KANE455

Flue Gas Analyser

with direct CO2 measurement

Stock No: 18859-7 October 2012

© Kane International Ltd
 CONTENTS

Page No:

KANE455 Overview 4
ANALYSER LAYOUT & FEATURES 5-6
1. BATTERIES 7

2. BEFORE USING THE ANALYSER EVERY TIME 8-9

2.1 FRESH AIR PURGE 8
2.2 STATUS DISPLAY 9

3. USING THE FOUR FUNCTION BUTTONS 10-12

4. USING THE ANALYSER 13-21

4.1 COMBUSTION TESTS 13-14
4.2 PRESSURE TEST 15-16
4.3 LET-BY & TIGHTNESS TESTING 17-18
4.4 DIFFERENTIAL TEMPERATURE 19
4.5 ROOM CO TESTING 20
4.6 KANE455 PRINTOUTS 21

5. USING THE MENU 22-23

6. USING THE KANE455 AS A THERMOMETER OR 24-25

PRESSURE METER

7. MEASURING FLUE GASES 26

8. ANALYSER PROBLEM SOLVING 27-28

9. ANALYSER ANNUAL RECALIBRATION AND SERVICE 29

10. ANALYSER SPECIFICATION 30-31

11. ELECTROMAGNETIC COMPATIBILITY 32

12. EN50379 REGULATED INSTRUCTIONS 33-37

KANE455 manual Page 2
APPENDIX 1 – MAIN PARAMETERS 38-40

ADDENDUM - OPTIONAL NITRIC OXIDE (NO) SENSOR 41-44

KANE455 manual Page 3

 KANE455 Overview
The KANE455 Combustion Analyser measures carbon dioxide (CO2), carbon
monoxide (CO), differential temperature and differential pressure. The direct
measurement of CO2 is achieved using a Kane designed infra-red sensing system.

CO2 is set to zero in fresh air automatically after the initial countdown.

If “RESET GAS ZERO” is indicated ensure that the unit is in fresh air before pressing
the button with an “Enter” symbol.

It calculates oxygen (O2), CO/CO2 ratio, losses, combustion efficiency (Nett, Gross or
Condensing) & excess air.

The KANE455 Combustion Analyser can also measure CO levels in ambient air -
useful when a CO Alarm is triggered. It can also perform a Room CO Test for up to 30
minutes duration.

The analyser has a protective rubber cover with a magnet for “hands–free” operation
and is supplied with a flue probe with integral temperature sensor.

The large display shows 4 readings at a time and all data can be printed via an
optional infrared printer. The printed data can be 'live' data or ‘stored’ data.

The memory can store up to:

99 combustion tests
20 pressure tests
20 let-by/tightness tests
20 temperature tests
20 room CO tests

Two lines of 20 characters can be added to the header of printouts.

The analyser is controlled using 4 function buttons and a rotary dial.

The four buttons (from left to right) switch on and off the analyser, switch on and off
the backlight and task light, switch on and off the pump and send data to a printer or to
the memory. The buttons with UP, DOWN and ENTER arrows also change settings
such as date, time, fuel, etc. when in MENU mode.

KANE455 manual Page 4

 ANALYSER LAYOUT & FEATURES

Tasklight and infra-red emitter

Menu controls
Scroll up/down
Function
Enter
buttons x 4

Particle Filter
Rotary Switch

Battery Compartment
(behind rubber sleeve)

Water Trap
“Battery Charging”
indicator

Temp and pressure Flue Gas Inlet

connections

KANE455 manual Page 5

KANE455 manual Page 6
1. BATTERIES

Battery Type
This analyser has been designed for use with disposable alkaline batteries or
rechargeable Nickel Metal Hydride (NiMH) batteries. No other battery types are
recommended.

WARNING
The battery charger unit must only be used when NiMH batteries are fitted.

Replacing Batteries
Turn over the analyser, remove its’ protective rubber sleeve and fit 4 “AA” batteries in
the battery compartment. Take great care to ensure they are fitted with the correct
battery polarity. Replace the battery cover and protective rubber sleeve.

Switch the analyser on and check that the analyser’s time and date are correct. To
reset see USING THE MENU, Section 5.

Charging NiMH Batteries

Ensure that you use the correct charger. The part number is KMCU250/UK.

To fully charge NiMH batteries:

Switch the KANE455 on.
The charger must then be connected and switched on.
When charging, the red Battery Charging Indicator will illuminate.
Now switch the KANE455 off. The display will show “BATTERY CHARGING”

The first charge should be for 12 hours continuously. NiMH batteries are suitable for
top up charging at any time, even for short periods.

An in-vehicle charger can be used to top up the analyser's batteries from a 12 volt
vehicle battery. The part number is KMCU450/12

Battery Disposal

Always dispose of depleted batteries using approved disposal methods that protect the
environment

KANE455 manual Page 7

2. BEFORE USING THE ANALYSER EVERY TIME:
Check the water trap is empty and the particle filter is not dirty:

- To empty water trap, unplug its rubber stopper and re-plug once it is empty.

- To change the particle filter, remove protective rubber sleeve, slide the water
trap unit from the analyser, remove the particle filter from its’ spigot and replace.
Reconnect the water trap unit and rubber protective sleeve.

Connect the flue probe hose to the analyser’s flue gas inlet and connect the flue
probe’s temperature plug to the T1 socket – check the plug’s orientation is correct -
see Page 6.

2.1 FRESH AIR PURGE

Position the flue probe in fresh air, then press / . The analyser’s pump
starts and the analyser auto-calibrates for approximately 90 seconds. When complete:

Select “Ratio” on the dial. In fresh air the CO reading should be zero.
Select “O2/Eff” on the dial. In fresh air the O2 reading should be 20.9% ± 0.1%.

RESET
GAS ZERO
IN FRESH
AIR Ð
This message indicates that the analyser needs to be reset in fresh air. To do so,

ensure that the analyser is in fresh air and press / .

To perform a manual ‘Gas Zero’, select ‘Ratio’ on the dial, hold down the
key and you will see the message above.

KANE455 manual Page 8

2.2 STATUS DISPLAY
Select “Status” on the dial to view the following:

BAT 39
Replace alkaline batteries if less than 10.
→ Recharge NiMH batteries if less than 20.

14:56:29 → Current time. Can be re-set via the “Menu”.

11/03/06 → Current date. Can be re-set via the “Menu”.

CAL 283
Shows number of days until next calibration is
→ due.

NOTE: The typical BAT status number for fully charged NiMH
batteries is 70+. For new professional alkaline batteries it
is typically 99.

SAFETY WARNING
This analyser extracts combustion gases that may be toxic in relatively low
concentrations. These gases are exhausted from the back of the instrument. This
analyser must only be used in well-ventilated locations by trained and
competent persons after due consideration of all the potential hazards.

Users of portable gas detectors are recommended to conduct a “bump” check before
relying on the unit to verify an atmosphere is free from hazard.

A “bump” test is a means of verifying that an instrument is working within acceptable

limits by briefly exposing to a known gas mixture formulated to change the output of all
the sensors present. (This is different from a calibration where the instrument is also
exposed to a known gas mixture but is allowed to settle to a steady figure and the
reading adjusted to the stated gas concentration of the test gas).

KANE455 manual Page 9

3. USING THE FOUR FUNCTION BUTTONS:

Switching ON
the Analyser Press / button to switch the unit ON. This must be
done in fresh air to ensure that the analyser auto calibrates its’
sensors properly.

When switched on, the analyser beeps and briefly displays battery
%, fuel and pressure units. Its’ bottom line counts down from 90
until the sensors are ready to use. If the analyser will not auto
calibrate, its’ sensors need to be replaced or recalibrated by an
authorised repair centre.

If an inlet temperature probe (optional) is connected into the T2

socket during its’ countdown, the measured temperature from the
inlet probe will be used as the inlet temperature.

If an inlet temperature probe is not connected to the analyser

during countdown the measured temperature from the flue probe
will be used as the inlet temperature.

If neither probe is connected during countdown the analyser’s

internal ambient temperature will be used as the inlet temperature.

Switching OFF
the Analyser Press / button to switch the analyser OFF. The
display counts down from 30 with the pump on to clear the sensors
with fresh air – If the probe is still connected, make sure analyser
and probe are in fresh air.

Press / if you want to stop the countdown and return

to making measurements.

Note: The analyser will not switch off unless the CO

reading is below 20ppm.

KANE455 manual Page 10

Backlight &
Tasklight Press / to switch the display's backlight and
tasklight on and off.

NOTE: Use of the backlight/tasklight significantly increases

the current drain on the batteries.

Switching The analyser normally operates with the pump on.

PUMP on / off
Press / to switch the pump off and on.

When the pump is switched off “-PO-" is displayed instead of the

O2, CO & CO2 readings. The analyser also displays "PUMP OFF"
on the top line approx every 40 seconds.

NOTES:
1) The pump will not switch off if the CO reading is above
20ppm . This helps to protect the CO sensor from damage.
2) The pump will automatically switch itself off when the
rotary switch is set to Menu, Status, Pressure, Tightness or
Differential Temperature.

Zeroing the To re-zero the pressure sensor when “Prs” is selected on the dial,
pressure
sensor press and hold / until the top line display shows
CAL ZERO.

Printing Data
Press and quickly release / to start the analyser
printing. The analyser displays a series of bars until this is
completed. Press and release the key again to abort printing.

Make sure the printer is switched on, ready to accept data and its’
infrared receiver is in line with the analyser’s emitter (on top of the
analyser).

KANE455 manual Page 11

Storing a set
of readings Press and hold / for approx. 2 seconds.

The top line briefly displays the log number.

Note: This STORE function is inhibited in normal operation if

the pump is switched off.

Using / The function buttons below the symbols / / are used

to navigate through the menu when the rotary switch is set to
/ MENU – See USING THE MENU, Section 5.
Buttons

KANE455 manual Page 12

4. USING THE ANALYSER:

4.1 COMBUSTION TESTS:

Insert the tip of the flue probe into the centre of the flue. The readings will stabilise
within 60 seconds assuming the boiler conditions are stable.

The rotary switch can be used to display the following information:

RATIO Display

NAT GAS → Fuel type can be changed via “Menu”.

R 0.0008 → CO/CO2 ratio.

COp 52 → Carbon monoxide (ppm).

CO2% 6.3 → Carbon dioxide (%).

Press / to print a full combustion test, (or send to PC via optional

Bluetooth).

Hold / for 2+ seconds to log a full combustion report.

O2/EFF display

O2% 9.8
Oxygen (%) left after combustion. Should be
→ 20.9% ± 0.1% in fresh air.

TFc 145.1 o
→ Flue temperature ( C).

Inlet temperature (oC). Normally set by flue

TIc 5.4 → probe during fresh air purge.

EfC 91.3
‘Net’, ‘Gross’ or ‘Condensing’ efficiency (%)
→ can be selected via “Menu”.

KANE455 manual Page 13

Press / to print a full combustion test, (or send to PC via optional
Bluetooth).

Hold / for 2+ seconds to log a full combustion report.

AUX display

P 0.00 → The AUX (auxillary) display can be

customised via MENU / SCREEN / AUX.

R 0.0008
The parameters displayed on lines 1, 2, 3 and
4 can be set by the user.

COp 52
They remain the AUX parameters until
changed by the user.

CO2% 6.3
Press / to print a full combustion test, (or send to PC via optional
Bluetooth).

Hold / for 2+ seconds to log a full combustion report.

Viewing / printing a logged combustion test

Select MENU / REPORT / COMB’N / VIEW

Use , and to select the log number to be viewed.

Use and to scroll through the individual readings on lines 2 & 3.

Hold or for 2+ seconds to scroll to the next / previous log number.

Press / to print the test, (or send to PC via optional Bluetooth).

KANE455 manual Page 14

4.2 PRESSURE TEST
Select “Prs”. The pump stops automatically. Press / to auto-zero the
pressure sensor. Using the black connectors and manometer hose, connect to P1 for
single pressure or P1 and P2 for differential pressure.

PRS display

PRESSURE
Normal response or smoothed (damped)
→ response can be selected via “Menu”.

P 0.01
‘High’ or ‘Low’ resolution readings can be
→ selected via “Menu”.

mbar → Pressure units can be selected via “Menu”.

14:56:29 → Displays time to enable manually timed tests.

Press / to print a full pressure test, (or send to PC via optional

Bluetooth).

Hold / for 2+ seconds to log a pressure report.

Viewing / printing a logged pressure test

Select MENU / REPORT / PRESSURE / VIEW

Use or to select the log number to be printed.

Press / to print the test, (or send to PC via optional Bluetooth).

WARNING
Before using the KANE455 to measure the pressure of a gas/air ratio valve, read the
boiler manufacturer’s instructions thoroughly. If in doubt contact the boiler
manufacturer.

After adjusting a gas/air ratio valve it is essential that the CO, CO2 and CO/CO2 ratio
readings are within the boiler manufacturer’s specified limits.

KANE455 manual Page 15

If using larger bore tubing when performing pressure tests:

;
Push ‘orange’ tube over the rim of the spigot to ensure a gas tight seal.

:
This may not produce a gas tight seal.

KANE455 manual Page 16

4.3 LET-BY & TIGHTNESS TESTING

Select “Tightness”. The pump stops automatically. Press / to auto-

zero the pressure sensor. Connect from the test point to P1 using a black connector
and manometer hose.

The display shows “LET BY?”. Use , and to select YES or NO.

If YES is selected set the let-by pressure then press to start the let-by test. The
display shows:

LET BY
The let-by test is automatically stored in the
→ memory.

P1 10.15 → Pressure at start of let-by test.

P2 10.15 → Real time pressure reading.

TIME 59
Let-by default time is 1 minute. Can be
→ changed via “Menu”.

If the let-by test fails simply move the rotary switch to any position other than
“tightness” to abort the test.

If the let-by test passes adjust the gas pressure for the tightness test and press to
start the stabilisation test. The display shows:

STABIL’N
P1 20.01 → Real time pressure reading.

mbar → Pressure units.

TIME 59
Stabilisation default time is 1 minute. Can be
→ changed via “Menu”.

KANE455 manual Page 17

When complete press to start the tightness test:

TIGHTN’S
P1 20.01 → Pressure at start of tightness test.

P2 20.01 → Real time pressure reading.

TIME 119
Tightness default time is 2 minutes. Can be
→ changed via “Menu”.

When complete the display will show:

LOG 01
The tightness test is automatically stored in
→ the memory.

P1 20.01 → Pressure at start of tightness test.

P2 19.98 → Pressure at end of tightness test.

PRINT Ð → Press to print the complete test.

Viewing / printing a logged Let-by and Tightness test

Select MENU / REPORT / TIGHTN’S / VIEW

Use or to select the log number to be printed.

Press / to print the test, (or send to PC via optional Bluetooth).

Note:
The analysers’s memory can store up to 20 tightness tests. Tightness tests are
logged automatically therefore the tightness section of the memory will be full after the
20th tightness test is complete. Before the 21st tightness test can be performed the
tightness section of the memory must be cleared. To do this select MENU / REPORT
/ TIGHTN’S / DEL ALL / YES then press .

KANE455 manual Page 18

4.4 DIFFERENTIAL TEMPERATURE
Select “Diff Temp” to measure flow, return and differential temperatures

DIFF TEMP display

TEMP
Pump stops automatically when dial is moved
→ to Diff Temp.

T1c 60.4
Use the T1 connection for the flow
→ temperature sensor.

T2c 55.2
Use the T2 connection for the return
→ temperature sensor.

∆Tc 5.2 → Real time temperature difference.

Press / to print a differential temperature test, (or send to PC via

optional Bluetooth).

Hold / for 2+ seconds to log a differential temperature report.

Viewing / printing a differential temperature test

Select MENU / REPORT / TEMP / VIEW

Use or to select the log number to be printed.

Press / to print the test, (or send to PC via optional Bluetooth).

KANE455 manual Page 19

4.5 ROOM CO TESTING
Select “Room CO” to measure and record CO readings for up to 30 minutes.

Press / to start Room CO testing.

ROOM CO display

ROOM CO
CO readings are recorded every minute for
up to 30 minutes.

COp 00 → Real time CO reading (ppm).

TEST 00
Test 00 = initial CO test in series.
→ Test 30 = maximum of 30 tests in series.

LOG 01 → The CO test series is automatically stored in

the memory as a log number.

The user can stop the Room CO test at any time by pressing / .

If not stopped earlier, the Room CO test will automatically end after 30 minutes.

The CO test series is automatically stored in the memory as a log number.

When completed the log can be printed immediately by pressing .

Viewing / printing a logged Room CO test

Select MENU / REPORT / ROOM CO / VIEW

Use or to select the log number to be printed.

Press / to print the test, (or send to PC via optional Bluetooth).

KANE455 manual Page 20

4.6 KANE455 PRINTOUTS

K455 1.0 K455 1.0 K455 1.0

YOUR COMPANY NAME & YOUR COMPANY NAME & YOUR COMPANY NAME &
PHONE NUMBER HERE PHONE NUMBER HERE PHONE NUMBER HERE

TEST PRESSURE DIFF TEMP

DATE 15/05/07 TIME 12:56 15/05/07 LOG 03

TIME 12:00:08 TIME 12:10 15/05/07
PRS mbar -0.037
o
COMBUSTION T1 C 60.1
o
………………………………………. T2 C 47.0
o
……………………………………………. ∆T C 13.1
FUEL NAT GAS Customer …………………………………………….
O2 % 5.4 Customer
CO2 % 8.8 …………………………………………….
CO ppm 12 Appliance …………………………………………….
o
FLUE C 55.1 Appliance
o
INLT C 17.2 …………………………………………….
o
NETT C 37.9 Ref. …………………………………………….
Ref.
EFF (C) 98.3 …………………………………………….
LOSSES 1.7 …………………………………………….
XAIR % 34.8

CO/CO2 0.0001 K455 1.0

YOUR COMPANY NAME & K455 1.0
PRS mbar 0.00 PHONE NUMBER HERE YOUR COMPANY NAME &
PHONE NUMBER HERE
…………….……………………………. ROOM CO TEST
Customer …………………………………………….. LOG 04
TIME 11:53 15/05/07
…………….……………………………. LOG 01
Appliance TIME 12:50 15/05/07 Let By Test
…………………………………………….
………….………………………………. TEST CO ppm
Ref. 0 00 PRS-1 mbar 10.12
1 00 PRS-2 mbar 10.11
…………….……………………………. 2 10 LET-BY MINS 1:00
3 04
4 01 Tightness Test
5 00 …………………………………………….
6 00
7 10 PRS-1 mbar 20.12
8 03 PRS-2 mbar 20.10
9 11 ∆PRS mbar -0.02
~~~~~~~~~~~~~~~~~~~~~ STABIL’N MINS 1:00
30 00 TIGHTN’S MINS 2:00

…………………………………………….. …………………………………………….
MAXIMUM CO 11 Customer

…………………………………………….. …………………………………………….
Customer Appliance

…………………………………………….. …………………………………………….
Appliance Ref.

…………………………………………….. …………………………………………….
Ref.

……………………………………………..

KANE455 manual Page 21

5. USING THE MENU
Select “Menu” on the rotary switch and navigate using the function buttons:

U = Scroll up V = Scroll down = Enter

MAIN SUB
OPTIONS / COMMENTS
MENU MENU
NAT GAS, L OIL, PROPANE, BUTANE, LPG,
SETUP SET FUEL
PELLETS (wood)

Ef(C) = condensing boiler nett efficiency

NÅCÆG
Ef(N) = nett efficiency, Ef(G) = gross efficiency

HH:MM:SS format
SET TIME
e.g. 7 am = 07:00:00, 7pm = 19:00:00

SET DATE DD/MM/YY format

EXIT

OFF = normal response.

PRESSURE SMOOTH
ON = slower (damped) response

LOW = e.g. 0.01mBar resolution.

RESOLVE
HIGH = displays to an extra decimal place

PS UNITS mBar, mmH2O, Pa, kPa, PSI, mmHg, hPa, InH2O

LET BY = Set duration of let-by test in minutes.

Default = 1 minute
STABIL’N = Set duration of stabilisation in minutes.
TIME
Default = 1 minute
TIGHTN’S = Set duration of tightness test in
minutes. Default = 2 minute

EXIT

KANE455 manual Page 22

MAIN MENU SUB MENU OPTIONS / COMMENTS

Stored combustion tests:

REPORT COMB’N
VIEW, DEL ALL, EXIT

Stored pressure tests:

PRESSURE
VIEW, DEL ALL, EXIT

Stored tightness tests:

TIGHTN’S
VIEW, DEL ALL, EXIT

Stored differential temperature tests:

TEMP
VIEW, DEL ALL, EXIT

Stored room CO tests:

ROOM CO
VIEW, DEL ALL, EXIT

EXIT

SCREEN CONTRAST Factory setting is 04

Enables users to customise the parameters on the

AUX
AUX display: LINE 1, LINE 2, LINE 3, LINE 4, EXIT

Printout header, 2 lines, 20 characters per line:

HEADER
HEADER 1, HEADER 2, EXIT

EXIT

Password protected for authorised service agents

SERVICE CODE
only. Leave set to 0000.

BLUE COM*

* Bluetooth is a factory fitted optional extra.

NOTE: To EXIT the MENU at any time simply move the rotary switch to any
position other than “Menu”. Any changes that have not been
“entered” will be ignored.

KANE455 manual Page 23

6. USING THE KANE455 AS A THERMOMETER OR
PRESSURE METER

With the KANE455 switched off, press and hold down the / button and

then press and release / . Release / after MANO_MOD

is displayed on top line.

The KANE455 will now operate as a fixed display thermometer/pressure meter with
the pump off and inhibited. The readings can be printed but not stored.

The display will show:

P 0.00 → Real time pressure reading.

T1 21.3
Use the T1 connection for the flow
→ temperature sensor.

T2 21.3
Use the T2 connection for the return
→ temperature sensor.

∆T 0.0 → Real time temperature difference.

The standard printout for this mode is as follows:

K455 1.0
YOUR COMPANY NAME &
PHONE NUMBER HERE

DATE 15/05/07
TIME 13:00:47

…………….…………………………

o
T1 C 21.3
o
T2 C 21.3
o
∆T C 0.0

PRS mbar 0.00

………………………………………
Ref.

………………………………………

Exit ‘Mano-Mod’ by switching the KANE455 off.

The ‘Menu’ and ‘Tighness’ positions still operate normally in ‘Mano-Mod’

KANE455 manual Page 24

If using larger bore tubing when performing pressure tests:

;
Push ‘orange’ tube over the rim of the spigot to ensure a gas tight seal.

:
This may not produce a gas tight seal.

KANE455 manual Page 25

7. MEASURING FLUE GASES
After the countdown is finished and the analyser is correctly set up, put its’ flue probe
into the appliance’s sampling point. The tip of the probe should be at the centre of the
flue. Use the flue probe’s depth stop cone to set the position.

With balanced flues, make sure the probe is positioned far enough into the flue so no
air can ‘back flush’ into the probe.

NOTE: Ensure that the flue probe handle does not get hot!

Make sure you do not exceed the analyser’s operating specifications. In particular:

• Do not exceed the flue probe’s maximum temperature (600oC)

• Do not exceed the analyser’s internal temperature operating range
• Do not put the analyser on a hot surface
• Do not exceed the water trap’s levels
• Do not let the analyser’s particle filter become dirty and blocked

View the displayed data to ensure that stable operating conditions have been achieved
and the readings are within the expected range.

Press and quickly release / to start the analyser printing. The analyser
displays a series of bars until this is completed. Press and release the key again to
abort printing.

Make sure the printer is switched on, ready to accept data and its’ infrared receiver is
in line with the analyser’s emitter (on top of the analyser).

KANE455 manual Page 26

8. ANALYSER PROBLEM SOLVING
If any problems are not solved with these solutions, contact us or an authorized repair
center.

Fault symptom Causes / Solutions

• Oxygen too high • Air leaking into probe, tubing, water trap,
connectors or internal to analyser.
• CO2 too low
• CO reading (- - - -) • Analyser was stored in a cold environment
and is not at normal working temperature.
• CO sensor needs replacing.

• Batteries not holding charge • Batteries exhausted.

• Analyser not running on mains • AC charger not giving correct output.
adapter.
• Fuse blown in charger plug.

• Analyser does not respond to flue • Particle filter blocked.

gas
• Probe or tubing blocked.
• Pump not working or damaged with
contaminants.

• Net temperature or Efficiency • Ambient temperature set wrong during

calculation incorrect. Automatic Calibration.

• Flue temperature readings erratic • Temperature plug reversed in socket.

• Faulty connection or break in cable or
plug.

• T flue or T nett displays (-OC-) • Probe not connected.

• Faulty connection or break in cable or
plug.

• Ratio, EFF, X-Air all display (- - - -) • CO2 reading is below 2%.

KANE455 manual Page 27

Fault symptom Causes / Solutions

• Analyser just continually • Turn dial back to MENU and press ENTER
beeps • Turn dial back to Tightness and press ENTER

• BAT only shows 65 with • This is not a problem and is to be expected.

fully charged NiMH NiMH batteries only deliver 1.25 V per cell
batteries fitted whereas Alkalines deliver 1.5 V per cell. Fresh
alkalines give a BAT value of 90 or so.

KANE455 manual Page 28

9. ANALYSER ANNUAL RECALIBRATION AND SERVICE
Although sensor life is typically more than five years, the analyser should be
re-calibrated and serviced annually to counter any long-term sensor or electronics
drift or accidental damage.

Local regulations may require more frequent re-calibration.

KANE455 manual Page 29

10. ANALYSER SPECIFICATION
(NOTE: MAY BE SUBJECT TO CHANGE)

Parameter Range Resolution Accuracy

Temp Measurement
Flue Temperature 0-600oC 0.1oC +2.0oC
+0.3% reading

Inlet Temperature 0-50oC 0.1oC +1.0oC

(Internal sensor) +0.3% reading

Inlet Temperature 0-600oC 0.1oC +2.0oC

(External sensor) +0.3% reading
Gas Measurement
Oxygen*2 0-21% 0.1% +0.3%*1

Carbon monoxide 0-20ppm 1ppm +3ppm

21-2,000ppm nom +5% reading
4,000ppm max for
15 mins

Carbon dioxide 0-20% 0.1% +0.3% reading

Efficiency (Net or Gross) *2 0-99.9% 0.1% +1.0% reading
Efficiency High (C) *2 0-119.9% 0.1% +1.0% reading
Excess Air *2 0-250% 0.1% +0.2% reading
CO/CO2 ratio *2 0-0.999 0.0001 +5% reading
Pressure (differential)
Nominal range +80mBar +0.2 mBar Maximum +0.005 mBar
Maximum over range without 0.001 mBar
damage to sensor is +1 mBar <25mBar +0.03 mBar
+400mBar
+80 mBar +3% of reading

Pre-programmed Fuels Natural gas, Propane, Butane, LPG, Light Oils (28/35 sec),
Wood Pellets
Storage Capacity 99 Combustion tests
20 Pressure tests
20 Tightness tests
20 Temperature tests
20 Room CO tests

*1
Using dry gases at STP
*2
Calculated

KANE455 manual Page 30

Ambient Operating Range 0oC to +40oC 10% to 90% RH non-condensing
Battery Type / Life 4 AA cells
>8 hours using Alkaline AA cells
Chargers (optional) 220v charger, for NiMH batteries only
12v in vehicle charger, for NiMH batteries only
Dimensions
Weight: 0.8kg handset with protective cover
Handset: 200 x 45 x 90mm
Probe: 300mm long including handle.
6mm diameter x 240mm long stainless steel shaft with
3m long neoprene hose. Type K thermocouple

KANE455 manual Page 31

11. ELECTROMAGNETIC COMPATIBILITY

European Council Directive 89/336/EEC requires electronic equipment not to generate

electromagnetic disturbances exceeding defined levels and have adequate immunity
levels for normal operation. Specific standards applicable to this analyser are stated
below.
As there are electrical products in use pre-dating this Directive, they may emit excess
electromagnetic radiation levels and, occasionally, it may be appropriate to check the
analyser before use by:
Use the normal start up sequence in the location where the analyser will be
used.
Switch on all localized electrical equipment capable of causing interference.
Check all readings are as expected. A level of disturbance is acceptable.
If not acceptable, adjust the analyser’s position to minimize interference or
switch off, if possible, the offending equipment during your test.
At the time of writing this manual (December 2009) Kane International Ltd are not
aware of any field based situation where such interference has occurred and this
advice is only given to satisfy the requirements of the Directive.

This product has been tested for compliance

with the following generic standards:

EN 61000-6-3 : 2001
EN 61000-6-1 : 2001

and is certified to be compliant

Specification EC/EMC/KI/K455 details the

specific test configuration, performance and
conditions of use.

Please Note:
Batteries used in this instrument should be disposed of in accordance with current
legislation and local guidelines.

At the end of the product's life it should be re-cycled in accordance with current
legislation and local guidelines.

KANE455 manual Page 32

12. EN 50379 REGULATED INSTRUCTIONS
EN 50379 Section 4.3.2 “Instructions” defines a number of specific points that must be
included in the relevant instruction manuals. The paragraph numbering below relates
to that section of EN 50379.

a) The KANE455 is compliant the EN 50379 Part 2 and Part 3 as detailed in the
third party approvals issued by TUV. Reference numbers M-E 1085-00/09
applies.

b) The KANE455 is intended to be used with the following fuels:

Natural gas
Light oil (28/35 sec)
Propane
LPG
Wood pellets
Butane

c) The KANE455 is designed for use with either non-rechargeable alkaline AA cells
or rechargeable NiMh AA cells. Four cells are needed. Types cannot be mixed.
Under no circumstances should any attempt be made to recharge alkaline cells.

The battery charger supplied with the KANE455 is rated for indoor use only. Its
voltage input must be in the range 100 – 240 V ac at 50 – 60 Hz with a current
capability of 0.3 A. The chargers output voltage is 9 V dc at a maximum of 0.66A.

The charger has no user serviceable components.

Only a correctly specified and rated charger must be used with the KANE455.

d) The KANE455 is not designed for continuous use and is not suitable for use as a
fixed safety alarm.

e) An explanation of all the symbols used on the analyser’s display is given in

Appendix 1 of this manual.

f) The recommended minimum time required to perform one complete

measurement cycle and achieve correct indication of the measured values in EN
50379 Part 2 is 110 seconds. This is based on the T90 times defined in the
standard, always assuming that parameters being measured have reached
stability. This time is the summation of the times for a draught test (10 secs) and
a combustion test (90 secs) plus the time to move the hose connection from the
pressure input to the water trap (10 secs)

KANE455 manual Page 33

g) The recommended minimum time required to perform one checking procedure in
EN 50379 Part 3 is 110 seconds as described in section f) above.

h) Some commonly occurring materials, vapour or gases may affect the operation of
the KANE455 in the long or the short term though in normal use Kane
International Ltd is not aware of any specific issues that have affected the
product. The following list is included to satisfy the stated requirements of
EN 50379:
Solvents
Cleaning fluids
Polishes
Paints
Petrochemicals
Corrosive gases

i) The KANE455 is fitted with an electrochemical CO sensor and an infra-red CO2

sensor which have an expected life of more than 5 years. The calibration of these
sensors must be confirmed on an annual basis.

The batteries have an expected operational life of more than 500 re-charge
cycles.

j) The KANE455 is designed to operate at ambient temperatures in the range 0oC

to +45oC with relative humidity of 10% to 90% non-condensing. Whilst it is
recommended that the analyser is given the protection of a carry case during
transportation it is not required for normal operation.

k) The KANE455 has an initial start up delay following switch on of approx. 90

seconds. There is no additional delay after battery replacement.

l) Most sensors used in combustion analysers give a zero output when they fail and
it is widely recommended that analysers are regularly checked (also known as a
bump test) using either a can of test gas or a known source of combustion
products.

The KANE455 must have its calibration checked on an annual basis and be
issued with a traceable Certificate of Calibration.

The sensor within the KANE455 can only be replaced by Kane International Ltd
or one of its trained and approved service partners.

The water trap should be checked on a regular basis whilst the analyser is in use
(every few minutes) as the amount of condensate generated varies with the fuel
type, atmospheric conditions and the appliances operating characteristics.

KANE455 manual Page 34

 The particle filter should be checked at least on a daily basis when using ‘clean’
fuels and more often when using liquid or solid fuels.

Detailed instructions regarding the changing of the filter and the emptying of the
water trap are given in Section 2 of this manual.

m) WARNING!
When using a KANE455 to test an appliance a full visual inspection of the
appliance, in accordance with its manufacturer’s instructions, must also be
carried out.

KANE455 manual Page 35

KANE455 manual Page 36
KANE455 manual Page 37
Appendix 1 - Main Parameter:
Here are the legends used and what they mean:

O2 : Oxygen (Calculated) reading in percentage (%)

CO : Carbon monoxide (Measured) reading displayed in ppm (parts per

million). If ‘- - - -’ is displayed there is a fault with the CO sensor or the
instrument has not set to zero correctly. Switch off instrument and try
again.

CO2 : Carbon dioxide (Measured) reading in percentage (%).

TF : Temperature measured by the flue gas probe in centigrade (oC). It

displays ‘- OC -’ if the flue probe is disconnected or faulty.

TI : If an inlet temperature probe (optional) is connected into the T2 socket

during its’ countdown, the measured temperature from the inlet probe
will be used as the inlet temperature.

If an inlet temperature probe is not connected to the analyser during

countdown the measured temperature from the flue probe will be used
as the inlet temperature.

If neither probe is connected during countdown the analyser’s internal

ambient temperature will be used as the inlet temperature.

T Nett : Nett temperature calculated by deducting the INLET temperature from

the measured FLUE temperature. It displays ‘- OC -’ if the flue probe
is not connected or broken.

EFF : Combustion efficiency calculation displayed in percentage either as

Gross Ef(G) or Nett Ef(N) or Condensing Nett Ef(C) - Use MENU to
change. The calculation is determined by fuel type and uses the
calculation in British Standard BS845. The efficiency is displayed
during a combustion test, ‘- - - -’ is displayed while in fresh air.

Loss : Losses calculated from oxygen and type of fuel. Displays reading
during a combustion test. ‘- - - -’ is displayed while in fresh air.

X - AIR : Excess air calculated from the calculated oxygen and type of fuel.
Displays reading during a combustion test. ‘- - - -’ is displayed while in
fresh air.

CO/CO2: CO/CO2 Ratio: measured CO (ppm) divided by (CO2 (%) x 10,000).

PRS : Pressure reading, either single point or differential.

KANE455 manual Page 38

BAT : Displays the Battery power available.
Replace alkaline batteries if reading is less than 10
Recharge NiMH batteries if reading is less than 20
Readings may be affected if used with low power batteries.

DATE : Date shown as day, month and year, DD/MM/YY. Date is recorded
when each combustion test is printed or stored.

TIME : The time shown is expressed in “Military” time HH:MM:SS. Time is

recorded when each test is printed or stored.

Note! When changing the batteries on the instrument the memory

will store the date and time for up to one minute, if outside this
time it may be necessary to re-enter the details.
Date and time may also need to be reset if re-chargeable batteries
are allowed to totally discharge.

FULL : The maximum number of tests have been stored in the memory. To
delete the stored memory, Select Reports then select the tests to be
deleted (see Page 23).

KANE455 manual Page 39

SYMBOLS used on the display

P Pressure

R CO/CO2

λ Excess Air

Loss %: 100% minus loss % = efficiency %

TF Flue temperature

TI Inlet temperature

∆T Nett temperature

EfG Gross efficiency

EfN Nett efficiency

EfC Condensing efficiency

- PO - Pump off

‘- - - -’ Calculated oxygen greater than 18% so calculation is disabled

-OC- Open circuit temperature input

CAL Number of days left before recalibration is due

KANE455 manual Page 40

 ADDENDUM

Instructions for
KANE455 analysers
fitted with optional
Nitric Oxide (NO)
sensors

KANE455 manual Page 41

 DISPLAYING THE NO READING
Select “Menu” on the rotary switch and navigate using the function buttons:

U = Scroll up V = Scroll down = Enter

The MENU main structure is as follows:

MAIN MENU SUB MENU OPTIONS / COMMENTS

SETUP

PRESSURE

REPORT

SCREEN CONTRAST

Enables users to customise the parameters on the

AUX AUX display:
LINE 1, LINE 2, LINE 3, LINE 4, EXIT

HEADER

EXIT

SERVICE

BLUE COM*

* Bluetooth is a factory fitted optional extra.

NOTE: To EXIT the MENU at any time simply move the rotary switch to any
position other than MENU. Any changes that have not been “entered” will
be ignored.

KANE455 manual Page 42

Use or to navigate to the main menu option SCREEN.

Press .

Use or to navigate to the sub menu option AUX.

Press .

The display will show

AUX
LINE 1

Press and a third line will appear.

Use or to navigate to the desired parameter to be displayed on line 1.

Press to select the parameter for Line 1 and repeat the process to select the
display parameter for all four lines and then EXIT

Rotate the dial from MENU to AUX to display all your chosen settings.

PRINTING and STORING

The NO reading are printed and stored in the same way as the other combustion gas
readings. On the printouts the NO readings appear directly below the flue CO
readings.

Note the rotor needs to be in the AUX, O2/Eff or Ratio positions to print or store flue
combustion readings

KANE455 manual Page 43

NITRIC OXIDE SENSOR SPECIFICATION

Gas Measurement Resolution Accuracy Range

Nitric Oxide (NO) 1 ppm + 2ppm <30ppm*1 0 to 100 ppm

(low range) +5 ppm > 30ppm

Nitric Oxide (NO) 1ppm +5ppm <100ppm*1 0 to 1000 ppm

(high range) +5% reading
>100ppm

*1 Using dry gases at STP

KANE455 manual Page 44

 Thank you for reading this data sheet.

For pricing or for further information, please contact us at our UK Office, using the details
below.

UK Office
Keison Products,
P.O. Box 2124, Chelmsford, Essex, CM1 3UP, England.
Tel: +44 (0)330 088 0560
Fax: +44 (0)1245 808399
Email: sales@keison.co.uk

Please note - Product designs and specifications are subject to change without notice. The user is responsible for determining the
suitability of this product.