TESTO 325-3 User manual

Instruction manual en
testo 325-3
CO
°F
inch H2O
∆∆T
∆∆P
3
CO-Analyzer

Introduction
Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gas path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Diagram of analyser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operating the analyser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Example of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Measuring flue gas and ambient air temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flue gas measurement in burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Draught measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential temperature measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Printing the measured results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reference section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting date/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setting the units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Changing rechargeable batteries or batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Changing filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Condensate trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flue gas probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cleaning the flue gas pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Changing measurement cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Accessories22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testo log printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ordering data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dear Customer
You have made the right decision by choosing the testo 325 flue gas analyser. Thousands of customers
buy our high standard products every year. There are at least 7 good reasons for doing so:
1) Cost - performance ratio. Reliable quality at a fair price.
2) Extended warranty times of up to 3 years - depending on instrument.
3) We have the ideal solutions for your measuring tasks based on our expert experience gained
over 40 years.
4) Our high quality standard is confirmed by the ISO 9001 certificate.
5) Of course, our instruments carry the CE symbol required by the EU.
6) Calibration certificates for all relevant parameters. Seminars, advice and calibration on location.
7) Our after-sales service. Ask for more details.
Contents
Introduction
2
TÜV By RgG 188

Operation via plug-in mains unit
The original mains unit should be used when operating the
analyser.
Tightness
The complete measuring system (probe, condensate trap, hoses
and plug-in connections) must be checked for tightness e.g. by
attaching a rubber bladder, which has been pressed together, on
the probe tip. Measurements may be inaccurate if additional air
is drawn in.
Gas outlet
When measuring ensure that the gas outlet in the analyser is free
of any obstacles so that the gas can escape unhindered.
If this is not the case the results measured may be incorrect.
Condensate trap
Empty the condensate trap once maximum levels have been
reached. The pump has to be switched off (the measurement
cells are at risk otherwise)!
Measurement cells
There is a low level of concentrated acid (CO sensor) in the
measurement cells. Please dispose of these measurement cells
carefully.
Analyser
Storage of the analysers in rooms containing solvents will
damage the measurement cells.
Warnings
Initial operation
3
Analyser conforms with EN 50 082-1, EN 55 081-1

Initial operation
4
P
Kapillare
CO
p
¡C/AT
testo 325
¡C/VTzusätzlich
Kondensatfalle
mit Filter
Ausgang ·
Gas
ug
RGS
testoterm
RG
Pumpe
Gas path
FG = Flue gas
°F FT = Flue gas temperature
°F AT = Separate ambient air temperature
p = Pressure
Power supply
Standard rechargeable batteries or batteries
- Use standard rechargeable battery type (1.5V IEC KR 15/51
corresponding to type AA) or battery type (1.5V AA size alkaline
IEC LR6 •AA• ) (4 off).
Testo mains unit (0554.0054)
- Ensure that the connection plug in testo 325 is securely
connected.
- Operation with mains unit is possible if rechargeables/
batteries are empty (batteries cannot be recharged in analyser)
Capacity display
Voltage >4.6 V (Service life: approx. 3 hours, at an
ambient temperature of68 °F.
Flashing symbol, voltage <4.6 V
Lifetime of rechargeable battery: 0.5 h
Lifetime of battery: approx. 2.5 h
If the voltage in the rechargeable battery drops below
4.2 V, the analyser is switched off automatically to
protect against total discharge.
It is normal for the mains unit to heat up. If temperatures are too
high (e.g. due to an error in the analyser) the mains unit is
protected by a thermal protection switch against overheating.
Draught
FG °F/AT additional
°F/FT
Condensate trap
with filter Pump Capillary
Output
Low Bat
Low Bat

Initial operation
5
Gas inlet
(red)
FT
AT
Mains unit
connection
Inlet for draught
measurement or
pressure
connection (blue)
Diagram of analyser
Time
Print
Battery capacity
Initialisation
phase
Flue gas
temperature
Ambient air
temperature
Pump
measurement -
On/Off
Print button
Cancel/Return
Draught/pressure
button
Menu button
and
confirmation
Temperature
measurement
Date Parameters
Measuring
units
Draught/pressure
measurement
Pump active
On/Off button
Selection button
Scroll buttons
Readings
testo 325-3
CO Analyzer

Initial operation
Operating the analyser
6
Button panel
- Scroll buttons
Use the up/down arrow buttons / to scroll between
the measured value windows (in
the measurement menu) or to select a menu point in a list. If the
last window or the last menu item has been reached, you
automatically go to the first window or the first menu item.
- Selection button
Use the arrow button pointing to the right to access the
parameters which can be changed in the Date/Time Menu and in
the Display Sequence Menu.
The parameters are set using the and buttons.
- Print
The measurement data in the display is printed by pressing
Print .
- I/O button
Press I/O to switch instrument on or off. A switch-off
message appears in the display before the
instrument is switched off completely. You can still stop the
instrument from being switched off by pressing any button except
.The instrument then returns to the measurement menu.
- Escape button
By pressing you can cancel selected procedures or a
planned selection or you can leave sub-menus. When you leave
the sub-menus, by pressing you generally go back one
menu window until you are in the main menu.
- OK button
The button takes you from the measurement menu to the
main menu.
Chosen functions are selected or executed.

7
Example of measurement
Measuring flue gas and
ambient air temperature
The flue gas temperature is measured via the thermocouple at
the tip of the flue gas probe. The probe has openings in this area
in the probe stem so that the thermocouple is protected but at
the same time comes into contact with the flue gas.
There are two ways to measure the ambient air temperature with
testo 325:
1. Measuring the ambient air temperature using the flue gas
probe
The temperature is already measured during the initialisation
phase and is shown in the display.
The temperature measured by the flue gas probe is interpreted
by the testo 325 as the ambient air temperature and is saved
as the ambient air temperature value once the initialisation
phase is completed.
This type of ambient air temperature measurement is sufficient
for systems which are dependent on ambient air. During the
initialising phase, ensure that the tip of the flue gas probe is
held near the burner´s intake duct.
2. Measuring the ambient air temperature via a separate
ambient air probe
The probe is connected to the additional probe socket (AT) at
the bottom connection panel of testo 325. As soon as a
separate temperature probe is inserted, the temperature is
automatically recognised as the ambient air temperature and is
measured continually.
USA V 13
6.0
43
Switch on
testo 325
Self-test
Battery capacity
Initialisation phase
In order to measure the exact flue gas temperature and therefore
be able to measure the exact flue gas loss, the thermocouple
should always be positioned in the flue gas flow. It should not
be covered by the probe stem frame. The flue gas probe
must be plugged into the FT connection socket.
Flue gas flow
Thermocouple
Wrong Right
Wrong Right
The tip of the thermocouple should not touch the protection
casing. Bend back the tip of the thermocouple if necessary.

8
Example of measurement
Flue gas measurement in burners
5 s 3 s 60 s
USA V 13
6.0
43
T325-3
257
100
T325-3
100
T325-3
If the flue gas probe is in a vertical position or at an angle of
45°, the condensate drops which develop could result in a
sudden drop in temperature.
Remedy:
Position the flue gas probe horizontally.
After every measurement rinse the measurement cells
with fresh air (Pump Start/Stop) until the CO level is below
50 ppm.
Connect probe
Self-test
Measurement menu
Printout
Pump is
on
Battery capacity Initialisation phase
Switch on
testo 325
testoterm
T325-3
78
T325-3
0.048
T325-3
64
100

Draught measurement/Gas flow pressure
Example of measurement
9
Measurement menu
Initialisation phase
Symbol for draught
measurement
appears
The flue gas probe is used to measure draught. Draught can be
measured before or after a flue gas measurement.
Draught can only be measured if the pump is switched off.
If the draught is measured following flue gas measurement
there will still be impact pressure in the hose, after the
pump is stopped, which first has to be reduced (approx.
30 seconds).
The analyser’s position should not be changed when
draught is being measured.
Any remaining condensate in the flue gas probe
must be removed (shake the probe with the tip
nearest the ground).
Do not switch between rechargeable battery and mains
operation when measuring draught (fluctuations in voltage
may influence the measured result).
Initialising the pressure sensor:
Probe must be outside the flue.
Negative sign means negative pressure, positive sign means
positive pressure in the flue.
254.5
100
T325-3
0.00
5
0.977
Data is not
saved
Data is saved.
Return to
measurement
menu.
testoterm
testoterm

Only for measuring temperature e.g. flow/return temperature.
Attach probe T1 and T2.
Confirm with .
Reconfirm with . Jump to measurement menu with display of
differential temperature .
Return to main menu by pressing .
Example of measurement
Differential temperature measurement
10
Gas inlet
(red)
FT
(T2)
AT
(T1)
Mains unit
connection
Inlet for draught
measurement
(blue)
∆T
140.0
104.0
Measurement menu
Measurement menu
Symbol for
flue gas
temperature
(T2)
254.5
100
68
100
T325-3
UNITES
DAT/TIME
∆T
Scroll with the arrow buttons through the main menu until you
come to the ∆T setting.
Symbol for
differential
temperature
(T1)
T325-3

11
All readings are printed with
- Date/Time
- Set parameter sequence
- Measuring units
(How to set date/time. See reference section)
*These values are entered by hand on the printout.
testo 325-3
12.31.1998 00:17:13
CO 0 ppm
FT ______ °F
AT ______ °F
DRFT 0.00 inH2O
CO 101 ppm
∆T ______ °F
# 00397205
Date/Time
Fuels
Readings
Example of measurement
Printing the measured results
Measurement menu
253
100
T325-3
253.0
3.5
T325-3
The readings can be printed by pressing the button.
Printing is only possible if the pump is not in operation.
Printing can be stopped by pressing .

12
Change the field to be set by pressing .
Increase value by pressing , reduce value by pressing .
Confirm settings with and return to main menu.
: return to the main menu without taking over the settings.
Scroll with the arrow buttons through the main menu until you
reach Dat/Time.
Reference section
Setting date/time
0315
1998
14:15
Field to be
set flashes
Symbol
for time
Symbol
for date
Measurement menu
254.5
100
T325-3
UNITES
DAT/TIME
∆T

Setting the units
Reference section
13
Measuring units
Select the parameter with or .
Select list of all possible measuring units via .
Accept measuring unit by pressing , jumps to measurement
menu.
Cancel selection by pressing , settings are not accepted.
Measurement menu
Main menu
254.5
100
T325-3
Possible measurement parameters
Temperature °C, °F
Gas ppm, mg/m3
Draught/Pressure hPa, mbar, mmH2O
DRAFT
UNITES
TEMP
DAT/TIME
∆T

Condensate trap
Changing filters
The filter must be exchanged if dirt particles can be seen.
To do this, unlock the condensate trap and remove from housing.
Remove the filter and replace with a new one. Order spare filter
(Part no. 0554.0040).
Only this filter should be used.
A tightness test should be carried out every time a filter is
changed (See page 3).
The max. level in the condensate trap should not be exceeded.
Remove the emptying plugs to empty the condensate trap.
Remove empty/defect rechargeable battery or empty battery from
the battery compartment and replace with new rechargeable
batteries or batteries.
Warning
Observe the correct polarity of the rechargeable
batteries/batteries
Switch off analyser before changing battery or
rechargeable battery.
Complete change in 1 -2 minutes or plug in mains
unit.
The set date/time may otherwise be lost.
Empty the condensate trap
before changing filter.
14
Maintenance
Changing rechargeable batteries or batteries
Filter
Max. level
indicator
Condensate
emptying
1
2
3
4
max
max

15
Maintenance
Flue gas probe
Cleaning the flue gas probe if the gas path is clogged
Remove the probe stem and place in hot water. Move about in
hot water. Blow air through pipe or clean with a round brush (e.g.
made of brass).
Changing a defect thermocouple
Pull out the bending protection spring from the guide at the back
outlet with a counterclockwise movement and pull out the tube
to the left. Pull out the thermocouple by the tube.
Lever the thermocouple out of the handle with the aid of a
screwdriver.
Remove the bending protection spring and take the tube out of
the holder in the handle and out of the slit. Push the bending
protection spring over the new thermocouple.
When inserting the new thermocouple do not press on the
thermocouple tube. Press it into place with the help of a small
screwdriver.
Only remove the thermocouple if it is defect. The
thermocouple may be damaged when pulled out by the
connection tube.
testoterm
testoterm
testoterm
testoterm
Cleaning the flue gas pump
Open the housing on the measuring instrument (See page 16,
Items 1 - 8).
- Take out the pump carefully.
- Insert “Pump Tool” in the pump head guides.
- Take off “Pump Tool” together with the pump head.
- Remove diaphragm holder from pump head and take out
diaphragm.
- Clean pump diaphragm, pump plate and pump head with
spirit or water.
- Place pump diaphragm in the diaphragm holder and insert in
the pump head
- Place pump head on pump.
- Remove “Pump Tool”.
- Place pump in assembly block.
- Reassemble measuring instrument (see page 17).
PUMP
TOOL
Pump
Part no.
(0239.0015)
Pump plate
Pump head
Pump Tool
Pump Tool
(Part no.
0192.0468)
Diaphragm
0193.0072
Diaphragm
holder

Reduce electric charge in your own body before touching the
electronics.
Avoid contact with electronic parts.
Maintenance
16
Battery compartment
cover
Condensate trap
Positioning
plate
Measurement
chamber
CO
measurement
cell
Fastening screws
NO filter
Filter
Mounting block
Measurement chamber cover
Board
Holder screws
Changing CO measurement cells
1.) Remove temperature probe and hose connector of the flue
gas probe and the mains unit from the testo 325.
2.) Empty condensate trap before removing it.
3.) Unlock the condensate trap and remove from housing
(See page 14).
4.)Remove filter insert (See page 14).
5.) Remove positioning plate using a screwdriver.
6.) Open battery compartment and remove
batteries/rechargeables (See page 14).
7.) The testo 325 housing is opened by moving the housing
parts in the direction of the arrows (See diagram).
8.) Remove bottom part of housing.
9.) Release holder screws (See diagram).
10.) Remove the mounting block with the
electronics from the top of the housing
(see below).
11.) Remove mounting block from the board.
12.) Release fastening screws (3 off) on
measurement chamber cover. Remove
cover.
Positioning plate
Lower housing section
Upper part of housing
Holding screws

17
Changing the CO measurement cell
Before installing the new CO measuring cell, carefully
remove the short-circuit spring from the contacts.
- Remove measurement cell from measurement chamber cover
and attach the new measuring cell.
Assembling testo 325
- Place the measurement chamber cover on the measurement
chamber. Tighten the fastening screws (3 off).
- Connect the mounting block with the electronics.
- Place the mounting block and electronics in the upper part of
the housing.
- Attach the mounting block and the electronics to the upper
part of the housing with the holder screws (2 off).
- Put upper part of housing in position and close in the opposite
direction to the arrow.
- Insert positioning plate and filter.
- Insert condensate trap. Ensure that it snaps into position.
- Put batteries/rechargeables into place and close battery
compartment cover.
- Remove the NO filter from the measurement chamber. When
installing the new filter ensure that the area with the bore holes
faces downward in the measurement chamber.
Maintenance
Changing CO measurement cells
When changing a CO measurement cell the NO filter should
also be replaced.
Short.circuit spring
CO measuring cell

Inputting CO cell coefficient
The CO cell coefficient is written on the sheet enclosed with the
spare CO measurement cell.
Once the coefficient has been entered and confirmed via
the system then goes to the initialisation phase.
During the calibration phase you can go to the initialisation phase
anytime by pressing the button twice.
and must be pressed simultaneously within 3
seconds during the capacity display.
Recalibration is available from Testo service
points, subsidiaries and agencies.
18
Maintenance
Changing CO measurement cells
CO-COEFF
CO-COEFF
°C
32.18
25.8
Select number
position
Increase
number
value
Reduce
number
value
3 s
<3 s
USA V 13
6.0
and
press simultaneously
Main menu
Initialisation phase
Battery
capacity
3 s
43
You will receive false readings
if the calibration phase is interrupted

Error message
Error messages during measurement
Symbols are flashing
CO, and are flashing
During the initialisation phase
CO is flashing
Before switching off
CO are flashing
19
Error messages
Cause / Remedy
1. Flue gas temperature probe not
connected.
2. Temperature probe is not connected properly.
Flue gas temperature and its calculated values are
not measured, the remaining values are listed.
Check the temperature probe connection or insert
new temperature probe.
Admissible operating temperature has been
exceeded. The ambient air changes to non-
permissible values. Adapt to ambient air
temperature.
Measurement of the zero point is not stable. Let
the initialising phase run several times. If this is not
successful, the CO measurement cell is probably
defect.
There is still flue gas in the analyser or very high
concentrations were measured or the initialising
phase is taking longer.
Cause: Insufficient air was rinsed through after the
last measurement or the probe is in the flue gas.
→Probe should be brought into contact with
fresh air. If there is still no change after several
runs of the initialising mode the cell is probably
defect or the cell is used up.
The analyser supply voltage is too low.
Recharge rechargeable/battery or connect to
mains.
LOW BAT

testo 325
Temperature measurement
Measurement range: -40 to +600 °C
Resolution: 0.1 °C
Accuracy: ±0.5 °C (0 to +99.9 °C)
±0.5 % of m.v. (from +100 °C)
Sensor: Thermocouple Type K
(NiCr-Ni) to DIN IEC 584
Part 2, Class 1
Draught/pressure measurement
Measurement range: ± 40 mbar
Resolution: 0.01 mbar
Accuracy: < 3.00 mbar ± 0.03 mbar
> 3.00 mbar ± 1.5% of m.v.
Max. overload: 1000 mbar
CO measurement
Measurement range: 0 to 2000 ppm
Accuracy: ± 20 ppm (to 400 ppm)
± 5 % of m.v.
H2level: < 10%
Resolution: 1 ppm
Response time t90:Max. 60 s, typically 40 s
Weight: 500g
Dimensions: 216 x 68 x 47 mm
Transport/
storage temperature: -20 to +50 °C
Ambient temp. -5 to +45 °C
Power supply: Via plug-in mains unit, batteries
or exchangeable rechargeable
batteries
Warrany
nstrument: 2 years
Probes: 1 year
Accessories 6 months
CO measuring cell 6 months
Printer 1 year (excluding printing
mechanism )
Technical data
20