Kane KM940 User manual

KM940
Hand-held Combustion
Analyser
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com

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CONTENTS
Page No:
1. ANALYSER LAYOUT AND FEATURES............................................................ 4-7
1.1 Instrument features and keypad...........................................................................4
1.2 Instrument layout (Rear) .....................................................................................5
1.3 Standard Probe Configuration.............................................................................6
1.4 Analyser connections ..........................................................................................7
2. SAFETY WARNING ...................................................................................................8
3. FIRST TIME USE ........................................................................................................8
4. NORMAL START UP SEQUENCE...................................................................... 9-15
4.1 Every Time You Use The Analyser ....................................................................9
4.2 Automatic Calibration .........................................................................................9
4.3 Main Display Parameters ..................................................................................11
4.3.1 4 Page Mode.........................................................................................11
4.3.2 Line Scroll Mode..................................................................................12
4.3.3 8 Page Mode.........................................................................................12
4.4 Sampling the Flue Gas ......................................................................................13
4.5 Taking a Pressure Reading................................................................................13
4.6 Regular Checks During Sampling.....................................................................14
4.7 Normal Shutdown Sequence .............................................................................14
4.8 Electromagnetic Compatibility .........................................................................15
5. MOVING THROUGH THE MENUS.................................................................. 16-22
5.1 Basic Operation .................................................................................................16
5.2 Menu Options and Settings ...............................................................................17
5.2.1 Main Menu ............................................................................................17
5.2.2 Select Menu ..........................................................................................17
5.2.3 Units Menu ............................................................................................19
5.2.4 Display Menu ........................................................................................20
5.2.5 Set-Up Menu .........................................................................................20
6. PRINTING INFORMATION.....................................................................................23
6.1 Printing a ‘Live’ Test..........................................................................................23
6.2 Standard Printout ................................................................................................23
7. STORING AND RETRIEVING DATA .............................................................. 24-25
7.1 Storing a ‘Live’ Test .........................................................................................24
7.2 Viewing and Printing a ‘Stored’ Test................................................................24
7.3 Deleting Data.....................................................................................................25

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8. MAINTENANCE .......................................................................................................26
8.1 Emptying and Cleaning the in-line water trap ..................................................26
8.2 Changing the particle filter................................................................................26
9. PROBLEM SOLVING ...............................................................................................27
10. ANNUAL RE-CALIBRATION .................................................................................27
11. PRODUCT SPECIFICATION ............................................................................. 28-29
APPENDICES:
A. MAIN DISPLAY PARAMETERS ............................................................................30
B. COMBUSTION EFFICIENCY CALCULATION............................................... 32-33
C. CALCULATION OF FUEL DATA...........................................................................34
D. ELECTROMAGNETIC COMPATABILITY STATEMENT ...................................35

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1. ANALYSER LAYOUT AND FEATURES
1.1 Instrument Features and Keypad
ON/OFF
UP
Scrolls up through options ie Fuel
MENU
Allows access to all menu functions
DOWN
Scrolls down through options
PUMP
Turns pump on and off
STORE
Enters data storage menu
ENTER
Accepts a command ie enters a
menu option
PRINT
Prints current data
Flue Temperature
Connector (underside)
RS232 (8 pin din)
Charger socket
Store
Print
Pump
Enter
Menu
On/Off
Up
Down
Keypad
Inlet Port (side)
Pressure Inlet
Infra-red emitter

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1.2 Instrument Layout (Rear)
SENSORS FITTED
Charger Socket
NOTE! - Cover
Does Not Remov
e
Serial Number
Options Label
Exhaust Port
*NOTE! Do not cover exhaust port as this will
severely affect analyser operation

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1.3 Standard Probe Configuration

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1.4 Analyser Connections
Gas Connection
to Instrument
Particle Filter
In-line Water Trap
Neoprene Hose
Flue Temperature
Connector

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2. SAFETY WARNING
This analyser extracts combustion gases that may be toxic in relatively low concentrations.
These gases are exhausted from the side 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.
Protection Against Electric Shock (in accordance with EN 61010-1 : 1993)
This instrument is designated as Class III equipment and should only be connected to SELV
circuits. The battery charger is designated as:
Class II equipment
Installation category II
Pollution degree 2
Indoor use only
Altitude to 2000m
Ambient temperature 0°C-40°C
Maximum relative humidity 80% for temperatures up to 31°C decreasing linearly to 50%RH
at 40°C
Mains supply fluctuations not to exceed 10% of the nominal voltage.
3. FIRST TIME USE
Charge the battery for 12 hours, following this an overnight charge should be sufficient for an
average 8 hour day. See Main Parameter displays for Battery Indicator.
The KANE940 has a rechargeable lead acid battery which uses a different charger than other
Kane analysers. Ensure the correct charger is used or damage may occur to the instrument.
Check that you have all the items you have ordered.
Take time to read this manual fully.
When using the analyser for the first time you will need to choose from:-
Language selection
Calibration countdown time
CO gas alarm
NOx percentage for calculation
Time and Date
Printed header name and telephone number
The SET UP MENU (Section 5.2.5) gives details of how to change the above settings.

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4. NORMAL START UP SEQUENCE
4.1 Every Time You Use The Analyser
BEFORE SWITCH-ON CHECK THAT:
the particle filter is not dirty
the water trap and probe line are empty of water
all hose connections, etc, are properly made
the probe is sampling CLEAN AMBIENT air
the water trap is correctly fitted and the instrument upright
the flue temperature is connected
Switch ON the instrument by pressing
4.2 Automatic Calibration
During this sequence the analyser pumps fresh air into the sensors to allow toxic sensors (if
fitted) to be set to zero and the Oxygen sensor to be set to 20.9 %.
After switch-on the analyser will briefly display header information :-
Kane International
(44)-1707-375550
And then show the countdown screen :-
ZERO CAL
Time : 180
FRESH AIR PURGE
The calibration time will count down in seconds to zero. Calibration time may be changed
from 2 to 6 minutes. See Set-Up menu section 5.2.5.
Note ! Three minutes is recommended to allow the sensors to stabilise fully. Anything less
than this may result in drift of the toxic and oxygen sensors in clean ambient air.
To obtain the quoted specification an instrument should be calibrated with clean ambient air
at standard temperature and pressure (STP).

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Once the time has reached zero an audible beep will be heard and will show the selected fuel
on the following display:-
NATURAL GAS
∗PRESS -MENU- KEY∗
Press
This zeros the toxic sensor and sets Oxygen to 20.9%. The next screen is the MAIN
DISPLAY of the analyser:-
NETT C . . . . 0.0
O2 % . . . 20.9
CO ppm . . . 0000
EFF (G) % . . . 0.0
Use and to change the display.
CO2 % . . . . . . . 0.0
FLUE C. . . . . . 0.0
INLT . . . . NOT FITTED
AMBIENT C . . . . 21
All parameters are detailed in Appendix A - MAIN DISPLAY PARAMETERS.

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4.3 Main Displays
The main display can be changed to show either 4 or 8 parameters at one time. Two options
are available when 4 parameters are selected.
• 4 Page Mode displays 4 lines of data in set format, each page is predefined.
• Line scroll mode allows you to customise the display to show the data you require.
• 8 Page Mode displays 8 parameters on 4 lines in set format, the bottom two can be
changed.
Changing between the different modes is detailed in Display Menu Section 5.2.4.
4.3.1 4 Page Mode
Use the and keys to change the information that is displayed on the screen. The
following pages are available.
NATURAL GAS
DATE . . . 07-08-96
TIME . . . 12:31:35
BATTERY % . . 54
NETT C . . . 0.0
O2 % . . . 20.9
CO ppm . . 0000
EFF (G) % . . . 0.0
CO2 % . . . 0.0
FLUE C . . . 0.0
INLT NOT FITTED
AMBIENT C . . . 21
CO/CO2 R . . 0.0001
P INDEX % . . . 0.01
XAIR % . . . 0.0
Prs mbar 0.00
This screen only displayed on an
analyser fitted with an NO sensor
NO ppm . . 0000
NOx ppm . . 0000
NOx calc% . . . 5
O2 ref % . . . 3.0
TIP - In 4 page mode only turns the backlight ON and OFF.

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4.3.2 Line Scroll Mode
Line scroll mode allows you to customise the display.
Use the and keys to change the bottom line of the display. Once the correct line
is displayed press to confirm and move the line up. Select the next parameter and
repeat until all lines display the desired parameters.
Change bottom line using
and
NETT C . . . 0.0
O2 % . . . 20.9
CO ppm . . 0000
CO2 % . . . 0.0
to select and move
parameter up
O2 % . . . 20.9
CO ppm . . 0000
CO2 % . . . 0.0
CO2 % . . . 0.0
Select next parameter.
Repeat above until
display reads desired data
O2 % . . . 20.9
CO ppm . . 0000
CO2 % . . . 0.0
CO/CO2 R . . 0.0001
4.3.3 8 Page Mode
Displays 8 parameters on the screen at one time. Symbols used in this mode are different to
those used in 4 page and line scroll modes and are detailed in Appendix A - MAIN DISPLAY
PARAMETERS.
O2
CO
PI
λ
:20.9 %
:0ppm
:- -
:- -
CO2
Eff
∆T
Tf
:- -
:- -
:0C
:21C
The bottom line of the display can be changed to display other parameters.
Use the and keys to change this line.

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4.4 Sampling the Flue Gas
Once the automatic calibration procedure has been completed and the specific fuel has been
selected (See SELECT menu) 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. With balanced flues and other
domestic units the probe should be positioned far enough into the flue so that no air can ‘back
flush’ into the probe. This will be indicated by a low oxygen reading and/or a low ‘Poison
Index’ reading.
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 13/16 inch).
The standard probe is rated at 650°C. 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 key to turn ON and OFF the pump.
4.5 Taking a Pressure Reading
With the optional pressure module fitted a flue draught measurement can be made at any time.
Connect the standard probe to the pressure sensor inlet and the probe in the flue.
The pressure reading will be displayed :-
CO/CO2 R . . 0.0001
P INDEX % . . . 0.01
XAIR % . . . 0.0
Prs mbar 0.00
To perform a combustion test and display draught pressure at the same time a special probe is
required. Contact Kane International or Authorised Distributor for details.

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4.6 Regular Checks During Sampling
Care must be taken at all times not to exceed the analysers operating specifications, in
particular ensure the following :-
• Do not exceed the maximum temperature of the flue probe.
• The analyser internal temperature does not exceed normal operating range, typically 0-
40°C.
• DO NOT PLACE THE INSTRUMENT ON A HOT SURFACE.
• The water trap is vertical at all times. Water condenses in the probe line and can quickly
fill the water trap when the probe is moved. Take care and watch the water trap closely.
• The in-line particle filter is clean and does not become blocked.
4.7 Normal Shutdown Sequence
DO THIS EVERY TIME YOU USE THE ANALYSER
Remove the probe from the flue - TAKE CARE ! THE PROBE WILL BE HOT - 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 press and the analyser will count down from 30
to switch off.
OFF 30
MENU TO ESCAPE
If you have not finished but press by mistake, you can press to return to normal
operation and not switch OFF.

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4.8 Electromagnetic Compatibility
The European Council Directive 89/336/EEC requires that electronic equipment does not
generate electromagnetic disturbances that exceed defined levels and has an adequate level of
immunity to enable it to be operated as intended. The specific standards applicable to this
product are detailed in the appendices.
Since there are many electrical products in use that pre-date this Directive and may emit
electromagnetic radiation in excess of the standards defined in the Directive there may be
occasions where it would be appropriate to check the analyser prior to use.
The following procedure should be adopted:
Go through the normal start up sequence in the location where the equipment is to be
used.
Switch on all localised electrical equipment that might be capable of causing
interference.
Check that all readings are as expected. (A level of disturbance in the readings is
acceptable). If not adjust the position of the instrument to minimise interference or
switch off, if possible, the offending equipment for the duration of the test.
N.B. Maximum cable lengths must be less than 3 metres.
At the time of writing this manual (November 2005) Kane International Ltd is not aware of
any field based situation where such interference has ever occurred and this advice is only
given to satisfy the requirements of the Directive.

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5. MOVING THROUGH THE MENUS
5.1 Basic Operation
From the MAIN DISPLAY
NETT C . . . . 0.0
O2 % . . . 20.9
CO ppm . . . 0000
EFF (G) % . . . 0.0
Press
to access the MAIN MENU
MAIN MENU
1. SELECT 3. DISPLAY
2. UNITS 4. SETUP
Press and
to move cursor up and down
MAIN MENU
1. SELECT 3. DISPLAY
2. UNITS 4. SETUP
Press
to access selected Menu
MAIN MENU
1. SELECT 3. DISPLAY
2. UNITS 4. SETUP
Press
to select parameter
FUEL
O2 Ref
SMOKE
RESET
: LIGHT OIL
: OFF
: OFF
: NO
Use and
to change setting i.e. fuel selected
FUEL
O2 Ref
SMOKE
RESET
: NATURAL GAS
: OFF
: OFF
: NO
Press
to enter value and move to next
parameter
FUEL
O2 Ref
SMOKE
RESET
: LIGHT OIL
: OFF
: OFF
: NO
Press
to save settings and return to the
MAIN MENU
MAIN MENU
1. SELECT 3. DISPLAY
2. UNITS 4. SETUP
Press to return to the MAIN DISPLAY

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5.2 Menu Options and Settings
5.2.1 Main Menu
The MAIN MENU consists of 4 sub menus which are shown below and detailed on the
following pages.
MAIN MENU
1. SELECT 3. DISPLAY
2. UNITS 4. SETUP
All sub-menus are accessed using and exited using
The and keys move the cursor within a menu and allow
parameters to be changed.
TIP Holding down one of these keys scrolls through the data quicker.
5.2.2 Select Menu
FUEL
O2 Ref
SMOKE
RESET
: NATURAL GAS
: OFF
: OFF
: NO
This menu allows selections to be made for the parameters detailed below.
FUEL : Select the fuel being used by the boiler from either a standard fuel stored in the
analyser or by entering the user fuel. Once the correct fuel has been selected
press to view the fuel constants.
NATURAL GAS
K1g
K_2
K_4
: 0.350
:11.89
:32
K1n
K_3
O2r
:0.390
:9.83
:3.0

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Calculation of fuel constants are detailed in the Appendix. Fuel constants will
have to be calculated before a user fuel can be entered.
To enter the user fuel select ‘User Fuel’ and Press
USER FUEL
K1g
K_2
K_4
:0.000
:0.00
:00
K1n
K_3
O2r
:0.000
:0.00
:00
Use and to select the correct value.
USER FUEL
K1g
K_2
K_4
:0.350
:0.00
:0
K1n
K_3
O2r
:0.000
:0.00
:00
Use to move to the next parameter, repeat above until all parameters
are correct. Press to return to SELECT menu.
O2 Ref : Toxic gas measurements can be referenced to defined oxygen levels. Reference
values can be set from 1-20%, to AUTO or more normally to the default value
- OFF. Setting to AUTO uses the figure in the FUEL constants data.
Oxygen referencing is required by some regulations such as TA-LUFT. If a
reference value is selected then toxic gas measurements will be displayed with
the symbol (n) attached to the reading. i.e. CO(n)
What does Oxygen reference mean ?
If 3 % O2reference is selected and 5 % O2is 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.
SMOKE: Allows the user to enter a smoke test number from 0-9. This value will be
printed on the standard printout. Default value is OFF.
RESET : Allows the user set the Oxygen to 20.9% and zero the toxic sensors without
turning the analyser off.

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Selecting YES and will display the following screen.
RESET SENSORS
O2 % : 20.9 CO & NO = 0
PRESS ENTER
MENU TO ESCAPE
After pressing the analyser will count down for 5 seconds and
then return to the main display.
WARNING : The sensors must only be reset if you are sure they have been
sampling fresh air for at least 3 minutes. Errors in
measurement will occur if the sensors are reset during or just
after sampling.
5.2.3 Units Menu
TEMP
GAS
PRESS.
EFF.
: C
: ppm
: mbar
: GROSS
Allows all displayed units to be changed.
TEMP : Choose selections from Centigrade °C or Fahrenheit °F.
GAS : Changes the toxic gas measurement units. Select from volumetric readings,
parts per million (ppm) or mass flow reading milligrams per cubic meter
(mg/m3) .
PRESS. : Flue draught can be displayed in millibar (mbar), hectaPascals (hPa),
millimeters water gauge (mmWG) or inches water gauge (in WG).
EFF. : Efficiency can be selected for Gross or Net values. Gross efficiency assumes
latent heat of vapourisation is lost in the boiler and hence will be lower than
Net efficiency. For Natural Gas the difference will be approximately 11%.

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5.2.4 Display Menu
LIGHT
MODE
CONTRAST
: OFF
: 8-PAGE
: DEFAULT
Allows the configuration of the display to be changed.
LIGHT : Choose from ON or OFF.
MODE : Select 4 or 8 Page Mode or Line Scroll Mode as detailed in section 4.3 Main
Displays.
CONTRAST :The contrast is set to a DEFAULT value or can be adjusted
↑LIGHTER or ↓DARKER. Use the and keys to
adjust.
5.2.5. Set-Up Menu
The set up menu allows the following parameters to be set / altered.
• Language.
• Automatic calibration time
• CO gas alarm
• NOx percentage for calculation
• Date and time
• Printout Header
LANG
CO AL
CALEN
: ENGLISH
ARM : 400
DAR
ZERO :3
NOx% :5
HEADER
Parameter Description Settings
LANG : Changes the analysers displayed and printed
language.
ENGLISH
SPANISH
DUTCH
FRENCH
ITALIAN
ZERO : Allows setting of the Autocalibration time in
minutes. Care must be taken when changing this
parameter as sensors may drift from zero if too
short a time is used. Kane International advise 3
minute countdown.
2-6 minutes
CO ALARM : Allows an alarm level to be set on for the CO
reading. This is set as a default at 1000 ppm.
OFF
0-4000 ppm