TESTO 325M User manual

Instruction manual en
testo 325 M/XL
Flue gas analyser

Preface / Copyright
2
Preface
Dear Customer
Thank you for purchasing a Testo product. We hope you will
enjoy the benefits of this product for a long time to come and
that it will aid you with your work.
Please read this instruction manual carefully and familiarise
yourself with the operation of the instrument before putting it to
use.
If problems should occur which you cannot rectify yourself,
please consult our Customer Service Department or your
nearest distributor. We will do our best to help you quickly and
competently to reduce downtimes.
Copyright
This documentation is subject to the copyright of Testo AG.
Reproduction and use contrary to the legitimate interests of
Testo AG are prohibited without the prior, written consent of the
company.
We reserve the right to modify technical details from the
descriptions, specifications and illustrations contained in this
documentation.
Testo AG
Postfach 11 40
D-79849 Lenzkirch

General Information
Symbols
Incorrect operation of this instrument could lead to danger. Particularly important information, which
has to be observed when working with this product, is highlighted in this instruction manual as
follows:
Warnings are highlighted by a warning triangle. The Warning title indicates the danger level:
Warning! means death or serious physical injury may occur if the specified safety
measures are not carried out.
Caution! means minor physical injury or damage to property may occur if the specified
safety measures are not carried out.
Read all the warnings carefully and carry out all the specified safety measures to avoid
danger.
Notes on special cases and peculiarities in the handling of your unit are indicated by an
exclamation mark.
Standards/tests
The conformity certificate confirms that this product fulfills the guidelines in accordance with
89 / 336 / EEC.
This product is TÜV approved.
Test Code Number: testo 325 M: TÜV By RgG 218
testo 325 XL: TÜV By RgG 222
3
Warning title

Contents
4
Preface / Copyright............................................2
General information ..........................................3
Contents............................................................4
1. Basic safety instructions ..................................6
2. Intended use ....................................................7
3. Product description ..........................................8
3.1 Power supply ................................................................8
3.2 Dispaly and control elements ......................................8
3.3 Menu overview ..........................................................10
3.4 Gas path ....................................................................10
4. Initial operation................................................11
4.1 Putting in rechargeable batteries / batteries ..............11
4.2 Connecting the mains unit..........................................11
4.3 Connecting sensors / probes ....................................11
5. Basic instructions............................................12
5.1 Switching on ..............................................................12
5.2 Selecting menu items ................................................12
5.3 Measuring ambient air temperature ..........................12
5.4 Measuring flue gas temperature ................................13
5.5 Regular maintenance ................................................13
5.6 Switching off ..............................................................14
6. Settings ..........................................................15
6.1 Selecting fuel..............................................................15
6.2 Setting display sequence ..........................................15
6.3 Selecting units............................................................16
6.4 Setting date/time ........................................................16
7. Measuring ......................................................18
7.1 Measuring flue gases ................................................17
7.2 Measuring pressure....................................................17
7.3 Measuring differential temperature ............................18
7.4 Measuring undiluted CO ............................................19
7.5 Measuring ambient CO ..............................................19
7.6 Printing readings taken ..............................................20
7.7 Saving/reading/deleting readings ..............................21
7.8 Printing saved readings..............................................22

Contents
8. Maintenance ..................................................23
8.1 Changing rechargeable batteries/batteries ................23
8.2 Emptying the condensate trap ..................................23
8.3 Changing the filter ......................................................24
8.4 Cleaning the analyser ................................................24
8.5 Cleaning the flue gas probe ......................................24
8.6 Changing the thermocouple ......................................25
8.7 Cleaning the flue gas pump ......................................25
8.8 Changing the measuring cells....................................26
9. Troubleshooting ..............................................29
10. Technical data ................................................31
10.1 Measuring ranges and accuracies ............................31
10.2 Other instrument data ................................................32
10.3 Calculation fundamentals ..........................................32
10.4 Calculation formulae ..................................................33
11. Accessories / Spare parts................................34
Short instructions............................................35
5

1. Basic safety instructions
6
Avoid electrical hazards:
Never make measurements with the unit and its external probes on or near live components
unless the unit is expressly approved for current and voltage mesurements.
Use only the supplied power supply unit when using the instrument under mains power.
Allow only authorised persons to replace damaged mains cables.
Protect the unit/measuring cells:
Never store the unit together with solvents (e.g. acetone).
The condensate trap should be emptied once the maximum line has been reached. Switch off the
pump to empty.
Measure correctly:
Prior to every measurement, check the complete measurement system (probe, condensate trap,
hoses and connections) for leaks in order to avoid incorrect measurements caused by the intake
of air.
Ensure that the gas output in the instrument is always free of obstacles so that the sample gas
can escape unhindered.
Preserve product safety/warranty entitlement:
Operate the instrument only within the parameters specified in the technical data.
Please handle the instrument with care.
Force should never be applied.
The temperature data for the probes only refer to the sensor measuring range. Never subject
handles or pipes to temperatures greater than 70°C unless they are expressly approved for higher
temperatures.
The instrument should only be opened for maintenance and repair work if expressly described in
the Instruction manual.
Only carry out the maintenance and repair work described in the Instruction manual. Please follow
instructions. For safety reasons, only original spare parts from Testo should be used.
Any other work should only be carried out by authorised trained personnel. Otherwise
responsibility for the perfect functioning of the instrument following repairs and for the validity of
approvals will be denied by Testo.
Ensure correct disposal:
The measuring cells contain low concentrations of alkaline solutions and acids. Please dispose of
carefully.
Dispose of defective rechargeable batteries and spent batteries responsibly.
You can return your instrument directly to us at the end of its service life. We will dispose of it
responsibly.

2. Intended use
Employ the analyser for the following applications only:
testo 325 M / XL is a hand-held instrument for the professional
analysis of flue gas in burners:
- Small-scale burners (oil, gas, wood)
- Low temperature and condensing boilers
- Gas heaters
These systems can be adjusted using testo 325 M / XL and
checked for their adherence to valid limit valids.
testo 325 M / XL can be used to carry out the following tasks:
- Adjustment of O2, CO and CO2values in burners in order to
guarantee smooth operation
- Measurement and adjustment of gas flow pressure in gas
heaters
- Measurement and adjustment of flow and return temperatures
in heating systems
7

3.1 Power supply
testo 325 M / XL can be powered as follows:
- 4 batteries (1.5V round cell alkaline IEC LR6 Type AA)
- 4 rechargeable batteries (1.5V IEC KR 15/51 corresp. Type AA)
- Mains connection via mains unit (Part no. 0554 1084)
- Rechargeable battery pack (testo 325 XL only)
3.2 Display and control elements
Display
3. Product description
8
Time
Print
Battery capacity
Flue gas temperature
Ambient air
temperature
Temperature
measurement
Date Fuel name/
menu item
Parameters
Measuring units
Pump on
Readings
Save
Battery capacity
A warning flashes in the display if the battery is running low
during rechargeable batttery/battery operation:
Remaining capacity is then approx. 1 hour for batteries, approx.
1 hour for rechargeable batteries
The instrument switches itself off automatically when the
rechargeable battery/battery capacity is too low, in order to
protect from total discharge.
Parameters

3. Product description
Keyboard
➀Start/stop flue gas pump
➁Select display, select menu items
➂Switch analyser on/off
➃Interrupt operation, return to superior menu level
➄Open main menu / sub-menu / menu item, confirm selection
➅Select parameters
➆Print current readings
➇Switch display light on/off
Connections
➀Mains unit
➁Probes: ambient air temperature (AT) / temperature T2
➂Probes: flue gas temperature (FT) / temperature T1
➃Flue gas (red)
➄Pressure + (blue)
➅Pressure - (p-)
Other
➀Infrared interface (on front side)
➁Gas outlet
➂Battery compartment
➃Condensate trap
➄Filter (behind the condensate trap)
9
➂
➃
➁➇
➁
➅➄
➆
➀
➂
➃
➁
➄
➀
➅
➂
➃
➁
➄
➀

Memory 1
delta p
delta t
View
Fuel
Dat/Clk
Unit
co amb
co undil
3. Product description
10
3.4 Gas path
P
CO O2
p
testo 325
RGS
testoter
m
3.3 Menu overview
Nat gas
L oil
H oil
LPG
Butane 1
Coal 1
Measurement
view
Main menu
Pressure
Temperat
Gas
delta p1
delta p2
Line 1
Line 12
·
·
·
Measurement
menu Sub-menus
memory1
memory20
·
·
·
1(testo 325XL only)

4. Initial operation
4.1 Putting in rechargeable batteries /
batteries
testo 325XL:Insert and connect rechargeable battery pack. No
other steps are necessary.
testo 325M:4 batteries are included, please insert prior to
initial operation:
1Remove battery cover at rear of instrument.
2Insert batteries correctly (+/-).
3Close cover on battery compartment.
Refer to Chapter 6, Setting up on page 15 for information on
how to set date/time, fuel and measurement units.
4.2 Connecting the mains unit
Operation via mains unit (0554 1084) is also possible if the
rechargeable batteries/batteries are spent. It is normal for the
mains unit to heat up. If the temperature becomes too high
(e.g. due to a defect in the analyser), the mains unit is
protected from overheating by a thermal safety switch.
The rechargeable battery block in testo 325 XL is recharged
in the analyser when it is switched off and is connected to the
mains (battery symbol flashes during recharging, recharging
stops and battery symbol disappears when rechargeable
battery is full). Conventional rechargeable batteries cannot be
recharged in the analyser.
1Connect plug to analyser.
2Connect mains plug to mains.
4.3 Connecting sensors/probes
Flue gas probe (accessory)
1Connect hose for gas (red) to the socket marked by red.
2Connect hose for pressure (blue) to the pressure + socket
(blue).
3Connect flue gas temperature probe pipe to the FT socket.
Ambient air probe (accessory)
Connect ambient air probe pipe to the AT socket ➀.
11
➀

12
5. Basic instructions
5.1 Switching on
1Press to switch on analyser.
➀Display test: All segments in the display light up for approx.
5s.
➁The software version number and the power is displayed for
3s (rechargeable batteries / batteries: ,
mains unit: ---- ).
➂Zeroing phase: CAL lights up, pump runs for approximately
60s (remaining time is shown in display).
The flue gas probe must be located in fresh air during
zeroing!
In the case of error messages, refer to “Troubleshooting” on
page 28.
➃The set fuel flashes in the display
2Use or to select the required fuel and confirm
with .
➄Selected fuel now applies. The analyser changes to the
measurement menu and is ready to operate.
5.2 Selecting menu items
The pump stops automatically when the main menu is
opened.
1Open main menu using .
2Select required menu item via or and confirm via .
If sub-menu is available:
3Select required menu item via or and confirm via .
Press to go back one menu level.
➂➃
➁➀
➄

13
5. Basic instructions
5.3 Measuring ambient air temperature
There are 2 ways to measure the ambient air temperature:
1. Measurement using flue gas probe
If a separate ambient air probe is not connected, the
temperature measured by the flue gas probe thermocouple
during the zeroing phase is used as the ambient air temperature.
All dependent variables are calculated with this value. This type
of ambient air temperature measurement is sufficient for systems
dependent on ambient air.
Ensure that the flue gas probe is located near the intake duct
of the burner during the zeroing phase.
2. Measurement using separate probe
If a separate ambient air probe is connected, the ambient air
temperature is measured continuously by this probe.
5.4 Measuring flue gas temperature
The flue gas temperature is measured via the flue gas probe
thermocouple. The probe pipe has openings at the side so that
the thermocouple is protected and can simultaneously come into
contact with the flue gas.
Ensure that the thermocouple is positioned in the flue gas
flow.
The thermocouple should not be covered by the probe stem
frame. This is the only way to make it possible to measure the
flue gas temperature accurately and consequently to determine
the exact flue gas loss.
The tip of the thermocouple should not touch the protective
casing!
If possible, bend back the tip of the thermocouple.
Inserting probe pipe in flue gas duct
Insert flue gas probe pipe, horizontally if possible, in the
flue gas duct.
Condensation drops running down the probe pipe could lead to a
dramatic drop in the temperature measured.

5.5 Regular maintenance
Check the level in the condensate trap
Condensate trap overflowing
Damage to pump and measuring cells
Check the level in the condensate trap prior to every
measurement: Hold the instrument horizontally or
vertically. The condensate trap should be emptied once
the MAX level has been reached (See 8.2 Emptying the
condensate trap, P. 23)!
Check the state of the filter
Filter dirty
Damage to pump!
The state of the filter should be checked on a regular
basis: change the filter when clogged (See 8.3
Changing the filter, P.24).
Rinse measuring cells
The measuring cells should be rinsed with fresh air after each
measurement :
1Remove flue gas probe from flue gas duct.
2Start pump using .
3Wait until the O2level is above 20.0% and the CO level is
below 50ppm.
4Press to stop pump.
You will find more information about servicing and maintaining
your analyser in Chapter 8. Maintenance, P.23!
5.6 Switching off
The readings stored in the instrument are lost when the
analyser is switched off.
In the case of error messages, refer to “Troubleshooting” on
page 29.
Switch off analyser using .
- The analyser automatically rinses the measuring cells if the
O2level drops below 20% or the CO level exceeds 50ppm ➀.
-OFF is displayed for 5s ➁(press to discontinue switch-
off), the analyser then switches off.
5. Basic instructions
14
➁➀
Caution
Caution

6. Settings
15
6.1 Selecting fuel
1Select Fuel in main menu ➀and confirm selection
using .
- The set fuel flashes in the display ➁.
2Select required fuel via or and confirm selection using
.
- Selected fuel is accepted and the analyser changes to the
measurement menu.
6.2 Setting display sequence
The sequence in which the parameters are shown in the display
can be selected as required. In this way, frequently used
parameters can be combined and then called up quickly
1Select View in the main menu and confirm selection
with .
-Line1 flashes in the display and the set parameters and units
for line 1 and 2 are shown.
2Use to select required parameter for line 1.
3Use to change to Line 2 and select required parameter
for line 2 with .
4Set up additional parameters for lines 3 to 12. Repeat
procedure as described in step 3.
5Confirm settings with .
- Selected settings are accepted and the analyser changes to
the measurement menu.
Selectable parameters:
O2Oxygen level
Flue gas temperature (FT)
Ambient air
temperature (AT)
Differential temperature
(FT - AT)
EFFNET Efficiency referred to Hu
EFFGROS Efficiency referred to Ho
rat Ratio
EAAExcess Air (EXA)
CO2Carbon dioxide
CO Carbon monoxide
uCO Carbon monoxide
undiluted
Air ratio
P1Pressure (0 to 40hPa)
P2Pressure (0 to 200hPa)
td Dew point 1
CO*CO maximum
CO CO ambient
1(testo 325XL only)
➁➀

16
6. Settings
6.3 Selecting units
1Select Unit in the main menu ➀and confirm
with .
-Pressure flashes and the set unit for pressure is shown in
the display ➁.
2Select required pressure unit using .
3Change to Temperat using and select required
temperature unit using .
4Change to GAS using and select required gas unit using
.
5Confirm settings using .
- Selected units are accepted and the analyser changes to the
measurement menu.
6.4 Setting date/time
1Select Dat/Clk in the main menu ➀and confirm selection
selection via .
- The set date is shown and “Day” flashes ➁.
2Set “Day” using or .
3Change to “Month” and “Year” using and set using or
respectively.
4Change to time setting via .
- The set time is shown and “Hour” flashes ➂.
5Set “Hour” via or .
6Use to change to “Minutes” and set via or
“Minutes”.
7Confirm selection via .
- Selected date and time are accepted and the analyser
changes to the measurement menu.
➀
➂
➁➀
➁

17
7. Measuring
Measurements are carried out with the flue gas probe unless
otherwise indicated.
7.1 Measuring flue gases
Select fuel (See: 6.1 Selecting fuel, P. 15).
1Insert flue gas probe pipe in the flue gas duct.
2Begin measurement by pressing .
- The pump starts, flashes and the current readings are
displayed ➀.
Use or to change between the different views.
3End measurement with .
- The pump stops and the last readings are retained in the
analyser until the next flue gas measurement.
7.2 Measuring pressure
With this function, you can measure the draught in a flue gas
channel or the flow pressure in gas heaters.
Draught is measured using the flue gas probe.
You will need the pressure set (Part no. 0554 0315) to
measure the gas flow pressure.
Please observe the following when measuring pressure:
It is only possible to measure pressure if the pump is
switched off.
When the pump is switched off, there is still a dynamic
pressure in the hose which first has to be reduced.
Wait approximately 30 s before starting to measure
pressure.
Remove any condensate in the flue gas probe prior to
measuring pressure (shake probe with tip pointing towards
the ground).
Hold flue gas probe in fresh air during the zeroing phase.
Do not change the position of the analyser while measuring
pressure.
Do not change between rechargeable battery/battery
operation and mains operation when measuring pressure;
fluctuations in the current could influence the measured
result.
Reading display: negative symbol stands for negative
pressure, positive sign stands for positive pressure.
➀

18
7. Measuring
Measuring draught
1Select Delta P in the main menu ➀and confirm selection
via .
2Select required pressure range:
Delta P1 ( 0 to 40hPa) or Delta P2 (0 to 200hPa) ➁.
3Confirm selection via .
- The analyser starts zeroing (duration: 5s), CAL lights up in the
display ➂.
4Once the zeroing phase is complete, insert the flue gas probe
pipe in the flue gas duct.
- The selected pressure range and the current reading are
displayed ➃.
5End measurement via .
- The last reading is retained in the analyser until the next
draught measurement.
Measuring gas flow pressure
Gas flow pressure is measured in the same way as draught is
measured. Please note the following:
The silicone hoses from the pressure set should only be
connected to the gas heater after the zeroing phase.
7.3 Measuring differential temperature
Use this function to measure the flow and return temperature in
heating systems.
You will need 2 pipe clamp probes (Part no. 0628 0020)
for the measurement.
1Connect probes to analyser.
2Select Delta t in the main menu ➀and confirm selection
via .
➁The temperature at the FT socket (T1) is shown in the top
reading line.
➂The temperature at the AT socket (T2) is shown in the bottom
reading line.
3End measurement with .
- The last reading is retained in the analyser until the next
differential temperature measurement.
➂➃
➀
➁
➀
➂
➁

19
7. Measuring
7.4 Measuring undiluted CO
Always carry out a COundiluted measurement prior to a
flue gas measurement because the values for O2, CO and
in the instrument are overwritten during a COundiluted
measurement.
1Select CO undil in the main menu ➀and confirm via .
- The pump starts automatically and the measured value for
undiluted CO (uCO) is shown ➁.
2End measurement via .
- The last reading is retained in the instrument until the next
COundiluted measurement.
7.5 Measuring ambient CO
Always carry out an ambient CO measurement before a
flue gas measurement since a value for CO, retained in
the analyser, will be written over when ambient CO is
measured.
Carry out zeroing in fresh air (preferably outdoors) prior to
measuring ambient CO.
1Select CO amb in the main menu ➀and confirm selection
with .
- The pump starts automatically and the measured value for
ambient CO ( ) is displayed.
2End measurement via .
- The last reading is retained in the analyser until the next
ambient CO measurement.
➁➀
➁➀
CO undil CO undil
CO amb CO amb

-----------------------
t325XL
-----------------------
30.06.2002 10:05:38
NAT GAS
FT 130.6 °C
O2 4,5 %
AT 26.6 °C
AmCO 150 ppm
dP 1 -0.50 hPa
CO2 12.1 %
1.27
CO 101 ppm
HCT: ______
SmoN: ______
-----------------------
# 00000000
-----------------------
20
7. Measuring
7.6 Printing readings taken
You will need the Testo printer 0554 0545 to print the
readings in the analyser. Follow the instructions in the printer
manual.
You will have to be in the measurement menu before you can
start printing and the pump must be switched off.
Start printing procedure by pressing .
- lights up and the following data is printed:
➀Header: Device name
➁Date / Time
➂Selected fuel
➃Parameters with corresponding reading and unit: the
printout is completed according to the display sequence
set in the instrument (See: 6.2 Setting display sequence,
P. 15), parameters which occur twice are only printed
once.
AmCO = ambient CO, COmx = CO*
➄HCT: / SmoN: Heat carrier temperature or smoke number
can be entered by hand
➅Serial number of instrument
➂
➃
➁
➅
➄
➀