advice.

Fault symptom Causes
Oxygen too high
CO2 too low

Air leaking into probe, tubing, water trap,
connectors or internal to instrument.

Oxygen cell needs replacing.
Analyser not holding charge
Analyser not charging

Battery 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.
Flue temperature readings erratic Temperature plug reversed in socket.

Faulty connection or break in cable or plug.
Analyser automatically switches
off in operation.

Battery below alarm level.

Battery quickly discharging and is faulty.
Display is blank. The contrast setting has been lost and

requires resetting. Disconnect handset

lead and reconnect. Set contrast as in

MENU : SCREEN : CONTRAST

HOW TO GET EXPERT HELP

There will be occasions when despite having read the manual there will be problems that
you cannot resolve and so you need external help.

Before calling Kane International or one of its International Distributors please first check
the following:

Find the serial number of the instrument. It is located on the label close to where the
charger and handset leads plug into the analyser. Also make a note of which sensor are
fitted by observing the tick unites on the same label.

If the handset and analyser are operating you can also determine the issue of software
loaded in the analyser and its handset by viewing STATUS. If you can, take a printout of
STATUS and a printout of the measurement screen so that they can be faxed or emailed to
your technical support advisor.

46

ANALYSER ANNUAL RECALIBRATION AND SERVICE

The analyser should be re-calibrated and serviced annually to stop 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 service (check www.kane.co.uk for
details) you have the opportunity to extend the warranty on your analyser to 5 years.

47

RETURNING YOUR ANALYSER TO KANE

When returning your KANE9206, please always ensure that you enclose:

 Your full contact details
 A daytime telephone number
 Details of faults you might have experienced
 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 your analyser, please pack it appropriately to prevent any damage during
transit.

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

For UK customers:

For non-UK customers:

Northern Service Centre

Kane International Ltd

Gibfield Park Avenue

Atherton

Manchester

M46 0SY

Southern Service Centre

Kane International Ltd

Kane House, Swallowfield

Welwyn Garden City

Hertfordshire

AL7 1JG

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.

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

For UK customers:

For non-UK customers:

Tel: [phone]

Fax: [phone]

Email: [e-mail]

Tel: [phone]

Fax: [phone]

Email: [e-mail]

48

Service Returns

(Simply cut out and attach to your package)

Southern Service Centre

Kane International Ltd

Kane House, Swallowfield

Welwyn Garden City

Hertfordshire

AL7 1JG

Northern Service Centre

Kane International Ltd

Gibfield Park Avenue

Atherton

Manchester

M46 0SY

Southern Service Centre

Kane International Ltd

Kane House, Swallowfield

Welwyn Garden City

Hertfordshire

AL7 1JG

49

50

PRODUCT SPECIFICATION

UNIT

Temp Measurement

Resolution

Range Accuracy

Flue Temperature

0.1o (C/F) 0-1100°C
32-2140°F
* Use high temperature probe for gases

>600°C/1112°F

1.0 o C +0.3% of
reading

Inlet Temperature 0.1o (C/F) 0-600°C

0-999°F

1.0 o C +0.3% of
reading

Gas Measurement*1 Resolution Range Overrange Reading Accuracy

Oxygen (02): 0.01% 0-25% 30% - -0.1% +0.2%

Carbon monoxide (CO):
(standard: H

compensated)

1ppm 2000 4000 <100ppm

>100ppm <2000ppm
>2000ppm <4000ppm

+/-5ppm
+/-5% of reading
+/-10% reading

Nitric oxide (NO):
(high range0)

1ppm 1000 5000 <100ppm

>100ppm <1000ppm
>1000ppm <5000ppm

+/-5ppm
+/-5% of reading
+/-10% reading

Nitric oxide (NO)
(low range)

1ppm 100 300 <100ppm

>100ppm <300ppm

+/-5ppm
+/-10% of reading

Nitrogen dioxide (NO2):

1ppm 100 1000 <100ppm

>100ppm <1000ppm

+/-5ppm
+/-10% of reading

Sulphur dioxide (SO2)
(low range):

1ppm 100 500 <100ppm

>100ppm <500ppm

+/-5ppm
+/-10% of reading

Sulphur dioxide (SO2)
(high range):

1ppm 2000 5000 <100ppm

>100ppm <2000ppm
>2000ppm <5000ppm

+/-5ppm
+/-5% of reading
+/-10% reading

Hydrogen sulphide
(H2S):

1ppm 200 300 <100ppm

>100ppm <200ppm
>200ppm <300ppm

+/-5ppm
+/-5% reading
+/-10% of reading

Gas Measurement*1 Resolution Range Accuracy

Pressure 0.01mbar 0-150 mbar + 0.5% Full Scale

Carbon dioxide (CO

2

)*2

0.1% 0 – Fuel Value + 0.3%

Efficiency *2 0.1% 0-100% + 1%

*1

using dry test gases at STP

*2

calculated

NB: all ppm reading can be displayed in mg/m3 and can be normalised

51

OPTIONAL IR MODULE

Hydrocarbons:

Range: Overrange Accuracy Resolution
0-5,000ppm 10,000ppm +5% of reading and + 12ppm vol. 1ppm

CO2:

Range: Overrange Accuracy Resolution
0-20% 40% +5% of reading and + 0.5% vol. 0.1%

CO:

Range: Overrange Accuracy Resolution
0-10% 20% +5% of reading and + 0.2% vol.

<30%

0.1%

Response time T90: 30 seconds
Warm up time: 3 minutes
Operating temperature range: 5 to 50 deg C.
Operating humidity: 10-80% non condensing
Power: Supplied by KANE9206

Conversion Factors from a Hexane Calibration

Hexane multiply by 1
Propane multiply by 0.5
Methane multiply by 0.05

HANDSET

Dimensions 240 mm long

135 mm high

70 mm wide
Keypad tactile keys
Display graphical with backlight and contrast control

ANALYSER

Dimensions 420 mm long

345 mm high

225 mm wide

52

EXTENSION CABLE

Specification: 8 pin DIN cable
Cable lengths: 10m Standard

5-20m-Optional

MAIN BATTERY AND OPTIONAL HEATER BATTERY

Type: NiMH Rechargeable (12V, 2AH)
Life: 8 hours from full charge
Charge time: 12 hours trickle

4 hours fast charge

BATTERY CHARGER

Input: 100V-240V AC 60 watts
Output: 15V DC @ 4 amps

PUMP

Flow rate: 2 Litres/Minute nominal

500 mbar static suction

INTEGRAL PRINTER

16 character dot matrix.
Plain paper

AMBIENT OPERATING RANGE

-10°C to + 55°C

< 85% RH non condensing

Storage: -10°C to 55°C

For regulated testing to EN50379, ambient temperature range: 0°C to + 55°C

53

KMHL3000: HEATED SAMPLE LINE

Power supply: 220V ac @ maximum 300 watts

KMHP1200: HEATED PROBE: KMHP1200

Power supply: 220V ac @ maximum 100 watts
1200mm insertion length, 8 mm diameter rated to 1000 o C

KMDM110/230: SAMPLE CONDITIONING UNIT

Power supply: 220 Vac @ 5 amps peak.

PROBE

Choose from a range of probe options. See probe leaflet.

OPTIONAL PORTABLE PRINTERS

Compatible with KMIRP-2

54

ELECTROMAGNETIC COMPATIBILITY (CE) STATEMENT

This product has been tested for

compliance with the following generic

standards:

EN 61000-6-3 : 2011
EN 61000-6-1 : 2007

and is certified to be compliant

Specification EC/EMC/KI/KANE9206

details the specific test configuration,

performance and conditions of use.

SAFETY STANDARD

This product complies with the EN61010

Safety Standard

(Safety requirements for electrical

equipment for measurement, control

and laboratory use):

EN61010-1 : 2010

Protection Class 3 (SELV)

END OF LIFE DISPOSAL

The Waste Electrical or Electronic Equipment (WEEE) Directive requires countries in the
EU to maximise collection and environmentally responsible processing of these items.

Products are now labelled with a crossed out wheeled bin symbol to remind you that they
can be recycled.

BATTERY DISPOSAL

All the user replaceable batteries used in this product are NiMh and are suitable for
recycling through any local waste portable battery recycling scheme.

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

55

EN 50379 REGULATED INSTRUCTIONS

EN 50379 Section 4.3.3 “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 KANE9206 is compliant the EN 50379 Part 2 as detailed in the third party

approvals issued by TÜV.

b) The KANE9206 is intended to be used with the following fuels:

Natural gas, Natural gas 2, Light oil (28/35 sec), Heavy oil, Coal, Anthractite, Coke,
Propane, Butane, Gascor, Kinsale gas, LPG, Bio gas, Wood pellets and 5 user fuels.

c) The KANE9206 handset is designed for use with 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 KANE9206 analyser is designed for use with a KANE9206 rechargeable NiMH
battery pack. Under no circumstances should any attempt be made to use another
type of battery pack other than the manufacture specified one.

The battery charger supplied with the KANE9206 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 1.5A. The chargers output voltage is 15 V dc at a maximum of 4A.

The charger has no user serviceable components.

Only a correctly specified and rated charger must be used with the KANE9206.

d) The KANE9206 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

A 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) This section is non-applicable.

56

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

KANE9206 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 KANE9206 can be fitted with up to 6 electrochemical sensors although only CO,

NO, SO2 & O2 are covered under EN50379. They have an expected life of more
than 2 years. 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 KANE9206 is designed to operate at ambient temperatures in the range -10oC to

+55oC with relative humidity of 10% to 90% non-condensing although the analyser
was only tested under EN 50379 with ambient temperatures in the range -0oC to
+55oC. 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 KANE9206 has an initial start-up delay following switch on of approx. 180

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 KANE9206 must have its calibration checked on an annual basis and be issued

with a traceable Certificate of Calibration.

The sensor within the KANE9206 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.

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 Maintenance of this manual.

57

m) WARNING!
When using a KANE9206 to test an appliance a full visual inspection of the

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

n) WARNING!

When using a KANE9206, a regular inspection of the water trap and filter must be
carried out as blockages can lead to inaccurate measurements.

o) Instructions for testing for leaks and blockages of the gas sample system is covered

in the Section Problem Solving of this manual

p) The KANE9206 changeable parameters and their valid ranges are:

Languages: English, French, German & Dutch
Auto purge: Yes & No
Main purge duration time: 2 to 60 minutes
Main purge interval time: 10 to 120 minutes
Auto zero: Yes & No
Auto pump flow: Yes & No
Printer: KANE IRP, KANE IRP-2, Serial, Wireless, Analyser

printer
Auto set time: Yes & No
Set time: 00:00:00 to 23:59:59
Set date: 01/01/01 to 31/12/99
Heater status: Auto & Off
Wireless setup: Off, To PC & to Analyser
Wireless passkey: 0000 to 9999
Fuel origin: UK, France, Germany, Netherlands, Italy, Spain,

Hungary, Poland, Finland, Sweden, China, North

America.
Fuel type: Natural gas, Natural gas 2, Light oil (28/35 sec),

Heavy oil, Coal, Anthractite, Coke, Propane, Butane,

Gascor, Kinsale gas, LPG, Bio gas, Wood pellets and

5 user fuels.
Efficiency: Net, Gross, Condensing Net & Condensing Gross.
Gas units: ppm, ppm(n), mg/m3 & mg/m3(n)
Temperature: Celsius and Fahrenheit
Pressure: psi, hPA, mm H2O, In H2O, mbar & m/s
Set percentage reference O2: 0.0% to 10.0%
Set NOx Calculation: NO, NO2 & SUM
Reference NOx: 0% to 20%
Set compensation: on & off
Pitot: 0.10 to 1.00
CO alarm set: on & off
CO alarm level: 0000 to 9999
Display contrast: 0 to 15
Display backlight: 30 to 300 seconds
Display mode: small font & large font

58

Display Lines (1 to 30): Analyser main battery, Analyser heater battery, CO2

reading, HC reading, CO reading, NO reading, NO2

reading, NOx reading, SO2 reading, H2S reading,

O2 reading, flue temperature reading, inlet

temperature reading, ambient temperature reading,

nett temperature reading, total loss reading, dry loss

reading, wet loss reading, CO loss reading,

poison index reading, CO_CO2 ratio reading,

efficiency reading, excessive air reading, pressure

reading, atmospheric pressure reading, GPS

longitude reading, GPS latitude reading, blank &

lambda reading.
Auto log /print time: 10seconds to 90 minutes
Start auto log: yes & no
Start auto printing: yes & no
Printer header line 1: 16 alpha numeric characters
Printer header line 2: 16 alpha numeric characters

q) The KANE9206 data storage based on EEPROM & flash technology and has a data

retention if the battery is removed of greater than 100 years

59

60

APPENDICES

A – PARAMETER MEANINGS

The parameters and their meanings are detailed as follows : -

DATE : Analyser date.

TIME : Analyser time.

MAIN BATTERY/ Displays the battery level from 0-100%. The analyser will flash
HEATER BATTERY: RECHARGE BATTERY at less than 10 % of charge. The analyser

may show levels greater than 100% when the charger is connected.

----- : Displayed when a calculation cannot be performed because a probe
is not fitted or a parameter is out of range.

FUEL : The fuel used in calculation of efficiency and carbon dioxide.

K1g: Gross calorific fuel constant. See Appendix for calculation.

K1n : Gross calorific fuel constant. See Appendix for calculation.

K2 : Percentage Maximum theoretical CO2 (dry basis).

K3: Percentage wet loss.

K4 : Percentage unburnt carbon loss.

O2r : Toxic gas measurements can be referenced to defined oxygen levels.

Oxygen referencing is required by some regulations such as TA­LUFT. If a reference value is selected the toxic gas measurements
will be displayed with the symbol n attached to the units. i.e.ppmn
What does oxygen reference mean ?
If 3 % O2 reference is selected and 5 % O2 is measured in the flue
then toxic gas values will be recalculated as if 3 % were measured.
The equation for referencing is detailed in the Appendix.
oxygen referencing prevents false readings being submitted, e.g.
allowing more air into the boiler will increase the oxygen level in the
flue and hence dilute any toxic gas reading. Oxygen referencing
gives readings as if they were undiluted.

NETT : Nett temperature calculated by deducting the internal AMBIENT

temperature from the measured FLUE temperature. Displays in
either Centigrade C or Fahrenheit F and will display NOT FITTED if
flue probe not connected.

If an external INLET probe is used then INLET is deducted from

FLUE.

61

O2 : Oxygen reading in percentage %.

CO : Carbon monoxide reading indicated in ppm or mg/m3. If the figures

are referenced to oxygen then the display will show ppmn or
mg/m3n. Note with a high CO sensor fitted the reading will be
displayed in percentage %.

EFF (G) : Combustion Efficiency calculation displayed in percentage. Gross (G)

or Net (N) can be set. The calculation is determined by fuel type see
Appendix for calculation. The efficiency is displayed during a
combustion test, 00.0 is displayed while in fresh air.

CO2: Carbon dioxide reading in percentage % when measured , not

calculated

CO2c: Carbon dioxide calculation determined by the type of fuel. This only

shows a reading when a combustion test is being carried out. Zero
(0.0) is displayed while in fresh air.

FLUE : Temperature measured by flue gas probe in Centigrade or

Fahrenheit. Will show ambient temperature after fresh air calibration
and N\F if probe disconnected.

INLET : Temperature measured by the optional inlet air probe or stored using

the Flue probe. The air probe is plugged into the instrument through
the INLET socket. This figure is used to calculate the NET
temperature instead of AMBIENT when fitted. Will show N\F if not
fitted.

AMBIENT : Temperature measured by the internal sensor, used in the NET

temperature

CO/CO2 R : The CO/CO2 ratio, is the ratio of measured CO divided by CO2.
It gives an indication of the following :­ How good a gas sample the instrument is reading.

How clean the boiler is running.

For example : A new or clean domestic boiler will display a ratio of

less than 0.004, a unit in need of cleaning 0.0040-0.0080 and a unit
in need of major overhaul will show greater than 0.008.

This only shows a reading when a combustion test is being carried

out. 0.0000 is displayed while in fresh air.

P INDEX : The CO/CO2 ratio expressed as a percentage %, called the ‘Poison

Index” i.e. P INDEX % = 100 x CO/CO2. 0.00 is displayed while in
fresh air.

XAIR % : Excess air calculated from the measured oxygen and type of fuel

used.

Displays reading during a combustion test +++ is displayed while in

fresh air.

62

PRESSURE: Pressure reading. Units can be changed to different scales.

NO: Nitric oxide reading in ppm or mg/m3. Displayed when nitric oxide

sensor fitted. Reading can also be referenced to oxygen ppmn or
mg/m3n.

NO2: Nitrogen dioxide reading in ppm or mg/m3. Displayed when nitrogen

dioxide sensor fitted. Reading can also be referenced to oxygen
ppmn or mg/m3n.

NOx : Calculated total nitric oxides displayed in ppm or mg/m3.
Reading can also be referenced to oxygen ppmn or mg/m3n.

SO2 : Sulphur dioxide reading in ppm or mg/m3. Displayed when sulphur

dioxide sensor fitted. Reading can also be referenced to oxygen
ppmn or mg/m3n.

H2S: Hydrogen sulphide reading in ppm or mg/m3. Displayed when

Hydrogen sulphide fitted. Reading can also be referenced to oxygen
ppmn or mg/m3n.

HC : Unburnt Hydrocarbon reading ppm of hexane, the sensor is

calibrated with hexane. Displayed when an infra red module is fitted.

Use equivalent factors for propane and methane.

LOSS : Total losses calculated from Combustion Theory. This is the

summation of the next three parameters.

DRY : Calculated heat lost in turning the carbon in the fuel to carbon ioxide

(CO2).

WET : Calculated heat lost in turning the hydrogen in the fuel into water

(H2O).

CO LOSS % : Calculated loss due to partially burnt carbon. Any carbon monoxide

(CO) in the flue has the potential to be turned into carbon dioxide and
release more heat, hence this heat is lost up the flue.

GPS (Y): Latitude DDMM.MMM 5148.1060

GPS (X): Longitude DDDMM.MMM -00011.450

ATM: Atmospheric pressure in mbar

63

B. NOx CALCULATIONS

ONLY AN NO SENSOR FITTED

WORKING IN PPM: NOX REFERENCED TO NO

The user can select the assumed NO2 percentage and the O2 normalised level

then: NOx in ppm = NO in ppm multiplied by (1 + assumed NO2 percentage)

in this setup NOx can only be displayed as NOx = NO

then normalising:

NO in ppmn = NO in ppm multiplied by (21 minus the O2norm setting) and then divided by
(21 minus the actual O2 reading)

For a worked example assume:

NO is 1000ppm
NO2 is 5% of NO
O2norm is set to 3%
actual O2 is zero

NOx in ppm = 1000 x (1 +5/100) =1000 x1.05 = 1050 ppm

NO ppmn = 1000 x (21 - 3)/(21-0) = 1000 x 18 / 21 = 857 ppmn

NOx ppmn = 1050 x 18 / 21 = 900 ppmn

or

NOx ppmn = 857 x 1.05 = 900 ppmn

WORKING IN mg/m3: NOX REFERENCED TO NO OR NO

2

The user can select the assumed NO2 percentage, the O2 reference level and whether the
NOx reading is referenced to NO or NO2

WORKING IN mg/m3: REFERENCED TO NO

NO in mg/m3 = NO in ppm multiplied by 1.34

NOx in mg/m3 = NO in mg/m3 multiplied by (1 + assumed NO2 percentage)

64

WORKING IN mg/m3: NOX REFERENCED TO NO2

NOx in mg/m3 = NO in ppm multiplied by 2.05 multiplied by (1 + assumed NO2
percentage)

or

NOx in mg/m3 = NO in mg/m3 divided by 1.34, multiplied by 2.05 and multiplied by (1 +
assumed NO2 percentage)

NORMALISING READINGS

normalised reading = initial reading multiplied by (21 minus the O

2norm

setting) and then

divided by (21 minus the actual O2 reading)

BOTH NO AND NO2 SENSORS FITTED

WORKING IN PPM: NOX = NO + NO2

normalising readings

ppmn = initial reading in ppm multiplied by (21 minus the O

2norm

setting) and then divided

by (21 minus the actual O2 reading)

WORKING IN MG/M3

The user can select how the readings are referenced.

NOx = SUM
NOx = NO
NOx = NO

2

NOX = SUM

NOx in mg/m3 = NO in ppm multiplied by 1.34 plus NO2 in ppm multiplied by 2.05

NOX = NO

NOx in mg/m3 = (NO in ppm plus NO2 in ppm) multiplied by 1.34

NOX = NO2

NOx in mg/m3 = (NO in ppm plus NO2 in ppm) multiplied by 2.05

65

NORMALISING READINGS

ppmn = initial reading in ppm multiplied by (21 minus the O

2norm

setting) and then divided

by (21 minus the actual O2 reading)

mg/m3n = initial reading in mg/m3 multiplied by (21 minus the O

2norm

setting) and then

divided by (21 minus the actual O2 reading)

ONLY AN NO2 SENSOR FITTED

When there is only an NO2 sensor fitted the NOx function is disabled

NO2 in mg/m3 = NO2 in ppm multiplied by 2.05

NORMALISING READINGS

ppmn = initial reading in ppm multiplied by (21 minus the O2norm setting) and then
divided by (21 minus the actual O2 reading)

mg/m3n = initial reading in mg/m3 multiplied by (21 minus the O2norm setting) and then
divided by (21 minus the actual O2 reading)

HIGH CO PURGE OPERATION

If there is a requirement to measure CO to concentrations above 10,000ppm then a High
Purge module should be fitted (this comprises both a purge pump and a solenoid) in
addition to the IR triple gas bench.

The CO measurement reading uses the electrochemical sensor’s reading from 0 to
4000ppm and the IR gas module takes over at 4000ppm to instruments upper limit.

When the electrochemical sensor’s reading passes 5500ppm, the solenoid operates and
the high CO purge pump switches on and pumps fresh air across the electrochemical CO
sensor. When the IR gas module reading goes below 5500ppm, the solenoid is
deactivated and the high purge pump is stopped.

66

C. COMBUSTION EFFICIENCY CALCULATION

The efficiency calculation is based upon British Standard BS845.

This identifies three sources of loss associated with fuel burning:

LOSSES DUE TO FLUE GASSES:

Dry Flue gas loss,
Moisture and hydrogen
Sensible heat of water vapour
Unburned gas

LOSSES DUE TO REFUSE:

Combustible in ash
Combustible in riddlings
Combustible in dust

OTHER LOSSES:

Radiation
Convection
Conduction
Other unmeasured losses

Net efficiency calculations assume that the energy contained in the water vapour (formed
as a product of combustion and from wet fuel) is recovered and the wet loss term is zero.
Gross efficiency calculations assume that the energy contained in the water vapour is not
recovered.

Since the fuel air mixture is never consistent there is the possibility of unburned/partially
unburned fuel passing through the flue. This is represented by the unburned carbon loss.

Losses due to combustible matter in ashes, riddlings, dust and grit, radiation, convection
and conduction are not included.

EFFICIENCY CALCULATION:

Known Data - Fuel: Qgr = Gross Calorific Value (kJ/kg)
Qnet = Net Calorific Value (kJ/kg)
K1 = Constant based on Gross or Net Calorific Value:
K1g = ( 255 x %carbon in fuel )/Qgr

K1n = ( 255 x %carbon in fuel )/Q

net
K2 = % max theoretical CO2 (dry basis)
K3 = % Wet Loss

Measured Data: Tf = Flue Temperature
Ti = Inlet Temperature
O2m = % Oxygen in flue gas

Calculated data: Tnet = Net Temperature
% CO2 content in flue gas
% Dry Flue Gas losses
% Wet losses
% Unburned carbon loss
% Efficiency

67

%CO2 = (20.9 - %O2m) x K2 / 20.9

Tnet = Flue Temperature - Inlet Temperature

Dry flue gas loss = 20.9 x K1n x (Tnet) / K2 x (20.9 - %O2m)

Wet loss = 9 x %H2 + %H2O / Qgr x [2488 + 2.1Tf - 4.2 Ti]

simplified = [(9 x %H2 + %H2O) / Qgr] x 2425 x [1 + 0.001 Tnet]

Wet loss = K3(1+0.001xTnet)

Where K3 = [(9 x %H2 + %H2O) / Qgr] x 2425

Net Efficiency = 100% - dry flue gas losses

= 100% - 20.9 x K1n x (Tnet) / K2 x (20.9 - % O2m)

Gross Efficiency = 100% - {dry flue gas losses + wet losses}

= 100% - [20.9 x K1g x (Tnet) / K2 x (20.9 - %O2m)] +
[K3 x (1 + 0.001 x Tnett)]

Excess Air % = [(20.9% / (20.9% - 02m%)) – 1] x 100%

Air Index = 20.9% / (20.9% - 02m%)

NB: Either Excess Air or Air Index can be referred to as LAMBDA in the context of flue gas
analysis dependent on local preferences.

For typical condensing gas boiler Excess Air = 31% and Air Index = 1.31

CO2% = [(20.9% - O2m%) x K2% / 20.9%]

Unburned fuel Loss = K4 x CO% / ( CO% + CO2% )

Where K4 = 70 for coke
= 65 for anthracite
= 63 for Bituminous coal
= 62 for coal tar fuel
= 48 for liquid petroleum fuel
= 32 for natural gas

The formula for K4 is based on the gross calorific value Qgr. To obtain the loss based on
net calorific value multiply by Qgr/Qnet. Since this loss is usually small this conversion has
been ignored.

OXYGEN REFERENCE

CO(n) = CO x

(20.9 - O2r)

(20.9 - O2m)

68

D. CALCULATION OF FUEL DATA

For any fuel not specified by Kane International the net calorific value, gross calorific value
and composition should be obtained from the fuel supplier.

The following fuel data has been calculated with reference to the efficiency calculation.

Example 1:

Chemical composition: C 25%
H2 3%
H2O 50%
Q

net

8.35 MJ/kg
Qg 9.3 MJ/kg *
Max CO2 20.4%

K1n = (255 x % carbon in fuel) / Q

net

(kJ/Kg)

= (255 x 25) / 8350 = 0.763

K1g = (255 x % carbon in fuel) / Qg (kJ/Kg)
= (255 x 25) / 9300 = 0.685

K2 = Max % CO2 = 20.40

K3 = Wet Loss = [(9 x %H2 + %H2O) / 9300] x 2425

= [(9 x 3 + 50) / 9300] x 2425
= (77 / 9300) x 2425 = 20.08

K4 = 65 (an approximation for wood) *

The fuel values to program into the Analyser are as follows:

NATURAL GAS
K1g
K_2
K_4

:

0.763

: 20.4
: 65

K1n
K_3
O2r

:

0.685

: 20.08
: 8.0

* Assumed values in the absence of supplied data. See previous appendix for other fuels.

69

PRODUCT REGISTRATION

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

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Product Details

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

Date Purchased:

as numbers (28.01.14):

Purchased From:

Model Number:

KANE9206

Product Serial Number:

located on the rear product label
beneath the protective rubber sleeve

70

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

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

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71

Thank you for reading this data sheet.

For pricing or for further information, please contact us at our UK Office, using the details

below.

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Tel: [phone]
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Please note - Product designs and specifications are subject to change without notice. The user is responsible for determining the

suitability of this product.