1. Manuals
  2. Brands
  3. Bacharach Manuals
  4. Analytical Instruments
  5. PCA 2
  6. Operation and maintenance manual

Bacharach PCA2 Operation And Maintenance Manual

Portable combustion analyzer
Hide thumbs Also See for PCA2:
Table of Contents

Advertisement

Quick Links

Download this manual
Portable Combustion Analyzer
Instruction 24-9448
Operation & Maintenance
Rev. 4 - July 2009
Product Leadership • Training • Service • Reliability

Advertisement

Table of Contents
loading

Related Manuals for Bacharach PCA2

Summary of Contents for Bacharach PCA2

  • Page 1 Portable Combustion Analyzer Instruction 24-9448 Operation & Maintenance Rev. 4 - July 2009 Product Leadership • Training • Service • Reliability...
  • Page 2 Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach, to the replacement of this Product or parts thereof that are defective in title.

  • Page 3: Table Of Contents

    Contents Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 PCA 2 General Descrpton .
  • Page 4 Contents 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Operatng Tps .
  • Page 5 Contents 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 PCA 2 Dsassembly .

  • Page 6: Instruction

    Contents Notes: Instruction 24-9448...

  • Page 7: Introduction

    Introduction 1 Introduction 1.1 PCA 2 General Description The PCA 2 s a commercal-grade hand-held combuston and emssons analyzer desgned for on-demand samplng of lght ndustral, nsttu- tonal, commercal and resdental furnaces, applances, and bolers. The basc nstrument s suppled wth a probe and hose assembly, nstructon manual, factory calbrated smart sensors, 4 'AA' alkalne batteres, Data Download Software wth USB cable and carryng case.
  • Page 8 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 Prmary / Ambent Ar Temperature Carbon Monoxde Low (CO Pressure / Draft...
  • Page 9 Introduction Sales Combo 24-8353 24-8354 24-8355 Sales Combo (Kit) 24-8373 24-8374 24-8375 Model Type PCA2 Only Part Number 24-7304 24-7305 24-7306 Measurements Oxygen (O Stack Temperature Prmary / Ambent Ar Temperature Carbon Monoxde Low (CO Pressure / Draft Carbon Monoxde Hgh (CO...

  • Page 10: Features & BenefTs

    Introduction 1.3 Features & Benefits • Powered by 4 ‘AA’ alkalne batteres, or NMH rechargeable batteres. An optonal AC power adapter provdes contnuous operaton. • Internal chargng crcut allows rechargeable batteres to be charged nsde the analyzer wth the use of the optonal AC power adapter. •...

  • Page 11: OperatOnal OvervEw

    Introduction •Language optons ncludng Englsh, French, and Spansh •Custom Dsplay Formats •Calbraton Remnders - PCA2 can be set up to remnd the user that calbraton s past due. 1.4 Operational Overview The PCA 2 s powered by ether ts 4 nternal batteres, or by an optonal AC power adapter that operates from any convenent source of 100–...

  • Page 12: Connector DescrPtOns

    Introduction analyzer and s placed n the burner’s prmary-ar stream. Begn the combuston test by frst nsertng the analyzer’s probe tube nto the stack-gas stream of the applance under test, and then pressng the RUN/HOLD button to dsplay the Combuston Test RUN screen. The ana- lyzer wll begn to contnuously montor the stack temperature, %O emsson levels n the stack gas and then dsplay measured and calculated values on ts LCD.
  • Page 13 Introduction IrDA – Wireless printer LCD – 160 x 160 communications port graphic display F1 / F2 / F3 – ENT: Soft Menu Buttons, • Selects a highlighted whose functions are menu item, or confirms the defined by labels entry of data appearing above them on LCD USB –...

  • Page 14: T-Air (PrMary AR Thermocouple)

    Introduction 1.5.2 T-AIR (Primary Air Thermocouple) If thermocouple P/N 104-1797 (10 feet long) or Utlty Wand P/N 104-1799 (12 nch rdged probe wth handle and 5 foot coled cable) s to be used to measure the burner’s prmary ar temperature, then connect ether of these thermocouples to the analyzer’s T-AIR connector.

  • Page 15: Opt (OptOn)

    Introduction compatble IrDA wreless prnter by algnng ther IrDA communcaton ports. Refer to Secton 4.16. 1.5.7 OPT (Option) The opton connector s used for optonal external measurement features. 1.6 Front Panel Buttons Descrptons of the front panel buttons are gven below. Note that a control may perform multple functons as determned by what screen s beng dsplayed at the tme.
  • Page 16 Introduction The arrow buttons move the cursor on the LCD n the d- recton of the arrow. In screens that requre the entry of alphanumercal data, use the buttons to move cursor across the screen and then use the buttons to ncre- ment and decrement the data.

  • Page 17: Specifications

    Specifications 2 Specifications The PCA 2 Directly Measures and Displays: The gases dsplayed depend on the analyzer’s model number. Refer to Secton 1.2. Oxygen ..........0 to 20.9% Stack Temperature .
  • Page 18 Specifications Normal Operating Conditions: Temperature: Analyzer ....... 32 to 104 ºF (0 to 40 ºC) Probe Tp .
  • Page 19 Specifications Power Requirements: Four dsposable ‘AA’ alkalne batteres provde at least 15 hours of contnu- ous operaton. NMH rechargeable batteres can also be used, wth the operatng tme dependent on battery type and condton. An optonal AC power adapter, whch runs from any convenent source of 100–240 VAC, 50/60 Hz power, can be used to power the analyzer on a con- tnuous bass.
  • Page 20 Specifications Notes: Instruction 24-9448...

  • Page 21: Initial Setup

    Initial Setup 3 Initial Setup 3.1 Scope Before usng the PCA 2, you MUST: • Install batteres, or plug n the optonal AC power adapter (Secton 3.2) • Connect the probe and hose assembly (Secton 3.3) • Check, and f necessary, make changes to the analyzer’s confguraton (Secton 3.4) 3.2 Power 3.2.1 Installing or Replacing Batteries...

  • Page 22: UsNg The Ac Power Adapter

    Initial Setup 3.2.2 Using the AC Power Adapter The AC power adapter s capable of powerng the analyzer on a contnuous bass. The adapter plugs nto an approprate 100–240 VAC, 50/60 Hz wall outlet, and produces an output of +9 VDC. The adapter’s output connector plugs nto the analyzer’s POWER jack located on the bottom of the unt (Fgure 3-2).
  • Page 23 Initial Setup Option Primary / Connector Ambient Air (Optional External Thermocouple Measurement) T-STACK T-AIR (T-AIR) (Optional) POWER AC Power Adapter Jack (POWER) Differential Pressure Hose (— ∆P) (Optional) Stack Gas Draft Gas Sample Thermocouple Hose Hose Connector (+ ∆P) (GAS) (T-STACK) Probe Tube Water Trap /...

  • Page 24: OperatNg Parameters

    Initial Setup 3.4 Operating Parameters The PCA 2 s set up at the factory for the followng operatng parameters: Fuel .....Natural Gas Temperature Unts .

  • Page 25: Temperature Units Selection

    Note: In addition to the standard fuels programmed into the PCA2, Bacharach can develop custom fuel codes based on the customers specific needs. The PCA2 can be programmed with 2 additional fuels which can be added to the instrument using the PC based software provided.

  • Page 26: Pressure Units Selection

    Initial Setup 3.7 Pressure Units Selection Select to dsplay pressure n Inches of Water Column (nwc), mllbar (mb), Pascals (Pa), or hectoPascals (hPa) as follows: MAIN MENU FUEL 1. Dsplay the MAIN MENU by pressng the PRESSURE MENU (F2) button. If necessary, press ESC TEMPERATURE untl MENU appears above F2.

  • Page 27: Pollution Units Selection

    Initial Setup 3.8 Pollution Units Selection The PCA 2 s capable of convertng the measured ppm levels of CO, NO, , and SO to varous polluton unts usng CFR40 Part 60 emsson factors. Note that the polluton-unt conversons for NO, NO and NOx are based on the molecular weght of NO Select to dsplay polluton unts n parts per mllon (ppm), pounds of pol-...

  • Page 28: Date Setup

    If the batteries are removed for extended periods of time such as when the PCA2 is not in use (off-season storage), simply reset the time and date after fresh batteries are installed when it is placed back in service.

  • Page 29: Time Setup

    Initial Setup 3.10 Time Setup The tme s stored n the format: hh:mm:ss AM/ MAIN MENU PM. Its value s part of the date and tme stamp FUEL that s saved along wth each combuston test re- PRESSURE TEMPERATURE cord. MEMORY SETUP Set the analyzer’s nternal clock to the current...
  • Page 30 Initial Setup 3.11 O Reference Setup MAIN MENU The measured values of CO, NOx, and SO can be FUEL ndvdually referenced to a specfc O percentage PRESSURE of between 0 and 15%. TEMPERATURE MEMORY SETUP Indvdually set up the O reference value for each CALIBRATION of the above gases as follows:...

  • Page 31: Print Pressure Selection

    Initial Setup 3.12 Print Pressure Selection MAIN MENU Select whether to prnt or not prnt the pressure FUEL measurement on the combuston test prntout as PRESSURE follows: TEMPERATURE MEMORY 1. Dsplay the MAIN MENU by pressng the SETUP CALIBRATION MENU (F2) button. If necessary, press ESC DIAGNOSTICS untl MENU appears above F2.

  • Page 32: Zoom-DSplay SelectOn

    Initial Setup 3.13 Zoom-Display Selection Hold NGas Combuston test data n the Run/Hold screen can be shown wth enlarged characters to make vew- ng easer. The operator can set zoom levels to CO 12 Standard, 2X, or 3X. The Standard zoom settng wll dsplay 8 lnes of combuston test data at one tme, 2X whch wll dsplay 4 lnes of combus- EFF 82.6...

  • Page 33: Battery Charger SelectOn

    OFF, thus requrng the operator to turn TIME the charger back ON when needed. REFERENCE PRINT PRESSURE ZOOM Note: The PCA2 must be left turned ON to BATTERY CHARGER charge the batteries. LOGGING (more) Turn the battery charger crcut ON and OFF as...

  • Page 34: Button Sound

    Initial Setup 3.15 Logging Selection – SETUP MENU When the loggng functon s actvated, up to 500 (more) combuston test records wll be automatcally LOGGING stored n memory at a preset nterval over a prede- TEST ID termned length of tme. USERNAME RUN/HOLD FORMAT LANGUAGE SELECTION...

  • Page 35: Test Id Information

    Initial Setup 3.17 Test ID Information Test records can be dentfed (e.g. customer's name, burner number, and locaton) by manually enterng up to three lnes of text, wth each lne con- tanng a maxmum of 20 alphanumerc characters. When a Test ID s se- lected ths nformaton wll be assocated wth all succeedng test records, and wll appear at the top of each test record when prnted, and n Excel fles when records are downloaded to a PC.
  • Page 36 Initial Setup end ths procedure by hghlghtng Edt Complete and pressng the ENT key to return to the Edt Test ID Menu. 9. Press ESC to go to the Test ID Menu or the RUN/HOLD key to return to the Run/Hold screen. Select a Test ID: 1.

  • Page 37: Username

    Initial Setup 3.18 Username The name of the user or owner of the analyzer (e.g. company name, ad- dress, phone number) can be stored n memory by manually enterng up to three lnes of text, wth each lne contanng up to 20 alphanumerc characters.
  • Page 38 Initial Setup To Clear a Username proceed as follows: MAIN MENU FUEL 1. Dsplay the MAIN MENU by press- PRESSURE ng the MENU (F2) button. If necessary, TEMPERATURE press ESC untl MENU appears above MEMORY SETUP CALIBRATION DIAGNOSTICS 2. Use the buttons to hghlght SETUP, and STATUS then press ENT to dsplay the SETUP MENU.

  • Page 39: Language

    Initial Setup 3.19 Language Informaton on the dsplay screen can be shown n Englsh, French, or Spansh. Select the desred language as follows: MAIN MENU 1. Dsplay the MAIN MENU by press- FUEL ng the MENU (F2) button. If necessary, PRESSURE TEMPERATURE press ESC untl MENU appears above...

  • Page 40: Cal RemNder PerOd

    Initial Setup 3.20 Cal Reminder Period The analyzer can be set to ndcate a calbraton remnder durng the 60 second warm-up perod. Calbraton remnders can be preset to occur 6, 8, 10, 12, or 15 months after the last calbraton. When the preset perod s exceeded the nstrument wll dsplay the remnder, and how long snce the sensors were last calbrated.

  • Page 41: Run/Hold Screen Format

    Initial Setup 3.21 Run/Hold Screen Format PCA2 testdata s located n the Run/Hold screen. By pressng the Run/ Hold key, you should hear the pump runnng and see the word RUN at the upper-left hand corner of the dsplay. The nstrument s contnuously measurng and calculatng the data that s shown n the Run/Hold screen.
  • Page 42 Initial Setup MAIN MENU Change the order n whch data s dsplayed as FUEL follows: PRESSURE TEMPERATURE 1. Dsplay the MAIN MENU by press- MEMORY ng the MENU (F2) button. If necessary, SETUP CALIBRATION press ESC untl MENU appears above DIAGNOSTICS STATUS 2.
  • Page 43 Initial Setup Reset Dsplay format back to factory default settngs as follows: 1. Dsplay the MAIN MENU by press- MAIN MENU ng the MENU (F2) button. If necessary, FUEL press ESC untl MENU appears above PRESSURE TEMPERATURE MEMORY 2. Use the buttons to hghlght SETUP, and SETUP CALIBRATION...

  • Page 44: Operation

    Operation 4 Operation 4.1 Operating Tips • When an analyzer s brought n from a cold vehcle, let t warm up slowly to mnmze condensaton. Temperatures below freezng wll not dam- age the analyzer; however, brngng a cold analyzer nto a warm, humd envronment may cause condensate to form nsde the case.

  • Page 45: TurnNg On The Analyzer And Warm Up

    Operation 4.2 Turning ON the Analyzer and Warm Up 1. Connect the probe and hose assembly, and make sure that the analyzer s properly set up per Secton 3 Initial Setup. IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer! 2.
  • Page 46 Operation 4.3 Selecting a Fuel HOLD NATURAL GAS 20. 9 % The top lne of the Combuston Test HOLD screen 0 ppm --- % shows the fuel currently selected. In the example --- % shown, the current fuel s NATURAL GAS. If nec- T-STK 71.5 °F essary, change the fuel as follows:...

  • Page 47: SamplNg PoNt

    Operation 4.4 Sampling Point Stack Temp. FORCED AIR FURNACE – For atmospherc burner or gravty vented, forced ar heatng equpment wth a clamshell or sectonal heat exchanger de- sgn, test each of the exhaust ports at the top of the heat exchanger.

  • Page 48: Performing A Combustion Test

    Operation 4.5 Performing a Combustion Test Ensure that the followng has been completed, and then proceed wth the combuston test as descrbed below: • Turn ON analyzer and allow t to warm up (Secton 4.2). • Select fuel beng burned (Secton 4.3). •...
  • Page 49 Operation TABLE 4-1 . LIST OF COMBUSTION TEST DATA Display Description of Measurement or Calculation Name % Oxygen Carbon Monoxde (1) Combuston Effcency % Carbon Doxde T-STK Stack Temperature T-AIR Prmary / Ambent Ar Temperature as measured ether n- ternally or by an optonal external thermocouple plugged nto the analyzer’s T-AIR connector CO(O) Carbon Monoxde ppm level referenced to a % of oxygen (2)

  • Page 50: Pressure Label SelectOn

    The pressure measurement can be labeed wth types ncludng gas pres- sure, dfferental across heat exchanger, draft readng, and dfferental pressure. See Secton 4.6 of the PCA2 Instructon Manual 24-9448 for pressure and draft measurement procedures. Label data as follows: 1.

  • Page 51: Temperature Measurement Label

    Operation 4.7 Temperature Measurement Label The dfference n temperature between two areas can be measured by us- ng the analyzer's two temperature channels and the Temperature screen. By usng the T-Ar channel as a reference, the temperature appled to the T-Stack channel wll be dsplayed on the Temperature Measurement screen as dfferental temperature between the two channels.

  • Page 52: MakNg A Draft / Pressure Measurement

    Operation 4.8 Making a Draft / Pressure Measurement The dfference n pressure (∆P) between two areas can be measured by usng the analyzer’s two pressure ports and the PRESSURE screen. By usng the –∆P port as the reference, the pressure appled to the +∆P port wll be dsplayed on the PRESSURE screen as the dfferental pressure between the two ports.

  • Page 53: Saving Test Data

    Operation a. Press the ZERO (F2) button. PRESSURE ZERO b. Dsconnect any hoses connected to the +∆P and –∆P ports, and then press ENT Disconnect hose then to zero the pressure sensor. press ENTER c. Reconnect any hoses. When measurng draft, simply leave the –∆P port open to the atmosphere and connect the probe’s PRINT...

  • Page 54: Ending A Combustion Test

    Operation 4.10 Ending a Combustion Test WARNING! Burn Hazard. Do not touch the probe after removing it from the stack. Allow the probe to cool before handling (about 5 minutes). 1. Remove probe from stack. 2. Allow the pump to run untl all combuston gases have been flushed from the analyzer as ndcated by the O readng returnng to 20.9%.

  • Page 55: Low Battery Alarm

    Operation 4.12 Turning OFF the Analyzer & Purging Turn OFF the analyzer by pressng the I/O but- ton for at least 2 seconds, or untl two beeps are heard. The unt wll count down 5 seconds before shuttng down, gvng the operator an opportu- nty to keep the analyzer turned ON by pressng the RUN/HOLD button.

  • Page 56: Data Logging

    (refer to Secton 4.14). Downloaded data s stored on the computer’s hard drve as a comma-separated-value ASCII text fle wth a CSV extenson, whch can be opened by most spreadsheet programs for analyss. TIP: The latest PCA 2 data recovery software can be download- ed from http://www.bacharach-inc.com/downloads. Instruction 24-9448 4-13...

  • Page 57: Data LoggNg

    Operation 4.14.1 Turning ON Data Logging IMPORTANT: Before turning ON data logging and starting the data logging process, the analyzer should already be set up to perform a combustion test per Section 4.5. Turn ON data loggng as follows: MAIN MENU 1.

  • Page 58: Setting The Logging Interval And Duration

    Operation 4.14.2 Setting the Logging Interval and Duration The loggng nterval s the length of tme between measurements, whle the loggng duraton s the tme allocated to the loggng process. Set the loggng nterval and duraton as follows: TIP: If the duration is set for more than 10 hours, we recom- mend using the optional AC power adapter to power the analyzer.

  • Page 59: StartNg The Data LoggNg Process

    Operation 4.14.3 Starting the Data Logging Process After turnng ON data loggng and settng the LOGGING SUMMARY nterval and duraton, the analyzer wll pause at the LOGGING SUMMARY screen, where the Interval 1 min currently selected nterval and duraton tme Duration 2 hr perods are dsplayed.

  • Page 60: Ending The Data Logging Process

    Operation 4.14.4 Ending the Data Logging Process Data loggng wll stop and the pump wll turn OFF after the prescrbed duraton, or after all 500 memory locatons are flled. To ext the Combuston Test LOG screen, press LOG NATURAL GAS 4.0 % the RUN/HOLD button twice to dsplay the Com- 12 ppm...

  • Page 61: Recalling Combustion Test Data

    Operation 4.15.1 Recalling Combustion Test Data Recall ndvdual combuston test data records as MAIN MENU follows: FUEL PRESSURE 1. Dsplay the MAIN MENU by pressng the MEMORY MENU (F2) button. If necessary, press ESC SETUP untl MENU appears above F2. CALIBRATION DIAGNOSTICS 2.

  • Page 62: Recalling Logged Test Data

    Operation 4.15.2 Recalling Logged Test Data Recall ndvdual logged combuston test data records as follows: MAIN MENU 1. Dsplay the MAIN MENU by pressng the FUEL MENU (F2) button. If necessary, press ESC PRESSURE untl MENU appears above F2. MEMORY SETUP 2.

  • Page 63: Clearing Memory

    Operation 4.15.3 Clearing Memory When all memory (“snap shot”) locatons used to MAIN MENU store ndvdual combuston test records have been FUEL PRESSURE flled, the next combuston test record saved wll MEMORY overwrte the oldest. SETUP CALIBRATION When all loggng memory locatons n the loggng DIAGNOSTICS drectory are full, they must be manually cleared STATUS...

  • Page 64: Downloading Stored Data To A Computer

    Operation 4.16 Downloading Stored Data to a Computer The combuston test data that was stored n ether the analyzer’s Memory Drectory (Secton 4.9), or Loggng Drectory (Secton 4.14), can be down- loaded to a computer usng the PCA 2 Data Recovery Program and USB cable that are suppled wth the analyzer.

  • Page 65: Pca 2 Data Recovery Program InstallatOn

    (P/N 24-1448). Install ths program as follows: 1. Insert the PCA 2 CD nto the computer’s CD-ROM drve. 2. Locate the CD-ROM drve n Wndows Explorer and open the PCA2 folder. Double-clck the Setup.exe program to start the nstallaton process.
  • Page 66 5. Clck Install to confrm the destnaton folder and user nformaton. 6. Clck Finish after all fles have been coped nto the destnaton folder. 7. At ths tme the PCA2 Data Recovery Program con should appear under "Start All Programs menu.
  • Page 67 Operation 4.16.2 Computer to PCA 2 Connection & USB Device Driver Installation Connect the USB cable (P/N 104-4032) that was suppled wth the PCA 2, and, f necessary, nstall the analyzer’s USB devce drver as follows: 1. Insert the PCA 2 CD nto the computer's CD-ROM drve. 2.
  • Page 68 Operation 4. Select “Install the software automatcally (Recommended)” and clck Next. Name of new USB hardware Select (Advanced). 5. At the Hardware Installaton wndow, clck Continue Anyway. 6. After the Found New Hardware Wzard has fnshed nstallng the software, clck Finish to close the Wzard. Instruction 24-9448 4-25...

  • Page 69: RecoverNg Data

    t a flename by clckng the Open Log File button. The followng example screens show that the downloaded fle wll be placed nto a pre-exstng PCA2 Logging Data folder and gven the flename Customer XYZ. 4-26...
  • Page 70 Operation Use this section Use this section of window of window to Recover to Recover Combustion Logging Data Data Start the download process by Status line clicking the showing PCA 2 desired Open is successfully Log / Data File connected to button the computer Select a...
  • Page 71 Step 2, but ths tme usng the rght-hand secton of the “Bacharach PCA 2 Data Recovery Program” wndow. NOTE: Once either the logging data or combustion data has been recovered, that portion of the recovery program’s window...

  • Page 72: Importing Saved Data Into A Spreadsheet

    Operation 4.17 Importing Saved Data Into a Spreadsheet Data that was recovered and saved as an ASCII text fle wth a “CSV” extenson, as descrbed n Secton 4.14, can easly be opened for vewng n most spreadsheet programs by smply double-clckng the flename. For example: double-clckng the flename Customer XYZ.csv should automat- cally open the spreadsheet program and dsplay the contents of the fle.
  • Page 73 Operation TABLE 4-2 . DOWNLOADED DATA FIELDS Field Column Name Data Name or Value Date Date of Test n mm/dd/yy Tme Tme of Test n 12 hour format (AM/PM) Test ID Informaton Input by User Fuel Fuel Name Oxygen Level Carbon Monoxde Level (see feld 26) ppm CO(O2) Carbon Monoxde Level referenced to a...

  • Page 74: Printing Test Data

    Operation (1) %O reference as selected per Section 3.12 (2) Pressure units as selected per Section 3.8 (3) Pollution units as selected per Section 3.9 (4) Shown only on prntout, not on LCD dsplay. 4.18 Printing Test Data Combuston or pressure data that s currently beng dsplayed can be sent to a prnter usng IrDA protocol as descrbed below.
  • Page 75 Operation BACHARACH, INC. PCA 2 SN: xxxxxx ===================== TIME 01:00:00 PM DATE 10/06/06 FUEL NATURAL GAS 4.0 % 12 ppm 82.6 % 9.5 % T-STACK 374 °F T-AIR 68.0 °F 21 % 3 to 18 in. 18 ppm (7.62 to 45.72 cm) NO Temp 70.5 °F...
  • Page 76 Operation Instruction 24-9448 4-33...

  • Page 77: Calibration

    ON. 5.1 Smart Sensors The PCA 2 uses Bacharach’s new “Smart Sensor” technology, meanng that the calbraton data for each sensor s stored n nonvolatle memory on the sensor’s prnted crcut board.

  • Page 78: Pressure Sensor CalBratOn

    Calibration Any errors detected durng warm-up wll ERRORS DETECTED be lsted on the dsplay mmedately fol- Low Battery lowng warm-up. For example, the screen to the rght shows that the battery s low. Correct any errors before proceedng. Refer to Secton 7.3 for a lstng of error messages and ther meanng.
  • Page 79 Calibration Section 3.8. In the following procedure inwc is CALIBRATION MENU selected, but note that any unit-of-measure can Pressure be used for calibration purposes. T-Stack T-Air 1. Assemble the pressure sensor calbraton CO-LO equpment as shown n Fgure 5-1, but DO NOT connect the analyzer to the calibration equipment at this time.

  • Page 80: T-Stack CalBratOn

    Calibration 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. 7. Wat untl the Measured readng stablzes, and then press to cal- brate the pressure sensor’s Measured value to that of the Appled value;...
  • Page 81 Calibration known temperature that will be applied for CALIBRATE TS-ZERO calibration purposes. Measured 34 °F Applied 032 °F 4. Set thermocouple smulator to 32 °F (0 °C), and then use the buttons to enter Press ENT an Appled value that exactly equals the set- to calibrate tng of the smulator.
  • Page 82 Calibration 5.5 T-Air Calibration Ths procedure frst zeros and then spans the ambent-temperature chan- nel to known temperature values. The use of an electronc thermocouple smulator s the preferred method of producng the desred calbraton temperatures. Alternatvely, contaners of ce water and bolng water can be used. Material Required: •...
  • Page 83 Calibration 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 High” (or Low) to appear at the bottom of the screen. 5. Wat untl the Measured readng stablzes, and then press calbrate the TA-Zero Measured value to that of the Appled value;...

  • Page 84: Co-Lo Sensor CalBratOn

    Calibration 5.6 CO-LO Sensor Calibration Note that the CO-LO sensor also measures H for the purpose of com- pensatng the CO readng for the presence of H n the gas sample. Ths procedure frst spans the CO-LO sensor and, optonally, spans the H part of the sensor to known gas levels.
  • Page 85 Calibration 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. The sen- sor will now be marked as being BAD in the DIAGNOSTICS screen. NOTE: H calibration can be bypassed by pressing the ESC button, after which the CALIBRATION LIST screen is re-dis- played.

  • Page 86: Sensor CalBratOn

    Calibration 5.7 SO Sensor Calibration Ths procedure spans the optonal sulfur doxde sensor to a known gas level. Material Required: • Calbraton Kt, P/N 24-7059 • Gas Cylnder: 100 ppm SO n Ntrogen, P/N 24-1158 Procedure: 1. If not already done, turn ON the analyzer and dsplay the CALIBRATION LIST screen per Secton 5.2.

  • Page 87: No Sensor Calibration

    Calibration 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 by the CALIBRATION LIST screen being re-displayed. The sensor will now be marked as being BAD in the DIAGNOSTICS screen. 6.

  • Page 88: Sensor CalBratOn

    Calibration by the CALIBRATION LIST screen beng re-dsplayed. If the sensor’s output is low, but still usable, then the message “Good Calibration WARNING Low Sensor” will appear. The sensor will now be marked as being Low in the DIAGNOSTICS screen. If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life, Entry Not Saved”...

  • Page 89: Co-Hi Sensor CalBratOn

    Calibration 5. Adjust regulator for a flowmeter ndcaton of approxmately 2 SCFH. Wat untl the Measured readng stablzes (approxmately 3 mnutes), and then press to calbrate the NO Measured value to that of the Appled value. The message “Good Calbraton” should brefly appear followed by the CALIBRATION LIST screen beng re-dsplayed.
  • Page 90 Calibration this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. CALIBRATE CO-HI 5. Adjust regulator for a flowmeter ndca- Measured 3895 PPM ton of approxmately 2 SCFH. Wat untl Applied 4000 PPM the Measured readng stablzes (approx- mately 3 mnutes), and then press Press ENT...

  • Page 91: Maintenance

    Sensor replacement (Secton 6.3) • Probe thermocouple replacement (Secton 6.6) • Pump (gas or purge) replacement (Secton 6.7) • Cleanng the probe (Secton 6.8) All other mantenance should be performed by an authorzed Bacharach Servce Center. Refer to Secton 8.3. Instruction 24-9448...

  • Page 92: Pca 2 DSassembly

    Maintenance 6.1 PCA 2 Disassembly The followng procedure descrbes how to dsassemble the analyzer, whle Fgures 6-1 thru 6-4 llustrate how the analyzer s put together. Tools Requred: • Medum Phllps Screwdrver Procedure: Rear Case Screws (typical 4 places) 1. Unplug all thermocouples from bottom of analyzer.
  • Page 93 Maintenance Sensor Positions Model 24-7301 24-7302 24-7303 24-7304 24-7305 24-7306 Position Sensors Sensor Retainer Type and position determined by model number Gas Pump Purge Pump Motor Connector Motor Connector Battery & Pump Chassis Pressure Sensor on printed circuit board Battery Connector +∆P (Top) on printed circuit board –∆P (Bottom)
  • Page 94 Maintenance PRESSURE SENSOR on printed circuit board +∆P (Top) PURGE PUMP –∆P (Bottom) –∆P PRESSURE To Sensors +∆P PURGE AIR GAS PUMP Gas OUT Gas IN Models 235 & 245 Model 225 P/Ns 24-7302 & 24-7303 P/N 24-7301 Elbow Elbow Model 255 Models 265 &...
  • Page 95 Maintenance LCD Connector Sensor Connector (opposite side of board) (typical 4 places) Factory Test Connector Purge Pump Pump to J9 to J8 Battery to J14 Wire Routing Connectors Lock Tabs (both ends) Solder (2 Places) Battery to J14 Ribbon Cable Conection between LCD Assembly and Red dot on pump Printed Circuit Board...

  • Page 96: Water Trap / FLter MaNtenance

    Maintenance 6.2 Water Trap / Filter Maintenance 6.2.1 Emptying the Water Trap Chamber The water trap chamber should be empted after every test, or when the water condensate approaches the tp of the rser tube (refer to Secton 4.9). 1. Remove water trap chamber per Fgure 6-5. 2.

  • Page 97: Smart Sensor Replacement

    Maintenance 6.3 Smart Sensor Replacement Bacharach’s Smart sensor technology allows new sensors to be nstalled wthout needng to be calbrated nsde the analyzer. NOTE: Sensors may be purchased with and without the Smart sensor technology PCB. See Section 6.4 on how to change just the sensor itself. Calibration must be performed if the sensor is purchased without the Smart technology PCB.

  • Page 98: Sensor Only Replacement

    Maintenance 6.4 Sensor Only Replacement All sensors are replaced n a smlar manner. Do the followng to replace ether 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 99 Maintenance 12. Plug the sensor nto analyzer; and then reattach tubng to gas cup. 13. Install the sensor retaner and battery cover. 14. Allow the sensor that was just nstalled tme to stablze n the crcut before contnung wth ths procedure. Stablzaton tme for all sen- sors (except for the NO sensor) s about 1 hour.

  • Page 100: Nitric Oxide Sensor Battery Replacement

    Maintenance 6.5 Nitric Oxide Sensor Battery Replacement A sngle lthum battery, located on the NO Smart Sensor assembly, apples a bas voltage to the NO sensor to prevent the sensor from destablzng when the analyzer s turned off. The NO bas battery s expected to last at least the lfe of the NO sensor.

  • Page 101: Thermocouple Replacement

    Maintenance 6.6 Thermocouple Replacement Usng the approprate thermocouple replacement kt lsted below, replace the probe’s thermocouple as follows: Thermocouple Replacement Kits: Part Number Replaces Thermocouple in a Probe with a Tube Length of . . . 24-8413 6 nches 24-8414 12 nches 24-8415 24 nches...
  • Page 102 Maintenance 3. Pull old thermocouple from probe body and dscard. 4. The new thermocouple has been coled for shppng purposes. Straghten the thermocouple usng your thumb and ndex fnger. 5. If not already done, nstall suppled O-Rngs onto thermocouple. 6. Insert thermocouple nto probe body untl t “bottoms out.” 7.

  • Page 103: Pump Replacement

    Maintenance 6.7 Pump Replacement Parts & Tools Required: • Replacement Pump: Gas Pump P/N 24-1393 Purge Pump P/N 3015-1716 • Solderng Iron and Solder • Medum Phllps Screwdrver • Small Flat Blade Screwdrver Procedure: 1. Gan access to both the gas and purge pumps by removng the rear case.

  • Page 104: Cleaning The Probe

    Maintenance 6.8 Cleaning the Probe The probe tube and gas-sample hose wll become drty under normal use. Note that the water trap’s flter element should prevent soot from reachng the analyzer’s nternal components. If the probe s not kept clean, t could become clogged and restrct the flow of gas nto the analyzer, resultng n ncorrect combuston test readngs and calculatons.

  • Page 105: ReplacNg The FLter Element

    Replacng ether the gas or purge pump Informaton on how to perform these repars s provded n Secton 6. All other repars should be performed by an authorzed Bacharach Servce Center (refer to Secton 8.3). Any repars performed by an unauthor- ized servce organzaton wll vod the analyzer’s warranty and release...

  • Page 106: Error Messages DSplayed After Warm-Up

    Troubleshooting 7.3 Error Messages Displayed After Warm-Up If there were problems detected durng warm-up, error messages that descrbe the nature of the problems are dsplayed mmedately followng the analyzer’s 60 second warm-up perod. If problems were detected, the analyzer wll not automatcally swtch to the Combuston Test HOLD screen after warm-up.

  • Page 107: Diagnostics And Status Screens

    Troubleshooting Pressure sensor s measurng pressure outsde the range of +/ - 3 nches of water column at startup. Ensure that the analyzer s samplng atmospherc pressure and restart. The analyzer was turned on wth the probe samplng flue gas. Move the probe to fresh ar and restart the analyzer.
  • Page 108 Troubleshooting 3. Use the buttons to hghlght the desred dagnostc topc, and then press to dsplay the nformaton under that topc. 4. Press ESC key to ext back to the Dagnostc menu or the Menu (F2) key to ext back to the Man Menu. The Status screen provdes a quck reference to key tems when trouble- shootng.

  • Page 109: Parts & Service

    Parts & Service 8 Parts & Service 8.1 Replacement Parts Item (Fig. 8-1) Description Part No. Man PCB Assembly ......24-1442 LCD Module .
  • Page 110 Parts & Service Item (Fig. 8-1) Description Part No. Screw, #4 x 1/2 LG ......02-2144 Battery Clp, Sngle .
  • Page 111 Parts & Service Figure 8-1. Parts (2 of 2) Instruction 24-9448...

  • Page 112: AccessorEs

    Parts & Service 8.2 Accessories Part No. Standard Accessories Carryng Case ......... . 24-0865 Batteres, 'AA' Alkalne .
  • Page 113 Parts & Service Part No. Optional Accessories AC Power Adapter (Input: 100–240 VAC, 50/60 Hz; Output: 9 VDC @ 1 A) ..24-1404 Ambent Ar Thermocouples (T-AIR), K-Type: 10 ft..........104-1797 1 nch .

  • Page 114: Service Centers

    United States Bacharach Inc. 621 Hunt Valley Crcle New Kensngton, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Emal: help@bacharach-nc.com Canada Bacharach of Canada, Inc. 250 Shelds Court Unt #3 Markham, Ontaro L3R 9W7 Canada Phone: 905-470-8985 Fax: 905-470-8963 Emal: bachcan@drect.com México Bacharach de Méxco...
  • Page 115 Notes:...
  • Page 116 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 Website: www.bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A. ISO 9001:2000...

Table of Contents