Wohler A 450 User manual

The Measure of Technology
Operation Manual
Flue Gas Analyzer
Wohler A 450
Wohler A 450 L
.
Best.-Nr.24094 – 2018-07-25

Contents
2
Contents 1General Information..............................5
1.1 Operation Manual Information....................... 5
1.2 Notes............................................................. 5
1.3 Intended Use................................................. 5
1.4 Basic features ............................................... 6
1.5 Transport and stocking.................................. 6
1.6 Information on disposal................................. 7
1.7 Manufacturer................................................. 8
1.8 Important information .................................... 8
2Specifications........................................9
2.1 Readings....................................................... 9
2.2 Calculated Values....................................... 12
2.3 Technical Data............................................ 13
3Component Explanation ...................14
3.1 Probes, sensors and filters.......................... 16
3.2 Display ........................................................ 18
3.3 Gas sampling path Wohler A 450................ 19
4Getting started ....................................20
4.1 Activating the battery................................... 20
4.2 Tightness test.............................................. 20
4.3 Charging the battery.................................... 21
4.4 Connecting the flue gas probe .................... 22
5Using the Analyzer..............................23
5.1 Turning the analyzer on and off................... 23
5.2 Calibration................................................... 23
5.3 Measuring ................................................... 25
5.3.1 Readings screen......................................... 25
5.3.2 Selecting the fuel......................................... 27
5.3.3 Setting the fuel parameters......................... 27
5.3.4 Options........................................................ 28
6Readings Menu ...................................31
6.1 Delete data.................................................. 31

Contents
3
6.2 Print data.....................................................31
6.3 Save data in the customer menu.................32
6.4 Save data with the “Quick save” option ......33
7Menu ....................................................33
7.1 Device data..................................................34
7.2 Ambient CO.................................................35
7.3 Manifold Pressure........................................35
7.4 Temperature Measurement........................37
7.5 Tuning Guide...............................................38
7.6 SETUP.........................................................39
7.6.1 Option "Date"...............................................40
7.6.2 Option "Time"...............................................40
7.6.3 Option “Date format”....................................40
7.6.4 Option “Time format”....................................40
7.6.5 Option "Brightness"......................................40
7.6.6 Option "Buzzer" ...........................................40
7.6.7 WLAN configuration.....................................40
7.6.8 Option “Quick save”.....................................43
7.6.9 Option "Customer by"..................................43
7.6.10 Option "Device by".......................................43
7.6.11 NOx calculation ............................................43
7.6.12 Filter warning...............................................43
7.6.13 Signals.........................................................44
7.6.14 Customer Logo............................................44
7.7 Calibration ...................................................44
8Customer data ....................................45
8.1 Set up a new customer................................45
8.2 Save records................................................46
8.3 Search function : customer,device, customer
number, device number...............................47
8.4 New customer..............................................48
8.5 Delete customer...........................................48
8.6 Delete all......................................................48
9Data exchange with the PC...............48

Contents
4
10 Troubleshooting..................................48
11 Maintenance........................................49
11.1 Maintenance work....................................... 49
11.2 Removing condensate................................. 50
11.3 Changing the filters ..................................... 51
11.3.1 Cotton filter.................................................. 51
11.3.2 Water stop filter........................................... 51
11.4 Sensor diagnosis and replacement............. 52
11.5 Replacing the battery .................................. 59
11.5.1 Replacing the battery .................................. 59
12 Six-monthly check..............................60
13 Guaranty and Service.........................61
14 Declaration of conformity ..................62
15 Accessories.........................................63

General Information
5
1 General Information
1.1 Operation Manual In-
formation
This operation manual allows you to work safely
with the Wohler A 450. Please keep this manual
for your information.
The Wohler A 450 should be employed by profes-
sionals for its intended use only.
Liability is void for any damages caused by not
following this manual.
1.2 Notes
WARNING!
Not following this warning can cause injury or
death.
ATTENTION!
Not following this note can cause permanent
damage to the device.
NOTE!
Useful information
1.3 Intended Use
Use the Wohler A 450 for flue gas analysis and
control of heating appliances and for the meas-
urement of wood moisture.
The analyzer should be used indoors only.
The Wohler A 450 is not suitable for continuous
operation.
It takes about 3 minutes to take a typical meas-
urement.

General Information
6
1.4 Basic features
Device
Basic equipment
Wohler A 450 with
WiFi. USB- and IR
port
Probe and hose as-
sembly with 1,5 m
hose
Ambient Temperature
Probe
Charger with micro-
USB-cable
Li-Ion Battery
1.5 Transport and stocking
ATTENTION!
Improper transport can harm the instrument.
Always transport the analyzer in the provided car-
rying case in order to prevent damage.

General Information
7
Fig.
1: Transport lock
at the bottom of the
analyzer
ATTENTION!
For the transport deactivate the battery with the
transport lock.
The locking switch is located on the connection
plate at the bottomside of the device
.
•
Deactivate the battery by pushing the
transport lock to the left to the “0” with a point-
ed object (wire or pen).
•
Activate the battery by pushing the transport
lock to the right to the “I”.
When the instrument is delivered, the battery is
always deactivated.
1.6 Information on disposal
Electronic equipment does not belong into domes-
tic waste, but must be disposed in accordance
with the applicable statutory provisions.
You may hand in any defective batteries taken out
of the unit to our company as well as to recycling
places of public disposal systems or to selling
points of new batteries or storage batteries.
Analyzer Lock

General Information
8
1.7 Manufacturer
Wohler Technik GmbH
Wohler-Platz 1
33181 Bad Wünnenberg
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
1.8 Important information
ATTENTION!
In order to ensure the quality of the application and the measurement result, the ana-
lyser may only be used with original Wohler accessories and original Wohler spare
parts. This applies in particular to legally regulated measurement tasks
ATTENTION!
Do not expose the instrument to moist flue gas, if it has been exposed to temperatures
below 0°C for a certain time. This may harm the instrument.
ATTENTION!
The instrument is equipped with strong magnets to fix it during the measurement. The
magnetic field may harm heart pacemakers, hard disks, data mediums, magnetic stripe
cards, controls etc. Keep sufficient distance to magnet-sensitive objects.
ATTENTION!
Occasional measurements on cogeneration units (maximum 50 measurements)
are
permitted due to an internal
NOX-filter. If you do measurements on cogeneration units
more frequently, please use the external
Wohler CHP-Filter, see accessory.
When measuring in
flue gases of a cogeneration unit, the NOx concentration might be
multiple times higher, than in the
flue gases of a typical small-scale furnace. An early
loss of the cross
-insensitivity of the CO-sensor on NOx is perceived as an overload and
therefore not covered by your warranty.

Specifications
9
2 Specifications
2.1 Readings
Oxygen (O
2
) concentration in flue gas
Display
Volume % referenced to dry flue gas
Measurement
principle
electrochemical sensor
Range
0,0 to 21,0 %
Accuracy
± 0,3 Vol. -%

Specifications
10
Carbon monoxide (CO
V
100.000 ppm) in flue gas
(only Wohler A 450 L, article 4672
Display
Volume ppm referenced to dry flue gas
Meas. principle
Electrochemical sensor, H2 compensated
Range
0 to 100.000 Vol. ppm, resolution 1 Vol.-ppm
Accuracy
± 100 ppm (<1.000 ppm), otherwise 10% of reading (if H
2
< 5%
of reading)
Carbon monoxide (CO
V
10.000 ppm) in flue gas
(only Wohler A 450, article 7165)
Display
Volume ppm referenced to dry flue gas
Meas. principle
Electrochemical sensor, H2 compensated
Range
0 to 10.000 Vol. ppm, resolution 1 Vol.-ppm
Accuracy
± 20 ppm (<400 ppm), otherwise 5% of reading
Carbon monoxide (CO
V
10.000 ppm) in flue gas
(only Wohler A 450, article 5181)
Display
Volume ppm referenced to dry flue gas
Meas. principle
Electrochemical sensor, not H2 compensated
Range
0 to 10.000 Vol. ppm, resolution 1 Vol.-ppm
Accuracy
± 40 ppm (< 1,000 ppm), otherwise 10% of reading
(if H2 < 5% of reading)
Carbon monoxide (CO
V
5.000 ppm) in flue gas
(only Wohler A 450 L, article 4503)
Display
Volume ppm referenced to dry flue gas
Meas. principle
Electrochemical sensor, not H2 compensated
Range
0 to 5.000 Vol. ppm, resolution 1 Vol.-ppm
Accuracy
± 40 ppm (< 400 ppm), otherwise 10 % of reading (if H
2
< 5% of
reading)

Specifications
11
Nitrogen monoxide (NO
V
) in flue gas (option)
Display
Volume ppm referenced to dry flue gas
Measurement
principle
electrochemical sensor
Range
0 to 3,000 Vol. ppm resolution 1 Vol.-ppm
Accuracy
±5 vol. ppm (<100ppm), otherwise 5 % of reading
Chimney draught / differential pressure (PD)
Display
Pascal
Measurement
principle
Semi-conductor diaphragm
Range
0,00 to ± 110,00 hPa, resolution 1 Pa
Accuracy
2 Pa (< 40Pa), otherwise 5% of reading
Flue gas temperature (TS)
Unit
°C
Measurement
principle
Thermocouple (NiCr-Ni)
Range
-20,0 °C to 800,0 °C, resolution 0,1 °C
Accuracy
-20 - 133 °C: ± 2°C;
133 to 800 °C: 1.5% of reading
Ambient Temperature (TA)
Display
°C
Measurement
principle
Thermocouple (NiCr-Ni)
Range
-20,0 °C to 100 °C, resolution 0.1 °C
Accuracy
± 1°C

Specifications
12
2.2 Calculated Values
Calculated Value
Explanation
Efficiency /SL
Efficiency and losses in accordance to ASME standards
ETA/QS
Efficiency and losses in accordance to European standards
(0,0 to 120%)
CO
2
in Vol. -%
Range
0 – CO2max, resolution 0.1 %
CO
c
, SO
2c
; NO
c
, NO
2C
air free (corrected)
Default: 0% (oil and gas).
Dpt
°C
Dew Point in the flue gas
Medium soot level
Soot number ± 0.1
Excess air coefficient
Lambda λ(e.g. 1,25 when the excess of air is 25%)
C
on
Condensate quantity in condensing conditions
Toxication index GI
CO/CO
2
Air velocity
0,1 to 130 m/s, resolution < 0,1 m/s, for the measurement of
the ventilation loss (heating check)

Specifications
13
2.3 Technical Data
Description
Data
Power supply
Rechargeable Lithium-ion battery 3.7 V, 2250 mAh, charg-
ing via USB
Operation time
Approx. 6,5 h (depending on the operating mode and the
display backlight)
Charging time for a full
charge
Approx. 3 hours
Charging cycles of the
batteries:
After 500 charging cycles, at least 70% of the capacity are
still available
Storage Temperature
-20 °C to 50 °C
Operation temperature
+5 °C to 40 °C to guarantee the specified accuracy
Relative humidity
30% to 70 %
Weight
620g with NO-sensor included
Dimensions
220 x 160 x 55 mm (without probe)
Length of the hose
160 x 110 x 45 mm (no probe)

Component Explanation
14
3 Component Explanation
Fig. 2: Front view of the analyzer
On/Off
Gas probe connection
Connection plate for
temperature, pressure,
USB
condensate
trap

Component Explanation
15
Fig. 3: Connection plate on the bottom of the unit
Connections on the bottom of the unit
1 Lock Battery, cf. chapter 4.1
2 USB-port for data transfer and charging
3 IR interface for thermal printer
4 Gas temperature
5 Ambient Air Temperature
6 Positive pressure
7 Negative pressure
8 Speaker for alarm signals
2
3
4
5
6
7
8
6
7
1

Component Explanation
16
3.1 Probes, sensors and
filters NOTE!
The following probes and filters have to be be
purchased as accessories.
Fig. 6: S
-tube probe
S-tube probe for measuring the flow speed with
adapter
Fig.
4: Flexible capillaries
Flexible capillaries for the 4 PA test (an adapter is
needed)
If you frequently do measurements on cogenera-
tion units, please use the external Wohler CHP-
Filter, that has to be attached to the probegrip
Wohler A 450. Occasional measurements on co-
generation units (maximum 50 measurements)
are permitted because the analyzer disposes of
an external NOX-filter
Fig.
5: Ambient Temperature Plug
Ambient Temperature Plug
Fig. 10: Probegrip with CHP-Filter

Component Explanation
17
Fig.
63: combustion air temperature
probe
Combustion air temperature probe Wohler A 450 ,
185 mm
Hoses for pressure measurement

Component Explanation
18
3.2 Display
The Wohler A 450 is operated via Touchscreen. The measurement menu is similar to the
one of a smartphone. A fingertip on the icon starts the correspondent measurement
mode. The active icons are graphically emphasized.
If there is a bar on the right of the display, the display can be scrolled by pulling it with the
finger.
Fig.15: Display details
The display is divided into different segments:
The fuel is shown in the topline on the left. The
currently selected customer and measurement
mode are shown on the right of the fuel.
Date and time, system diagnostic status and bat-
tery level are shown on the right.
The readings segment displays the current read-
ings.
Click on PR key for zeroing the pressure sensor.
NOTE!
The user can set up the display according to his
needs. He can arrange the readings and chose
the units. Go to the setup-menu and select
"change units" (see chapter 7.6).
The icon segment offers different options. These
options are explained in chapter 5.3.1

Component Explanation
19
3.3 Gas sampling path Wohler A 450
Fig.17: Gas sampling path Wohler A 450 with flue gas probe 250 mm
The sensors are protected against condensate by a three-step-filter conditioning:
The first step is the coarse filter in the probe handle. Most of the particles will be re-
moved from the sample. After that the gas passes the condensate trap, where the gas
is cooled by a spiral and the condensate is collected.
The second step is an exchangeable cotton filter. Fine particles and rests of water will
be removed from the sample.
The last step is the Water Stop Filter. This filter will not allow any kind of moisture to
pass. The filter will clog automatically in contact with water, so that the sensors are
protected against moisture.
The flue now passes each sensor module (O2, CO and NO). During this process, the
CO-sensor is additionally protected by the internal NOXfilter.

Getting started
20
4 Getting started
4.1 Activating the battery
Fig
. 18: Battery lock to the right: Battery
activated;
Battery lock to the left: Battery
locked
•Before first use: Activate the battery by push-
ing the battery lock with a sharp object (paper
clip or other slim wire) to the right, cf. adjacent
figure.
The locking switch is located on the connection
plate at the bottom of the unit.
4.2 Tightness test
Fig.19: Ball
pump
Before the tightness test connect the gas probe.
Proceed as follows:
•
Squeeze the ball pump (part 1).
•
Plug the ball pump (part 1) on the gas probe
(part 2)
•
Release the ball pump.
After the ball pump has been released, it may not
fill with air or only fill very slowly. Otherwise the
connection is not tight.
ATTENTION!
Never plug the ball pump on the gas probe and
squeeze it afterwards. In this case the draft probe
will be damaged.