Kane 456 User manual

KANE456
Flue Gas Analyser
with direct CO2 measurement
Stock No: 1973 -2 February 2017
© Kane International Ltd

Page 2
CONTENTS
Page No:
KANE456 Overview 4
ANALYSER LAYOUT & FEATURES 5-6
1. BATTERIES 7
2. BEFORE USING THE ANALYSER EVERY TIME -9
2.1 FRESH AIR PURGE
2.2 STATUS DISPLAY 9
3. USING THE FOUR FUNCTION BUTTONS 10-11
4. USING THE ANALYSER 12-21
4.1 COMBUSTION TEST 12-14
4.2 COMMISSIONING TEST 15
4.3 PRESSURE/TEMPERATURE TESTS 16-17
4.4 LET BY AND TIGHTNESS 1
4.5 ROOM CO TEST 20
4.6 KANE456 PRINTOUTS 23-25
5. USING THE MENU 26
6. USING THE KANE456 AS A THERMOMETER
OR PRESSURE METER 30
7. MEASURING FLUE GASES 32
. ANALYSER PROBLEM SOLVING 33
9. FREQUENTLY ASKED QUESTIONS 34

Page 3
10. KANE DASHBOARD 35-36
11. ONLINE BOOKING PROCEDURE 37-39
12. ANALYSER ANNUAL SERVICE & RECERTIFY 40-43
12.1 SERVICE – CALIBRATE – RECERTIFY 40-41
12.2 RETURNING YOUR ANALYSER TO KANE 42
12.3 WHERE TO SEND YOUR ANALYSER 43
13. COLD WEATHER PRECAUTIONS 43
14. ANALYSER SPECIFICATION 44-45
15. ELECTROMAGNETIC COMPATIBILITY 46
16. END OF LIFE DISPOSAL 46
17. EN50379 REGULATED INSTRUCTIONS 47-49
APPENDIX 1 - MAIN PARAMETERS 50-52
ADDENDUM - OPTIONAL NITRIC OXIDE
(NO) SENSOR 53-56
PRODUCT REGISTRATION 57-5

Page 4
KANE456 OVERVIEW
The KANE456 Combustion Analyser measures carbon dioxide (CO2), carbon
monoxide (CO), differential temperature and differential pressure. The direct
measurement of CO2 is achieved using a Kane designed infra-red sensing system.
Below 1% CO2 the readings of CO2 are displayed to two decimal places
CO2 is set to zero in fresh air automatically after the initial countdown. The countdown
varies between 90 and 30 seconds dependent on ambient temperature.
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 (Net or
Condensing Gross).
The KANE456 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.
A structured Commissioning Test has been included for the installation of boilers.
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.
A low flow detection system warns of low flow and switches the pump off. This also
helps to prevent water ingress from overfilled water traps.
Its LCD display is protected with a toughened screen.
The large display shows 6 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:
60 combustion tests
20 AUX tests
20 let-by/tightness tests
20 temperature & pressure tests
20 room CO tests
20 commissioning Tests
Two lines of 20 characters can be added to the header of printouts. Printouts can be
made on the optional Kane IRP printers with ‘fast print’ capability using the IRP2
printer. Alternatively the analyser can be equipped with optional wireless
communications to either Android or Apple devices.
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 torch 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
Battery
Compartment
(behind rubber
cover)
Tasklight and infra-red emitter
Function
buttons x 4
Rotary Switch
“Battery Charging”
indicator
Water Trap
Particle Filter
Enter
Menu controls
Scroll up/down
Flue Gas Inlet

Page 6

Page 7
1. BATTERIES
Batte y 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 batte y cha ge unit must only be used when NiMH batte ies a e fitted. Do
not mix NiMH cells of diffe ent capacities o f om diffe ent manufactu e s. All
fou cells must be identical
Replacing Batte ies
Turn over the analyser, remove its protective rubber cover and fit 4 “AA” batteries in
the battery compartment. Take g eat ca e to ensu e they a e fitted with the co ect
batte y pola ity. Replace the battery cover and protective rubber cover.
Switch the analyser on and check that the analyser’s time and date are correct. To
reset see USING THE MENU, Section 5.
Cha ging NiMH Batte ies
Ensure that you use the correct charger. The part number is 1927 .
To fully charge NiMH batteries:
The charger must be connected and switched on.
When charging, the red Battery Charging Indicator will illuminate.
After a few seconds, the display will show “ CHARGING BATTERY” if they need
extra charge.
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 1 342.
Batte y 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 screw plug and re-tighten once it is
empty.
- To change the particle filter, remove protective rubber cover, 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 cover.
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. 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 O
2
reading should be 20.9% ± 0.3%.
FRESH AIR
PURGE
REMOVE
PROBE
FROM FLUE
PRESS

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:
NAT GAS
→Current fuel selection
14:56:29
→Current time. Can be re-set via the “Menu”
11/03/06
→Current date. Can be re-set via the “Menu”
Ta
23.8
→Ambient temperature of the analyser
AL
283
→Shows number of days until next calibration is
due
BAT
→Shows the charge level of the batteries
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
analyse must only be used in well-ventilated locations by t ained and
competent pe sons afte due conside ation of all the potential haza ds.
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
Rotate the dial to the mode you want to use before switching on.
This may eliminate the need for a full countdown in some of the
modes and save you time.
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
software version, date and time. Its bottom line counts down 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 / & hold for 2 seconds to switch the analyser
OFF. The display counts down from 30 or less 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 analyse will not switch off unless the CO
eading is below 40ppm.
Torch Light
Press / to switch the torch light on and off.
NOTE: Use of the to ch light significantly inc eases the
cu ent d ain on the batte ies.

Page 11
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 40 seconds.
NOTE:
The pump will automatically switch itself off when the ota y
switch is set to Menu, Status, P essu e, Tightness o
Diffe ential Tempe atu e.
Zeroing the
pressure
sensor
To re-zero the pressure sensor when “Prs/Temp” is selected on the
dial, press and hold / until the top line display
shows CAL ZERO.
Always disconnect the pressure hose before zeroing.
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).
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 no mal ope ation 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 12
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/CO2ratio.
O
52
p
→Carbon monoxide (ppm).
O2
6.3
%
→Carbon dioxide (%).
XAIR
88.7
→Excess air %
PRS
0.01m
→Pressure reading
Press / to print a full combustion test, (or send to PC via optional
Wireless module).
Hold / for 2+ seconds to log a full combustion report.

Page 13
O2/EFF display
NAT
GAS
→Fuel type
O2
9.8%
→Oxygen (%) left after combustion. Should be
20.9% ± 0.3% in fresh air.
Efg
81.
1%
→Gross efficiency
Tf
145.1
→Flue temperature (oC).
Ta
5.4
→Inlet temperature (oC). Normally set by flue
probe during fresh air purge.
∆
T
139.7
→Differential temperature
Press / to print a full combustion test, (or send to PC via optional
Wireless module).
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, 4,
5 and 6 can be set by the user.
O
52
p
→They remain the AUX parameters until
changed by the user.
O2
6.3
%
→
NO
-
N/F
-
→NO sensor not fitted
NOx
-
N/F
-
→NO sensor not fitted
Press / to print a full combustion test, (or send to PC via optional
Wireless module).
Hold / for 2+ seconds to log a full combustion report.

Page 14
Viewing / p inting ove view
The side lights on the display point to the active line.
Use or to change the pointer.
Press / to select a line. The side lights now flash.
Use or to scroll or change the selected line.
Press / to exit a line.
To view / p int a logged epo t
Select MENU / REPORT / COMBUSTION / VIEW.
The side lights will point to the top line.
Press / to select this line. The side lights will flash.
Use or to scroll or change the Log No. ( If only one report is logged, number
will not change).
Press / to confirm a Log No. The side lights will stop flashing.
To view logged data press or to move the pointer to another line.
Press / . Sidelights will flash on that line.
Use or to scroll through data.
To finish, press / . Sidelights stop flashing.
Use or to scroll down to “PRINT”
Press / to print.
Viewing / p inting a logged combustion test
Press / to print the test, (or send to PC via optional Wireless module).

Page 15
4.2 COMMISSIONING TEST
The Commissioning Test is based on TB143
Rotate the dial to to COM TEST position and follow the instructions on the screen
TEST 1 check the boiler at Max Gas rate.
The boiler is switched on at Max rate.
The analyser is first zeroed in fresh air.
Once the boiler is stable at max gas flow rate the probe is inserted into the air inlet of
the flue and the CO2 level is measure. The reading needs to be stable and less than
or equal to 0.20%.
TEST 2
The probe is then inserted into the exhaust outlet of the boiler and the RATIO, CO and
CO2 levels are measured. These levels must be as per manufacturers instruction.
Where manufacturers instructions are not available the CO must be less than 350 ppm
and the RATIO must be less than 0.0040.
TEST 3 checks the boiler at minimum gas flow rate where this is possible.
With the boiler operating stabley at minimum gas rate the RATIO, CO and CO2 levels
are measured.
These levels must be as per manufacturers instruction. Where manufacturers
instructions are not available the CO must be less than 350 ppm and the RATIO must
be less than 0.0040.
TEST 4 Measures Flow and Return Temperatures from the boiler
All the measured readings are logged and can be printed or transmitted to PC if an
optional wireless module is fitted.

Page 16
4.3 PRESSURE/TEMPERATURE TESTING
Select “Prs/Temp”. 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/TEMP display
PR
S
0.01m
→Normal response or smoothed (damped)
response can be selected via “Menu”.
m=
mbar
→‘High’ or ‘Low’ resolution readings can be
selected via “Menu”.
→Pressure units can be selected via “Menu”.
T1
75.1
→Eg Flow Temp
T2
40.2
→Eg Return Temp
∆
T
34.9
→Differential Temp
Press / to print a full pressure test, (or send to PC via optional Wireless
module).
Hold / for 2+ seconds to log a pressure report.
Viewing / p inting a logged p essu e/temp test
Select MENU / REPORT / PRS-TEMP / VIEW
Use or to select the log number to be printed.
Press / to print the test, (or send to PC via optional Wireless module).
WARNING
Before using the KANE456 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 17
If using la ge bo e tubing when pe fo ming p essu e 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 18
4.4 LET-BY & TIGHTNESS TESTING
Select “Tightness”. The pump stops automatically. Press / to auto-
zero 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.
P
R
1
10.15
m
→Pressure at start of let-by test.
P
R
2
10.15
m
→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
→
P
R
1
20.01
m
→Real time pressure reading.
TIME
59
→Stabilisation default time is 1 minute. Can be
changed via “Menu”.
When complete press to start the tightness test:

Page 19
TIGHTNES
S
→
P
R
1
20.01
m
→
Pressure at start of tightness test.
P
R
2
20.01
m
→
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.
P
R
1
20.01
m
→Pressure at start of stabilisation test.
P
R
2
19.
98m
→Pressure at end of stabilisation test.
PR1
19.98m
→Pressure at start of tightness test
PR2
19.97m
→Pressure at end of tightness test
PRINT

→Press to print the complete test.
Viewing / p inting a logged Let-by and Tightness test
Select MENU / REPORT / TIGHTNESS / VIEW
Use or to select the log number to be printed.
Press / to print the test, (or send to PC via optional Wireless module).
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 / TIGHTNESS / DEL ALL / YES then press
.

Page 20
4.5 ROOM CO TESTING
Select “Room CO” to measure and record CO readings for up to 30 minutes.
SELE T
→
ROOM
O
→
TEST TYPE
→
GENERAL
→Use / to select the test type from
the following:
TEST TYPES
GENERAL: 15 minute test with results
stored every minute
LIMIT = 10ppm
ALARM = 30 ppm
SWEEP TEST: 2 minute test with max reading
stored at end
LIMIT = 10ppm
ALARM = 30 ppm
MIGRATION TEST: 15 minute test with results
stored every minute
LIMIT = 10ppm
ALARM = 30 ppm
TYPE C SEALED APPLIANCE: 15 minute test with results
stored every minute
LIMIT = 10ppm
ALARM = 30 ppm
TYPE B BOILER OPEN FLUE: 15 minute test with results
stored every minute
LIMIT = 10ppm
ALARM = 30 ppm
TYPE A COOKER: 30 minute test with results
stored every miute
LIMIT = 30ppm
ALARM = 90 ppm
TYPE A WATER HEATER: 5 minute test with results
stored every minute
LIMIT = 10ppm
ALARM = 30 ppm
TYPE A SPACE HEATER: 30 minute test with results
stored every 1 minute
LIMIT = 10ppm
ALARM = 30 ppm
Press / to start Room CO testing.