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ECA 450 

Introduction 

Instruction 0024-9400 

1 

1 Introduction 

 

 

1.1  General Description 

 

The Bacharach Environmental Combustion Analyzer Model 450 (hereafter 

referred to as the ECA 450) is an industrial grade environmental and 

combustion efficiency analyzer that is designed for the testing of fuel-burning 

combustion equipment. This analyzer is for furnace and boiler technicians 

who need to determine combustion safety, environmental compliance, and 

efficiency of small to large commercial industrial heating systems. 

 

 

1.2  Features 

 

•  Measures and displays O

2

 and CO in the flue gas, pressure (draft), 

primary air temperature, and stack temperature. 

 

•  Calculates combustion efficiency, excess air, and CO

2

. 

 

•  Optionally measures and displays NO, NO

2

, SO

2

, HC (methane equivalent 

combustibles), and CO (in the high range of 4,000 to 80,000 ppm). 

 

•  Optionally calculates NOx (the combination of NO and NO

2

), and 

calculates CO, SO

2

, and NOx individually referenced to a user defined 

Oxygen level of between 0 and 15%. 

 

•  Automatically purges the low-range CO sensor with fresh air if the CO 

level exceeds 4,000 ppm. At this time the analyzer also automatically 

switches over to its optional high-range CO sensor, if installed. 

 

•  Automatically zeros all sensing channels on ambient air when the 

analyzer is first turned on.  

 

•  Displays temperature in either °C or °F.  

 

•  Displays pressure in either inches of water column (inwc), millibars (mb), 

Pascals (Pa), or hecto Pascals (hPa). 

 

•  Optionally displays pollution conversions for CO, NO, NO

2

, and SO

2

. 

Pollution conversions include parts per million (ppm), pounds of pollutant 

per million BTU (#/MBTU), milligrams of pollutant per cubic meter of gas 

(mg/m

3

), and grams of pollutant per gigajoule (g/GJ).  

 

•  Low battery warning message. 

 

•  Stores over 1000 individual combustion and/or pressure test records, 

which can later be recalled for viewing or printing. 

 

•  Stored test records can be downloaded to a personal computer in comma-

delimited format, which can be captured as a text file and then opened in a 

spreadsheet program. 

 

 

 

Summary of Contents for 450

Page 1: ...Environmental Combustion Analyzer Model 450 Instruction 0024 9400 Operation Maintenance Rev 6 June 2013 Product Leadership Training Service Reliability ...

Page 2: ...limitation incidental or consequential damages No agreement varying or extending the foregoing warranties remedies or this limitation will be binding upon Bacharach Inc unless in writing signed by a duly authorized officer of Bacharach Note The probe is considered a consumable item and is therefore not covered under the terms of this warranty HAZARDOUS AREA WARNING This instrument has not been des...

Page 3: ...Stored in Memory 17 2 10 Printing Data 19 2 11 Downloading Data to a Personal Computer 20 2 12 Data Logging 22 2 12 1 Turning Data Logging On 22 2 12 2 Turning Data Logging Off 24 2 13 Importing Saved Data Into a Spreadsheet 25 2 14 Primary Air Temperature Measurement 27 2 14 1 Thermocouple Method 27 2 14 2 Probe Thermocouple Method 27 2 14 3 Thermometer Method 29 2 14 4 Internal Temperature Senso...

Page 4: ...ir Ambient Temperature Channel 53 3 7 Calibrate HC Sensor 54 3 8 Calibrate CO LO Sensor 55 3 9 Calibrate SO2 Sensor 57 3 10 Calibrate NO Sensor 58 3 11 Calibrate NO2 Sensor 59 3 12 Calibrate CO HI Sensor 60 4 Maintenance 61 4 1 Battery Charging 61 4 2 Water Trap Filter Assembly 62 4 3 Printer Paper Replacement 63 4 4 Sensor Replacement 64 4 4 1 O2 CO NO NO2 SO2 Sensor Replacement 65 4 4 2 Nitric O...

Page 5: ...SO2 and NOx individually referenced to a user defined Oxygen level of between 0 and 15 Automatically purges the low range CO sensor with fresh air if the CO level exceeds 4 000 ppm At this time the analyzer also automatically switches over to its optional high range CO sensor if installed Automatically zeros all sensing channels on ambient air when the analyzer is first turned on Displays temperat...

Page 6: ...zer This information appears at the top of each printout Displays information in either English French or Spanish Can be set up to automatically turn off the front panel display to conserve battery life 1 3 Technical Data The ECA 450 Directly Measures and Displays Oxygen content in flue gas in the range of 0 1 to 20 9 O2 Stack gas temperature in the range of 4 to 2400 ºF 20 to 1315 ºC Primary air ...

Page 7: ... 15 to 90 Relative Humidity non condensing Air Pressure Analyzer Atmospheric Probe 10 H2O 25 mb negative pressure max at probe tip Accuracy Oxygen 0 3 O2 on a practical concentration of flue gas mixtures of O2 CO2 and N2 Carbon Monoxide 5 of reading or 10 ppm whichever is greater between 0 and 2 000 ppm CO and 10 of reading between 2 001 and 40 000 ppm CO Nitric Oxide 5 of reading or 5 ppm whichev...

Page 8: ... Hz Operating Time A fully charged battery pack will provide at least 8 hours of continuous operation with the pump running Unlimited operating time when using the AC adapter Warm Up Time 60 seconds Printer Internal 2 wide paper 20 characters Materials High impact ABS plastic briefcase with storage for the standard probe instruction manual and AC adapter Nickel plated brass quick connect hose fitt...

Page 9: ...one POWER LED A sampling probe and hose assembly with an integral thermocouple and water filter trap provides the means of drawing in gas samples and for measuring stack temperature and pressure A burner s combustion efficiency is calculated by first entering the fuel being burned and then allowing the analyzer to measure the burner s primary air temperature stack temperature and percent Oxygen in...

Page 10: ...lays Memory screen ESC Displays previous menu or previously viewed screen Moves cursor left Moves cursor up through screen or increments an alphanumerical value Moves cursor down through screen or decrements an alphanumerical value Moves cursor right ENTER Chooses a menu item that has been selected by the cursor s position VACUUM FLUORESCENT DISPLAY PANEL 4 Lines by 20 Characters PRINTER BATTERY C...

Page 11: ...r can also be used as an external power supply to simulta neously charge and run the analyzer if its battery pack should become depleted during use 1 5 4 P REF Differential Pressure The Differential pressure between two areas can be measured by first connecting pressure hose P N 0024 1103 to the analyzer s P REF connector and inserting the open end of this hose into the area being used as the refe...

Page 12: ...whenever sensor errors are being displayed will also cause the Combustion Test HOLD screen to be displayed PRINT Prints the contents of either the Combustion Test or Pressure screen on the local printer This key is inactive in all other screens SAVE Saves the contents of the Combustion Test or Pressure screen to memory The saved data can then later be recalled for viewing on the display and printe...

Page 13: ... require the and keys to be used to make a numerical or alphabetical selection i e Date Time O2 Reference Test ID Display Timeout User Name and Calibrate screens the ENTER key is used to save those selections to memory ESC Displays a previous menu or previously viewed screen Moves cursor in direction of arrow In screens that require an operator to enter alphanumerical data i e Date Time O2 Referen...

Page 14: ...Introduction ECA 450 10 Instruction 0024 9400 Notes ...

Page 15: ...splay of the Combustion Test HOLD screen If however a problem was detected during warm up the analyzer will display the message Problem s Detected and sequentially display a list of those problems at the bottom of the screen and then wait for operator intervention Refer to Section 5 2 Troubleshooting Guide for a list of possible error messages and the recommended corrective action 2 2 Turning Off ...

Page 16: ... OIL4 Oil 4 OIL5 Oil 5 OIL6 Oil 6 PROP Propane COAL Coal WOOD Wood KERO Kerosene BGAS Bagasse To select a different fuel 1 Press FUEL key to display the Fuel menu screen FUEL ª Natural Gas Oil 2 Oil 4 Oil 5 Oil 6 Propane Coal Wood Kerosene Bagasse 2 Use keys to scroll through fuel list until cursor is next to desired fuel 3 Press ENTER key to store the fuel selection in memory The corresponding fu...

Page 17: ...urner s primary air temperature is different from that of room air be sure to either immerse primary air thermocouple into primary air stream or take a primary air temperature measurement using either the probe s thermocouple or a thermometer Section 2 14 4 See Figure 2 2 Screw probe stop into sampling hole Next insert probe through probe stop positioning its tip near center of stack Secure probe ...

Page 18: ...operator s selected Oxygen reference level of between 0 and 15 Refer to Section 2 17 7 3 The SO2 sensor cannot be installed without the NO2 sensor also being installed 8 Use keys to scroll to the T STACK reading Loosen thumbscrew on probe stop and move probe in and out of the stack until stack s core temperature hot spot is located then tighten thumbscrew to prevent further movement of probe Locat...

Page 19: ...alyzer per Section 2 2 Turning Off the Analyzer 2 6 Performing a Draft Measurement 1 If not already done turn on analyzer and place probe inside stack as previously described Sections 2 1 and 2 4 2 Press PRESSURE key to display the Pressure screen PRESSURE n nn xxxx Where n nn current pressure reading xxxx pressure units refer to Section 2 17 2 3 If desired pressure sensor can be zeroed at this ti...

Page 20: ...ll memory locations are filled an attempt to save additional data will cause the message Memory Full to be momentarily displayed To save additional data memory must first be cleared per Section 2 8 Clearing Memory Tip Before clearing memory its contents can be downloaded to a personal computer for permanent storage per Section 2 11 2 8 Clearing Memory Clear all memory locations as follows 1 Press ...

Page 21: ... Directory then press ENTER to show the directory of all stored test data MEMORY ª Memory Directory Transmit Memory Clear Memory 3 Use keys to place cursor next to memory location that contains data to be recalled Note that memory locations are identified by the date and time the data was stored Also note that memory locations that do not contain data are identified as Memory Empty Memory Director...

Page 22: ... with the test data this information is displayed at the bottom of the screen Refer to Section 2 17 8 for additional information on Test ID MEM nnnn NGAS O2 4 5 CO 12 ppm EFF 82 2 CO2 9 9 T STACK 374 F T AIR 68 F SO2 3 1 ppm xxxx MEM nnnn PRESS 0 25 inwc xxxx Where nnnn memory location number xxxx test ID information Tip Use keys to quickly advance to the top and bottom of screen 5 Press ESC to re...

Page 23: ... Stored in Memory User Name Line 1 User Name Line 2 User Name Line 3 BACHARACH INC ECA 450 SN xxxxxx Test ID Line 1 Test ID Line 2 Test ID Line 3 TIME 04 27 35 pm DATE 01 20 2000 FUEL Natural Gas O2 4 0 CO 12 ppm EFF 82 2 CO2 9 5 T STACK 374 F T AIR 68 F T EA 21 NO 18 ppm NO2 6 ppm NOX 24 ppm SO2 1 ppm HC 0 01 CO 3 13 ppm NO 3 19 ppm NO2 3 6 ppm NOX 3 25 ppm SO2 3 1 ppm PRESSURE 0 02 inwc COMMENTS...

Page 24: ...ppropriate connectors on each end 2 At the computer start HyperTerminal by doing one of the following If HyperTerminal has already been set up to communicate with the ECA 450 then click Start point to Programs point to Accessories point to Communications click HyperTerminal and double click the file name or icon that has been associated with the ECA 450 If HyperTerminal has never been run in assoc...

Page 25: ...ory 6 Use keys to select one of the following transmit options then press ENTER to choose that option What happens next depends on the option chosen Transmit Memory ª Last Range All Last Immediately transmits the last memory location that contains data Observe that the analyzer displays Transmitting while also displaying the record number being transmitted Range When chosen the range select screen...

Page 26: ...n either be 1 sent to the analyzer s internal memory 2 sent to a personal computer as a comma delimited ASCII text file for storage on its hard drive or 3 sent to both the analyzer s internal memory and a PC 2 12 1 Turning Data Logging On Turn on data logging and begin the logging process as follows 1 Press SETUP key to display the Setup List screen SETUP LIST Temperature Units Pressure Units Poll...

Page 27: ...s is 10 minutes To change this value use keys to select either 1 5 10 15 30 seconds 1 2 5 10 15 30 minutes or 1 hour Then press ENTER to make the selection and display the Logging Duration screen Logging Interval 10 min 6 The logging duration is the length of time allocated to collecting data Use the keys to select either 1 5 10 15 30 minutes 1 2 5 10 24 48 or 72 hours Then press ENTER to make the...

Page 28: ...is being sent to only a personal computer Tip Logging can be stopped without loosing data that has already been collected by pressing the ESC key 9 At the conclusion of the logging process the message Logging Complete will appear And if data was being stored in the analyzer s internal memory then the message Data in memory nnnn to nnnn will also appear where nnnn denotes the internal memory locati...

Page 29: ...Measure used in field 31 PRESS UNIT 7 Pollution Unit of Measure used in fields 11 18 thru 21 24 26 27 28 30 POLL UNIT 8 Date of Test DATE 9 Time of Test TIME 10 O2 Concentration in O2 11 CO Concentration CO 12 Combustion Efficiency in EFF 13 CO2 Concentration in CO2 14 Stack Temperature TSTACK 15 Primary Air Temperature Measurement Source TAIR SOURCE 16 Primary Air Temperature TAIR 17 Excess Air i...

Page 30: ... different spreadsheet program then please refer to its instruction manual for information on how to import comma delimited text files Tip If the text file was saved with the filename extension CSV as described in Section 2 11 Downloading Data to a Personal Computer a spreadsheet will automatically be created when that file is opened in Microsoft Excel 97 1 Start Microsoft Excel 97 2 Click File th...

Page 31: ... s primary air stream Note that when a thermocouple is plugged into the T AIR connector its temperature reading takes priority over all other methods of temperature measurement When viewing the T AIR value on the Combustion Test HOLD RUN screen the designation T will appear to the left of the temperature value The letter T signifies that a Thermocouple is being used to measure the primary air temp...

Page 32: ...ence Test ID Display Timeout Display Format ª Primary Air Data Logging Statistics User Name Keypad Sound High Res NOX Enabl Print Pressure Information 3 Use keys to place cursor next to Measure then press ENTER to display the message Place probe in primary air stream then press ENTER Primary Air ª Measure Enter Place probe in primary air stream then press ENTER 4 As instructed above place probe in...

Page 33: ...tion E will appear to the left of the temperature value The letter E signifies that the primary air temperature value was manually Entered For example T AIR 86 5 F E Measure the primary air temperature using a thermometer and manually enter that value as follows 1 Use a thermometer to measure the primary air temperature 2 Press SETUP key to display the Setup List screen 3 Use keys to place cursor ...

Page 34: ...temperature value in the analyzer s temperature memory buffer and return to the Setup List screen Note The temperature memory buffer is cleared when the analyzer is turned off or when the T AIR thermocouple is installed after the entered number is saved 2 14 4 Internal Temperature Sensor Method If a thermocouple is not plugged into the T AIR connector and there is no data stored in the temperature...

Page 35: ...isconnect all hoses from the P REF and PRESSURE connectors This step ensures that both of these connectors are sampling the same pressure c Press ENTER to zero pressure sensor to atmospheric pressure after which reconnect probe hose that was removed in Step 3b Reconnect Hose 3 Connect pressure hose assembly P N 0024 1103 to analyzer s P REF connector see Figure 1 1 Then insert open end of this hos...

Page 36: ...s Pressure Units Pollution Units Language Date Time O2 Reference Test ID Display Timeout Display Format Primary Air Data Logging ª Statistics User Name Keypad Sound High Res NOX Enabl Print Pressure Enhanced Printout Information 2 Use keys to place cursor next to Statistics then press ENTER to display the Statistics screen 3 Press key to place cursor next to On then press ENTER to display the Stat...

Page 37: ...display the first Statistics screen and repeat Steps 3 4 and 5 Statistics Summary Interval 10 sec Duration 5 min Press ENTER to start 7 With the analyzer set up per Section 2 4 Performing a Combustion Test press ENTER to begin collecting data for statistical analysis Before data is collected however the ECA 450 first waits 60 seconds to allow the sensor readings to stabilize Stabilizing Sensors ST...

Page 38: ...average and standard deviation Final Statistics AVG 1SD O2 14 5 0 3 CO ppm 10 1 3 NO ppm 37 0 3 NO2 ppm 6 0 3 NOX ppm 43 1 5 SO2 ppm 0 0 0 HC 0 10 0 01 or Rdgs 30 Duration 5 min In this example the average oxygen reading was 14 5 with a one standard deviation of 0 3 meaning that there is a 68 chance the oxygen readings taken during the sampling duration were between 14 2 and 14 8 AVG 1SD and a 95 ...

Page 39: ... CO EFF CO2 T STACK T AIR EA NO NO2 NOX SO2 HC CO 0 NO 0 NO2 0 NOX 0 SO2 0 Primary Air No preset Data Logging Off Statistics Off User Name blank Keypad Sound On High Resolution NOx Enable Off Print Pressure Off Values for these parameters can be entered or changed by selecting the desired parameter from the Setup List screen which is displayed by pressing the SETUP key SETUP LIST ª Temperature Uni...

Page 40: ...up List screen 2 Use keys to place cursor next to Pressure Units then press ENTER to display the Pressure Units screen Pressure Units ª inwc mb Pa hPa 3 Use keys to place cursor next to either inwc mb Pa or hPa then press ENTER to activate selection and return to Setup List screen 2 17 3 Pollution Units The analyzer is capable of converting the measured ppm levels of CO NO NO2 and SO2 to various p...

Page 41: ...o display the Setup List screen 2 Use keys to place cursor next to Language then press ENTER to display the Language screen Language ª English Español Français 3 Use keys to place cursor next to either English Español or Français then press ENTER to activate selection and return to Setup List screen 2 17 5 Date The date is stored in the format month day year MM DD YY Set the analyzer s internal cl...

Page 42: ...rsor over first digit of time display 4 Press key to place cursor over the hour minute or second digit to be changed Then use keys to set that digit to the desired number Repeat this step until all digits are set correctly 5 To change am pm setting first use the key to place cursor over first letter of am or pm Then use the keys to select correct value 6 Press ENTER to save selections and start cl...

Page 43: ...t with each line containing a maximum of 20 alphanumerical characters This information will be associated with all succeeding test records and will appear at the top of each test record when printed and at the bottom of saved test records when viewed on the display The chosen Test ID remains in effect until such time as the Test ID is unselected a new Test ID is selected or the instrument is shut ...

Page 44: ...ing that line 6 Use keys to display first desired character Then press key to move to next character position Repeat this step until line is complete maximum of 20 alphanumerical characters 7 When finished press ENTER to save information and move cursor back to left of screen 8 At this time either return to Step 5 to choose another line to edit or end this procedure by pressing the ESC key as nece...

Page 45: ...tion can be transmitted a personal computer must be connected to the analyzer and set up to receive the data refer to Section 2 11 Downloading Data to a Personal Computer Download all pre entered Test ID records to a personal computer as follows 1 Press SETUP key to display the Setup List screen 2 Use keys to place cursor next to Test ID then press ENTER to display the Test ID menu Test ID Select ...

Page 46: ... place the cursor next to Clear Test ID then press ENTER to display the Clear Test ID menu Clear Test ID ª Individual Records All Records 4 Do one of the following to either clear individual records or all records Individual Records Use keys to place cursor next to Individual Records then press ENTER to display the Clear Individual menu Again use keys this time to choose the record to clear then p...

Page 47: ...er in which data is displayed in the Combustion Test HOLD RUN screen can be rearranged to better suit an operator s needs The default order of this data is as follows Note Depending on what sensors are installed some of the data listed below may not be displayed O2 Oxygen CO Carbon Monoxide EFF Combustion Efficiency CO2 Carbon Dioxide T STACK Stack Temperature T AIR Room Primary Air Temperature EA...

Page 48: ...play Format ª 0 O2 1 CO 2 EFF 23 4 Change data shown for a particular location by first using keys to place cursor next to desired numbered location Next press ENTER to move cursor into that location s data field then use keys to choose desired data to appear at that location Finally press ENTER to make the selection and move cursor back to left of screen 5 Change data displayed at other numbered ...

Page 49: ...d in memory by manually entering up to three lines of text with each line containing up to 20 alphanumerical characters This information will appear at the top of each printout until such time as new information is entered 2 17 14 1 Enter Edit User Name Information Enter or edit a User Name as follows 1 Press SETUP key to display the Setup List screen 2 Use keys to place cursor next to User Name t...

Page 50: ...tup List screen 2 Use keys to place cursor next to User Name then press ENTER to display the User Name menu User Name Edit User Name ª Clear User Name 3 Use keys to place cursor next to Clear User Name then press ENTER to display the Clear User Name confirmation screen 4 Use keys to choose Yes then press ENTER to clear all information Clear User Name No ª Yes 5 When finished press ESC to return to...

Page 51: ...en SETUP LIST Temperature Units Pressure Units Pollution Units Language Date Time O2 Reference Test ID Display Timeout Display Format Primary Air Data Logging Statistics User Name Keypad Sound ª High Res NOX Enabl Print Pressure Enhanced Printout Information 2 Use keys to place cursor next to High Res NOX Enabl then press ENTER to display the High Res NOX Enable screen 3 Use keys to place cursor n...

Page 52: ...display the Setup List screen 2 Use keys to place cursor next to Print Pressure then press ENTER to display the Print Pressure screen Print Pressure ª No Yes 3 Use keys to place cursor next to either No or Yes then press ENTER to make the selection and return to the Setup List screen 2 17 18 Information To display the analyzer s Serial Number Part Number Software Version and optional sensor s inst...

Page 53: ...k Important Before turning on the analyzer or performing any of the calibration procedures ensure that the analyzer will be sampling fresh air and the probe is at room temperature When the analyzer is first turned on and allowed to cycle through its 60 second warm up period and while sampling fresh air the sensors are checked read and calibrated set to the following ambient conditions Oxygen senso...

Page 54: ... appropriate fixture as required by the calibration procedure being performed See Figure 3 1 Figure 3 1 Calibration Fixtures OPT T STACK T AIR PRESSURE GAS P REF ECA 450 MENU PRINT I O RUN SAVE 1 2 3 4 5 Leave Top Port Open 3 3 GAS FIXTURE GAS INLET PORT RS 232 POWER OPT T STACK T AIR PRESSURE GAS P REF ECA 450 MENU PRINT I O RUN SAVE PRESSURE INLET PORT Parts Shown 1 Gas Cylinder 2 Regulator 3 Tu...

Page 55: ...ppear Note Sensors that are not installed will not appear in the Calibration List CALIBRATION LIST ª Pressure T Stack T Air HC CO LO SO2 NO NO2 CO HI Use keys until cursor is in front of desired calibration function then press ENTER to display that function s corresponding Calibrate screen After the desired calibration procedures have been completed press the ESC key to return to the Combustion Te...

Page 56: ... 4 00 inwc 4 Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed 5 Remove calibration equipment 3 5 Calibrate T Stack Stack Temperature Channel The following procedure first zeros and then spans the stack temperature channel to known temperature values Mat...

Page 57: ...red reading on screen stabilizes Then use the and keys to enter an Applied value of 572 F 300 C Typical Calibrate TS Span Screen During Calibration CALIBRATE TS SPAN Measured 560 F Applied 572 F 8 Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear followed by the Calibration List screen being redisplayed 9 Remo...

Page 58: ...just simulator to 212 F 100 C The calibration range is from 194 to 230 F 90 to 110 C An applied value entry that is outside this range will cause the message Bad Calibration Entry to appear 7 Wait until Measured reading on screen stabilizes Then use the and keys to enter an Applied of 212 F 100 C Typical Calibrate TA Span Screen During Calibration CALIBRATE TA SPAN Measured 200 0 F Applied 212 0 F...

Page 59: ...lied 2 50 5 Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed If the message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide 6 Turn off regulator then remove gas cylinder from calibration fixture 3 8 Calibrate C...

Page 60: ...r on CO calibration gas cylinder then remove gas cylinder from calibration fixture 7 Attach a combination CO and H2 calibration gas cylinder to calibration fixture 8 Use the and keys to enter a CO value that equals the CO concentration stamped on the gas cylinder Then press ENTER to display the Calibrate H2 screen Typical Testgas CO H2 Screen During Calibration TESTGAS CO H2 CO value 1000 Enter CO...

Page 61: ...is step the pump should be running 2 Using the Gas Fixture shown in Figure 3 1 attach an SO2 calibration gas cylinder to the analyzer s GAS inlet port 3 Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH 4 Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the and keys to enter an Applied value that equals the concentration st...

Page 62: ...f approximately 2 SCFH 4 Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the and keys to enter an Applied value that equals the concentration stamped on the NO gas cylinder The calibration range is from 10 to 550 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate NO Screen During Calibration CAL...

Page 63: ...proximately 2 SCFH 4 Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the and keys to enter an Applied value that equals the concentration stamped on the NO2 gas cylinder The calibration range is from 10 to 150 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate NO2 Screen During Calibration CALIB...

Page 64: ...tion of approximately 2 SCFH 4 Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the and keys to enter an Applied value that equals the concentration stamped on the CO gas cylinder The calibration range is from 250 to 11 000 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate CO HI Screen During Ca...

Page 65: ...creen after which the analyzer will operate from 5 to 15 minutes before automatically shutting itself off Recharge the analyzer s internal battery pack by first plugging the supplied AC adapter in a source of 100 240 VAC 50 60 Hz power A green LED on the adapter should glow indicating that it is operational Then insert the adapter s output plug into the analyzer s POWER connector Figure 1 1 A full...

Page 66: ...er Tube Filter Element End Cap End Cap Drain the water condensate after every use Procedure 1 Pull off end cap from inlet end of the Water Trap Filter Assembly 2 Pour out all of the water condensate then replace end cap Replace the filter element when it becomes excessively dirty Parts Required Filter Element refer to Section 6 1 Procedure 1 Pull off end cap from outlet end of Water Trap Filter As...

Page 67: ...ier then remove paper retainer disk and empty roller from carrier 4 Install a new paper roll and the paper retainer disk onto the paper carrier 5 With analyzer turned on position paper at entry point of printer s feed mechanism The paper will be sensed by the mechanism and be automatically fed through the printer and into the proper position for printing Tip To correct for minor paper misalignment...

Page 68: ...fer to Section 5 4 Troubleshooting Guide for other possible causes of the error Caution Static damage When handling any printed circuit board be sure to follow all established industry procedures for the prevention of static buildup that when discharged may damage electrical components on the board Figure 4 3 Sensor Compartment SENSOR COVER COVER SCREW 2 PLACES O2 SENSOR PCB NO SENSOR PCB LITHIUM ...

Page 69: ...d NO2 sensors have a shorting spring installed between two of their pins Remove and discard this spring before installing the sensor 5 Insert sensor into its holder and turn clockwise to lock in place Ensure that the sensor pins are positioned as was noted in Step 3 6 Plug the circuit board which was removed in Step 2 into the top of the sensor Important When replacing the O2 sensor be sure that t...

Page 70: ...ent See Figure 4 3 2 Remove old battery from its holder on the Nitric Oxide printed circuit board 3 Insert new battery positive side facing upwards into holder 4 Install sensor cover plate that was removed in Step 1 5 Before powering up and using the analyzer allow the Nitric Oxide sensor to stabilize as described below Note that recalibration of the Nitric Oxide sensor is not required after repla...

Page 71: ...ving plate see Figure 4 3 2 Unplug the HC sensor s printed circuit board from its connector jack 3 Remove the sensor s printed circuit board by first removing the board s four corner screws and then lifting the board with the HC sensor attached out from the sensor compartment 4 Unplug old sensor and discard 5 Remove replacement sensor from its plastic canister then plug sensor into its printed cir...

Page 72: ...Do the following to replace the internal particulate filter Material Required Medium Phillips screwdriver Replacement Internal Particulate Filter refer to Section 6 1 Procedure 1 Turn off analyzer and remove screws from control panel 2 Lift up front of control panel to gain access to the particulate filter located on the right hand side of the analyzer See Figure 4 4 3 Remove tubing from old filte...

Page 73: ...aned will become evident Equipment Required Aerosol can of automotive carburetor cleaner Alcohol Mild liquid detergent Method of forcing water through sampling hoses see text Clean rags Source of compressed air optional Procedure 1 If not already done disconnect the probe s gas and pressure fittings and its thermocouple connector from the analyzer 2 Remove gas and pressure hoses from barbed fittin...

Page 74: ...ucet adapter connected to a small piece of rubber hose can be used to supply a rapid flow of water through the sampling hose 6 Wipe off surfaces of probe and sampling hoses with a clean rag 7 Allow parts to dry completely If available blow compressed air through probe and hoses to expedite the drying process 8 Reassemble parts of probe assembly 4 7 Resetting the Microprocessor If the analyzer lock...

Page 75: ...ECA 450 Maintenance Instruction 0024 9400 71 Notes ...

Page 76: ...mmediately following the analyzer s 60 second warm up period Note that the analyzer will not automatically switch to the Combustion Test HOLD screen if problems were detected The analyzer however can still be used to perform any test that does not depend on the sensor that is in error Press the RUN key to manually enter the Combustion Test HOLD screen to continue using the analyzer The following i...

Page 77: ...elds of combustion test data that cannot be calculated because the current measurements will not provide a meaningful calculation For example if the Oxygen level is greater than 16 or the stack temperature is greater than 2000 F 1093 C or the ambient air temperature is greater than 999 9 F 537 8 C then the value for EFF combustion efficiency cannot be calculated x x x x indicates an over range con...

Page 78: ...ttached to the printed circuit board c Microprocessor needs reset Remove analyzer s top panel and press the Reset button shown in Figure 4 5 Display screen is blank when analyzer is turned on but pump runs during warm up cycle a Microprocessor needs reset Remove analyzer s top panel and press the Reset button shown in Figure 4 6 b Loose display connector s Remove analyzer s top panel and ensure th...

Page 79: ...h probe in stack Remove probe from stack allow it to cool to room temperature then restart c Temperature being measured during start up is outside the range of 4 to 212 F 20 to 100 C d Thermocouple defective Replace probe assembly TA Sensor Error message appears at bottom of display a Analyzer was turned on with its primary air thermocouple measuring a temperature that was outside the range of 4 t...

Page 80: ...sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor SO2 Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b SO2 sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor Pressure Sens Erro...

Page 81: ...at is outside the analyzer s detection range This symbol also appears in the number field of the HC sensor when there is not enough Oxygen present to accurately measure the combustible gas level appears in a sensor s data field The field s associated sensor was reported as being in error when the analyzer was turned on Gas pump motor sounds sluggish a Gas flow restricted somewhere between the prob...

Page 82: ...ace any sensor that does not calibrate and then recalibrate b Leak in gas path Check tightness of all hose connections on probe and tightness of all hose connections internal to the analyzer Sensor does not calibrate properly a Wrong calibration gas or insufficient flow being applied to sensor Ensure that the calibration setup is correct b Depleted sensor Replace sensor and recalibrate c If the NO...

Page 83: ...007 1563 Instruction Manual 0024 9400 O Ring Kit 2 sets 0024 1471 O Ring Sensor Blank 0105 5104 Probe Hose Assembly 12 probe Complete Assembly 0024 3023 Hose Connector Gas 0024 0877 Hose Connector Pressure 0024 0878 Filter Water Trap Assembly Complete Assembly 0024 1172 Filter Element package of 3 0007 1644 Printer Paper box of 5 rolls 0024 0980 Pump Gas 0024 3009 Screw Phillips PH 6 32 x 1 2 Sens...

Page 84: ... Nitrogen 0024 1156 NO2 100 ppm in Nitrogen 0024 1157 SO2 100 ppm in Nitrogen 0024 1158 Methane 2 5 CH4 0051 1121 Hose Extension 20 feet extends reach of probe 0024 1124 Probe and Hose Assemblies 24 in 0024 3024 36 in 0024 3025 Sensor Option Kits CO high 4 000 to 80 000 ppm CO 0024 3026 NO 0024 3027 Combustibles 0024 3028 NO2 0024 3029 SO2 requires NO2 option 0024 3030 Serial Communications Cable ...

Page 85: ...acharach Service Center at the following locations United States Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5723 Email help mybacharach com Canada Bacharach of Canada Inc 20 Amber St Unit 7 Markham Ontario L3R SP4 Canada Phone 905 470 8985 FAX 905 470 8963 E mail bachcan idirect com ...

Page 86: ...Headquarters 621 Hunt Valley Circle New Kensington PA 15068 Ph 724 334 5000 Fax 724 334 5001 Toll Free 1 800 736 4666 Website www mybacharach com E mail help mybacharach com ...

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