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Bacharach PCA2 Instruction, Operating & Maintenance

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Enlarged version
Portable Combustion Analyzer
Instruction 0024-9448
Operation & Maintenance
Rev. 6 - September 2010
Headquarters:
621 Hunt Valley Circle, New Kensington, PA 15068
Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666
Website: www.MyBacharach.com • E-mail: help@MyBacharach.com
Printed in U.S.A.
Product Leadership • Training • Service • Reliability

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  • Page 1 Portable Combustion Analyzer Instruction 0024-9448 Operation & Maintenance Rev. 6 - September 2010 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 Website: www.MyBacharach.com • E-mail: help@MyBacharach.com Printed in U.S.A. Product Leadership • Training • Service • Reliability...

  • Page 2: Calibration

    WARRANTY Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in mater ial and manufac ture and will conform substan tially to Bach arach Inc.’s ap plicable spec i fi ca tions. Bacharach’s li a bil i ty and Buyer’s remedy under this warranty are lim it ed to the repair or replacement, at Ba charach’s option,...

  • Page 3: Table Of Contents

    Contents Contents 1 Introduction ........1-1 1.1 PCA 2 General Description ....... 1-1 1.2 Sales Combo &...
  • Page 4 Contents Notes: 3.21 Run/Hold Screen Format ......3-21 4 Operation ........4-1 4.1 Operating Tips .
  • Page 5 6.6 Thermocouple Replacement ......6-11 Bacharach of Canada, Inc. 6.7 Pump Replacement ........6-13 250 Shields Court Unit #3 6.8 Cleaning the Probe .
  • Page 6 Contents Parts & Service Notes: Optional Accessories Part No. AC Power Adapter (Input: 100–240 VAC, 50/60 Hz; Output: 9 VDC @ 1 A) ..24-1404 Ambient Air Thermocouples (T-AIR), K-Type: 10 ft..........104-1797 1 inch .

  • Page 7: Introduction

    Parts & Service Introduction 1 Introduction 8.2 Accessories 1.1 PCA 2 General Description Standard Accessories Part No. Carrying Case ......... . 24-0865 The PCA 2 is a commercial-grade hand-held combustion and emissions Batteries, 'AA' Alkaline .

  • Page 8: Sales Combo & Model Configurations

    Introduction Parts & Service 1.2 Sales Combo & Model Configurations Sales Combo 24-8350 24-8351 24-8352 Sales Combo (Kit) 24-8370 24-8371 24-8372 Model Type PCA2 Only Part Number 24-7301 24-7302 24-7303 Measurements Oxygen (O ✓ ✓ ✓ Stack Temperature ✓ ✓...
  • Page 9 Screw, #4 x 1/2 LG ......02-2144 PCA2 Only Part Number 24-7304...

  • Page 10: Features & Benefits

    Introduction Parts & Service 1.3 Features & Benefits 8 Parts & Service • Powered by 4 ‘AA’ alkaline batteries, or NiMH rechargeable batteries. 8.1 Replacement Parts An optional AC power adapter provides continuous operation. • Internal charging circuit allows rechargeable batteries to be charged Item inside the analyzer with the use of the optional AC power adapter.

  • Page 11: Operational Overview

    •Custom Display Formats 4. Press ESC key to exit back to the Diagnostic menu or the Menu (F2) key •Calibration Reminders - PCA2 can be set up to remind the user that to exit back to the Main Menu. calibration is past due.

  • Page 12: Connector Descriptions

    Introduction Troubleshooting Begin the combustion test by first inserting the analyzer’s probe tube into Pressure sensor is measuring pressure outside the range of +/ - 3 inches the stack-gas stream of the appliance under test, and then pressing the of water column at startup. Ensure that the analyzer is sampling button to display the Combustion Test RUN screen.
  • Page 13 Troubleshooting Introduction 7.3 Error Messages Displayed After Warm-Up IrDA – Wireless printer LCD – 160 x 160 communications port graphic display If there were problems detected during warm-up, error messages that describe the nature of the problems are displayed immediately following the F1 / F2 / F3 –...

  • Page 14: T-Air (Primary Air Thermocouple)

    OFF to prevent the batteries from overheating. As a precaution, the charger circuit is automatically toggled back to its OFF All other repairs should be performed by an authorized Bacharach Service state when the analyzer is turned OFF.

  • Page 15: Irda (Printer Interface)

    Maintenance Introduction 6.8 Cleaning the Probe 1.5.6 IrDA (Printer Interface) Data that has been stored in the analyzer’s memory can be printed on a The probe tube and gas-sample hose will become dirty under normal use. compatible IrDA wireless printer by aligning their IrDA communication Note that the water trap’s filter element should prevent soot from reaching ports.
  • Page 16 Introduction Maintenance 6.7 Pump Replacement When viewing the Memory or Logging PAGE+ (F3): Directory, each press of this button pages up through the directory. Holding this button down speeds up the Parts & Tools Required: paging process. Replacement Pump: The arrow buttons move the cursor on the LCD in the di- rection of the arrow.

  • Page 17: Caution: Possible Need For Smoke Test

    Maintenance Introduction 1.7 Caution: Possible Need for Smoke Test 3. Pull old thermocouple from probe body and discard. 4. The new thermocouple has been coiled for shipping purposes. When the instrument is used in an inefficient furnace or boiler CAUTION: Straighten the thermocouple using your thumb and index finger.

  • Page 18: Specifi Cations

    Specifi cations Maintenance 2 Specifications 6.6 Thermocouple Replacement Using the appropriate thermocouple replacement kit listed below, replace The PCA 2 Directly Measures and Displays: the probe’s thermocouple as follows: The gases displayed depend on the analyzer’s model number. Refer to Section 1.2. Thermocouple Replacement Kits: Oxygen .
  • Page 19 Maintenance Specifi cations 6.5 Nitric Oxide Sensor Battery Replacement Normal Operating Conditions: Temperature: A single lithium battery, located on the NO Smart Sensor assembly, applies Analyzer ....... 32 to 104 ºF (0 to 40 ºC) a bias voltage to the NO sensor to prevent the sensor from destabilizing Probe Tip .

  • Page 20: Power Requirements

    Specifi cations Maintenance Power Requirements: page 6-4. 12. Plug the sensor into analyzer; and then reattach tubing to gas cup. Four disposable ‘AA’ alkaline batteries provide at least 15 hours of continu- 13. Install the sensor retainer and battery cover. ous operation.
  • Page 21 Maintenance Specifi cations 6.4 Sensor Only Replacement Notes: All sensors are replaced in a similar manner. Do the following to replace either the O2, CO-LO, CO-HI, NO, NO2, or SO2 sensor. Refer to Section 8.1 Replacement Parts for list of sensors and part numbers. Turn OFF the analyzer.

  • Page 22: Initial Setup

    Maintenance 3 Initial Setup 6.3 Smart Sensor Replacement Bacharach’s Smart sensor technology allows new sensors to be installed 3.1 Scope without needing to be calibrated inside the analyzer. NOTE: Sensors may be purchased with and without the Smart sensor technology PCB.

  • Page 23: Using The Ac Power Adapter

    Maintenance Initial Setup 6.2 Water Trap / Filter Maintenance 3.2.2 Using the AC Power Adapter The AC power adapter is capable of powering the analyzer on a continuous basis. The adapter plugs into an appropriate 100–240 VAC, 50/60 Hz wall 6.2.1 Emptying the Water Trap Chamber outlet, and produces an output of +9 VDC.
  • Page 24 Initial Setup Maintenance Option Primary / LCD Connector Sensor Connector Connector Ambient Air (opposite side of board) (typical 4 places) (Optional External Thermocouple Measurement) T-STACK T-AIR (T-AIR) (Optional) POWER Factory Test AC Power Connector Adapter Jack (POWER) Differential Pressure Hose (—...

  • Page 25: Operating Parameters

    Maintenance Initial Setup Initial Setup Initial Setup 3.4 Operating Parameters PRESSURE SENSOR The PCA 2 is set up at the factory for the following operating parameters: on printed circuit board +∆P (Top) Fuel .....Natural Gas PURGE PUMP –∆P (Bottom) Temperature Units .

  • Page 26: Temperature Units Selection

    Initial Setup Initial Setup Maintenance appear at the top of the screen. Sensor Positions Note: In addition to the standard fuels programmed into the Model PCA2, Bacharach can develop custom fuel codes based on the 24-7301 24-7302 24-7303 24-7304 24-7305 24-7306 Position customers specific needs.

  • Page 27: Pca 2 Disassembly

    Maintenance Initial Setup 6.1 PCA 2 Disassembly The following procedure describes how to disassemble the analyzer, while Figures 6-1 thru 6-4 illustrate how the analyzer is put together. Tools Required: Medium Phillips Screwdriver Rear Case Screws Procedure: (typical 4 places) 1.

  • Page 28: Pressure Units Selection

    Initial Setup Maintenance 3.7 Pressure Units Selection 6 Maintenance Select to display pressure in Inches of Water Column (inwc), millibar (mb), Customer maintenance of the PCA 2 is limited to the following: Pascals (Pa), or hectoPascals (hPa) as follows: Battery replacement or charging using AC power adapter (Section 3.2) MAIN MENU 1.

  • Page 29: Pollution Units Selection

    Calibration Initial Setup 3.8 Pollution Units Selection this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. The PCA 2 is capable of converting the measured ppm levels of CO, NO, CALIBRATE CO-HI 5.

  • Page 30: Date Setup

    CO-LO periods of time such as when the PCA2 is not in use (off-season stor- 3. Attach a 4,000 ppm CO cylinder to the age), simply reset the time and date after fresh batteries are installed regulator of the calibration fixture shown in when it is placed back in service.

  • Page 31: Time Setup

    Calibration Initial Setup 3.10 Time Setup by the CALIBRATION LIST screen being re-displayed. If the sensor’s output is low, but still usable, then the message “Good The time is stored in the format: hh:mm:ss AM/PM. MAIN MENU Calibration WARNING Low Sensor” will appear. The sensor will now Its value is part of the date and time stamp that is FUEL be marked as being Low in the DIAGNOSTICS screen.

  • Page 32: O2 Reference Setup

    Initial Setup Calibration 3.11 O Reference Setup If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life, Entry Not Saved” will appear followed MAIN MENU by the CALIBRATION LIST screen being re-displayed. The sensor will The measured values of CO, NOx, and SO can be FUEL...

  • Page 33: Print Pressure Selection

    Calibration Initial Setup 5.7 SO Sensor Calibration 3.12 Print Pressure Selection MAIN MENU This procedure spans the optional sulfur dioxide sensor to a known Select whether to print or not print the pressure FUEL gas level. measurement on the combustion test printout as PRESSURE follows: TEMPERATURE...

  • Page 34: Zoom-Display Selection

    Initial Setup Calibration 3.13 Zoom-Display Selection If the sensor’s output is too low to be usable, then the message “Bad Hold NGas Calibration Sensor End of Life, Entry Not Saved” will appear. The sen- sor will now be marked as being BAD in the DIAGNOSTICS screen. Combustion test data in the Run/Hold screen can NOTE: H calibration can be bypassed by pressing the ESC...

  • Page 35: Battery Charger Selection

    CALIBRATION MENU 1. If not already done, turn ON the analyzer PRINT PRESSURE Pressure and display the CALIBRATION LIST screen ZOOM Note: The PCA2 must be left turned ON to T-Stack per Section 5.2. BATTERY CHARGER charge the batteries. T-Air LOGGING 2.

  • Page 36: Logging Selection

    Initial Setup Calibration 3.15 Logging Selection The calibration range is from 32 to 41 °F (0 to 5 °C). An attempt to calibrate outside this range will cause the message “Applied Value – SETUP MENU High” (or Low) to appear at the bottom of the screen. When the logging function is activated, up to 500 (more) combustion test records will be automatically...

  • Page 37: Test Id Information

    Calibration Initial Setup 5.5 T-Air Calibration 3.17 Test ID Information This procedure first zeros and then spans the ambient-temperature chan- Test records can be identified (e.g. customer's name, burner number, and nel to known temperature values. location) by manually entering up to three lines of text, with each line con- taining a maximum of 20 alphanumeric characters.
  • Page 38 Initial Setup Calibration end this procedure by highlighting Edit Complete and pressing the ENT known temperature that will be applied for CALIBRATE TS-ZERO key to return to the Edit Test ID Menu. calibration purposes. Measured 34 °F Applied 032 °F 4.

  • Page 39: Username

    Calibration Initial Setup 3.18 Username The calibration range is from –6 to –2 inwc (–15 to –5 mb). An attempt to calibrate outside this range will cause the message “Applied Value High” (or Low) to appear at the bottom of the screen. The name of the user or owner of the analyzer (e.g.
  • Page 40 Initial Setup Calibration To Clear a Username proceed as follows: Section 3.8. In the following procedure inwc MAIN MENU CALIBRATION MENU is selected, but note that any unit-of-measure FUEL Pressure 1. Display the MAIN MENU by press- can be used for calibration purposes. PRESSURE T-Stack ing the...

  • Page 41: Language

    Calibration Initial Setup 3.19 Language Any errors detected during warm-up will ERRORS DETECTED be listed on the display immediately fol- Low Battery lowing warm-up. For example, the screen Information on the display screen can be shown in English, French, or to the right shows that the battery is low.

  • Page 42: Cal Reminder Period

    Run/Hold Format play the Setup Menu. Language Selection The smart sensors should be calibrated by an authorized Bacharach Ser- Button Sound vice Center (Section 8.3) every 6 months to 1 year to assure that the ana- Note: The date and time settings must be correct CAL Reminder Period lyzer continues to meet its published accuracy specifications.

  • Page 43: Run/Hold Screen Format

    Initial Setup 3.21 Run/Hold Screen Format PCA2 testdata is located in the Run/Hold screen. By pressing the Run/ Hold key, you should hear the pump running and see the word RUN at the upper-left hand corner of the display. The instrument is continuously measuring and calculating the data that is shown in the Run/Hold screen.

  • Page 44: Notes

    Initial Setup Operation BACHARACH, INC. MAIN MENU PCA 2 Change the order in which data is displayed as FUEL SN: xxxxxx follows: PRESSURE ===================== TEMPERATURE TIME 01:00:00 PM MEMORY 1. Display the MAIN MENU by press- DATE 10/06/06 SETUP ing the button.
  • Page 45 Operation Initial Setup 4.18 Printing Test Data Reset Display format back to factory default settings as follows: Combustion or pressure data that is currently being displayed can be sent 1. Display the MAIN MENU by press- to a printer using IrDA protocol as described below. MAIN MENU ing the button.

  • Page 46: Operation

    Operation Operation 4 Operation TABLE 4-2. DOWNLOADED DATA FIELDS Field Column Name Data Name or Value 4.1 Operating Tips Date Date of Test in mm/dd/yy Time Time of Test in 12 hour format (AM/PM) • When an analyzer is brought in from a cold vehicle, let it warm up slowly Test ID Information Input by User to minimize condensation.

  • Page 47: Turning On The Analyzer And Warm Up

    Operation Operation 4.17 Importing Saved Data Into a Spreadsheet 4.2 Turning ON the Analyzer and Warm Up Data that was recovered and saved as an ASCII text file with a “CSV” 1. Connect the probe and hose assembly, and make sure that the analyzer extension, as described in Section 4.14, can easily be opened for viewing is properly set up per Section 3 Initial Setup.

  • Page 48: Selecting A Fuel

    Step 2, but this time using the right-hand section of DIAGNOSTICS the “Bacharach PCA 2 Data Recovery Program” window. STATUS NOTE: If custom fuels were added to the instrument, they will be located at the bottom...

  • Page 49: Sampling Point

    Operation Operation 4.4 Sampling Point Stack Temp. – For atmospheric burner or FORCED AIR FURNACE Use this section gravity vented, forced air heating equip ment with Use this section of window a clamshell or sectional heat exchanger design, of window to Recover to Recover test each of the exhaust ports at the top of the...

  • Page 50: Performing A Combustion Test

    The following example screens show that the downloaded file will be range (i.e., oxygen level above 16%). placed into a pre-existing PCA2 Logging Data folder and given the filename Customer XYZ. 2. Use the up and down arrow keys to scroll to the T-STK reading. Loosen the thumbscrew on probe stop and move probe in and out of the stack until the stack’s core temperature (hot spot) is located as indicated...
  • Page 51 Operation Operation 4. Select “Install the software automatically (Recommended)” and click Next. 5. At the Hardware Installation window, click Continue Anyway. TABLE 4-1. LIST OF COMBUSTION TEST DATA Display Description of Measurement or Calculation Name of new USB Name hardware % Oxygen Carbon Monoxide (1) Combustion Efficiency...

  • Page 52: Pressure Label Selection

    USB device driver as follows: pressure. See Section 4.6 of the PCA2 Instruction Manual 24-9448 for pressure and draft measurement procedures. 1. Insert the PCA 2 CD into the computer's CD-ROM drive.

  • Page 53: Temperature Measurement Label

    (F2) if needed. *** °F 5. To label the data use the buttons to scroll 7. At this time the PCA2 Data Recovery Program icon should appear Type: Diff Temp through the available temperature label types. under "Start All Programs menu.

  • Page 54: Making A Draft / Pressure Measurement

    1. Insert the PCA 2 CD into the computer’s CD-ROM drive. will be displayed on the PRESSURE screen as the differential pressure between the two ports. 2. Locate the CD-ROM drive in Windows Explorer and open the PCA2 folder. Double-click the Setup.exe program to start the installation process.

  • Page 55: Saving Test Data

    Operation Operation 4.16 Downloading Stored Data to a Computer a. Press the button. ZERO (F2) PRESSURE ZERO b. Disconnect any hoses connected to the The combustion test data that was stored in either the analyzer’s Memory +∆P and –∆P ports, and then press Disconnect hose then Directory (Section 4.9), or Logging Directory (Section 4.14), can be down- zero the pressure sensor.

  • Page 56: Ending A Combustion Test

    Operation Operation 4.10 Ending a Combustion Test 4.15.3 Clearing Memory MAIN MENU When all memory (“snap shot”) locations used to WARNING! Burn Hazard. Do not touch the probe after FUEL store individual combustion test records have been removing it from the stack. Allow the probe to cool before PRESSURE filled, the next combustion test record saved will TEMPERATURE...

  • Page 57: Low Battery Alarm

    Operation Operation ting down, giving the operator an opportunity to keep the analyzer turned 4.15.2 Recalling Logged Test Data ON by pressing the button. RUN/HOLD Recall individual logged combustion test data If the PCA 2 was not purged with fresh air as MAIN MENU records as follows: described in Section 4.8, then the analyzer may...

  • Page 58: Data Logging

    MENU TIP: The latest PCA 2 data recovery software can be downloaded from http://www.bacharach-inc.com/downloads. 5. Press to display the data contained in the selected memory location. MEMORY DIRECTORY...

  • Page 59: Turning On Data Logging

    Operation Operation 4.14.4 Ending the Data Logging Process 4.14.1 Turning ON Data Logging Data logging will stop and the pump will turn OFF after the prescribed IMPORTANT: Before turning ON data logging and starting the duration, or after all 500 memory locations are filled. data logging process, the analyzer should already be set up to perform a combustion test per Section 4.5.

  • Page 60: Setting The Logging Interval And Duration

    Operation Operation 4.14.2 Setting the Logging Interval and Duration 4.14.3 Starting the Data Logging Process The logging interval is the length of time between measurements, while After turning ON data logging and setting the the logging duration is the time allocated to the logging process. Set the interval and duration, the analyzer will pause LOGGING SUMMARY logging interval and duration as follows:...

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