TESTO 335 User manual

Instruction manual en
testo 335
Flue gas analyser

General notes
Please read this documentation through carefully and familiarise yourself with the opera-
tion of the product before putting it to use. Keep this document to hand so that you can
refer to it when necessary.
This document describes the country-specific version GB of the testo 335 measuring
instrument.
Identification
Symbol Meaning Comments
Warning advice: Warning! Read the warning advice carefully and
Serious physical injury could be caused if the specified take the specified precautionary measures!
precautionary measures are not taken.
Warning advice: Caution! Read the warning advice carefully and
Slight physical injury or damage to equipment could take the specified precautionary measures!
occur if the specified precautionary measures are not
taken.
Important note. Please take particular notice.
Text Text appears on the instrument's display -
Key Press the key.
Function key with the function “OK”. Press function key.
xyz Short form for operating steps. See Short form ,p.3.
OK
General notes
2

Short form
This document uses a short form for describing steps
(e.g. calling up a function).
Example: Calling up the Flue gas function
Short form: Measurements Flue gas 
(1) (2) (3) (4) (5)
Steps required:
1Open the Main menu: .
2Select Measurements menu: , .
3Confirm selection: .
4Select Flue gas menu: , .
5Confirm selection: .
OK
OK
OKOK
General notes 3

Content
See also Functional overview , p. 60.
General notes ........................................................................................2
Content ..................................................................................................4
A. Safety advice..........................................................................................7
B. Intended purpose ..................................................................................8
C. Product description ..............................................................................9
C.1 Measuring instrument ....................................................................9
C.1.1 Overview ....................................................................................9
C.1.2 Keypad ....................................................................................10
C.1.3 Display......................................................................................10
C.1.4 Instrument connections ............................................................11
C.1.5 Interfaces..................................................................................12
C.1.6 Components ............................................................................12
C.1.7 Carrying strap ..........................................................................13
C.2 Modular flue gas probe ................................................................13
D. Commissioning ....................................................................................14
E. Operation..............................................................................................15
E.1 Mains unit/rechargeable battery....................................................15
E.1.1 Changing the battery ................................................................15
E.1.2 Charging batteries ....................................................................16
E.1.3 Operation with the mains unit....................................................16
E.2 Probes/sensors ............................................................................17
E.2.1 Connecting probes/sensors ......................................................17
E.2.2 Replacing the probe module ....................................................18
E.3 Regular care ................................................................................18
E.3.1 Condensate trap ......................................................................18
E.3.2 Checking/replacing the particle filter..........................................19
Content
4

E.4 Basic operating steps ..................................................................20
E.4.1 Switching the measuring instrument on ....................................20
E.4.2 Calling up the function ............................................................20
E.4.3 Entering values ........................................................................21
E.4.4 Printing data ............................................................................22
E.4.5 Saving data ..............................................................................22
E.4.6 Confirming an error message ....................................................22
E.4.7 Switching the measuring instrument off ....................................22
E.5 Memory........................................................................................23
E.5.1 Folders......................................................................................23
E.5.2 Location....................................................................................24
E.5.3 Protocols ..................................................................................26
E.5.4 Extras Memory..........................................................................26
E.6 Instrument diagnosis ....................................................................27
F. Configuration........................................................................................28
F.1 Instrument settings ......................................................................28
F.1.1 Display edit ..............................................................................28
F.1.2 Printer ......................................................................................29
F.1.3 Start keys edit ..........................................................................30
F.1.4 AutoOff ....................................................................................30
F.1.5 Date / Time ..............................................................................31
F.1.6 Language..................................................................................31
F.2 Sensor settings ............................................................................32
F.3 Fuels ............................................................................................35
G. Measuring ............................................................................................36
G.1 Preparing measurements..............................................................36
G.1.1 Zeroing phases ........................................................................36
G.1.2 Using the modular flue gas probe..............................................37
G.1.3 Configuring the reading display ................................................37
G.2 Measurements..............................................................................38
G.2.1 Flue gas, Flue gas + m/s, Flue gas + ∆p2 ................................38
G.2.2 Program....................................................................................39
G.2.3 Draught ....................................................................................40
G.2.4 Smoke# /HCT ..........................................................................41
G.2.5 Gas flow rate ............................................................................41
G.2.6 Oil flow rate ..............................................................................42
G.2.7 m/s ..........................................................................................42
G.2.8 ∆p2 ..........................................................................................43
G.2.9 Burner control ..........................................................................44
Content 5

H. Transferring data ..................................................................................46
H.1 Protocol printer ............................................................................46
H.2 PC / Pocket PC............................................................................46
I. Care and maintenance ........................................................................47
I.1 Cleaning the measuring instrument ..............................................47
I.2 Replacing measuring cells ............................................................47
I.3 Recalibrating measuring cells........................................................48
I.4 Replacing additional filter..............................................................48
I.5 Cleaning the modular flue gas probe ............................................49
I.6 Replacing probe preliminary filter ..................................................49
I.7 Replacing thermocouple ..............................................................49
J. Questions and answers ......................................................................50
K. Technical data ......................................................................................51
K.1 Standards and tests ....................................................................51
K.2 Measuring ranges and accuracies ................................................51
K.3 Other instrument data ..................................................................53
K.4 Principles of calculation ................................................................54
K.4.1 Fuel parameters........................................................................54
K.4.2 Calculation formulae..................................................................54
K.5 Recommended rinsing times ........................................................57
L. Accessories/spare parts ......................................................................58
Functional overview ............................................................................60
Content
6

A. Safety advice
Avoid electrical hazards:
Never use the measuring instrument and probes to measure on or near live parts!
Protect the measuring instrument:
Never store the measuring instrument/measuring cells together with solvents
(e.g. acetone). Do not use any desiccants.
Product safety/ preserving warranty claims:
Operate the measuring instrument only within the parameters specified in the Techni-
cal data.
Handle the measuring instrument properly and according to its intended purpose.
Never apply force!
Temperatures given on probes/sensors relate only to the measuring range of the
sensors. Do not expose handles and feed lines to any temperatures in excess of
70 °C unless they are expressly permitted for higher temperatures.
Open the measuring instrument only when this is expressly described in the instruc-
tion manual for maintenance purposes.
Carry out only the maintenance and repair work that is described in the instruction
manual. Follow the prescribed steps exactly. For safety reasons, use only original
spare parts from Testo.
Any additional work must only be carried out by authorised personnel. Testo will
otherwise refuse to accept responsibility for the proper functioning of the measuring
instrument after repair and for the validity of certifications.
Ensure correct disposal:
Dispose of defective rechargeable batteries and spent batteries at the collection
points provided for that purpose.
Send the measuring instrument directly to us at the end of its useful life. We will
ensure that it is disposed of in an environmentally friendly manner.
A. Safety advice 7

B. Intended purpose
This chapter describes the areas of application for which the measuring instrument is
intended.
The testo 335 is a handheld measuring instrument used in professional flue gas analysis
for:
· Engineers servicing/monitoring industrial combustion plants (process systems, power
stations)
· Emissions inspectors
· Engine manufacturers and operators
· Service engineers/mechanics of burner/boiler manufacturers in the industrial sector
Typical measuring tasks and particular characteristics of the testo 335 include:
· Measurement on engines of all kinds (CO/NO dilution)
· Measurement on gas turbines (high precision CO and NO plus optional dilution)
· Emissions measurement (integrated flow speed and real moisture content
measurement)
testo 333 should not be used:
· for continuous measurements
· as a safety (alarm) instrument
B. Intended purpose
8

C. Product description
This chapter provides an overview of the individual components of the product.
C.1 Measuring instrument
C.1.1 Overview
On/Off button
Interfaces: USB, PS2, infrared
Do not point infrared beam at
people's eyes!
Condensate trap (on rear)
Fixing eyelet for carrying strap (left and
right)
Display
Magnetic holders (on rear)
Strong magnets
Damage ttooother iinstruments!
Keep well away from
products which could be
damaged through the
effects of magnetism (e.g.
monitors, computers, heart
pacemakers, credit cards).
Keypad
Service cover (on rear)
Gas outlet
Instrument connections: flue gas probe,
sensor, pressure probe, mains unit
Placeholder:
Pbersicht.tif
C. Product description
C.1 Measuring instrument 9











C.1.2 Keypad
Key Functions
Switch measuring instrument on/off
Function key (orange, 3x), relevant function is shown on the display
Scroll up, increase value
Scroll down, reduce value
Back, cancel function
Open Main menu: press briefly (changed settigs are stored, measurement values are carried over into the menu
Flue gas); open Measurements menu: press and hold down for 2s (changed settigs are stored, measurement
values are carried over into the menu Flue gas)
Open Inst’ diagnosis menu
Change display light: display light stays on permanently or display light is switched on for 10s every time the key
is pressed.
C.1.3 Display
Depending on the menu that is active, the display shows a variety of elements.
Header (active in all views)
Warning symbol (only if there is a device error;
device errors are displayed in the Inst’ diagnosis menu).
Active folder and location.
Power supply symbol:
Symbol Characteristic Symbol Characteristic
Mains operation Rech. battery operation, capacity: 26-50%
Rech. battery operation, capacity: 76-100% Rech. battery operation, capacity: 6-25%
Rech. battery operation, capacity: 51-75% Rech. battery operation, capacity: 0-5%
Function select view
Active menu, activated fuel
Function selection field:
The selected function has a grey background.
Unavailable functions are written in grey type
Scroll bar
Function keys for entering commands
C. Product description
C.1 Measuring instrument
10






Settings view
Active menu
Function fields for entering commands
Scroll bar
Selection field for adjustable values:
The selected value is shown with a grey
background. Unavailable values are written in grey
type.
Function keys for entering commands
Measuring view
Active menu, depending on the selected function:
Additional information (e.g. activated fuel, date and
time)
Scroll bar
Display field for readings, parameters
Function keys for entering commands
C.1.4 Instrument connections
Sensor socket
Flue gas socket
Mains unit socket
Pressure socket p+ (can only be used with the
option "Pressure/flow speed measurement")
Pressure socket p- (can only be used with the
option "Pressure/flow speed measurement")
C. Product description
C.1 Measuring instrument 11







 





C.1.5 Interfaces
USB interface:
connection to PC
PS2 interface:
Adapter for automatic furnaces
Infrared interface (IrDA):
connection to Testo-printers/Pocket PC
C.1.6 Components
Rechargeable battery
Measuring gas pump
Measuring cells - slot 2: CO, NO2, SO2
Measuring cells - slot 1: O2
Measuring cells - slot 3: NO, SO2
Additional filter
C. Product description
C.1 Measuring instrument
12






 

C.1.7 Carrying strap
To secure the carrying strap:
1Remove sealing caps from the sides of the
housing.
Fix ssealing ccaps oontthe iinside ooftthe sservice ccover:
1 Place the measuring instrument on its front.
2 Pick the service cover up at the markings
(arrows) using your index finger and thumb and
press gently to release the lock.
3 Lift the service cover up and remove.
4 Secure the sealing caps in the two holders on
the inside of the service cover ().
5 Fit the service cover and clip into place.
2Engage the carrying strap clip in the fixing eyelets
on the side of the device. Note the guide groove.
The strap must point "down" ().
C.2 Modular flue gas probe
Removable filter chamber with window and particle
filter
Probe handle
Connecting lead
Connecting plug for measuring instrument
Probe module release
Probe module
Placeholder:
Abgassonde.tif
Placeholder:
Halterung_Verschluss-
stopfen.tif
Tragegurt.tif
C. Product description
C.1 Measuring instrument 13









D. Commissioning
This chapter describes the steps required to commission the product.
Remove the protective film from the display.
The measuring instrument is supplied with a rechargeable battery already fitted.
Charge the rechargeable battery up fully before using the measuring instrument
(see
Charging batteries , p. 16).
D. Commissioning
14

E. Operation
This chapter describes the steps that have to be executed frequently when using the
product.
Please read this chapter carefully. The following chapters of this document will
assume you are already familiar with the content of this chapter.
E.1 Mains unit/rechargeable battery
If the mains unit is connected, the measuring instrument is automatically powered from
the mains unit. It is not possible to charge the rechargeable battery in the measuring
instrument during operation.
E.1.1 Changing the battery
The measuring instrument must not be connected to a mains socket via the mains
unit. The measuring instrument must be switched off. Change the rechargeable bat-
tery within 60 minutes, otherwise instrument settings (e.g. date/time) will be lost.
1Place the measuring instrument on its front.
2Remove the service cover: Take hold of it at the
markings (arrows) using the index finger and
thumb, press slightly, fold up and remove.
3Open the rechargeable battery compartment:
Press the orange key and push in the direction of
the arrow.
4Remove the rechargeable battery and insert a new
one. Use only Testo 0515 0100 rechargeable bat-
teries!
5Close the rechargeable battery compartment:
Press the orange key and push against the direc-
tion of the arrow until the rechargeable battery
engages.
6Fit the service cover and clip into place.
E. Operation
E.1 Mains unit/rechargeable battery 15

E.1.2 Charging batteries
The rechargeable battery can only be charged at an ambient temperature of ±0...+35°C.
If the rechargeable battery has discharged completely, the charging time at room tem-
perature is approx. 5-6 hrs.
Charging in the measuring instrument
The measuring instrument must be switched off.
1Connect the plug of the mains unit to the mains unit socket on the measuring instru-
ment.
2Connect the mains plug of the mains unit to a mains socket.
- The charging process will start. The charge status will be shown on the display.
The charging process will stop automatically when the rechargeable battery is fully
charged.
Charging in the charger (0554 1087)
Refer to the documentation that comes with the charger.
Battery care
If possible, always discharge the rechargeable battery and recharge it fully.
Do not store the battery for long periods when discharged. (The best storage condi-
tions are at 50-80 % charge level and 10-20 °C ambient temperature; charge fully
before further use).
E.1.3 Operation with the mains unit
1Connect the plug of the mains unit to the mains unit socket on the measuring instru-
ment.
2Connect the mains plug of the mains unit to a mains socket.
- The measuring instrument is powered via the mains unit.
- If the measuring instrument is switched off and a rechargeable battery is inserted, the
charging process will start automatically. Switching the measuring instrument on has
the effect of stopping rechargeable battery charging and the measuring instrument is
then powered via the mains unit.
E. Operation
E.1 Mains unit/rechargeable battery
16

E.2 Probes/sensors
E.2.1 Connecting probes/sensors
Sensor ssocket:
Sensor detection is carried out at the sensor socket during the activation process:
Always connect the sensors you need to the measuring instrument before switching
it on or switch the device on and then off again after a change of sensor so that the
correct sensor data are read into the measuring instrument.
Flue ggas ssocket:
Probe/sensor detection at the flue gas socket is carried out continuously. It is possi-
ble to change the probe/sensor even while the measuring instrument is switched on.
Connecting flue gas probes
Plug the connector onto the flue gas socket and
lock by turning it clockwise gently (bayonet lock).
There must be no more than two extension leads
(0554 1201) between the measuring instrument
and the flue gas probe.
Connecting other sensors
Insert the connector of the sensor into the sensor
socket.
Connecting the pressure tube
Pressure sockets p+ and p- can only be used with
instruments offering the "Pressure/flow speed meas-
urement" option.
Connect the pressure tube/tubes to the connect-
ing nipple/nipples of the pressure socket(s).
B. Operation
E.2 Probes/sensors 17

E.2.2 Replacing the probe module
1Press the key on the top of the probe handle and
remove the probe module.
2Fit a new probe module and engage it in place.
E.3 Regular care
E.3.1 Condensate trap
The fill level of the condensate trap can be read from the markings on the trap. A warn-
ing message is displayed if the level in the condensate trap reaches 90% ( , red flash-
ing light).
Emptying the condensate trap
The condensate consists of a weak mix of acids. Avoid contact with the skin. Make
sure that the condensate does not run over the housing.
Condensate entering the gas path.
Damage ttotthe mmeasuring ccells aand fflue ggas ppump!
Do not empty the condensate trap while the flue gas pump is in
operation.
1Hold the measuring instrument so that the
condensate outlet points up.
2Open the condensate outlet of the condensate
trap: Push out approx. 5 mm to the stop ().
3Let the condensate run out into a sink ().
4Mop up any remaining drops on the condensate
outlet using a cloth.
5Close the condensate outlet.
The condensate outlet must be completely closed
(marking), otherwise measuring errors could occur
if external air gets in.
Placeholder:
Kondensatfalle_oeffnen.tif
Kondensatfalle_leeren.tif
E. Operation
E.2 Probes/sensors
18



E.3.2 Checking/replacing the particle filter
Checking the particle filter:
Check the particle filter of the modular flue gas
probe for contamination at regular intervals: Check
visually by looking through the window of the filter
chamber.
Replace the filter if there are signs of contamination
Replacing the particle filter:
The filter chamber may contain condensate
1Open the filter chamber by turning it gently
anticlockwise.
2Remove the filter plate and replace it with a new
one (0554 3385).
3Fit the filter chamber again and close it by turning it
gently clockwise.
E. Operation
E.3 Regular care 19

E.4 Basic operating steps
E.4.1 Switching the measuring instrument on
.
- The start screen is displayed (for about 5 s).
- Display light is switched on for 10 s.
Option:
To go directly to a measurement while the start screen is being displayed, press
the function key for the desired measurement. See also
Start keys edit , p. 30.
- The Measurements menu is opened.
-oor-
- If the power supply was interrupted for a longer period: the Date/Time menu is
opened.
-oor-
- There is a device error: The Error diagnosis is displayed.
E.4.2 Calling up the function
Functions which cannot be selected because the required sensor/probe is not con-
nected are shown in grey type.
1Select function: , .
- The selected function is shown with a grey background.
2Confirm selection: .
- The selected function is opened.
OK
E. Operation
E.4 Basic operating steps
20