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Operation manual
Leakage Tester
Wöhler DC 430
Leakage Tester
The Measure of Technology

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Summary of Contents for Wohler DC 430

  • Page 1 Operation manual Leakage Tester Wöhler DC 430 Leakage Tester The Measure of Technology...

  • Page 2: Table Of Contents

    Contents Contents General Information ......4 Operation Manual Information ....... 4 Notes ............. 4 Intended Use ..........4 Components ..........5 Transport ............5 Information on disposal ......... 5 Manufacturer ..........5 Specifications ........6 Measured values ........... 6 Calculated Values ......... 8 Logger ............
  • Page 3 Contents 6.5.1 Leakage rate (Decrease of pressure) ..39 Option “Regulator test” ........ 44 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 Option “Graph / record” ....... 50 Option “Air speed”...

  • Page 4: General Information

    General Information General Information Operation Manual In- This operation manual allows you to safely work with the Wöhler DC 430. Please keep this manual formation for your information. The Wöhler DC 430 Leakage Tester should be employed by professionals for its intended use only.

  • Page 5: Components

    General Information Components Device Components Wöhler DC 430 Leakage Tester Control report Measuring hose, 1.7 m, with quick connect- 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.

  • Page 6: Specifications

    Specifications Specifications 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...
  • Page 7 Specifications External temperature measure- Description Data ment Range: 2 canals, -20.0 °C to (optional, e.g. with Measuring Pli- +800.0 °C ers for Temperature Measurement or Special Wall Temperature Accuracy < ± 1 °C at 0°C to Probe) 67°C, otherwise 1.5 % of the reading, accord- ing to the directive EN 50379-2...

  • Page 8: Calculated Values

    Specifications Calculated Values Variable Calculation Pressure units hPa, Pa, mmH O, PSI, in bar, mbar, conversion ac- cording to the general con- version rules Temperature °C to °F, conversion accord- unit 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...

  • Page 9: Logger

    Specifications Logger Description Data Number of data rec- 9999 data records, ords 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.

  • Page 10: Technical Data

    Specifications 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...

  • Page 11: Component Explanation

    Component explanation Component explanation Basic unit © © © © Fig. 1: Overview...
  • Page 12 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.

  • Page 13: Probes And Components

    Component explanation Probes and components 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...
  • Page 14 Gas bladder connection for measuring the leakage rate with gas. NOTE! Please observe the valid accident prevention regu- lations! Fig. 3: DC 430 with hose assembly and a filled gas bladder for the leakage test. S-tube probe for measuring the flow speed (see chapter 6.3) ...
  • Page 15 Component explanation 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. 5: Connections 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.
  • Page 16 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. 8: Wöhler DC 430 connected to the gas fan burner (for the measurement of...
  • Page 17 Component explanation 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.

  • Page 18: Function

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

  • Page 19: Display And Key Setup

    If a filled gas bladder is connected to the pump entry, the test can be done with gas. The Wöhler DC 430 has a color 2.4' display. Display and key setup The OLED-technology allows reading the display from almost any angle of view.
  • Page 20 Component explanation 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.

  • Page 21: Getting Started

    Fig. 14: Position of the batteries in the treatment. Never touch the liquid. If you got in Wöhler DC 430 contact to the liquid remove it with water. If the liquid got into your eyes, remove it with water and see your doctor as soon as possible.
  • Page 22 Getting started ATTENTION! - Ensure rechargeable batteries are equipped in the DC 430 before charging. Never try to charge disposable batteries. Use 4 AA rechargeable batteries only. - Only use the Wöhler charger. How to charge the batteries:  Before you plug the recharger into the outlet, connect it to the charging connection of the DC 430 (Fig.

  • Page 23: Tightness Test

    Getting started Tightness test Before the Wöhler DC 430 is used as a leakage tester the tightness of the device, of the measur- ing hoses and of the connectors should be tested. Please, proceed as follows:  Switch on the Wöhler DC 430.

  • Page 24: Operation

    Operation Operation Turning the meter on ATTENTION! Before the meter is used, a visual check must en- sure each and every time that all functions work properly. Before performing a leakage test, a tightness test, according to chapter 4.2 must be done.

  • Page 25: Using The Pressure Computer

    Operation  Using the Pressure Holding the left button depressed (ESCAPE) will always stop the current menu and call up computer the main menu. On/Off Escape Scroll/Zoom Fig. 20: Display and keys  In the measuring mode, press the up or down key to enter the zoom-mode.
  • Page 26 The magnetic holders will fix the analyzer on any magnetic material surface.  It is also possible to fix the Wöhler DC 430 with the supporting loop during the measure- ment. Fig. 22: DC 430 with supporting loop While measuring, either ...

  • Page 27: Measurement Modes In The Main Menu

    Measurement modes in the main menu Measurement modes in the main menu Calling up the main Press the left key "Menu" to select the main menu. In the main menu you can select all meas- menu urement and setup modes. The following sub- menus can be selected: Fig.
  • Page 28 The user can change the settings with the up and down keys. When the test pressure is lower than 300 hPa, the pumps integrated in the DC 430 will inflate the gas line automatically. NOTE!

  • Page 29: Option "Tightness Test

    Measurement modes in the main menu In the display the request "Inflate up to 1000 hPa" will appear. Pump air into the tube until the display indi- cates a pressure of at least 1000 hPa. As soon as the default test pressure of 1000 hPa is reached, the stabilization phase will start (10 minutes according to TRGI).
  • Page 30 Measurement modes in the main menu HINWEIS! During the tightness test of the whole installation no pressure regulator may be connected. (insert plate if necessary).
  • Page 31 Measurement modes in the main menu Close the gas line and seal it with a suitable test plug. Connect the DC 430 via a hose and an adapt- er to the test plug. WARNING! Please observe the valid accident prevention reg- ulations! Fig.
  • Page 32 Measurement modes in the main menu The integrated pumps of the Wöhler DC 430 will inflate the gas line automatically until a test pres- sure of 300 hPa is reached. If desired, the user can also pump manually. NOTE! If the tightness test shall be done with the hand operated method, the hoses and the pump have to be connected with the Wöhler Leakage Test...
  • Page 33 Measurement modes in the main menu After that, the readings and an evaluation accord- ing to the TRGI will be indicated in the display. The test result is OK, when the following condi- tions are fulfilled. The initial pressure is higher or equal to the preset test pressure.

  • Page 34: Option "Leakage Rate

    Measurement modes in the main menu Option “Leakage rate” Leakage rate, The serviceability of gas lines which are already in use can be checked by the leakage rate test (ser- automatic viceability check). ATTENTION! Protect the gas bladder against direct sunlight, because it could damage the material (natural rubber).
  • Page 35 Fig. 37: Wöhler DC 430 connected to the pressure. gauge connection via hose and adapter. Fig. 38: Plan of the connections for the leakage rate test with the Wöhler DC 430 with gas bladder.
  • Page 36 It is absolutely necessary to clear the tube with an inert gas before doing the test with air. If the DC 430 is equipped with an integrated abso- Fig. 40: Lower part of the display lute pressure sensor (optional), the air pressure before the leakage rate test.
  • Page 37 Select "Start Measurement" and start the measurement. The Wöhler DC 430 will pump until the preset test pressure is reached and the stabilization time will start. After that, the leakage rate test will start automatically.
  • Page 38 P the pressure of the internal pressure tank of the DC 430 during the injection. Fig. 42. Leakage rate during the test After the test time has expired, the readings and...

  • Page 39: Leakage Rate (Decrease Of Pressure)

    Measurement modes in the main menu 6.5.1 Leakage rate (Decrease of pressure) Theoretical background According to the decrease-of-pressure-method (hand-operated method) the leakage rate will be calculated automatically according to the two fol- lowing equations. Thus, this method observes the rules of the Technical Rules for Gas Installations (TRGI) worksheet G 624 of the DVGW.
  • Page 40 Measurement modes in the main menu Performing the test NOTE! If the user wants to pump manually, he needs an air pump (or an electrical compressor), a cross piece and connection hoses. Close the gas line and seal it with a suitable test plug.
  • Page 41 “automatic” or “pump with air pump” are indicated in the display. Now the user can select if the DC 430 shall pump automatically or if the user will pump with an air pump.
  • Page 42 VP 952 Select "Start Measurement" and press "Start" (Fig. 11). Parameter: "Inflate automatically". The Wöhler DC 430 will pump until the preset test pres- sure is reached and the stabilization time will start. After that, the measurement will start au- tomatically.
  • Page 43 Measurement modes in the main menu During the test, the current readings and the re- maining test time are indicated in the display. Fig. 48: Leakage rate during the test (decrease-of-pressure-method) After the test time has expired, the readings and an evaluation according to the TRGI will be indi- cated in the display: NOTE!

  • Page 44: Option "Regulator Test

    Measurement modes in the main menu Option “Regulator In the menu "Regulator test" the functions of the pressure regulator (SAV) can be checked. test” NOTE! If the installation is equipped with a diaphragm control valve, observe the following: The inlet pressure must be higher or equal to the outlet pressure.

  • Page 45: Option "Determination Of The Volume

    The user can modify the test pressure value. A test pressure of 5 hPa is recommended. If the Wöhler DC 430 is not equipped with an ab- solute pressure sensor, the user must enter the air pressure value, see chapter 6.13, parameter "air pressure".

  • Page 46: Determination Of The Volume (Hand-Operated Method)

    Absoulte air pressure, has to be entered in the setup menu by the user (Default: 1013 hPa) The DC 430 measures the pressure difference ∆p. For an exact measuring result, the pressure dif- ference ∆p should at least amount to 200 Pa, so that an exact result can be reached.
  • Page 47 Measurement modes in the main menu In case of a higher pressure, the stabilization time during the temperature compensation will be longer and the influence of leakages that might exist is higher.
  • Page 48 WARNING! Please observe the valid accident prevention reg- ulations! Switch the Wöhler DC 430 on before connect- ing the overpressure socket (+) via a hose to the test plug. Connect the soot test pump with a second Fig. 55. Hand-operated method for the hose and the cross piece (see Fig.
  • Page 49 Measurement modes in the main menu NOTE! If the Wöhler DC 430 is not equipped with an ab- solute pressure sensor, the user must enter the air pressure value into the meter, see chapter PARAMETER "air pressure". Press "Start". In the display the request to take the sample vol- ume will appear.

  • Page 50: Option "Graph / Record

    Measurement modes in the main menu Option “Graph / The "graph / logging" mode is used to start a per- manent data recording. A graph of the records will record” be indicated. The user can modify the log interval, the number of measurements, the stop date and the stop time as follows: Go to the next digit by pressing the left-/right-...

  • Page 51: Option "Air Speed

    Connect the static pressure connector of the S-tube to the (-) underpressure socket of the Wöhler DC 430. Switch on the Wöhler DC 430. When folded up, the S-tube can be inserted through the measurement opening into the Fig. 60. Measurement of the flow speed gas flow.
  • Page 52 Measurement modes in the main menu In the main menu, select "Flow speed" and confirm with OK. The flow speed v is indicated in the upper part of the display. The temperature measured by the sensor or the S-tube is indicated in the lower part of the display.

  • Page 53: Option "U-Value

    The temperature values measured by the Wöhler DC 430 and the Special Wall Temperature Probe are necessary for the determination of the heat transfer coefficient. The heat transfer coefficient U is determined with the following equation according Fig.

  • Page 54: Printing Out Measurement Records

    Option "Print" (right key): Click the right key to start the print out. Fig. 64: Transmission of data records from the DC 430 to the thermal fast printer TD 600. When printing is in progress, a status bar will dis- play the current process state and the Text “Print-...

  • Page 55: Option "Save Record

    Measurement modes in the main menu 6.12 Option "Save record" To save all records which are marked by a tick mark in the main menu, select the "SAVE REC- ORD" option, see chapter 7.1.1. 6.13 Option "Setup" Select the option "SETUP" to enter the main setup menu.
  • Page 56 Paderborn is calculated as fol- lows:   NOTE! It is possible to arm the Wöhler DC 430 with an air pressure sensor (see accessories). In this case it will not be necessary to enter the air pressure into the meter. Pressure unit...
  • Page 57 Measurement modes in the main menu Alpha Heat transmission coefficient for the u-value measurement Printer logo Enter a custom corporate logo (6 lines) that will appear in every printout. Default Reset the DC 430 to its factory default setting (except the calibration).

  • Page 58: Option 'Data Management

    Option ‘DATA MANAGEMENT’ There are two possibilities to select the customer option:  Select option 'Customer' directly after having switched on the DC 430, while the device is performing the self check.  Select the 'Data management' option from the main menu.

  • Page 59: Save Customer Records

    Option 'Data management' 7.1.1 Save customer records A later version of the Wöhler DC 430 will include the possibility to transfer Data to the PC. If one gas installation has to be checked by a stress test, a leakage test and a leakage rate test...

  • Page 60: Recalling Saved Information

    The data can be transferred from the Wöhler DC 430 to the PC or Notebook via an USB data cable. PC or notebook Proceed as follows:  Wöhler DC 430 mit dem im Lieferumfang enthaltenen USB-Kabel an den PC anschlie- ßen.  Unterpunkt „USB-Datenübertragung“ auswäh- len: Main menu >...
  • Page 61 Option 'Data management' Das Wöhler DC 430 befindet sich nun im USB Modus.  Datenverwaltungsprogramm am PC öffnen. Die weitere Steuerung der Datenübertragung erfolgt vom PC aus. Fig. 69: USB-Mode...

  • Page 62: Troubleshooting

    ATTENTION! Overpressure High pressure warning Deflate pressure when pumping manually. Maintenance Proper operation of the Wöhler DC 430 requires regular maintenance. Maintenance work Interval Maintenance work If required (user) Clean the device with a wet cloth and a smooth cleanser.

  • Page 63: Warranty And Service

    Warranty and Service 10.1 Warranty Each Wöhler Leakage Tester DC 430 will be test- ed in all functions and will leave our factory only after extensive quality control testing. The final control will be recorded in detail in a test report and delivered with any unit.

  • Page 64: Accessories

    Accessories Accessories Probes and sensors Special Wall Temperature Probe Order no. 4651 Measuring pliers for temperature measurement Order no. 6679 S-tube probe Order no. 9244 Tightness Leakage Test Set Order no. 21580 High pressure cone G 1/2 with sealing rings Order no.

  • Page 65: Declaration Of Conformity

    Declaration of conformity Declaration of conformity The manufacturer: Wöhler Technik GmbH Schützenstr. 41, D-33181 Bad Wünnenberg declares that the product product name: Leakage Tester model number Wöhler DC430 device class: V, according to the prescription G 5952 of the DVGW (German Association of Gas and Water Engineers) complies with the following requirements for conformity and electromagnetic compati- bility.

  • Page 66: Sales And Service Points

    Gneisenaustr.12 80992 München Tel.: +49 89 1589223-0 Fax: +49 89 1589223-99 sued@woehler.de International Czech Republic Wohler USA Inc. Wöhler Bohemia s.r.o. 20 Locust Street, Suite 205 Za Naspern 1993 Danvers, MA 01923 393 01 Pelhrimov Tel.: +1 978 750 9876 Tel.: +420 5653 49019...

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