INSPECTUSA C165 Residential Commercial Combustion Analyzer Instruction Manual

INSPECTUSA C165 Residential Commercial Combustion Analyzer

FUNCTIONS

• Flue temperature: 32° to 1112°F
• Inlet temperature: Internal/ External sensor 32° to 112°F
• O2: 0 – 21%
• CO: 2000 ppm
• CO2: 0 – 20 %
• Efficiency: Nett/Gross 99.9%
• Efficiency: High (calculated) 119.9%
• Excess air: 250%
• CO/CO2 ratio: 0.99%
• Differential pressure

FEATURES

• EOS Technology
• Pre-programmed fuels: Natural Gas, Propane, Butane, LPG, Light Oils (28/35 sec), Woodpellets, Town Gas, Coke Gas, Biogas, Biofuel
• Memory Positions: 30
• 6 line backlit display
• High altitude compensation
• User customizable parameter views
• Individual report printouts
• Real-time clock

GENERAL SPECIFICATIONS

• Operating Temperature: 32° to 112°F (0° to 45°C)
• Storage Temperature: 0° to 120°F (-18° to 50°C)
• Operating Humidity: 10% to 90% R.H.
• Back light: Yes
• Dimensions: 7.87 x 1.77 x 3.5 inch
• Item Weight: 1.35 lb
• Calibration: Recommended Annually
• Certification: CE Conformity, RoHS, REACH Compliant, AHRI 1260 standard
• Battery Size: Alkaline or NiMH AA 3
• Accuracy: ± (% of reading + # of least significant digits)

IMPORTANT SAFETY WARNINGS

Read entire Safety Notes section regarding potential hazard and proper instructions before using this analyzer. In this manual the word “WARNING” is used to indicate conditions or actions that may pose physical hazards to the user. The word “CAUTION” is used to indicate conditions or actions that may damage this instrument.

WARNING
To ensure safe operation and service of the tester, follow these instructions. Failure to observe these warnings can result in severe injury or death.

WARNING

• Do not use this analyzer during electrical storms or in wet weather.
• To avoid false readings, charge batteries if a low battery indicator appears.
• Always adhere to national and local safety codes. Use proper personal protective equipment (PPE)

WARNING

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

NOTE: 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 gas of the test gas.

SYMBOLS

ANALYZER OVERVIEW

• Infrared Printer Port

• On/ Off (Power) Button

• 6 Line Backlit Display

  • Press any button to turn Back light on (backlight duration can be set in Menu/Screen/Backlight)

• Display Line Lights

• Pump Toggle Button: short press is data hold, long press turns pump on and off

• UP Button

  • Short press to navigate “UP”

• Wireless/Store/Print Button: short press print, long press store

• Down Button: short press moves down, long press does a fresh air purge

• ENTER Button: short press works as enter, long press turns on work light

• Rotary Selector Dial

• Particle Filter (inside water trap)

• Water Trap

• LED Water Trap Indication

• Protective Rubber Boot with Magnets

• Serial Number QR Code: (Serial Number viewable under Protective Boot)

• Sensors Fitted: (label under Protective Boot) Sensors that can be fitted in unit when shipped (CO-H2, CO, CO2, NO, O2)

• Battery Compartment: (under Protective Boot)

• Grip Indentation: Indentation for fingers to grip analyzer

• Water Trap Drain Plug (Red plug; take caution NOT to damage plug when removing protective boot)

• Battery Charge USB Adapter Connection

• Temperature Connections

  • Flue Probe Temperature: T1
    Inlet Temperature: T2

• Flue Gas Inlet Connection

• Pressure Connections

  • Pressure: P1
  • Differential Pressure: P2

• Infrared Printer Port

ANALYZER OVERVIEW (CONT.)

OVERVIEW

The C165 Combustion Analyzer measures CO, CO2, differential temperature and differential pressure. CO2 is set to zero in fresh air automatically after the initial countdown. It is important that re-zeroing is done in outside fresh air as indoor CO2 levels are affected by human breath. It calculates oxygen (O2), CO/CO2 ratio, Losses, Combustion Efficiency (Gross, Nett, Gross Condensing, or Nett Condensing). The C165 Combustion Analyzer can also measure CO levels in ambient air – useful when a CO Alarm is triggered. It can also perform a Room CO Test for 30 minute duration. A structured Commissioning Test has been included for the installation of boilers A low flow detection system warns of low flow and switches the pump off. This also helps to prevent water ingress from overfilled water traps. The analyzer has a protective rubber boot with magnets for hands-free operation and is supplied with a probe with an integral temperature sensor. A large 6 line display provides the user with relevant information. All data can be printed via the infrared printer or Wireless Printer App. The C165 uses a new data storage system allowing the user to store the maximum number of logs of interest to them, rather than be restricted to an allowance of particular logs. The memory can store up to 30 logs of any combination of Combustion, AUX, Temperature, Heat Exchanger, Room CO, Commissioning tests.

PRE TEST CHECKLIST

• Clean particle filter
• Water trap and probe line are empty of water
• Power on and zero
• All hose and thermocouple connections are properly secured
• Flue gas probe is sampling ambient FRESH air
• Water trap is fitted correctly to the instrument
• Flue temperature plug is connected
• Ensure water trap plug is inserted correctly

SETTING INLET TEMPERATURE

• Turn on and zero the analyzer, without the flue probe connected, to use ambient temperature
• Connect the flue probe thermocouple to T1 during zero countdown use for inlet ducted system
• Connect a thermocouple to T2 to measure second temp source

ANALYZER CONNECTIONS

WARNING
Turning the pump off while the probe is in the flue will leave toxic gases inside the analyzer. Once data has been printed or copied, it is advisable to purge the unit with fresh air as soon as possible. To do this remove the probe from the flue and turn ON pump. Always allow the readings to return to zero (20.9% for O2) prior to shutting the unit off. The meter will not switch off until the CO reading is below 20 ppm.

CAUTION
The probe will be hot from flue gases. Remove the probe from the flue and allow it to cool naturally. Do not immerse the probe in water, as this will be drawn into the analyzer and damage the flue probe and the pump and sensors.

NOTE: Take care when inserting the temperature probes as the pins are polarized. Insert with the smaller pin (+) to the right.

EMPTYING & CLEANING THE IN-LINE WATER TRAP

• Remove the rubber plug
• Allow the water to drain out
• Re-insert the rubber plug

CHANGING THE PARTICLE FILTER

• Remove the protective rubber boot
• Slide the water trap unit from the analyzer
• Remove the particle filter from its’ spigot and replace
• Slide the water trap back into position and replace the protective rubber boot

QUICK START
Turn on the analyzer by pressing the On/Off Button for 2 seconds until the unit activates. As described the analyzer will perform a 60 second turn on purge. Once completed simply select the reading desired by the position of the rotary dial.

FRESH AIR PURGE

NOTE
Each time the analyzer is turned on it will perform a 60-second air purge, this is to clear the gas sampling path (including the probe, if connected). For these reasons, it is very important that the analyzer be in outside fresh air when powered on.

COOVER-RANGE PROTECTION PUMP

The analyzer’s intelligent protection system will automatically activate the protection pump once an over-gas condition is detected (see specification table for detection limits). When activated the main sampling pump will be shut down, allowing the sample system to be purged with fresh air. Once readings have returned to a safe level, the protection pump will shut down and the main pump will reactivate.

MEASURING FLUE GASES

After the initial countdown is finished and the analyzer is properly setup, put its’ flue probe in the appliance’s sampling point. The tip of the probe should be at the center of the flue. Use the flue probes depth stop cone to set the position.
With balanced flues, make sure the probe is positioned into the flue so no air can “back flush” into the probe.

CAUTION!: Ensure the flue probe handle does not get hot!

USING THE MENU

Select “Menu” on the rotary switch and navigate using the function buttons:

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.

As you scroll up or down the side LEDs illuminate to point to the active line

e .g . 7 am = 07:00:00, 7pm = 19:00:00

SET DATE| MM/DD/YY format
PRINTER| KM IRP KANE IRP-2

WIRELESS (if installed)

SERIAL

PASSKEY| 1111 (wait 5 secs after entering last digit)
BACK|

As you scroll up or down the side LEDs illuminate to point to the active line

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.

OIL, BIO OIL, WOOD PELLETS, BIO GAS, USER 1 to 5
FUEL ORIGIN| UK, FRANCE, SPAIN, N AMERICA, BELGIUM, NETHERLAND
EFFICIENCY| GROSS, NET, GROSS COND, NET COND
PRESSURE| See next table below
GAS| ppm, ppm(n), mg/m3, mg/m3(n), mg/kWh, mg/kWh(n)
TEMP| C, F
02 REF| Up/down to set value (3% default)
NOx CALC| Up/down to set value (5% default)
BACK|

As you scroll up or down the side LEDs illuminate to point to the active line

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.

USING THE MENU CONT.

response
RESOLUTION| LOW = e .g . 0 .00i inH20 resolution .

HIGH = displays to an extra decimal place

UNITS| mbar, Pa, PSI, mmHg, hPa, inH2O, mmH20, kPa, psi
BACK|

As you scroll up or down the side LEDs illuminate to point to the active line

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.

LINE 2, LINE 3, LINE 4, LINE 5, LINE 6, BACK
BACK|

As you scroll up or down the side LEDs illuminate to point to the active line

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.

LINE 2

BACK

BACK|

As you scroll up or down the side LEDs illuminate to point to the active line

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.

set to 000000 .

As you scroll up or down the side LEDs illuminate to point to the active line

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.

USING THE MENU

The Menu position on the Rotary Dial allows for the customization of the default settings for the analyzer as per the user’s requirements. Navigation through the Menu system is via the dedicated user’s interface buttons (Up, Down, Enter).
As you navigate up or down through the Menu, the items will scroll accordingly, eventually back to the beginning.

• Rotate Selector Dial to MENU to set up or customize your settings.
• Selected parameter are centered, highlighted with arrow icons on either side.
• Use buttons to scroll menu options.
• Press to a select a parameter to edit. Press button to scroll fields to change.
• Press  buttons to change field contents.
• Press to enter content selected.

The analyzer will perform a 60 second purge in Rotary Dial settings of Aux, Flue 1and Flue 2. This should be done in fresh air.

COMBUSTION TESTS

Insert the tip of the flue probe into the center of the flue. The readings will stabilize within 60 seconds assuming the system conditions are stable. The rotary switch can be used to display the following information:

FLUE 1

• Fuel type can be changed via “MENU” or “STATUS” setting. Carbon Dioxide (%)
• Oxygen (%) left after combustion. Should be 20.9% ± 0.3% in fresh air. Gross efficiency
• Flue temperature (°F).
• Inlet temperature (°F). Normally set by flue probe during fresh air purge.
• Press to print a full combustion test, (or send to Smart Device via optional Wireless module).
• Hold for 2+ seconds to log a full combustion report.

FLUE 2

• Fuel type can be changed via “Menu” or “STATUS” setting.
• Carbon monoxide (ppm).Losses calculatedExcess air %Pressure reading
• Press to print a full combustion test, (or send to Smart Device via optional Wireless module).
• Hold for 2+ seconds to log a full combustion report.

AUX display

• The AUX (auxiliary) display can be customized via “MENU” / “SCREEN” / “AUX”.
• The parameters displayed on lines 1, 2, 3, 4, 5 and 6 can be set by the user.
• They remain the AUX parameters until changed by the user.
• Press to print a full combustion test, (or send to Smart Device via optional Wireless module).
• Hold for 2+ seconds to log a full combustion report.

COMBUSTION TEST – OPTIONAL NITRIC OXIDE SENSOR

Instructions for C165 Analyzers fitted with optional Nitric Oxide (NO) sensors

Displaying the Nitric Oxide (NO) reading
Select “Menu” on the rotary switch and navigate using the function buttons:

Select SCREEN and then select AUX Choose a line to display the required readings as below

AUX display

The AUX (auxiliary) display can be customized via MENU / SCREEN / AUX. The parameters displayed on lines 1, 2, 3, 4, 5 and 6 can be set by the user. They remain the AUX parameters until changed by the user.

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.

• Use to navigate to the main menu option SCREEN Press .
• Use  to navigate to the sub menu option AUX Press  .

The display will show

• Press and a third line will appear.
• Use 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 readings 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. OR AUX The dial needs to be in the Flue position or AUX to print or store. When the dilution pump is operating to protect the CO sensor the NO readings are also affected by an unspecified amount. The screen will typically show:

COMMISSIONING TEST

The Commissioning Test is based on TB143 Introduced in April 2013, Technical Bulletin 143 from the Heating and Hotwater Industry Council (HHIC), outlines a safer, clear and comprehensive procedure for commissioning condensing boilers without airgas ratio valves. Rotate the dial to “COM TEST” position and follow the instructions on the screen

TEST 1
Check the boiler at High Fire rate. (Max GAS) The boiler is switched on at High Fire rate. (Max GAS) The analyzer is first zeroed in outside fresh air. Once the boiler is stable at high fire rate the probe is inserted into the air inlet of the flue and the CO2 level is measured. The reading needs to be stable and less than or equal to 0.20%.

TEST 2
The probe is then inserted into the exhaust outlet of the boiler and the Ratio, CO and CO2 levels are measured. These levels must be as per manufacturers instruction. Where manufacturer’s instructions are not available the CO must be less than 350 ppm and the RATIO must be less than 0.0040.

TEST 3
Checks the boiler at Low Fire flow rate where this is possible. With the boiler operating stably at Low Fire rate the Ratio, CO and CO2 levels are measured. MIN GAS These levels must be as per manufacturers instruction. Where manufacturers’ instructions are not available the CO must be less than 350 ppm and the Flue 2 must be less than 0.0040.

TEST 4
Measures Flow and Return Temperatures from the boiler All the measured readings are logged and can be printed or transmitted to PC if an optional wireless module is fitted.

HEAT EXCHANGER INTEGRITY TEST

There are many methods to test heat exchange integrity. One of these is to observe the Excess Air, O2 and CO readings both before and after the blower turns on. If the heat exchanger is sealed, your O2 and CO readings should remain fairly stable. A breach in the heat exchanger may allow fresh air to be forced into the flue after the blower turns on due to pressure increase in the plenum. The result may be a rise in the measured O2 in the stack gas and an increase in Excess Air. In some sealed systems the fresh air drawn in through the breach may reduce the combustion air available leading to an increase in the CO reading. If either of these situations are present it is probable there is a problem with the Heat Exchanger which may require additional testing and inspections.

NOTE: Many cracks are invisible to borescopes or the naked eye, and only open or separate from pressure or temperature changes during operations. Rotate dial to “EXCH TEST” Rotate test selector to “EXCH TEST”. Call for heat on the system. Observe and wait for O2 readings to stabilize.

ROOM CO TEST

• No probes or hose connections are required for this test.
• Rotate selector dial to Room CO
• Press Enter Button to select GENERAL test type
• CO readings will be logged every 2 minutes for 30 minutes.
• Readings will be saved once the 30 minute test is completed.
• Test results and LOG number will be displayed.
• Press Print Button to Print the test results.
• This LOG will be saved in the REPORTS/ROOM CO MENU screen.

PRINTING

• Rotate selector Dial to Menu Position.
• Use Arrow Buttons to select Printer.
• Press button.
• Use Arrow Buttons to select Printer type (Wireless, KM IRP, Kane IRP-2, Serial)

Wireless Printer App
Please see pages 15 and 16 To charge Printer (if one is included with Printer) please use included USB Cable

PRINTOUTS

iOS APP GUIDE

Install the App

• Free download from Apple® App store
• Search for “Kane Wireless Printer” and install Upon opening App the first time, it will ask you a series of questions:
• Allow access to device location (GPS)
• Allow access to contacts (for emailing)

Kane Wireless Printer App Home iOS Screen
Pairing the Kane Wireless Printer app with your Analyzer Turn on your analyzer allowing a complete startup In the App Press PRINTOUT Select CONNECT TO ANALYZER

• Your Analyzer’s serial number, proceeded by a “K”, should appear
• Select your analyzer to pair

Kane Wireless Printer App Home Screen
Print to App from Analyzer

• When testing in AUX, FLUE 1, FLUE 2, Temp/PRES, HEAT EXCH screen
• Press FILE (Wireless) Button to enter the print menu
• Scroll ARROW Button to select Wireless
• Press the Button to print to App

To Disconnect an analyzer

• Select disconnect from the Printout screen

Adding Notes & Emailing from the Kane Wireless Printer App In the PRINTOUT screen, Select EMAIL PRINTOUT

• A message window will open
• Enter email address
• Add message/notes to Printout
• Send message

Select CLEAR CONSOLE to delete a Printout

• Press to Confirm the deletion

To print Saved LOGS from Analyzer to App

To print Saved LOGS from Analyzer to App

• Rotate Selector dial to MENU
• Press Arrow Buttons to select LOGS. Press Button
• In the LOGS screen. Press the  Button to VIEW.
• Press Arrow Buttons to select the LOGS VIEW you want. Press Button

ANDROID APP GUIDE

Installing the App

• Free download from Google Play
• Search for “Kane Wireless Printer” and install

Upon opening App the first time, it will ask you a series of questions:

• Allow access to device location (GPS)
• Allow access to contacts (for emailing)

Kane Wireless Printer App Home Android Screen

Start up

• Press the Menu icon in top left of the screen
• Press Settings
  • Select “Your Name”, enter your name and Press “OK”
  • Select “Your Company Name”, enter name and Press “OK”
  • Select “Analyser Type” and select “Other Kane Analyser”

Kane Wireless Printer App Android Settings Screen
Pairing the Kane Wireless Printer app with your Analyzer

• Turn on your analyzer and allow it to complete its startup
• Touch the Kane Wireless Printer banner of the home page
• From the “Pick a device” screen, touch “Scan For Devices” at the bottom of the page
• Your Analyzer’s serial number, proceeded by a “K”, appears of the list. Select it to pair

Print to App from Analyzer

• When testing in AUX, FLUE 1, FLUE 2, Temp/PRES, HEAT EXCH screen
• Press the FILE (Wireless) Button to enter the print menu
• Scroll Arrow Button to select Wireless
• Press the Button to print to App

To Disconnect an analyzer

• Select disconnect from Printout screen

Adding Notes & Emailing from the Kane Wireless Printer App
-After a report is on the app, Press the Pen icon on the top right of the app screen.

• Press “Write your note here” and you can type your notes for the report. Press “OK”icon when done and it will save the note under the report.
• Press the “3 vertical dots” icon on the right side of the screen
• From that drop-down menu, Press “Email” icon
• Find and select your email app from the list. The email app will open to a new message and your report will be attached

Kane Wireless Printer App Android Personal Details Screen
To print Saved LOGS from Analyzer to App

• Rotate Selector dial to MENU
• Press Arrow Buttons to select LOGS. Press  Button
• In the LOGS screen. Press  Button to VIEW.
• Press Arrow Buttons to select LOGS VIEW you want. Press Button

PRESSURE/TEMPERATURE TESTING

• Select the Temperature Rotary Dial position.
• Use the T1 connection for the Flue Probe temperature sensor
• Use the T2 connection for the Inlet temperature sensor
• Real time temperature difference
• Real time pressure reading

WARNING
NEVER ATTEMPT TO TAKE A PRESSURE READING WITHOUT KNOWING THE MAXIMUM PRESSURE THAT MIGHT BE PRESENT. THIS INSTRUMENT’S PRESSURE TRANSDUCER IS RATED AT 1.1 PSI WITH A MAXIMUM OVER RANGE OF 5.8 PSI. Select “PRS/TEMP”. The pump stops automatically. Using the black connectors and manometer hose, connect to P1 for single pressure or P1 and P2 for differential pressure.

• Pressure units can be selected via “MENU”.
• Eg Flow Temp
• Eg Return Temp
• Differential Temp
• Press to print a full pressure test, (or send to Smart Device via optional Wireless module).
• Hold for 2+ seconds to log a pressure report.

PRESSURE MEASUREMENT GOOD PRACTICE

WARNING
Before using the UEi C165 to measure the pressure of a gas/air ratio valve, read the manufacturer’s manual thoroughly. If in doubt, contact the manufacturer. After adjusting a gas/air ratio valve, it is essential the CO, CO2 are within the manufacturer’s specified limits.

LARGE BORE TUBING ISSUES

If using larger bore tubing when performing pressure tests:

• Push tubing over the rim of the spigot to ensure a gas tight seal.
• This may not produce a gas tight seal.

ANALYZER SPECIFICATIONS

Temp Measurement

Flue Temperature

Inlet Temperature (Internal sensor)

Inlet Temperature (External sensor)

| ****

32°-1112°F

32°-122°F

32°-1112°F

| ****

0 .1°F

0 .1°F

0 .1°F

| ****

±3 .6°F

±0 .3% reading

±3 .6°F

±0 .3% reading

±3 .6°F

±0 .3% reading

Flue Gas Measurement

Oxygen*2

Carbon monoxide*1

Carbon dioxide1 Efficiency (Net or Gross)2 Efficiency High (C)2 Excess Air2

CO/CO2 ratio*2

| ****

0-21%

0-20ppm 21-2,000ppm

Above 2000ppm Purge pump operates

0-20%

0-99 .9%

0-119 .9%

0-250%

0-0 .999

| ****

0 .1%

1ppm

0 .1%

0 .1%

0 .1%

0 .1%

0 .0001

| ****

±0 .3%

±3ppm

±5% reading unspecified

±0 .3% volume

±1 .0% reading

±1 .0% reading

±0 .2% reading

±5% reading

Nitric Oxide Sensor

(optional)

| 0 to 100ppm

Overrange to 1500ppm

| 1ppm| + 2ppm <30ppm*1

+5ppm <100ppm*1

+5% reading >100ppm

Pressure (differential)

Nominal range 32”

Maximum over range without damage to sensor is 60”

| ****

±0 .2 mbar (±0 .080 inWC)

±1 mbar (±0 .401 inWC)

±80 mbar (±32 inWC)

| ****

Maximum 0 .001 mbar

<25 mbar

(0 .001 inWC < 10 .016)

| ****

±0 .005 mbar (±0 .002 inWC)

±0 .03 mbar (±0 .080 inWC)

±3% of reading: same

Pre-programmed Fuels| Natural gas, Propane, Butane, LPG, Light Oils (28/35 sec), Wood Pellets, Town Gas, Coke Gas, Bio Oil, Bio Gas
User programmed Fuels| 5 user defined fuels
Storage Capacity| 30 Total Tests

ANALYZER SPECIFICATIONS CONT.
Carbon Dioxide resolution is 0.01% below 1% measured value.

8 hours using Alkaline AA cells

Chargers (optional)| 100-240v charger, for NiMH batteries only
Dimensions Weight: Handset: Probe:| ****

0 .8kg handset with protective rubber cover 7 .87 x 1 .77 x 3 .5 in (200 x 45 x 90mm)

11 .8 in (300mm) long including handle .

2 .3 dia . x 9 .4 in (6mm dia . x 240mm) long stainless-steel shaft with 6 .5ft (2m) long neoprene hose . Type K thermocouple

CO Protection Pump:| Operates at 2000ppm measured CO .

The C165 is in conformity with the relevant Union harmonization legislation listed below:

electronic equipment (RoHS)

CERTIFICATION

The UEi C165 is TUV-tested and certified to EN 50379, Parts 1, 2 & 3 in accordance with the 1st German Federal Emission Control Ordinance (BlmSchV)

EMC
EN507270:2015

Safety
EN61010-1:2010

RoHS
IEC62321-2:2013, IEC62321-1:2013; IEC62321-3-1;2013, IEC63321-5:2013, IEC623321-4:2013, IEC62321-7-2:2017, IEC62321-7-1:2015, IEC62321-6:2015, AHRI 1260

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 analyzer 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 analyzer before use by:
Use the normal start up sequence in the location where the analyzer 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 analyzer’s position to minimize interference or switch off, if possible, the offending equipment during your test.

At the time of writing this manual (November 2020) UEi Test Instruments is 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 and is certified to be compliant.

WHERE TO TEST

Air Conditioning / Heat Pump

Boiler & Water Heaters & High-Efficiency Modulating Hot Water Systems

WHERE TO TEST (CONT.)

Furnaces (continued): Atmospheric, Gas & Oil

WHAT RESULTS ARE GENERALLY ACCEPTABLE

 | Atmospheric Gas Fixed Burners| Gas Fired Burners| Oil Fired burners (#2 Oil Fuel)| Positive Overfire Gas & Oil
---|---|---|---|---
Oxygen| 7 to 9% O2| 3 to 6% O2| 4 to 7% O2| 3 to 9% O2
Stack temperature| 325˚ to 500˚F| 275˚ to 500˚F| 325˚ to 600˚F|
Draft (Water Column Inches)| -.02 to -0.4 InWC| -.02 to -0.4 InWC| -.04 to – 0.6 InWC| -.02 to -0.4 InWC
Carbon Monoxide (parts per million)| <100 ppm| <100 ppm| <100 ppm| <100 ppm
Overfire Draft (Water Column Inches)|  | -.02 InWC| -0.2 InWC| 0.4 to 0.6 InWC
Smoke|  |  | 0 (manufacturer’s recommendation)|

NOTE: Follow manufacturer guidelines for the specific equipment being serviced

Typical Excess Air Levels

POWERING OFF

When you power off the C165, there is a 5 second purge when on Flue 1, Flue 2 or AUX screens.
Make sure you do not exceed the analyzer’s operating specifications. In particular:

• Do not exceed the flue probes maximum temperature (1112˚F)
• Do not exceed the analyzer’s internal temperature range
• Do not put the analyzer on a hot surface
• Do not exceed the water trap’s level
• Do not let the 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.

POST-TEST

Remove the probe from the flue and allow analyzer to purge with fresh air until readings return to zero. O2 to 20.9%, CO to Zero (Be careful the probe tip will be HOT).

GENERAL MAINTENANCE

• Re-certify your instrument annually to ensure it meets original performance specification
• Keep your instrument dry, if it gets wet, wipe dry immediately. Liquids can degrade electronic circuits
• Whenever practical, keep the instrument away dust and dirt that cause premature wear
• Although your instrument is built to withstand the rigors of daily use, it can be damaged by severe impacts.
• Use reasonable caution when using and storing this meter

PERIODIC SERVICE

WARNING
Repair and service of this instrument is to be performed by qualified personnel only. Improper repair or service could result in physical degradation of the instrument. This could alter the protection from personal injury this meter provides to the operator. Perform only those maintenance tasks that you are qualified to do.

COLD WEATHER PRECAUTIONS

It is important you keep your flue gas analyzer in a warm and dry place overnight Electronic devices that become really cold, by being left in a vehicle overnight, suffer when taken into a warm room the next morning. Condensation may form which can affect the analyzer’s performance & cause permanent damage. See operating and storage temperature specifications. Electrochemical sensors used in flue gas analyzers can be affected by condensation or water being sucked into the analyzer, as the small apertures on top of sensors can become blocked with water, stopping sensors from seeing flue gas. When this happens, oxygen or carbon dioxide readings will display as “—” & sensors may be permanently damaged If you think that your analyzer is affected by condensation or water ingress, it may be possible to rectify the problem yourself. Simply leave the analyzer running in a warm place, with the pump ‘ON’ sampling fresh air for a few hours (use mains adapter/battery charger if needed). If, after doing this, you still experience problems please contact our Service Center.

REPLACING THE BATTERIES

This meter has been designed for use with both Alkaline or rechargeable Nickel Metal Hydride (NiMH) batteries. No other types are recommended and will void warranty. The analyzer is supplied with 3 (AA) size NiMH rechargeable batteries. These should be installed into the instrument.

CAUTION
Take great care when installing the batteries to observe correct polarity. Always check the meter for operation immediately after installing new batteries.

Using Rechargeable Batteries
The battery charger must only be used when NiMH batteries are fitted. Alkaline batteries are not rechargeable. Attempting to recharge alkaline batteries may result in damage to the product and create a fire risk. When changing the batteries, the time and date will need setting.

WARNING
Do not try and charge the unit with Alkaline batteries fitted. Do not mix NiMH cells of different capacities from different manufacturers, all cells must be identical. Turn over the analyzer, remove the protective rubber boot and fit 3 “AA” batteries in the battery compartment. Take great care to ensure they are fitted with the correct battery polarity. Replace the battery cover and the protective rubber boot.

Time and Date
When changing the batteries, the time and date will need setting.

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

Battery Charging
Ensure that you use the correct charger. This unit uses a 5V regulated charger. Ensure the batteries are fitted in the correct manner, and charge for at least 16 hours. Subsequent charges should be overnight. NiMH batteries may be charged at any time, even for short periods to conduct testing.

WARNING
Under NO circumstances should you expose batteries to extreme heat or fire as they may explode and cause injury. Always dispose of old batteries promptly in a manner consistent with local disposal regulations.

ANNUAL RECERTIFICATION

What You Get

• Calibration (or sensor replacement)
• 30-point inspection by factory-trained professionals
• Firmware and software updates
• Certificate of calibration
• Another 12-month warranty on the analyzer
• Return unit freight paid – within the continental US and Canada
• List of work performed, and parts replaced

RECERTIFICATION SERVICES

Turnaround
Before starting any service work, we stabilize your analyzer in ambient air. Our standard turnaround is 2 working days for standard pre-paid recertification. If your unit requires extensive diagnostic or repair work, we will contact you with a quotation and estimated repair time prior to starting work. Pre-authorizing payment for your repair on a credit card saves time. We will ask you for authority to charge the full cost of a service but if we only calibrate your unit, we’ll only charge the calibration fee. Charges will be applied upon completion of the recertification service. Shipping time for most repairs is 1 to 3 days. UEi pays return freight.

RETURNING YOUR ANALYZER

Before returning your analyzer to UEi Test Instruments, please ensure that you enclose:

• RMA label if you have used our online booking in process or via phone
• Your full contact details
• A daytime telephone number
• Details of faults you might have experienced
• Any relevant accessories (i.e. probe, printer, adapter & leak detectors). Any accessories that are returned will be checked

Packing Your Analyzer
Put analyzer and probes back in their cases The case should be put into a box with 1-2 inches of packing on each side for protection. When shipping an analyzer only, use a shoe-box size container with enough packing to fill the empty space. Print out the service paperwork (RMA) sent to you and include it in the packaging.

NOTE: If you are having specific problems that you want evaluated, please add those comments on the paperwork in detail.

Include any accessories that may be related to issues with the analyzer. Please be sure no personal items are packed with the return equipment. You pay to ship your analyzer to us and we’ll pay the return freight back to you – within continental US and Canada. We advise the use of couriers that provide insurance and tracking services.

When we receive your analyzer
Our Service Engineers will inspect the analyzer & accessories. If you haven’t booked and paid online, they will contact you to confirm the total recertification cost. Once accepted, the work will be carried out and on completion, returned to you.

WHERE TO SEND YOUR ANALYZER

USA

• UEi Test Instruments
• 800-547-5740
• 7601 East 88th Place, Suite 888
• Indianapolis, IN 46256

Canada

• Kane Canada Measurement Solutions
• 877-475-0648
• 150-13571 Verdun Place
• Richmond, BC V6V 1W5

OTHER IMPORTANT FACTORS RELATING TO COMBUSTION

The three T’s of combustion

• Time: Amount of time that the fuel and oxygen are together in the combustion chamber
• Temperature: How high the temperature is determines the rate of oxidation, or spread of combustion
• Turbulence: How well the fuel and air are mixed

These three factors are all interrelated and will move your results along the combustion curves.

COMBUSTION MEASUREMENT TERMS

Other parameters measured include Net temperature, draft and efficiency.

Net Temperature
Net temperature is the difference between the combustion air entering the combustion chamber and the flue gas temperature past the heat exchange. This is used to determine how efficient the system is extracting heat from the combustion process in addition to the performance of the combustion process. On sealed systems that have ducted inlet air for combustion air, the Net temperature must compare this air stream temperature with the flue gases. If the appliance simply uses room air for the combustion air, our analyzers have an internal temperature sensor in the handset, so it will use this temperature when calculating Net temperature. The most accurate results for efficiency are obtained when measuring flue gases at the point where flue temperature (not flame temperature) is the highest.

Draft
Draft is the difference between the ambient pressure level and the pressure level in the flue. This is created either by the natural buoyancy of the hot gases created in combustion lifting, or by an inducer fan that assists the flow of flue gases up the stack. Most combustion equipment will specify the amount of draft that is required for proper operation. The draft helps draw combustion air into the combustion chamber, and also helps in mixing the fuel and oxygen. Without proper draft, the combustion process can spill poisonous by-products into the space where the appliance is located. This can be a risk to those in the area, or create a danger to residents or employees working near the combustion equipment.

Efficiency
Efficiency is a measure of how well the fuel is burned to create heat, and how well the generated heat is captured for the intended use. The information used to create this value are based on the fuel’s heating value, the heat lost up the flue and the gas components in the flue gas. The original method to determine efficiency included many manual methods and lookup charts. As an example, you would measure the CO2 level and the stack temperature and then reference a sliding scale that would give you the relative efficiency number. UEi’s electronic combustion analyzers perform the measurements on a continuous basis and can calculate the efficiency as adjustments are being made. Combine this with a printout and you are able to provide a before and after comparison of the combination equipment in relatively little time as part of normal servicing. Combustion efficiency is not the same as AFUE (annual fuel usage efficiency). AFUE is not measurable with any portable flue gas analyzer.

Combustion Efficiency Calculations
This identifies three sources of loss associated with fuel burning:

• Losses due to flue gases: Dry Flue gas loss, moisture and hydrogen, Sensible heat of water vapor, Unburned gas
• Losses due to refuse: Combustible in ash, riddling and dust
• Other losses: Radiation, convection, conduction other unmeasured losses

Net efficiency calculations assume that the energy contained in the water vapor (formed as a product of combustion and from wet fuel) is recovered and the wet loss term is zero. Gross efficiency calculations assume that the energy contained in the water vapor is not recovered. Since the fuel-air mixture is never consistent there is the possibility of unburned/partially unburned fuel passing through the flue. This is represented by the unburned carbon loss. Losses due to combustible matter in ashes, riddling, dust and grit, radiation, convection, and conduction are not included.

CO Air Free
Certain standards (ANSI Z21.1) for Carbon Monoxide are stated in terms of air- free. Air-free refers to the concentration of CO in combustion gases undiluted with flue, or other gases containing little CO. This value is computed using an equation that takes into account the O2 concentration of the flue gas.

• If 5% O2 is measured (O2m) in the flue then the CO gas value will be recalculated as if 0% were measured. The equation for air-free is as follows:: COaf = CO PPM x [(20.9) / (20.9 – O2m)]
• In our example if a reading of 325 PPM were measured then the air-free value would be calculated as follows: COaf = 325 PPM x [(20.9) / (20.9 – 5)] COaf = 325 PPM x [(20.9) / (15.9)] COaf = 427

We may be given a limit on our gas range by the local authority, which stated that we must not emit more than 400-PPM Carbon Monoxide air-free. In the example we would be breaking the limit and corrective action should be taken to reduce the level of CO. Air-free values prevent false readings being submitted, e.g. allowing more air into the boiler will increase the oxygen level in the flue and dilute any toxic gas reading. Air-free referencing gives readings as if they were undiluted.

DISPOSAL

Caution: This symbol indicates that equipment and its accessories shall be subject to separate collection and correct disposal.

STORAGE

Remove the batteries when the instrument is not in use for a prolonged period of time. Do not expose to high temperatures or humidity. After a period of storage in extreme conditions exceeding the limits mentioned in the General Specifications section, allow the instrument to return to normal operating conditions before using it.

END-OF-LIFE DISPOSAL

The Waste Electrical or Electronic Equipment (WEEE) Directive requires countries in the EU to maximize collection and environmentally responsible processing of these items. Products are now labeled with a crossed-out wheeled bin symbol to remind you that they can be recycled.

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

WARRANTY

The C165 are warranted to be free from defects in materials and workmanship for a period of 1 year from the date of purchase. If within the warranty period, your instrument should become inoperative from such defects, the unit will be repaired or replaced at UEi’s option. This warranty covers normal use and does not cover damage that occurs in shipment or failure which results from alteration, tampering, accident, misuse, abuse, neglect or improper maintenance. Batteries and consequential damage resulting from failed batteries are not covered by warranty. Any implied warranties, including but not limited to implied warranties of merchantability and fitness for a particular purpose, are limited to the express warranty. UEi shall not be liable for loss of use of the instrument or other incidental or consequential damages, expenses, or economic loss, or for any claim or claims for such damage, expenses or economic loss. A purchase receipt or other proof of original purchase date will be required before warranty repairs will be rendered. Instruments out of warranty will be repaired (when repairable) for a service charge For more information on warranty and service, contact: This warranty gives you specific legal rights. You may also have other rights, which vary from state to state.

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References

• Kane USA

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