Bacharach PCA3 Operation And Maintenance Manual
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Bacharach PCA3 Operation And Maintenance Manual

Portable combustion analyzer siegert version
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Portable Combustion Analyzer
(Siegert Version)
Operation and Maintenance Manual
Instruction 0024-9473
Rev. 3 – August 2012
Product Leadership • Training • Service • Reliability

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Summary of Contents for Bacharach PCA3

  • Page 1  Portable Combustion Analyzer (Siegert Version) Operation and Maintenance Manual Instruction 0024-9473 Rev. 3 – August 2012 Product Leadership • Training • Service • Reliability...

  • Page 2: Warranty Policy

    Seller at the factory of manufacture and shown to Bacharach Inc.’s reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc. The Oxygen (O ) sensor has a limited warranty of one (1) year.

  • Page 3: Table Of Contents

     3 Manual TABLE OF CONTENTS CHAPTER 1. INTRODUCTION ................ 7 1.1. About This Manual ..................7 1.2. Conventions ....................7 1.3. Safety ......................7 1.4. General Description ..................9 1.5. Operation Overview ..................9 ® 1.5.1. Turning On the PCA 3 ..............
  • Page 4  3 Manual 4.7. Smoke Number ..................29 4.8. Oil Derivative ....................30 4.9. Boiler Temperature ..................30 4.10. Date Setup ....................31 4.11. Time Setup ....................32 4.12. O Reference Setup .................. 32 4.13. Print Pressure Selection ................33 4.14.
  • Page 5  3 Manual 5.13.2. Recalling Combustion Test Data ..........58 5.13.3. Recalling Logged Test Data ............59 5.13.4. Clearing Memory ................. 60 5.13.5. Print Average ................60 5.14. Downloading Stored Data to a Computer ..........61 5.15. Importing Saved Data into a Spreadsheet ..........62 5.16.
  • Page 6  3 Manual 7.1. Overview ....................82 ® 7.2. PCA 3 Disassembly ..................82 7.2.1. Tools Required ................82 7.2.2. Procedure ..................82 7.3. Emptying the Water Trap Chamber ............87 7.4. Replacing the Filter Element ..............87 7.4.1. Material Required ................87 7.4.2.

  • Page 7: Chapter 1. Introduction

    3 Manual CHAPTER 1. INTRODUCTION 1.1. About This Manual ® Thank you for investing in a Bacharach PCA 3 Combustion Analyzer. To assure ® operator safety and the proper use of the PCA 3, please read the contents of this manual for important information on the operation and maintenance of the analyzer.
  • Page 8 Except for sensor and battery replacement, this analyzer should only be opened and/or serviced by authorized Bacharach personnel. Failure to comply may void the warranty. HAZARDOUS AREA WARNING: This instrument has not been designed to be intrinsically safe for use in areas classified as hazardous locations.

  • Page 9: General Description

     3 Manual 1.4. General Description ® The PCA 3 is a commercial-grade hand-held combustion and emissions analyzer designed for on-demand sampling of light industrial, institutional, commercial and residential furnaces, appliances, and boilers. The basic instrument is supplied with probe hose assembly, instruction manual, factory calibrated...

  • Page 10: The Combustion Test

     3 Manual “ERRORS DETECTED” is displayed along with a list of the errors. These errors must be corrected before proceeding with the combustion test. Before starting a test be sure to select the fuel being burned. The default fuel selected is Natural Gas.
  • Page 11  3 Manual With the appropriate sensors installed, the analyzer optionally displays • pollution conversions for CO, NO, NO , and SO . Pollution conversions include ppm, #/MBTU, mg/m , and g/GJ. B-Smart® sensor technology allows pre-calibrated sensors to be installed in •...

  • Page 12: Sales Combo And Model Configurations

     3 Manual 1.7. Sales Combo and Model Configurations Sales Combo (0024-xxxx) Sales Combo Kit (0024-xxxx) Model Type ® 3 Only Part Number (0024-xxxx) Measurements Oxygen (O • • • • • • • Stack Temperature • • • • •...

  • Page 13: Specifications

     3 Manual 1.8. Specifications Measurement (Based on Installed Sensors) Display Range Oxygen 0.1 to 20.9% Stack Temperature -20 to 1,200 °C (-4 to 2,192 °F) Primary/Ambient Air Temperature -20 to 537 °C (-4 to 999 °F) Carbon Monoxide (CO) (H compensated) 0 to 4,000 ppm Pressure/Draft...
  • Page 14  3 Manual Equations (Some calculations vary by country) Definitions = Measured oxygen (in %) = Measured stack temp (in ° C) = Measured primary air temp (in ° C) = Measured carbon monoxide (in ppm) = Calculated carbon dioxide (in ppm) = Calculated stack loss (in %) Lambda = Calculated excess air...
  • Page 15  3 Manual Reading Performance Accuracy ±0.3% O on practical concentrations of stack gas (mix of O , CO , and N Greater of ±5% of reading or ±10 ppm, between 0-2,000 ppm. ±10% of reading between 2,001 and 4,000 ppm. Greater of ±5% of reading or 5 ppm between 0 and 2,000 ppm Greater of ±5% of reading or ±5 ppm between 0-500 ppm Greater of ±5% of reading or ±10 ppm between 0-2,000 ppm...

  • Page 16: Chapter 2. Hardware

     3 Manual CHAPTER 2. HARDWARE 2.1. Overview Figure 2-1. Front and Bottom Views Showing Key Components 0024-9472 Rev 2...

  • Page 17: Front Panel Buttons

     3 Manual 2.2. Front Panel Buttons ® The PCA 3 is controlled by various buttons, while a color graphic LCD (with automatic dimming feature) is used to display all combustion and emission test data and analyzer parameters. Descriptions of the front panel buttons are given below.

  • Page 18: Backlit Display

     3 Manual Note that a button may perform multiple functions depending on the current screen that is displayed. For example, the functions of the F1, F2, and F3 buttons are defined by labels appearing above them on the LCD. The labels that appear depend on the functions that can be performed in the particular screen being displayed.

  • Page 19: Probe Connectors (Gas, Pressure, T-Stack)

     3 Manual Figure 2-3. Battery Compartment Figure 2-4. Bottom View Showing Connectors 2.6. Probe Connectors (Gas, Pressure, T-Stack) The probe and hose assembly are connected to the analyzer by way of the following connectors. • Stack-gas thermocouple to the analyzer’s T-STACK connector •...

  • Page 20: Differential Pressure Connector (∆P)

     3 Manual Figure 2-5. Probe Connectors GAS, +∆P, and T-STACK 2.7. Differential Pressure Connector (∆P) Draft is measured by connecting the probe’s draft hose to the + ∆ P fitting, while leaving the -∆P fitting open to the atmosphere. See Figure 2-5 on page 20. In addition to measuring draft, the “+”...

  • Page 21: Chapter 3. Initial Setup

     3 Manual CHAPTER 3. INITIAL SETUP 3.1. Overview ® Before configuring or using the PCA 3, you MUST: provide power • connect the probe and hose assembly. • 3.2. Power ® Three options are available to power the PCA disposable alkaline batteries •...

  • Page 22: Connecting The Probe And Hose Assembly

     3 Manual NOTE: The battery charging icon should appear fully green once the new batteries have been installed. 3.3. Connecting the Probe and Hose Assembly To attach the probe and hose assembly to the analyzer follow the steps below and refer to Figure 3-2 on page 23.
  • Page 23  3 Manual Figure 3-2. Connecting the Probe to the Analyzer 0024-9473 Rev 3...

  • Page 24: Chapter 4. Configuration Procedures

     3 Manual CHAPTER 4. CONFIGURATION PROCEDURES 4.1. Default Operating Parameters ® The PCA 3 is set up at the factory for the following operating parameters. To change any of these parameters, perform the associated procedure that follows. Parameter Factory Default To Change Value, See…...
  • Page 25 NOTE: In addition to the standard fuels programmed into ® the PCA 3, Bacharach can develop custom fuel codes ® based on the customers specific needs. The PCA 3 can be programmed with 2 additional fuels which can be added to the instrument using the Fyrite User Software (FUS).

  • Page 26: Auto/Manual Co Zero Selections

     3 Manual NOTE: The CO Max value is returned to its default value when the analyzer is powered down. 4.3. Auto/Manual CO Zero Selections ® Select how the PCA 3 performs a zero function. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

  • Page 27: Temperature Units Selection

     3 Manual Auto Zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurements. Manual zero is used to detect CO that may be present during start-up. The auto/manual zeroing option allows the operator to select the start-up mode.

  • Page 28: Pollution Units Selection

     3 Manual Use the ▲▼ buttons to highlight the desired pressure units. In the example shown, InchesWater has been selected. Press ENT to save the selection and re-display the SETUP MENU. Figure 4-5. Pressure Units Selection 4.6. Pollution Units Selection ®...

  • Page 29: Smoke Number

     3 Manual 4.7. Smoke Number Three smoke numbers, as measured by the Bacharach True Spot® Smoke Tester, can be manually entered into the analyzer and their average automatically calculated. The average Smoke Number will be displayed on the Run / Hold screen. Enter smoke numbers as follows.

  • Page 30: Oil Derivative

     3 Manual 4.8. Oil Derivative This screen allows the user to manually enter YES or NO as to whether oil derivatives were present during the smoke test. This setting will be displayed on the Run / Hold screen. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

  • Page 31: Date Setup

    NOTE: The real time clock is powered by the main batteries and is maintained by a coin cell battery on the Main PCB in the absence of batteries. Bacharach recommends changing the coin cell (P/N 0204-0020) every 5 years. Figure 4-10. Date Setup...

  • Page 32: Time Setup

     3 Manual 4.11. Time Setup The time is stored in the format: hh:mm:ss. Its value is part of the date and time stamp that is saved along with each combustion test record. Set the analyzer’s internal clock to the current time as follows. Display the MAIN MENU by pressing the MENU (F2) button.

  • Page 33: Print Pressure Selection

     3 Manual Use the ▲▼ buttons to highlight the desired measurement, and then screen for that measurement. In press ENT to display the REF TO O the example shown, CO has been selected. First use the ◄► buttons to move the cursor across the screen until it is over the digit to be changed, and then press the ▲▼...

  • Page 34: Zoom Display Selection

     3 Manual Figure 4-13. Print Pressure Selection 4.14. Zoom Display Selection Combustion test data in the Run/Hold screen can be shown with enlarged characters to make viewing easier. The operator can set zoom levels to Standard, 2X, or 3X. The Standard zoom setting will display seven lines of combustion test data at one time, 2X which will display five lines of combustion test data with enlarged characters, and 3X which will display four lines of combustion test data with enlarged characters.

  • Page 35: Logging Selection

     3 Manual 4.15. Logging Selection When the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined length of time. Refer to Data Logging starting on page 54 for detailed information on how to select the logging function, how to set the interval and duration time periods, and how to view or download the stored data.

  • Page 36: Test Id Information

     3 Manual 4.17. Test ID Information Test records can be identified (e.g., customer’s name, burner number, and location) by manually entering up to three lines of text, with each line containing a maximum of 20 alphanumeric characters. When a Test ID is selected this information will be associated with all succeeding test records, and will appear at the top of each test record when printed, and in CSV files when records are downloaded to a PC.

  • Page 37: Selecting A Test Id

     3 Manual Figure 4-17. Editing a Test ID 4.17.2. Selecting a Test ID From the Test ID menu, use the ▲▼ buttons to highlight SELECT TEST ID, and then press ENT to display the SELECT TEST ID menu, which displays the first line of each Test ID record. Figure 4-18.

  • Page 38: User Name

     3 Manual Press ESC to end this procedure and return to the Test ID menu or press the RUN/HOLD key to return to the Run/Hold screen. Figure 4-19. Clearing a Test ID 4.18. User Name The name of the user or owner of the analyzer (e.g., company name, address, phone number) can be stored in memory by manually entering up to three lines of text, with each line containing up to 20 alphanumeric characters.

  • Page 39: Clearing A User Name

     3 Manual Press ESC to go to the Main Menu or the RUN/HOLD key to return to the Run/Hold screen. Figure 4-20. Entering a User Name 4.18.2. Clearing a User Name Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

  • Page 40: Calibration Reminder Period

     3 Manual Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. Use the ▲▼ buttons to highlight LANGUAGE SELECTION, and then press ENT to display The Language Selection Menu.

  • Page 41: Run/Hold Screen Format

     3 Manual Figure 4-23. Selecting the Calibration Reminder Period 4.21. Run/Hold Screen Format ® 3 test data 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.
  • Page 42  3 Manual NOTE: A number sign (#) denotes the current O Reference selected. Stars (***) appear in measurement and calculation fields of sensors that are not installed. Change the order in which data is displayed as follows. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.
  • Page 43  3 Manual Use the ▲▼ buttons to highlight RESET FORMAT, then press ENT to display the Reset Format screen. Use the ▲▼ buttons to select YES, then press ENT to reset the display and return to the Run/Hold Format screen. Figure 4-25.

  • Page 44: Chapter 5. Operation

     3 Manual CHAPTER 5. OPERATION 5.1. Operating Tips When an analyzer is brought in from a cold vehicle, let it warm up slowly to • minimize condensation. Temperatures below freezing will not damage the analyzer. CAUTION: Although the analyzer itself is not damaged by an extremely cold environment, the electrochemical sensors may be damaged.

  • Page 45: Turning On The Analyzer

     3 Manual 5.2. Turning On the Analyzer Connect the probe and hose assembly, and make sure that the analyzer is properly set up according to Initial Setup (page 21) and Configuration Procedures (page 24). IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer! Place the probe in an area that contains fresh air.

  • Page 46: Locating Sampling Points

     3 Manual Figure 5-2. Low Battery Indicator After a low battery alarm occurs, the analyzer will continue to operate for only a few minutes. The amount of operating time that remains depends on many factors (e.g., pump and keypad backlight being ON or OFF, and the type and condition of the batteries).

  • Page 47: Performing A Combustion Test

     3 Manual 80% Efficiency Fan 90% Efficiency Atmospheric/Gravity Assist or Power Vented Condensing Furnace Vented Boiler Furnace Figure 5-7. Figure 5-5. 90% Figure 5-6. 80% Atmospheric/Gravity Efficiency Condensing Efficiency Fan Assist or Vented Boiler Furnace Power Vented Furnace Boilers, which have a “bell’ Condensing Combustion testing of fan furnaces/boilers can be...
  • Page 48  3 Manual Figure 5-8. Performing a Combustion Test Press the RUN/HOLD button to start the test. You should hear the pump start running and see the word RUN appear at the top of the Combustion Test screen. Sensor Indicators: The following indicators appear in the sensor’s data field depending on certain conditions: (* * *)
  • Page 49  3 Manual List of Combustion Test Data Display Description of Measurement or Calculation Name % Oxygen Carbon Monoxide Lambda Excess Air % Carbon Dioxide Carbon Dioxide in flue gas assuming perfect combustion CO/CO PPM CO divided by PPM CO T-STK Stack Temperature Primary/Ambient Air Temperature as measured either...

  • Page 50: Selecting A Pressure Label

     3 Manual 5.6. Selecting a Pressure Label The pressure measurement can be labeled with types including, differential across heat exchanger, draft reading, and differential pressure. See page 51 for pressure and draft measurement procedures. Label data as follows. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

  • Page 51: Performing A Draft / Pressure Measurement

     3 Manual Figure 5-10. Performing a Temperature Measurement 5.8. Performing a Draft / Pressure Measurement The difference in pressure ( ∆ P) between two areas can be measured by using the analyzer’s two pressure ports and the PRESSURE screen. By using the –∆P port as the reference, the pressure applied to the + ∆...

  • Page 52: Saving Test Data

     3 Manual Figure 5-11. Performing a Draft/Pressure Measurement Do one of the following to measure draft or differential pressure: To measure draft, simply insert the probe into the stack • and observe the draft reading on the PRESSURE screen. To measure differential pressure, connect two sampling •...

  • Page 53: Ending A Combustion Test

     3 Manual NOTE: When memory is full, the next reading will not be saved until space is made available by clearing the data (see Clearing Memory section on page 60). Figure 5-14. Saving Test Data 5.10. Ending a Combustion Test WARNING: Burn Hazard.

  • Page 54: Data Logging

     3 Manual Figure 5-15. Emptying the Water Trap 5.12. Data Logging 5.12.1. Overview When the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined duration. The maximum duration that data can be collected is determined by the interval.

  • Page 55: Turning On Data Logging

     3 Manual Logging Intervals and Durations Logging Intervals Logging Durations 1 second 5 minutes 5 second 10 minutes 10 second 15 minutes 15 second 30 minutes 30 second 1 hour 1 minute 2 hours 2 minutes 5 hours 5 minutes 10 hours 10 minutes 24 hours...

  • Page 56: Setting The Logging Interval And Duration

     3 Manual Figure 5-16. Turning On Data Logging 5.12.3. Setting the Logging Interval and Duration The logging interval is the length of time between measurements, while the logging duration is the time allocated to the logging process. Set the logging interval and duration as follows.

  • Page 57: Starting The Data Logging Process

     3 Manual Figure 5-17. Setting the Logging Interval 5.12.4. Starting the Data Logging Process After turning ON data logging and setting the interval and duration, the analyzer will pause at the LOGGING SUMMARY screen, where the currently selected interval and duration time periods are displayed. Press to start the combustion test and logging process.

  • Page 58: Memory Functions

     3 Manual 5.13. Memory Functions 5.13.1. Overview There are two memory banks, each containing 500 memory locations. The first bank is used to store combustion test data as described in Saving Test Data (page 52), while the second bank is used to store logged combustion test data as described in Data Logging (page 54).

  • Page 59: Recalling Logged Test Data

     3 Manual Figure 5-19. Recalling Combustion Test Data 5.13.3. Recalling Logged Test Data Recall individual logged combustion test data records as follows. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. Use the ▲▼...

  • Page 60: Clearing Memory

     3 Manual 5.13.4. Clearing Memory When all memory locations used to store individual combustion test records have been filled, the next combustion test record saved will not overwrite the oldest. When all logging memory locations in the logging directory are full, they must be manually cleared in order to store new data.

  • Page 61: Downloading Stored Data To A Computer

    (provided in .PDF format) on the software disk. The Fyrite ® User Software installation manual may also be downloaded from the PCA page of the Bacharach website (www.MyBacharach.com). Refer to manual 0024-9465. Minimum computer requirements for installation and use of the ®...

  • Page 62: Importing Saved Data Into A Spreadsheet

     3 Manual ® Minimum Computer Requirements for Fyrite User Software Category Minimum Requirement Operating System Windows XP or higher Drive CD ROM drive Access Port USB port (USB 1.1, 2.0, or 3.0) ® Software: 205 MB for the Fyrite User Software Hard Drive Space Data:...

  • Page 63: O 2 Reference Setup

     3 Manual Field Column Name Data Name or Value TempUnit Temperature Units Nitric Oxide Level (see field 32) ppm NO(O Nitric Oxide Level referenced to a % of O (see field 28) Nitrogen Dioxide Level (see field 32) ppm NO Nitrogen Dioxide Level referenced to a % of O (see field 28) Nitrogen Oxides (NO+NO...
  • Page 64  3 Manual Figure 5-23. Printer Alignment and Sample Printout 0024-9473 Rev 3...

  • Page 65: Turning Off The Analyzer And Purging

     3 Manual The printout shown in Figure 5-23 shows typical combustion test results of an , CO , NO, and NO sensors. Note that since the SO analyzer containing O sensor is not installed, three stars (* * *) appear in their data fields. NOTE: Three Stars (***) appear in the data field of sensors that are not calibrated or installed, and in the data fields of that sensor’s related calculated values.

  • Page 66: Chapter 6. Calibration

    (Good, Low, Bad). ® B-Smart sensors should be calibrated by an authorized Bacharach Service Center (see Service Centers on page 99) every 6 months to 1 year to assure that ® the analyzer continues to meet its published accuracy specifications. B-Smart...

  • Page 67: B-Smart ® Sensor Replacement And Calibration

    CALIBRATION MENU. If an incorrect code was entered, the screen will display “Invalid Code”. Check to make sure the correct code has been entered. If the problem persist, contact your nearest Bacharach Service Center. ® NOTE: To save time, B-Smart codes can be entered using the Fyrite User Software.

  • Page 68: Pressure Sensor Calibration

     3 Manual Bacharach also offers a convenient exchange program that allows the customer to regularly send in old sensors and, as scheduled, receive calibrated replacements. Contact Bacharach customer service for more details about the exchange program. 6.4. Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value.

  • Page 69: T-Stack Calibration

     3 Manual NOTE: 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. Figure 6-2.

  • Page 70: Material Required

     3 Manual The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures. Alternatively, containers of ice water and boiling water can be used. 6.5.1. Material Required Thermocouple Simulator (K-type): • Range: 0 to 300 °C Accuracy: ±0.3 °C (Alternatively) Ice Water, Boiling Water, Thermometer...

  • Page 71: Ts-Span Procedure

     3 Manual Figure 6-4. T-Stack Zero and Span 6.5.3. TS-Span Procedure Set thermocouple simulator to 300 °C (572 °F), and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the setting of the simulator. Alternatively: Submerge probe tip into a container of boiling water with a thermometer, wait several minutes, and then use...
  • Page 72  3 Manual Alternatively: Plug the probe’s thermocouple into the T-AIR connector located at the bottom of the analyzer. DO NOT attach the probe’s gas hose to the analyzer’s GAS port; otherwise water will be drawn into the analyzer! If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to Calibration on page 66).

  • Page 73: Ta-Span Procedure

     3 Manual 6.6.3. TA-Span Procedure Set thermocouple simulator to 100 °C (212 °F), and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the setting of the simulator. Alternatively: Submerge probe tip into a container of boiling water with a thermometer, wait several minutes, and then use the ▲▼...

  • Page 74: Procedure

     3 Manual 6.7.2. Procedure If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to Calibration on page 66). Use the ▲▼ buttons to highlight CO-LO, and then press ENT to display the CALIBRATE CO screen. NOTE: “Measured”...
  • Page 75  3 Manual Turn OFF regulator of calibration fixture and remove the CO cylinder. Attach a combination 1,000 ppm CO and 1,000 ppm H cylinder to the regulator of the calibration fixture, and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the CO concentration stamped on the cylinder.

  • Page 76: So Sensor Calibration

     3 Manual 6.8. SO Sensor Calibration   This procedure spans the optional sulfur dioxide sensor to a known gas level. 6.8.1. Material Required Calibration Kit ( P/N 0024-7059) • Gas Cylinder (100 ppm SO in Nitrogen, P/N 0024-1158) • 6.8.2.

  • Page 77: No Sensor Calibration

     3 Manual NOTE: 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. NOTE: If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life, Entry Not Saved”...

  • Page 78: No Sensor Calibration

     3 Manual Figure 6-10. NO Sensor Calibration Adjust regulator for a flow meter indication of approximately 2  SCFH. Wait until the measured reading stabilizes (approximately 3  minutes), and then press ENT to calibrate the NO Measured value to that of the applied value.
  • Page 79  3 Manual NOTE: “Measured” is the current NO reading, while “Applied” is a known NO level that will be applied for calibration purposes. Attach a 100 ppm NO cylinder to the regulator of the calibration fixture shown in Figure 6-12 on page 80. Use the ▲▼...

  • Page 80: Co Sensor Calibration

     3 Manual 6.11. CO Sensor Calibration HIGH This procedure spans the optional carbon monoxide high sensor (4,001 to 20,000 ppm) to a known gas level. 6.11.1. Material Required Calibration Kit (P/N 0024-7059) • Gas Cylinder (4,000 ppm CO in Air, P/N 0024-1155) •...
  • Page 81  3 Manual   NOTE: The calibration range is from 250 to 11,000 ppm. An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. Figure 6-13. CO Sensor Calibration HIGH Adjust regulator for a flow meter indication of approximately 2  SCFH.

  • Page 82: Chapter 7. Maintenance

    • Sensor replacement (see page 88) • Cleaning the probe (see page 91). • All other maintenance should be performed by an authorized Bacharach Service Center. Refer to Service Centers on page 99. ® 7.2. PCA 3 Disassembly The following procedure describes and illustrates how to disassemble the analyzer.
  • Page 83  3 Manual Figure 7-1. Removing the Rear Case Model Number and Corresponding Sensor Configuration Sensor Position Empty Empty Empty HIGH Empty Empty HIGH 0024-9473 Rev 3...
  • Page 84  3 Manual Figure 7-2. Inside View with Rear Case Removed 0024-9473 Rev 3...
  • Page 85  3 Manual Figure 7-3. Tubing Connections - Main Figure 7-4. Tubing Connections - Sensors 0024-9473 Rev 3...
  • Page 86  3 Manual Figure 7-5. Wire Routing, Connectors, and Solder Connections 0024-9473 Rev 3...

  • Page 87: Emptying The Water Trap Chamber

     3 Manual 7.3. Emptying the Water Trap Chamber The water trap chamber should be emptied after every test, or when the water condensate approaches the tip of the riser tube. Remove water trap chamber (also see page 53). Pour out liquid condensate and then reassemble trap. 7.4.

  • Page 88: Sensor Replacement

     3 Manual 7.5. Sensor Replacement All sensors are replaced in a similar manner. Do the following to replace either the O , CO , CO , NO, NO , or SO sensor. Refer to Replacement Parts on HIGH page 94 for a list of sensors and part numbers. NOTE: The typical life expectancy of the O , SO and NO...
  • Page 89  3 Manual CAUTION: Figure 7-7. Sensor Assembly 12. Allow the sensor that was just installed time to stabilize in the circuit before continuing with this procedure. Stabilization time for all sensors (except for the NO sensor) is about 1 hour. The NO sensor baseline technically requires several days to stabilize, but should be sufficiently stabilized for use in approximately 4 hours.

  • Page 90: Nitric Oxide (No) Sensor Battery Replacement

     3 Manual 7.6. Nitric Oxide (NO) Sensor Battery Replacement A single lithium battery, located on the NO Smart Sensor assembly, applies a bias voltage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off. The NO bias battery is expected to last at least the life of the NO sensor.

  • Page 91: Cleaning The Probe

     3 Manual 7.7. Cleaning the Probe The probe tube and gas sample hose will become dirty under normal use. NOTE: The water trap’s filter element should prevent soot from reaching the analyzer’s internal components. If the probe is not kept clean, it could become clogged and restrict the flow of gas into the analyzer, resulting in incorrect combustion test readings and calculations.

  • Page 92: Chapter 8. Troubleshooting

     3 Manual CHAPTER 8. TROUBLESHOOTING 8.1. Error Symbols Error symbols are shown in the data fields of the Combustion Test screens and on the printout to indicate the following. Error Symbol Description Three hyphens or dashes indicates that the calculated data cannot be displayed because the measured data necessary to make the - - - calculation is out of range.

  • Page 93: Accessing The Diagnostic Menu

     3 Manual 8.3. Accessing the Diagnostic Menu Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. Figure 8-2. Accessing the Diagnostics Menu Use the ▲▼ buttons to highlight DIAGNOSTICS and then press ENT to display the DIAGNOSTICS MENU.

  • Page 94: Replacement Parts

     3 Manual Missing Sensor Replacement on page 88. BAD Sensors The oxygen sensor’s output is too low and can not be calibrated in the instrument, signifying that the sensor is depleted and needs to be replaced. Refer to Sensor Replacement on page 88. No B-Smart There are no B-Smart sensor(s) installed.
  • Page 95  3 Manual Item Description Part No. O-Ring, Pressure Fitting 0105-5103 O-Ring, Gas Fitting 0105-5102 Gas Cup, O 0024-1421 Gas Cup, CO 0024-1422 Gas Cup, NO/CO 0024-1420 HIGH Sensor, O 0024-0788 ® Sensor, B-Smart , CO 0024-1541 ® Sensor, B-Smart , CO 0024-1542 HIGH...
  • Page 96  3 Manual Main PCB Assembly (Replacement Part Not Available) Figure 8-3. Replacement Parts 0024-9473 Rev 3...

  • Page 97: Accessories

     3 Manual Figure 8-3. Replacement Parts (Continued) 8.7. Accessories Standard Accessories Description Part No. Carrying Case 0024-0865 Batteries, ‘AA’ Alkaline 0204-0004 12” Probe, Hose, and Water Trap/Filter Assembly 0024-3053 Water Trap/Filter 0019-3265 Filter Element (3 pack) 0007-1644 Probe Stop 0019-0580 Thumb Screw 0102-0875...
  • Page 98  3 Manual Figure 8-4. Hose and Probe Assembly (Parts) Optional Accessories Description Part No. AC Power Adapter: 0024-1254 (Input: 100-240 VAC, 50/60 Hz; Output: 6 VDC @ 1 A) Ambient Air Thermocouple (T-AIR), K-Type, 10 ft. 0104-1797 Ambient Air Thermocouple (T-AIR), K-Type, 1 inch. 0104-1798 Utility Wand (12 in.

  • Page 99: Analyzer Repair

    (Maintenance). All other repairs should be performed by an authorized Bacharach Service Center (refer to Service Centers on page 99). Any repairs performed by an unauthorized service organization will void the analyzer’s warranty and release Bacharach, Inc. of any implied or written product liability.

  • Page 100: Chapter 9. Declaration Of Conformity

    Characteristics Frequency Equipment Directive(s): 2004/108/EC EMC Directive Signature: Name: Doug Keeports Title: VP of Product Development Date: 18 October 2010 The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach, Inc. 0024-9473 Rev 3...
  • Page 101  3 Manual 0024-9473 Rev 3...
  • Page 102  3 Manual 0024-9473 Rev 3...
  • Page 103  3 Manual 0024-9473 Rev 3...
  • Page 104  3 Manual World Headquarters 621 Hunt Valley Circle, New Kensington, Pennsylvania 15068 Phone: 724-334-5000 • Toll Free: 1-800-736-4666 • Fax: 724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.com 0024-9473 Rev 3...

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