Kane KANE504 Owner's Manual & Maintenance Manual

KANE504

Combustion Analyser

Stock No: 19101-2 April 2012

© Kane International Ltd

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CONTENTS

Page No:

OWNERS MANUAL & MAINTENANCE 3

1. GETTING STARTED 4

1.1 SAFETY NOTES 4

1.2 PRE-TEST CHECKLIST 4

1.3 STORING INLET TEMPERATURE 4

1.4 SELECTING FUEL 5

1.5 ANALYSER CONNECTIONS 5

1.6 POST TEST 6

2. MAINTENANCE 6

2.1 GENERAL MAINTENANCE 6

2.2 PERIODIC SERVICE 6

2.3 ANNUAL RE-CALIBRATION 6

2.4 CLEANING 7

2.5 EMPTYING AND CLEANING THE IN-LINE WATER TRAP 7

2.6 CHANGING THE PARTICLE FILTER 7

2.7 BATTERIES REPLACEMENT 8

3. METER PROBLEM SOLVING 9

4. METER SPECIFICATION 10

5. ELECTROMAGNETIC COMPATIBILITY 11

6. GLOSSARY 12

6.1 SELECTOR AND DISPLAY PARAMETERS 12

6.2 FUELS AVAILABLE 13

7. CLEANING 13

8. ANNUAL RECALIBRATION AND SERVICE 13

8.1 RETURNING YOUR ANALYSER TO KANE 14

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OWNERS MANUAL & MAINTENANCE

The KANE504 Flue Gas Analyser tests heating appliances for carbon
dioxide (CO

2

), carbon monoxide (CO), Flue Temperature and

Combustion Efficiency.

It is suitable for use with all common ‘domestic’ fuels including Natural
Gas, Propane, Heavy Oil, LPG and Light Oil. (When used with oil
burning appliances the flue gases should only be sampled after the
smoke level has been measured and has been confirmed to be a very
low smoke number.)

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

2

and a long life electrochemical sensor to measure CO.

The meter is controlled using a rotary dial.

The dial positions are:

OFF
STANDBY Pump off
CO ppm carbon monoxide
CO2 % carbon dioxide
O2 % Oxygen
RATIO CO/CO2
T FLUE Flue temperature
EFF Combustion Efficiency

Note: Ratio is shown to 4 decimal places, but without a decimal point. So
0001 on the display is equivalent to 0.0001

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1. GETTING STARTED

1.1 SAFETY NOTES

Before using this meter, read all safety information carefully. In this
manual the word “WARNING” is used to indicate conditions or actions
that may pose physical hazards to the user. The word “CAUTION” is
used to indicate conditions or actions that may damage this instrument.

WARNING!

This analyser extracts combustion gases that may be toxic in relatively
low concentrations. These gases are exhausted from the back of the
instrument. This instrument must only be used in well-ventilated
locations. It must only be used by trained and competent persons after
due considerations of all the potential hazards.

1.2 PRE-TEST CHECKLIST

Clean particle filter
Water trap and probe line are empty of water
Power on and zero
All hose and thermocouple connections are properly secured
Flue gas probe is sampling ambient FRESH air
Water trap is fitted correctly to the instrument
Flue temperature plug is connected
Inlet temperature probe is connected if required

1.3 STORING INLET TEMPERATURE

To correctly calculate net temperature and combustion efficiency it is
important to have the correct inlet temperature set. Two methods are
available to properly establish the inlet temperature.

Non-ducted Systems. If the KANE504 is being used on a system that
uses combustion air from the space near the appliance, simply turn the
analyser on without the flue probe connected. The KANE504 will use an
ambient sensor inside the handset as the inlet temperature to determine
net temperature.

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Ducted Systems. If the KANE504 is being used on a system that brings
in outside air for combustion air it is important to set up the inlet
temperature prior to taking flue gas readings. To properly set inlet
perform the following steps during start-up of the KANE504:

Connect the flue temperature connector only to the KANE504.
Place the flue probe in the combustion air inlet system
Turn on and allow to complete the zero process.
Connect the flue gas connector and proceed to combustion
measurements.
The temperature measured during the zero countdown has now been
stored, and will be used to determine the net temperature.

1.4 SELECTING FUEL

When powering on, simply rotate the selector to the desired fuel. The
display will show this, and then it will complete the zero process.

NOTE: If you wish to use the same fuel as previously selected rotate the
selector to “Stand By” at power on. The fuel in use will be displayed and
then blink. If the fuel is not correct rotate the selector to the proper choice
before the zero countdown starts.

1.5 ANALYSER CONNECTIONS

NOTE: Take care when inserting the temperature probes as the pins are
polarized. Insert with the smaller pin into input marked positive. (+)

CAUTION!

Turning the pump off while the probe is in the flue will leave toxic gases
inside the analyser. Once data has been read, it is advisable to purge the
unit with fresh air as soon as possible. To do this, with the probe
removed from the flue, turn ON the pump. Always allow the readings to
return to zero (0.0 for CO2) prior to shutting the unit off.

CAUTION!

The probe will be hot from flue gases. Remove the probe from the flue
and allow it to cool naturally. Do not immerse the probe in water, as this
will be drawn into the analyser and damage the pump and sensors. Once
the probe is removed from the flue and the readings have returned to
ambient levels rotate the selector to “OFF” and switch off the analyser.
The instrument will count down from 10 to switch off.

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1.6 POST TEST

Remove the probe from the flue and allow the analyser to purge with
fresh air until the CO and the CO2 readings return to zero. (Be careful as
the probe tip will be HOT)
Drain water trap.
Check particle filter.

2. MAINTENANCE

2.1 GENERAL MAINTENANCE

Check calibration of your instrument annually to ensure it meets original
performance specifications.

Keep your instrument dry. If it gets wet, wipe dry immediately. Liquids
can degrade electronic circuits.
Whenever practical, keep the instrument away from dust and dirt that
can cause premature wear.
Although your instrument is built to withstand the rigours of daily use, it
can be damaged by severe impacts. Use reasonable caution when using
and storing the meter.

2.2 PERIODIC SERVICE

CAUTION!

Repair and service of this instrument is to be performed by qualified
personnel only. Improper repair or service could result in physical
degradation of the instrument. This could alter the protection from
personal injury this meter provides to the operator. Perform only those
maintenance tasks that you are qualified to do.

2.3 ANNUAL RE-CALIBRATION

While the sensor has an expected life of more than five years in normal
use it is recommended that the analyser is re-calibrated at least annually,
this is so that long-term drift on the electronics can be eliminated. Local
regulations may require more frequent re-calibration and users should
check with appropriate authorities to ensure they comply with relevant
guidelines.