Wohler DC 430 Installation manual

The Measure of Technology
Operation manual
Leakage Tester
Art. No. 22755 2016-07-17
Wöhler DC 430
Leakage Tester

Contents
2
Contents
1General Information..............................4
1.1 Operation Manual Information....................... 4
1.2 Notes............................................................. 4
1.3 Intended Use................................................. 4
1.4 Components.................................................. 5
1.5 Transport....................................................... 5
1.6 Information on disposal................................. 5
1.7 Manufacturer................................................. 5
2Specifications........................................6
2.1 Measured values........................................... 6
2.2 Calculated Values ......................................... 8
2.3 Logger........................................................... 9
2.4 Technical Data ............................................ 10
3Component explanation.....................11
3.1 Basic unit..................................................... 11
3.2 Probes and components ............................. 13
3.3 Function ...................................................... 18
3.4 Display and key setup................................. 19
4Getting started ....................................21
4.1 Check battery status.................................... 21
4.2 Tightness test.............................................. 23
5Operation.............................................24
5.1 Turning the meter on................................... 24
5.2 Measuring ................................................... 24
5.3 Using the Pressure computer...................... 25
6Measurement modes in the main menu
..............................................................27
6.1 Calling up the main menu............................ 27
6.2 Option “Stress test” ..................................... 27
6.3 Option “Tightness test” ................................ 29
6.4 Option “Leakage rate” ................................. 34
6.5 Leakage rate, automatic............................. 34

Contents
3
6.5.1 Leakage rate (Decrease of pressure)..........39
6.6 Option “Regulator test” ................................44
6.7 Option “Determination of the Volume” .........45
6.7.1 Automatic determination of the volume........45
6.7.2 Determination of the volume (hand-operated
method) .......................................................46
6.8 Option “Graph / record”...............................50
6.9 Option “Air speed”........................................51
6.10 Option "U-value"..........................................53
6.11 Printing out measurement records...............54
6.12 Option "Save record" ...................................55
6.13 Option "Setup".............................................55
7Option 'Data management' ................58
7.1.1 Save customer records................................59
7.1.2 Recalling saved information.........................60
7.1.3 Setting up a new customer ..........................60
7.2 Data transfer with the PC or notebook.........60
8Troubleshooting .................................62
9Maintenance........................................62
9.1 Maintenance work........................................62
10 Warranty and Service.........................63
10.1 Warranty......................................................63
10.2 Service.........................................................63
11 Accessories.........................................64
12 Declaration of conformity..................65
13 Sales and Service Points...................66

General Information
4
1General Information
1.1 Operation Manual In-
formation
This operation manual allows you to safely work
with the Wöhler DC 430. Please keep this manual
for your information.
The Wöhler DC 430 Leakage Tester should be
employed by professionals 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
The meter can be used to measure differential
pressure, flow speed, temperature and humidity.
(optional). It is especially designed for the follow-
ing purposes:
Stress test and Leakage test according to the
German Gas Installations Directive (TRGI 2008 -
G 600)
Measurement of the leakage rate according to the
German Gas Installations Directive (TRGI 2008 -
G 600)
Flow pressure, installation pressure, standing
pressure, jet pressure
Flow measurement in air and flue gas ducts (from
ca. 2.0 m/s on)
Data logger/dew point-difference

General Information
5
1.4 Components
Device
Components
Wöhler DC 430
Leakage Tester
Control report
Measuring hose, 1.7
m, with quick connect-
or
1.5 Transport
ATTENTION!
Improper transport can harm the instrument.
To prevent damage to the instrument, always
transport it in the provided carrying case. The
pressure connectors have to be protected by the
protection cap.
The case is included in the sets and can also be
bought separately.
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.
1.7 Manufacturer
Wöhler Technik GmbH
Schützenstr. 41
33181 Bad Wünnenberg
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]

Specifications
6
2Specifications
2.1 Measured values
Differential pressure
Description
Data
Range
± 2 bar
Accuracy
< 3 % of the reading
If the value is < ± 200
Pa, better than
± 6 Pa
Resolution
1 Pa at
–210 hPa up to
+210 hPa, otherwise
10 Pa
Leakage test according to the
DVGW directives (German Associ-
ation of Gas and Water Engineers)
Description
Data
Range
0,0 l/h to 10,0 l/h, test-
ed up to 8 l/h
Accuracy
< ± 0,2 l/h up to 4 l/h,
otherwise 5% of the
reading
Resolution
0.1 l/h
Internal temperature measurement
Description
Data
Range:
-20 °C to 60°C
Accuracy
< ± 1 °C
Resolution
0.1°C

Specifications
7
External temperature measure-
ment
(optional, e.g. with Measuring Pli-
ers for Temperature Measurement
or Special Wall Temperature
Probe)
Description
Data
Range:
2 canals, -20.0 °C to
+800.0 °C
Accuracy
< ± 1 °C at 0°C to
67°C, otherwise 1.5 %
of the reading, accord-
ing to the directive EN
50379-2
Resolution
0.1°C
Moisture measurement (optional)
Description
Data
Range
0 % to 100 % rh (rela-
tive humidity), non
condensing
Accuracy
< ± 2 % rh, (range: 0
up to 90 % rh), other-
wise < 3 % rh
Resolution
0.1 % rh
Absolute pressure (optional)
Description
Data
Range
300 hPa to 1100 Pa
Accuracy
± 1.5 hPa
Resolution
0.1 hPa

Specifications
8
2.2 Calculated Values
Variable
Calculation
Pressure units
hPa, Pa, mmH2O, PSI, inwc,
bar, mbar, conversion ac-
cording to the general con-
version rules
Temperature
unit
°C to °F, conversion accord-
ing to the general conversion
rules
Flow speed
measured with a Prandtl-S-
tube probe, indicated in m/s,
2 to 150 m/s
Pipeline volume
Automatic determination of
the pipeline volume
0.0 to 1000.0 l.
Leakage rate
Automatic (class V)
0.0 l/h to 10.0 l/h (tested
according to the directive VP
952 of the German Associa-
tion of Gas and Water Engi-
neers (DVGW).
In l/h (according to the work-
ing sheet G624 of the DVGW
–TRGI) There is a data base
integrated in the meter,
where the data necessary for
the measurements of differ-
ent gas types can be select-
ed.
With external sampling (de-
crease of pressure method),
class D: 0.0 l/h to 300.0 l/h
(The decrease of pressure
method is not tested.)
Decrease of
pressure
Stress test and leakage test
according to the Technical
Rules for Gas Installations
(TRGI), working sheet G600
of the DVGW (German As-
sociation of Gas and Water
Engineers).

Specifications
9
2.3 Logger
Description
Data
Number of data rec-
ords
9999 data records,
each with pressure
and humidity readings
(optional) and three
temperature values (if
the external tempera-
ture sensors are con-
nected) can be stored
in the internal
memory. The user can
set the log rate from 1
second to 24 hours.
USB data transfer and
Bluetooth (option)
Permanent online da-
ta, already during the
registration
User adjustable log
rate
The user can select a
sampling interval be-
tween 1 second and
24 hours.
NOTE!
Ensure that the device is connected to the power
supply or that the batteries are charged.

Specifications
10
2.4 Technical Data
Description
Data
Current consumption
4 AA rechargeable
batteries or 4 AA dis-
posable batteries 1.5
volt
- working mode:
ca. 60 mA,
- off-mode and log
mode:
ca. 45 µA for clock
and processor
Interfaces
USB- (COM-Port),
Bluetooth (optional)
- With the TD 600
thermal fast printer it is
possible to start the
printout of the read-
ings directly from the
main menu.
Storage Temperature
-20 °C to +60 °C
Operating Tempera-
ture
5 °C to +40 °C
Mass
ca. 450 g, with inte-
grated magnet
Dimensions
80 x 550 x 60 mm
Date and time
Date and time are
included in the meas-
urement report
Internal memory
2 MB

Component explanation
11
1
3
3Component explanation
3.1 Basic unit
Fig. 1: Overview
2
4
5
6
7
8
©
©
9
©
©
10
11
12
13

Component explanation
12
Number
Function
1
Mini-USB-Port
2
Connection for protection cap
3
Power jack
4
Color display
5 ESC key
The function of the key changes according to the con-
text.
Escape
NOTE!
Keeping this key depressed will always call up the main
menu.
6 Arrow keys
The function changes according to the context. Scroll
up and down.
7 ENTER
and On-/Off key
a) Confirm the setting.
b) The function changes according to the context.
c) Press and hold the key for 3 seconds to turn off the
unit.
8 Infrared interface
Thermal fast printer to print out the measurement report
9 Overpressure socket
(+)
Main socket for the leakage test
10 Underpressure sock-
et (--)
Socket for the measurement of the differential pressure
and static socket for the S-tube probe
11 Connection for the gas
bladder
Connect the gas bladder, needed for the leakage test.
12, 13
Standard jacks for temperature probes NiCr-Ni
14
Battery cover (in Fig. 1 on the rear side)
There are diffusion openings for the internal registration
of the humidity and temperature on the rear side of the
Wöhler DC 430. The internal temperature measurement
is necessary for the temperature compensation of the
pressure sensor.

Component explanation
13
3.2 Probes and components
Fig. 2: Hose assembly of the Wöhler DC
430 for the leakage test
Standard hose, 1.7 m, for leakage test. The over-
pressure socket (+) of the Wöhler DC 430 has to
be connected to the test opening of the gas instal-
lation.
A hose with an internal diameter of 5 - 6 mm or a
quick connector, type DN 2.7, can be connected to
the test opening.
ATTENTION!
Do not use silicone hoses when measuring high
pressure, because, from an overpressure of 1000
hPa on, perforations may appear in this material.
The Wöhler Leakage Test Set includes convenient
textile hoses (see Accessories).

Component explanation
14
Fig. 3: DC 430 with hose assembly and
a filled gas bladder for the leakage test.
Gas bladder connection for measuring the leakage
rate with gas.
NOTE!
Please observe the valid accident prevention regu-
lations!
Fig. 4: S-tube probe
S-tube probe for measuring the flow speed (see
chapter 6.3)
Insert the plug of the S-tube probe into jack 12
(Fig. 1) of the Wöhler DC 430.
Connect the overpressure hose (turned against
the flow) of the S-tube probe to the overpres-
sure socket (+) (Fig. 1, part 9) and the under-
pressure hose to the underpressure socket (-)
(Fig. 1, part 10).

Component explanation
15
Fig. 5: Connections
Connections for the hand-operated method for the
determination of the volume and the leakage rate
according to the falling-pressure method (without
internal pump).
Fig. 6: Wöhler Gas Line Sealing Set
Wöhler Gas Line Sealing Set:
1 X-connector
2 hose to be connected to the meter
3 hose to be connected to the pump
4 hoses to be connected to the gas pipe
Fig. 7: Connections when measuring the
differential pressure at a gas fat burner
Connections when measuring the differential pres-
sure at a gas fan burner:
Note!
A measurement hose 3,5 mm Ø, 1,5 m length and
two T-pieces 4 mm Ø are necessary (art. 9237,
see accessories).
Cut the hose in two equal parts and cut a 10
cm piece of hose from each half.
Plug each of the two longer hoses on the mid-
dle part of the T-piece and plug the two shorter
parts of hose on the exterior end of the T-
piece.
2
3
4
1

Component explanation
16
Fig. 8: Wöhler DC 430 connected to the
gas fan burner (for the measurement of
the differential pressure)
Remove the hoses of the burner and connect
the free parts of the two t-pieces.
After that connect the two 10 cm hoses to the
burner
Switch on the Wöhler DC 430 und read the
differential pressure in the measuring mode.
Fig. 9: Connection of two temperature
measuring pliers.
Two temperature measuring pliers can be con-
nected at the same time.
Insert the plug of the temperature measuring
pliers into the jacks 12 and 13 (Fig. 1) of the
Wöhler DC 430.
The temperature value measured by the meter
connected to jack 12 will be indicated in the display
as T1 and the one measured by the meter con-
nected to jack 13 will be shown as T2.
NOTE!
Any thermocouple type K may be connected to the
jacks 12 and 13.

Component explanation
17
Fig. 10: Connection of the Special Wall
Temperature Probe for measuring the
heat transmission coefficient.
Connection of the Special Wall Temperature Probe
to measure the heat transmission coefficient. (See
chapter 6.10) Two Special Wall Temperature
Probes can be connected at the same time.
Insert the plug of the Temperature Probe into
the jacks 12 and 13 (Fig. 1) of the Wöhler DC
430.

Component explanation
18
3.3 Function
Pump
Pressure tank
Valve
Overpressure socket (+) / connection to the
gas line
Gas bladder connection
Absolute-pressure
and humidity sensor
Fig. 11: Interior of the device

Component explanation
19
Functions
The Wöhler DC 430 performs the leakage test
according to the directions (class V) of the DVGW
(German Association of Gas and Water Engineers).
This means that a defined volume will be added to
keep the working pressure constant. - The volume
added will be divided by the measuring time, and
the result will be the correspondent leakage rate.
During this process, the volume is injected in dis-
continuous steps. First a small pressure storage is
emptied and filled by two pumps afterwards. Then
the volume flow is injected to the gas installation via
an electric valve.
If a filled gas bladder is connected to the pump
entry, the test can be done with gas.
3.4 Display and key setup
Fig. 12 : Display and keys
The Wöhler DC 430 has a color 2.4' display.
The OLED-technology allows reading the display
from almost any angle of view.
Four keys are available below the display to oper-
ate the Wöhler DC 430.
Escape
Scroll/Zoom
On/Off

Component explanation
20
Abb. 13: Display details
The display is divided into a status, a menu and a
readings segment.
The currently selected task is shown in the left
status segment.
- Date and time, client (if selected), system diag-
nosis status and battery level are shown in the
status segment on the right.
The readings segment displays the readings or
the menu items.
The menu segment is situated at the bottom of the
display. It consists of three soft keys.