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Wöhler A 550 Operation Manual

Flue gas analyzer
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Operation Manual
Flue Gas Analyzer
Wöhler A 550
Wöhler A 550 L
Wöhler A 550 H
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The Measure of Technology

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Summary of Contents for Wöhler A 550

  • Page 1 Operation Manual Flue Gas Analyzer Wöhler A 550 Wöhler A 550 L Wöhler A 550 H The Measure of Technology...

  • Page 2: Table Of Contents

    Component Explanation ......16 Probes and sensors ........19 Tightness test ..........21 Display ............22 Gas sampling path Wöhler A 550 ....23 Getting started ........25 Charging the battery ........26 Connecting the probe and cable-hose assembly ............. 27 5.2.1 Connecting the probe ........
  • Page 3 Spillage test ..........46 Tuning Guide ..........48 Manifold Pressure ........49 Temperatures ..........50 4 Pa - Test ........... 51 Logger Measurement (Wöhler A 550, only) . 56 8.10 SETUP ............59 8.11 Calibration ........... 65 Customer data ........65 Set up a new customer ........
  • Page 4 Contents 12.2.1 Coarse Filter ..........71 12.2.2 Removing condensate ......... 71 12.2.3 Replace cotton filter........72 12.2.4 Water Stop Filter ......... 72 12.3 Sensor diagnosis and replacement ..... 73 12.4 Replacing the battery ........77 12.5 Replacing the electrodes of the wood moisture probe ............

  • Page 5: General Information

    NOTE! Useful information Intended Use Use the Wöhler A 550 for flue gas analysis and control of heating appliances and for the meas- urement of wood moisture. The analyzer should be used indoors only. The Wöhler A 550 is not suitable for continuous operation.

  • Page 6: Basic Features

    General Information Basic features Device Basic equipment Wöhler A 550 Probe and hose as- sembly with 3 m hose and Wöhler A 550 H Flue Gas Probe 295 mm Ambient Temperature Probe (option) Wood Moisture Probe (option) Pressure adapter Charger with micro-...

  • Page 7: Information On Disposal

    General Information ATTENTION! Lock the For the transport deactivate the battery with the analyzer transport lock. Deactivate the battery by pushing the • transport lock to the right with a pointed object (wire or pen). When the instrument is delivered, the battery is always deactivated.

  • Page 8: Manufacturer

    CO cell and damages the cell. Do not use the CHP filter Wöhler A 550, if you want to measure the NO Concentration of the flue gas of the combustion engine with a CO cell.

  • Page 9: Features And Functions

    Features and functions Features and functions Wöhler A 550 Wöhler A 550 L Applications (depending on the accessories) 4 Pa-Test  Wood moisture   Spillage test   Tuning guide   Possible number of sen- sors Functionality Fresh air pump: search ...

  • Page 10: Specifications

    Range 0 to 4,000 Vol. ppm, resolution 1 Vol.-ppm Accuracy ± 20 ppm (< 400 ppm), otherwise 5% of reading Carbon monoxide in flue gas (Option for Wöhler A 550) Unit ppm of flue gas volume (dry conditions) Meas. principle...
  • Page 11 Range 0 to 5,000 Vol. ppm resolution 1 Vol.-ppm Accuracy ± 10 vol. ppm (0 ... 200 ppm), otherwise 5 % of reading Draft (PD) with 4 Pa Test (only Wöhler A 550) Unit Pascal Measurement Semiconductor principle...
  • Page 12 Specifications Draft (PD) (only Wöhler A 550L) Unit Pascal Measurement Semiconductor principle Range 0.00 to ± 110.00 hPa, resolution 1 Pa Accuracy 2 Pa (< 40Pa), otherwise 5% of reading Flue gas temperature (TS) Unit °C Measurement Thermocouple (NiCr-Ni) principle Range -20.0 °C to 800.0 °C, resolution 0.1 °C Accuracy...
  • Page 13 Specifications Wood moisture Reading water mass related to the absolute dry fuel mass Measurement resistance measurement principle Range 10.0 to 40.0 %, resolution 0.1 % Accuracy 40 % of reading wood 5 to 25° C temperature lifetime of the Depending on the frequency of utilization electrodes The electrodes will work correctly, if there is no surface damage or bending.

  • Page 14: Calculated Values

    Specifications Calculated Values Calculated Value Explanation Efficiency /SL Efficiency and losses in accordance to ASME standards ETA/QS Efficiency and losses in accordance to European standards (0.0 to 120%) in Vol. -% Range 0 – CO , resolution 0.1 % 2max , SO ;...

  • Page 15: Technical Data

    Specifications Technical Data Description Data Power supply Rechargeable Lithium-ion battery 3.7 V, 6700 mAh, charg- ing via USB Operation time Approx. 12 h (depending on the operating mode and the display backlight) Charging time for a full Approx. 7 hours charge Charging cycles of the After 500 charging cycles, at least 70% of the capacity are...

  • Page 16: Setting Up The Instrument

    Setting up the instrument Setting up the instrument Component Explanation Fig. 2: Device front Explanation On/off-button Condensate trap Opening handle for the condensate trap Probe compartment Opening handle for the probe compart- ment NOTE! Open the probe compartment by pulling down the opening handle.
  • Page 17 Setting up the instrument Fig. 3: Probe handle with gas probe (only Wöhler A 550) Probe probe handle: ON/Off-Key (only Wöhler A 550) Gas Probe 10 Union nut 11 Plexiglas plug with Coarse Filter On/Off-key (8) It is possible to start and stop the measurement with the On/Off-key (8) of the probe handle.
  • Page 18 19 Red point of orientation 20 Transport lock in the probe compartment Deactivate the battery by pushing the • transport lock to the right (see figure opposite) with a pointed object (wire or pen). Fig. 7: Interior of the probe compartment Wöhler A 550...

  • Page 19: Probes And Sensors

    Flexible capillaries for the 4 PA test (an adapter is needed) Fig. 9: Flexible capillaries Always use the CHP filter Wöhler A 550 (article 5523) when measuring the flue gas of combustion engines.. Fig. 10: Probe handle with CHP filter...
  • Page 20 Setting up the instrument Ambient Temperature Plug Fig. 12: Ambient Temperature Plug Ambient Temperature Probe Wöhler A 550, 185 mm Fig. 13: Ambient Temperature Probe Wood Moisture Probe Fig. 14: Wood Moisture Probe Spillage Probe Fig. 15: Spillage Probe...

  • Page 21: Tightness Test

    Setting up the instrument Tightness test Before the tightness test connect the gas probe (see chapter 5.2). Proceed as follows: Squeeze the ball pump (part 1). Plug the ball pump (part 1) on the gas probe (part 2) Release the ball pump. After the ball pump has been released, it may not fill with air or only fill very slowly.

  • Page 22: Display

    Setting up the instrument Display The Wöhler A 550 is operated via Touchscreen. The measurement menu is similar to the one of a smartphone. A fingertip on the icon starts the correspondent measurement mode. The active icons are graphically emphasized.

  • Page 23: Gas Sampling Path Wöhler A 550

    Setting up the instrument Gas sampling path Wöhler A 550 Fig. 18: Gas sampling path Wöhler A 550...
  • Page 24 Setting up the instrument The Wöhler A 550 has three pumps. A sample pump sucks the flue gas through the probe and the cable hose. A purge pump pumps fresh air to all sensors during the cali- bration phase. As the sample pump is cut-off during the calibration, the hotspot can already be searched during this time.

  • Page 25: Getting Started

    • probe handle the snap closure under the black probe handle. Snap closure Fig. 19: Wöhler A 550 with open probe compartment Before the first start up activate the batteries • by pushing the transport lock in the probe compartment (see Fig. 19) to the connector, see figure on the left.

  • Page 26: Charging The Battery

    Getting started Charging the battery The battery indication is displayed in the upper right corner of the screen. A fully charged battery is shown as a solid green battery symbol. If the battery symbol is red, the display illumina- tion is automatically reduced to save energy. In this case, charge the battery or use the Wöhler A 550 in mains operation.

  • Page 27: Connecting The Probe And Cable-Hose Assembly

    Getting started Connecting the probe and cable-hose assembly Fig. 22: Probe handle with gas probe Probe handle: ON/Off-Key (only Wöhler A 550) Gas probe Union nut Plexiglas plug with coarse filter 5.2.1 Connecting the probe Use different probes depending on the measurement to be done (one hole probe or multi hole probe).
  • Page 28 Fig. 24: Wöhler A 550 with open probe compartment dle and engage the snap closure. NOTE! The connectors of the probes Wöhler A 550 and Wöhler A 550 L are different. Fig. 25: Female connector for the probe Wöhler A 550 L Fig.

  • Page 29: Using The Analyzer

    NOTE! The Wöhler A 550 L is not equipped with a fresh air pump. Therefore it will not be pos- sible to search the hotspot during the calibration process, if you work with the Wöhler A 550 L. In this case expose the probe to fresh air during the calibration process.
  • Page 30 Click on the "Data Exchange” icon to finish the Data Exchange hotspot search and enter the data exchange mode. In this mode data can be exchanged be- tween the Wöhler A 550 and the PC via USB or WLAN. Opens the main menu. Only those submenus are Menu available which can be started without hotspot search.

  • Page 31: Measuring

    Using the Analyzer Measuring Upon conclusion of the 60 seconds calibration procedure and the hotspot search the analyzer will display the main combustion efficiency test screen. At the same time the purge pump will turn off and the sample pump will turn on. 6.3.1 Readings screen Al readings (measured and computed values) will...
  • Page 32 Using the Analyzer Possible units Measured and computed values: Vol.-% Oxygen content Vol.-% Carbon dioxide content Flue gas loss ppm; mg/m Carbon monoxide, referred to dry flue gas, diluted value ppm, mg/m , mg/kWh, mg/MJ Carbon monoxide, corrected (air free) kg/m or kg/kg (depending on Condensate qty.

  • Page 33: Selecting The Fuel

    Using the Analyzer 6.3.2 Selecting the fuel The selected fuel is shown in the topline on the left of the readings screen. Click on the fuel key to enter the fuel options • menu. Optional fuels as below: Natural gas, Fuel Oil 2, Fuel Oil 4, Fuel Oil 6, Bio- fuel, LPG, Propane, Kerosene, Digester Gas, Coal, Wood, Pellets and four user defined fuels NOTE!

  • Page 34: Options

    Using the Analyzer 6.3.4 Options In the readings screen a click on one of the icons at the bottom offers the following options: Graph A click on the Graph icon generates a graph of • the measured values. Above the graph the measured value, which is •...
  • Page 35 • dle to stop the measurement and hold the val- ues. (The sample pump continues.) NOTE! Only the Wöhler A 550 is equipped with a Start/Stop button. CO protection ON To protect the CO sensor (4,000 ppm), the CO (only Wöhler A 550) protection pump will start automatically to operate when a preset CO threshold value is exceeded.
  • Page 36 Using the Analyzer Pumps off Click on "Pumps OFF" to turn off the gas • pump and the CO protection pump. Pumps on Click on "Pumps on" to turn on the gas pump. • Purge on • If the measurement has stopped, click on "Purge on"...

  • Page 37: Readings Menu

    Readings Menu Readings Menu If the user accepts a record, the analyzer will en- ter the readings menu automatically. It is also possible to enter the readings menu by clicking on the readings icon in the main menu. In the read- ings menu a list with all possible measurements and tests is shown.

  • Page 38: Save Data In The Customer Menu

    After printing, the analyzer will enter the meas- urement mode again. Fig. 33: Printing the readings of the Wöhler A 550 on the Thermoprinter Wöhler TD 100. Save data in the cus- Click on the “Save” icon to save a customer •...

  • Page 39: Save Data With The "Quick Save" Option

    Menu Save data with the If the quick save option is activated in the Setup- Menu (see Chapter 8.10), the analyzer will auto- “Quick save” option matically save the measurement records under a new customer. The customer name will be the measurement date and the measurement time.

  • Page 40: Device Data

    Menu Device data In the “Device data” screen the user can enter information about the heating system. He can save this information together with the readings in the customer folder. Select a parameter. • Fig. 36: “Device data” screen Enter the correspondent information. •...

  • Page 41: Ambient Co

    Menu Ambient CO The option 'Ambient CO' offers a graphical assist- ed ambient CO test. The current ambient CO concentration is shown over the elapsed measurement time. The figure on the left shows an 'Ambient CO' test over a time period of 230 seconds and the current CO level is 2 ppm.

  • Page 42: Wood Moisture

    NOTE! It is necessary to connect the Wood moisture probe Wöhler A 550 to the analyzer be- fore performing the wood moisture test. ATTENTION! Before starting the test, check that the needles/electrodes are not bent. If the elec- trodes are bent, the distance will not be 25 mm any more, so that the measurement result may not be correct.

  • Page 43: Connecting The Probe

    Connecting the Probe Plug the connectors of the Wood Moisture • Probe Wöhler A 550 or the Wood Moisture Probe Wöhler HBF 420 to the female con- nector at the bottom of the analyzer. Fig. 39: Connectors for the wood mois-...
  • Page 44 Menu Selecting the type of wood Click on the wood in the upper left corner of • the screen. A list with different woods will appear : • The following woods can be selected. Maple, birch, beech, oak, ash, spruce, chestnut, pine, larch, linden, poplar, plane, fir, elm.
  • Page 45 Menu Measuring the wood moisture Split the wood log in the middle and perform • the measurement immediately after that at the inside part of the log. The electrodes should penetrate into the wood • approx. 6 mm. ATTENTION! Insert the electrodes only if possible without ap- plying force.

  • Page 46: Spillage Test

    1 Measurement of the condensation on the sensor board. 2 Temperature measurement NOTE! Connect the spillage probe Wöhler A 550 to the analyzer. Plug the connector of the Spillage Probe Wöh- • ler A 550 to the female connector at the bot- tom of the analyzer.
  • Page 47 Menu Guide the probe along the areas to be in- • spected. Fig. 45: Spillage test: Searching for condensate The dew point will be indicated on a scale from 1 to 100. (0% = no condensation) In the display the user can observe on the graph, when condensation rises.

  • Page 48: Tuning Guide

    Menu Tuning Guide In the "Tuning Guide" menu all combustion test related readings are presented in a graph over the excess air. The tuning guide offers an advanced guidance to the technician to properly adjust the burner. • In the main menu, click on the “Tuning guide” Tuning Guide icon.

  • Page 49: Manifold Pressure

    Menu Manifold Pressure • To perform a manifold pressure test click on the “Manifold Pressure” icon in the main menu screen. Connect a pressure hose to the negative • Pressure connector at the bottom of the ana- lyzer . Fig. 48: Pressure connector The options in the “Manifold Pressure”...

  • Page 50: Temperatures

    Menu Temperatures • To measure the temperature click on the “Temperature” icon in the main menu screen. NOTE! Make sure you connect the Ambient Air Plug, see Fig. 12. The options in the “Manifold Pressure” mode screen are: Option “Cancel”: click “Cancel” to exit the •...

  • Page 51: Pa - Test

    Menu 4 Pa - Test The 4 Pa Pressure Test is a simple control of the depression limit 4 Pa. With the 4 Pa- Test the user controls if there is sufficient combustion air in the room where the fire place is installed.
  • Page 52 Depression in the fireplace room in relation to the pressure at the reference point will lead to a negative differential pressure. Fig. 51: Probe handle with adapter for capillary hose (only Wöhler A 550) In the main menu select 4 Pa test. • 4 PA test...
  • Page 53 Menu How to perform the 4 Pa Pressure Test: Switch on appliance and all air conditioning (fan, dryer) with maximum power. Open an outside window or a door to the reference room and test proper operation of the appliance, ensure that there are no back- draft conditions.
  • Page 54 Menu The second capillary hose will stay uncut in the fireplace room. Click on "Start" to start the 4 PA-test. The meter will now record the pressure profile for 4 minutes. Open the window/door for about 30 seconds, so that the zero line can be registered. (Every 30 seconds an acoustic signal will sound.) Close the window/door for about 30 seconds, control depression.
  • Page 55 Menu Normally a diagram as shown in figure on the left will appear. The pressure peaks in the diagram are caused by the rapid movement of the window or the door and therefore they are not relevant for the interpretation of the diagram. In the figure on the left the pressure drop is about 2,8 Pa.

  • Page 56: Logger Measurement (Wöhler A 550, Only)

    3 min purging Automatic shut down of the analyser When the logger configuration is completed the Wohler A 550 will calculate the ending date and time of the measurement for information purpos- Fig. 54: schematic representation of a logger measurement...
  • Page 57 Menu Enter the start date and time • Enter the measurement interval, the interval • duration in the sample in the figure on the left is 10 seconds Enter the number of measurements (up to • 9,999 measurements are possible). NOTE! The analyzer calculates the date and time of completion of the logger measurement for infor-...
  • Page 58 • The ON/OFF button will flash during intervals > 8 min When the logger measurement is finished • connect the analyzer to a computer to down- load the data (please refer to Wöhler A 550 Data Management PC Software manual).

  • Page 59: Setup

    Menu 8.10 SETUP In the setup-menu the user can adjust the screen or the measurement process. In order to see all parameters, scroll to the top or the bottom of the screen by sweeping the left column with a finger. •...
  • Page 60 In the main menu select Setup > WLAN- • configuration • Select between 3 WLAN modes: Off, Direct connection and Router connec- tion. Fig: 58: WLAN configuration: Mode A: Mode „OFF“ It is not possible to use the Wohler A 550 App.
  • Page 61 Fig. 59: WLAN configuration – Direct connection Encryption Select the channel where the Wohler A 550 sends. You can select a channel where there are few other devices. NOTE! Normally it is not necessary to change this setting.
  • Page 62 OK, in the upper display the WLAN icon the selected customer will appear and the text “WLAN connected”. Connect your mobile device to the same rout- • er network. Open the Wohler A 550 App. • In the App, click on “Connect device”. •...
  • Page 63 Menu The App will now connect to the Wohler A 550. NO2 factor Here the user can enter the NO percentage on which the calculation of the NO value is based. The default NO percentage is 5 %. Only change...
  • Page 64 Menu readings segment • OK: Confirm the modification and return to the Setup menu. Fig. 62: Configuration of the readings segment. Customer Logo Click on "Change", enter your logo and con- • firm with OK. Your logo will now appear on all printouts.

  • Page 65: Calibration

    Customer data 8.11 Calibration In the calibration menu a digitally assisted calibra- tion of all sensors can be done. To open the cali- bration menu it is necessary to enter an internal password. This way unauthorized persons cannot calibrate the analyzer and incorrect settings are avoided.
  • Page 66 Customer data Enter the name and the number of the cus- • tomer and the fireplace. Confirm with OK. Fig. 63: Creating a new customer folder...

  • Page 67: Save Records

    Save records In the Readings menu (see chapter 7) click on • the Save-icon to save all marked measure- ment records under a customer and a fire- place. The analyzer will enter the customer menu. The customer menu shows a list of all customers. Click on a customer.

  • Page 68: Search Function : Customer, System, Customer Number, Installation Number

    Search function : In the customer menu click on the “customer • search” icon. customer, system, customer number, installation number • Enter any part of the customer name. In this case it is not necessary to observe the upper and lower case. At the bottom the first result will be shown.

  • Page 69: New Customer

    To delete all customers from the analyzer click • on the "Delete all" icon. Data exchange With the Wöhler A 550 Software it is possible to exchange the data with the PC via USB or WLAN. with the PC NOTE! The data transfer and the functions of the Software are explained in the Manual Wöhler...

  • Page 70: Maintenance

    Maintenance Maintenance Proper operation of the Wöhler A 550 requires regular maintenance. 12.1 Maintenance work Interval Maintenance work After every Press condensate out of the combustion test coarse filter. Control the condensate trap and remove condensate and water if necessary.

  • Page 71: Replacing The Filters

    Maintenance 12.2 Replacing the filters The sensible sensors are protected against condensate by different filters. The filters must be replaced or dried regularly. 12.2.1 Coarse Filter Plexiglas plug A coarse filter located in the probe handle • prevents soot from entering the hose. After every measurement control if it is wet.

  • Page 72: 12.2.3 Replace Cotton Filter

    Maintenance Condensate outlet. Remove the condensate cup from the con- • densate spiral. The condensate outlet remains in the cup. Spill the condensate out of the cup. • Condensate spiral Condensate cup Fig. 70: Condensate trap 12.2.3 Replace cotton filter The cotton filter is located in the condensate spi- ral.

  • Page 73: Sensor Diagnosis And Replacement

    4 years The sensors can be changed by the customer or by an authorized service point or at the factory. The Wöhler A 550 has an advanced electronic self diagnosis program. You can enter the diagnosis screen directly after having switched on the analyzer during self check and calibration .
  • Page 74 Maintenance The diagnosis screen shows the sensor status • (OK or NOT OK) and the firmware version. A click on the sensor opens a window with • important sensor information. Click on “Back” to start the search for the • hotspot again.
  • Page 75 The sensors can be replaced in the factory, in the service points or by the user himself. The order of the sensors is as follows (from the left to the right): O -Sensor, NO-Sensor, -Sensor (option: SO -Sensor) (only Wöhler A 550), CO -Sensor (only Wöhler A high 550), CO Sensor.
  • Page 76 Maintenance Battery Purge pump Flexible conductor Connecting tube 2 pin connector - sensor Sensor holder CO-sensor for gas channel of the O sen- Fig. 75: Bottom of the analyzer without cover • Slightly lift the left side of the sensor holder and remove the black connecting tube for the gas channel.

  • Page 77: Replacing The Battery

    Maintenance Replacing the other sensors Pull the small locking mechanism (1) forward. (NO, NO , SO , CO , CO) high Take off the white flexible conductor (2). • • Replace the sensor by a new one. Plug the flexible conductor in his place and •...
  • Page 78 The Wöhler A 550 is equipped with a rechargeable lithium ion battery 3.7 V. Only after a long working period the battery has to be changed. In this case send the analyzer to your dealer or change the battery as follows: Switch off the analyzer.

  • Page 79: Replacing The Electrodes Of The Wood Moisture Probe

    Analyzer check 12.5 Replacing the elec- Control if the electrodes are damaged. Take • care that the distance between the electrodes trodes of the wood is 25 mm. moisture probe Broken or damaged electrodes can be ex- • changed by the user. Loosen the damaged electrodes with an appropriate tool (gripper, screw wrench or ring wrench).

  • Page 80: Warranty And Service

    The final control will be recorded in detail in a test re- port and delivered with any unit. If used properly, the warranty period for the Wöhler A 550 will be 4 years from the date of sale. Consumables (e.g. thermocouple, batteries and special sensors) are not cov- ered by this warranty.

  • Page 81: Declaration Of Conformity

    Flue gas analyzer model number: Wöhler A 550 complies with the key safety requirements set down in the guidelines of the Council for the Harmonization of the Legal Requirements of the Member States 2014/53/EU.

  • Page 82: Accessories

    Accessories Accessories Probes Flexible Probe Wöhler A 550, 300 mm Order no. 3242 Multi Hole Probe Order no. 9615 Kit of capillary tubes Order no. 4521 Spillage Probe for the inspection of burner appliances for flue-gas Order no. 5512 spillage Ambient Air Probe 280 mm Order no.

  • Page 83: Points Of Sale And Service

    Points of sale and service Points of sale and service Germany Wöhler West Steiger-Stein-Str. 5 Wöhler Technik GmbH 44805 Bochum Wöhler-Platz 1 Tel.: +49 234 516993-0 33181 Bad Wünnenberg Fax: +49 234 516993-99 Tel.: +49 2953 73-100 west@woehler.de Fax: +49 2953 73-96100 Wöhler Süd info@woehler.de Gneisenaustr.12...

This manual is also suitable for:

A 550 lA 550 h

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