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Bacharach PCA 2 24-9448, Operating & Maintenance Instructions

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Instruction 24-9448

8-1

Parts & Service

8  Parts & Service
8.1  Replacement Parts

   

Item

(Fig. 8-1) 

Description 

Part No.

 

1 

Man PCB Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1371

 

2 

LCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1374

 

3 

Rear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1381

 

4 

Top Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1382

 

5 

Battery Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1383

 

6 

Wndow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1385

 

7 

LCD Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1386

 

8 

Keypad  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1387

 

9 

Chasss, Battery & Pump  . . . . . . . . . . . . . . . . . . . . . . . .24-1388

  10 

Lens, Infrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1391

  11 

Pump, Sample Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1393

  12 

Pump, Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3015-1716

  13 

Sensor Retaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1418

  14 

Hose Connector Plate (complete assembly)  . . . . . . . . . .24-1419

 

14A 

   Gas Fttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1416

 

14B 

   Pressure Fttng  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1415

 

14C 

   Retanng rng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-2886

  15 

O-Rng, Gas Fttng . . . . . . . . . . . . . . . . . . . . . . . . . . . .105-5102

  16 

O-Rng, Pressure Fttng . . . . . . . . . . . . . . . . . . . . . . . .105-5103

  17 

Gas Covers:

 

17A 

   O

2

 / SO

2

 / NO

2

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1421

 

17B 

   CO-H

2

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1422

 

17C 

   NO / CO

HI

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1420

  18 

Smart Sensors (pre-calbrated):

 

18B 

   CO-H

2

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1395

 

18C 

   CO

HI

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1397

 

18D 

   NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1401

 

18E 

   NO

2

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1399

 

18F 

   SO

2

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1398

Summary of Contents for PCA 2 24-9448

Page 1: ...Product Leadership Training Service Reliability Portable Combustion Analyzer Instruction 24 9448 Operation Maintenance Rev 1 October 2006 ...

Page 2: ...PRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IM PLIED WARRANTIES OF MERCHAN TABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGA TION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARIS ING FROM BACH A RACH S NEGLIGENCE ACTUAL OR IMPLIED The remedies of the Buyer shall be limited to those provided herein to the exclusion of any and all other remedies includ ing ...

Page 3: ...ce 1 8 1 5 7 OPT Option 1 8 1 6 Front Panel Buttons 1 9 2 Specifications 2 1 3 Initial Setup 3 1 3 1 Scope 3 1 3 2 Power 3 1 3 2 1 Installing or Replacing Batteries 3 1 3 2 2 Using the AC Power Adapter 3 2 3 3 Connecting the Probe and Hose Assembly 3 2 3 4 Operating Parameters 3 4 3 5 Fuel Selection 3 4 3 6 Temperature Units Selection 3 5 3 7 Pressure Units Selection 3 6 3 8 Pollution Units Select...

Page 4: ...Logging Process 4 15 4 13 Memory 4 15 4 13 1 Recalling Combustion Test Data 4 16 4 13 2 Recalling Logged Test Data 4 17 4 13 3 Clearing Memory 4 18 4 14 Downloading Stored Data to a Computer 4 19 4 14 1 PCA 2 Data Recovery Program Installation 4 20 4 14 2 Computer to PCA 2 Connection USB Device Driver In stallation 4 22 4 14 3 Recovering Data 4 24 4 14 4 Unplugging the USB Cable 4 27 4 15 Importin...

Page 5: ...ment 6 7 6 4 Sensor Only Replacement 6 8 6 5 Nitric Oxide Sensor Battery Replacement 6 10 6 6 Thermocouple Replacement 6 11 6 7 Pump Replacement 6 13 6 8 Cleaning the Probe 6 14 7 Troubleshooting 7 1 7 1 Analyzer Repair 7 1 7 2 Error Symbols 7 1 7 3 Error Messages Displayed After Warm Up 7 2 7 4 Diagnostics and Status Screens 7 3 8 Parts Service 8 1 8 1 Replacement Parts 8 1 8 2 Accessories 8 5 8 ...

Page 6: ...Instruction 24 9448 iv Contents Notes ...

Page 7: ...culations can be conducted for the following fuels natural gas oil 2 oil 4 oil 6 propane coal wood kerosene bagasse and digester gas A large backlit graphical display shows up to eight combustion test values simultaneously and includes a zoom capability that provides an extra large display of just the O2 CO and combustion efficiency values Smart sensor technology allows a new sensor to be installe...

Page 8: ... 3 3 3 Primary Ambient Air Temperature 3 3 3 Carbon Monoxide Low COLow 3 3 3 Pressure Draft 3 3 3 Carbon Monoxide High COHigh 3 Nitric Oxide NO 3 Nitrogen Dioxide NO2 Sulfur Dioxide SO2 Calculations Combustion Efficiency 3 3 3 Excess Air 3 3 3 Carbon Dioxide CO2 3 3 3 NOx NOx NO NO2 NOx referenced to O2 CO referenced to O2 3 3 3 NO referenced to O2 3 NO2 referenced to O2 SO2 referenced to O2 Refer...

Page 9: ...mperature 3 3 3 Primary Ambient Air Temperature 3 3 3 Carbon Monoxide Low COLow 3 3 3 Pressure Draft 3 3 3 Carbon Monoxide High COHigh Nitric Oxide NO 3 3 Nitrogen Dioxide NO2 3 Sulfur Dioxide SO2 3 3 Calculations Combustion Efficiency 3 3 3 Excess Air 3 3 3 Carbon Dioxide CO2 3 3 3 NOx NOx NO NO2 3 NOx referenced to O2 3 CO referenced to O2 3 3 3 NO referenced to O2 3 3 NO2 referenced to O2 3 SO2...

Page 10: ...COLow sensor with fresh air if the CO level exceeds 4 000 ppm thus protecting the COLow sensor from high CO levels To measure CO levels above 4 000 ppm the analyzer automati cally switches to its COHigh sensor if installed Automatic purging of the gas sample system if the detected gas levels are abnormally high when the analyzer is turned OFF Displays temperatures in either F or C Displays pressur...

Page 11: ...etected the message ERRORS DETECTED is displayed along with a list of the errors These errors must be corrected before proceeding with the combus tion test Before starting a test be sure to select the fuel being burned The default fuel selected is Natural Gas Note that the name of the fuel being burned is indicated at the top of the display To change the fuel first press the MENU F2 button next se...

Page 12: ...he run hold button In addition there is a gas purge feature that keeps the analyzer s pump running if the gas level inside the sensor chambers is abnormally high at shutdown With the probe removed from the stack and sampling fresh air the analyzer purges itself until the detected gas concentrations drop below predetermined levels 1 5 Connector Descriptions 1 5 1 Probe Connections Gas Pressure T St...

Page 13: ...ustion Emission Test Screens when in the RUN or HOLD mode RUN HOLD Starts and stops a combustion efficiency test Pressing this button during the 5 second turn off period will keep the analyzer turned ON ESC Displays previous menu or previously viewed screen I O Press from between 1 and 2 seconds to turn analyzer ON and OFF With analyzer turned ON press briefly to turn backlight ON and OFF POWER AC...

Page 14: ...robe s draft hose to the P fitting while leaving the P fitting open to the atmosphere In addition to measuring draft the and P fittings can also be used to measure the differential pressure between two areas by first connecting a hose P N 24 1103 to the P fitting and then inserting the open end of this hose into the area being used as the reference pressure The analyzer s probe is then inserted in...

Page 15: ...t and Pressure records can be saved After which the old est data will be overwritten ZERO F2 When viewing the Pressure screen this button zeros the pressure sensor to current atmospheric conditions PAGE F1 When viewing the Memory or Logging Directory each press of this button pages down through the directory Holding this button down speeds up the paging process PAGE F3 When viewing the Memory or L...

Page 16: ...n In addition if changes were made to one of the analyzer s operating parameters e g date time O2 reference etc pressing this button aborts those changes restores the old values and then displays the previously viewed screen Turns the analyzer ON and OFF and is also used to turn the backlight and button LEDs ON and OFF Note that when the analyzer is turned OFF there is a 5 second delay during whic...

Page 17: ...ide NO2 0 to 500 ppm Sulfur Dioxide SO2 0 to 5 000 ppm The PCA 2 Calculates and Displays Calculations are performed only when the measured oxygen level is below 16 0 and the stack temperature is below 2 000 F 1 093 ºC Combustion Efficiency 0 1 to 100 Excess Air 1 to 250 Carbon Dioxide dry basis 0 1 to fuel dependent maximum in NOx NOx NO NO2 0 to 3 500 ppm NOx referenced to O2 0 to 9 999 ppm CO re...

Page 18: ...n 0 2 000 ppm and 10 of reading between 2 001 20 000 ppm NO 5 of reading or 5 ppm whichever is greater between 0 2 000 ppm NO2 5 of reading or 5 ppm whichever is greater between 0 500 ppm SO2 5 of reading or 10 ppm whichever is greater between 0 2 000 ppm Stack Gas Temp 4 ºF between 32 and 255 ºF 2 ºC between 0 and 124 ºC 6 ºF between 256 and 480 ºF 3 ºC between 125 and 249 ºC 8 ºF between 481 and...

Page 19: ...0 60 Hz power can be used to power the analyzer on a con tinuous basis If using rechargeable batteries the AC power adapter can also be used to charge the batteries while inside the analyzer Warm Up Time 60 seconds Sensors are checked and auto zeroed during warm up Memory 500 complete combustion test records 500 complete logged combustion test records Interfaces Printer Infrared IrDA communication...

Page 20: ...Instruction 24 9448 2 4 Specifications Notes ...

Page 21: ...le batteries can used to power the an alyzer Note that if rechargeable batteries are used they can be recharged while installed inside the analyzer using the optional AC power adapter refer to Section 3 2 2 Install or replace the batteries as described below 1 Remove battery cover from back of unit Figure 3 1 2 Remove and properly dispose of any old batteries 3 Install a set of four AA alkaline or...

Page 22: ...connector the larger of the two connectors giv ing a slight twist onto the analyzer s GAS fitting 2 Push the draft hose connector the smaller connector giving a slight twist onto the analyzer s P fitting 3 Push the stack gas thermocouple connector into the T STACK jack con nector fits in only one way NOTE The analyzer has a built in temperature sensor for measuring ambient temperature Perform Step...

Page 23: ...STACK T AIR GAS Differential Pressure Hose P Optional Probe Handle Water Trap Filter Assembly Stack Gas Thermocouple Connector T STACK AC Power Adapter Jack POWER Option Connector Optional External Measurement Draft Hose P Gas Sample Hose GAS Probe Tube Probe Stop Primary Ambient Air Thermocouple T AIR Optional ...

Page 24: ...t the fuel being burned as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the buttons to highlight FUEL and then press ENT to display the FUEL MENU 3 Use the buttons to scroll through the list of available fuels until the desired fuel is highlighted In the example shown PROPANE has been selected TIP Use the buttons to quickly...

Page 25: ...Use the buttons to highlight TEMP UNITS and then press ENT to display the TEMP UNITS MENU 4 Use the buttons to highlight the desired temperature units In the example shown Fahrenheit has been selected 5 Press ENT to save the selection and re display the SETUP MENU MAIN MENU FUEL PRESSURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 MENU SETUP MENU TEMP UNITS PRESSURE UNITS POLLUTION UNITS ...

Page 26: ... MENU 3 Use the buttons to highlight PRESSURE UNITS and then press ENT to display the PRESSURE UNITS MENU 4 Use the buttons to highlight the de sired pressure units In the example shown InchesWater has been selected 5 Press ENT to save the selection and re display the SETUP MENU MAIN MENU FUEL PRESSURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 MENU PRESSURE UNITS MENU InchesWater milliB...

Page 27: ...s 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight POLLUTION UNITS and then press ENT to display the POLLUTION UNITS MENU 4 Use the buttons to highlight the desired pollution units In the example shown ppm has been selected 5 Pres...

Page 28: ...ues for month day and year have been set 6 Press ENT to save the displayed date values and re display the SETUP MENU or press ESC to abort this procedure and retain the old date values Note The Date and Time real time clock is powered by the main bat teries and is maintained by a supercap on the Main PCB for approxi mately 1 2 days in the absence of batteries The supercap is intended to maintain t...

Page 29: ...st use the buttons to move the cursor across the screen until it is over the digit to be changed and then press the buttons until the desired value is displayed 5 Repeat Step 4 until the values for hour min ute and meridiem have been set NOTE The value for seconds cannot be en tered but are displayed and stored as part of the combustion test record 6 Press ENT to save the displayed time values and...

Page 30: ...F TO O2 screen for that measurement In the example shown CO has been selected 5 First use the buttons to move the cursor across the screen until it is over the digit to be changed and then press the buttons until the desired value is displayed 6 Press ENT to save the displayed value and re display the O2 REFERENCE screen or press ESC to abort this procedure and retain the old O2 reference value 7 ...

Page 31: ... to display the SETUP MENU 3 Use the buttons to highlight PRINT PRESSURE and then press ENT to display the PRINT PRESSURE screen 4 Use the buttons to highlight either No do not print pressure or Yes print pressure In the example shown Yes has been selected 5 Press ENT to save the selection and re display the SETUP MENU MAIN MENU FUEL PRESSURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 ME...

Page 32: ...e MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight ZOOM and then press ENT to display the ZOOM screen 4 Use the buttons to highlight either No turn zoom OFF or Yes turn zoom ON In the example shown Yes has been selected 5 Press ENT to save the selection and re display t...

Page 33: ...left turned ON to charge the batteries Turn the battery charger circuit ON and OFF as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight BATTERY CHARGER and then press ENT to display the BATTERY CHARGER screen 4 Use the butt...

Page 34: ...MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight BUTTON SOUND and then press ENT to display the BUTTON SOUND screen 4 Use the buttons to highlight either OFF turn sound OFF or ON turn sound ON In the example shown OFF has been selected 5 Press ENT to save the selection ...

Page 35: ...e gas condensate is acidic and very corrosive It is important not to allow the analyzer s internal components to come in contact with condensate for long periods of time Before each use inspect the filter element of the water trap filter as sembly Replace the filter if it looks dirty Refer to Section 6 2 When sampling flue gas keep the analyzer above the water trap and keep the trap in a vertical ...

Page 36: ...message NO ERRORS DETECTED along with the oxygen sensor s output voltage is briefly displayed followed by the display of the Combustion Test HOLD screen TIP The O2 value at the end of warm up is reported as Good Low or BAD Consider replacing the oxygen sensor when its value is reported as Low If problems were detected during warm up the message ERRORS DETECTED is displayed along with a list of tho...

Page 37: ... is highlighted In the example shown PROPANE has been selected TIP Use the buttons to quickly scroll to the bottom and top of the list 4 Press ENT to save the selection and return to the Combustion Test HOLD screen The newly selected fuel should now appear in the top line of the display HOLD NATURAL GAS O2 20 9 CO 0 ppm EFF CO2 T STK 71 5 F T AIR 71 5 F EA CO 0 ppm PRINT MENU SAVE F1 F2 F3 MAIN ME...

Page 38: ...ing of fan assist or power vented furnaces boilers should be done through a hole drilled in the vent immediately above the inducer fan 90 Efficiency Condensing Condens ing furnaces boilers can be tested through a hole drilled in the plastic vent pipe when allowed by the manufacturer or local authority of jurisdiction or taken from the exhaust termination Atmospheric or Gravity Vented Boiler Boiler...

Page 39: ...play to show only the values of O2 CO and efficiency in large char acters Refer to Section 3 13 Sensor Indicators The following indicators appear in the sensor s data field depending on certain conditions Sensor that is not calibrated or defective XXX Sensor overrange The calculated data cannot be displayed because the measured data necessary to make the calculation is out of range i e oxygen leve...

Page 40: ...ption of Measurement or Calculation O2 Oxygen CO Carbon Monoxide 1 EFF Combustion Efficiency CO2 Carbon Dioxide T STK Stack Temperature T AIR Primary Ambient Air Temperature as measured either in ternally or by an optional external thermocouple plugged into the analyzer s T AIR connector EA Excess Air CO n Carbon Monoxide ppm level referenced to a of oxygen 2 NO Nitric Oxide 1 NO2 Nitrogen Dioxide...

Page 41: ...by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 3 Use the buttons to highlight PRESSURE and then press ENT to display the PRES SURE screen 4 Before taking a measurement the pressure sensor may need to be re zeroed if it is not already displaying zero with both pressure ports open to the atmosphere If necessary zero the pressure sensor as follows a Press the ZERO F...

Page 42: ... the pressure at the P port is higher than the P port then the pressure reading will be positive If it is lower then the reading will be negative 4 7 Saving Test Data Up to 500 individual sets snap shots of combustion test or pressure data can be saved in memory which can later be recalled for viewing from the Memory Directory Section 4 13 1 1 First display the screen that contains the data to be ...

Page 43: ...the Water Trap Filter Assembly in a vertical position with the gas flow arrow pointing up as shown in the illustration to the right Empty the water trap chamber after each combustion test or stop the test and empty the chamber if the liquid condensate level ap proaches the tip of the riser tube To empty the trap first pull apart the two halves of the Water Trap using a slight twist ing motion empt...

Page 44: ... purge itself with fresh air The 5 second shutdown sequence will not begin until the gas levels inside the analyzer drop below predetermined levels TIP Although not recommended the purg ing process can be bypassed by pressing the I O button a second time 4 11 Low Battery Alarm When the batteries are nearly depleted an empty battery icon appears in the upper right corner of the display and a short ...

Page 45: ...10 seconds 5000 seconds or 83 minutes If the operator chooses a duration that is longer than possible for the inter val chosen then the analyzer automatically selects the highest duration possible for the selected interval The stored logged data can either be viewed on the display using the ana lyzer s memory function refer to Section 4 13 or downloaded to a personal computer using the supplied PC...

Page 46: ...G screen TIP The amount of memory available for storing new data is displayed in the LOG GING screen maximum of 500 locations If previous logging sessions are stored and ad ditional memory is needed clear the logging memory per Section 4 13 3 NOTE At no time will new logging data over write old data 4 Use the buttons to highlight YES turn logging ON 5 Press ENT to make the selection and display th...

Page 47: ...s 2 Use the buttons to highlight the desired interval and then press ENT to make the selection and display the LOGGING DURA TION screen In this example 1 minute has been selected 3 Use the buttons to highlight the desired duration and then press ENT to make the selection and display the LOGGING SUM MARY screen In this example 2 hours has been selected NOTE If the selected duration requires more me...

Page 48: ...he bottom of the screen the memory location where the current log entry is being saved is displayed This number also repre sents the total number of test records that are stored in memory If there were previously stored log entries each new logging session will start to store data in the next available memory location At no time will new data overwrite old data The ENT button can be pressed while ...

Page 49: ...first bank is used to store combustion test data as described in Section 4 7 while the second bank is used to store logged combustion test data as described in Section 4 12 Each bank is independent of each other and can not share data or be combined Individual memory locations in each memory bank can be recalled for viewing on the display or printed refer to Sections 4 13 1 4 13 2 or the entire co...

Page 50: ... to display the data contained in the selected memory location Note the following The top line of the recalled combustion test data screen shows the memory location being viewed In this example MEM 1 is being displayed The ENT button can be pressed to view other memory test data screens The recalled combustion test data can be printed by pressing the PRINT F1 button refer to Section 4 16 MAIN MENU...

Page 51: ... ENT to display the logging data con tained in the selected memory location Note the following The top line of the log test data screen shows the log location being viewed In this exam ple Log 6 is being displayed The ENT button can be pressed to view other log test data screens The recalled logged test data can be printed by pressing the PRINT F1 button refer to Section 4 16 MAIN MENU FUEL PRESSU...

Page 52: ...hlight MEMORY and then press ENT to display the MEMORY MENU 3 Use the buttons to highlight one of the following CLEAR MEMORY DATA clears only the individual saved combustion test records CLEAR LOGGING DATA clears only the combustion test records that were saved during the logging process CLEAR ALL MEMORY clears all memory locations in both memory banks 4 Press ENT to display the CLEAR MEMO RY LOGG...

Page 53: ...olders and navigating the file structure of the Windows operating sys tem If necessary consult the Windows help files for instructions on how to perform these procedures The downloaded data is stored on the computer s hard drive or removable media of the operator s choosing as a comma separated value ASCII text file with a CSV extension This type of file can be opened by most spread sheet programs...

Page 54: ...2 CD into the computer s CD ROM drive 2 Locate the CD ROM drive in Windows Explorer and open the PCA2 folder Double click the Setup exe program to start the installation process 3 Click Next on the Welcome to the InstallShield Wizard for PCA2 window 4 Click Next to accept the default destination folder or click Change to install to a different folder Default Installation Folder Click to change ins...

Page 55: ...tion folder and user information 6 Click Finish after all files have been copied into the destination folder 7 At this time the PCA2 Data Recovery Program icon should appear under Start All Programs menu 8 This completes the installation of the software Remove CD from drive ...

Page 56: ...he appropri ate ends of the USB cable into the USB connectors on the PCA 2 and computer as shown in Figure 4 2 2 If this is the first time the PCA 2 is being connected to the computer then the Found New Hardware Wizard should shortly appear Select No not this time and click Next Figure 4 2 Computer to PCA 2 Connection Do not search for software NOTE The USB device driver only needs to be installed...

Page 57: ...to folder C Program Files PCA2Data Click Next 5 At the Hardware Installation window click Continue Anyway Our driver has been thoroughly tested in Windows for stability This message appears because Microsoft has not tested this product through WHQL certification Select Advanced Name of new USB hardware Select to search for driver in folder C Program Files PCA2Data ...

Page 58: ...n start menu The Bacharach PCA 2 Data Recovery Program window should appear Observe that the window is divided into two sections The left hand section is used to recover logging data while combustion data is recov ered from the right hand section In the following steps the logging data will be recovered The same procedure can be used to recover combustion data using the right hand section of the w...

Page 59: ...y clicking the desired Open Log Data File button Select a pre existing folder or create a new folder to store the downloaded file Enter filename Click here to create a new folder File type preset to cvs Click Open after selecting a folder and entering a filename Click Start to begin the download process Location of downloaded file Total number of records received out of 512 total Status line showi...

Page 60: ...actually contained data This occurs because the program checks for data in all 500 memory locations including 12 additional locations that contain sensor calibration data Note that the 12 files that contain sensor calibration data are saved in a separate CalibrationData csv file This file is automatically created and placed in the same folder that was selected in Step 2 4 This completes the proces...

Page 61: ...ystem tray Do the following before unplugging the USB cable 1 Double click the Safely Remove Hardware icon in the Windows XP system tray 2 If more than one USB device is plugged into the computer select the device labeled Bacharach PCA2 USB driver and then click Stop 3 Click OK to confirm that the device is to be stopped 4 Wait until Bacharach PCA2 USB driver is removed from the screen and then cl...

Page 62: ...preadsheet program and display the contents of the file If the spreadsheet program does not recognize the CSV file extension then refer to the spreadsheet s documentation for information on how to manually import comma delimited text files Table 4 2 contains a listing and description of the 27 data fields that are downloaded with each data record Note that for sensors that are not installed all re...

Page 63: ...rogen Dioxide Level see field 26 16 ppm NO2 O2 Nitrogen Dioxide Level referenced to a of O2 see field 22 17 NOx Nitrogen Oxides NO NO2 see field 26 18 ppm NOx O2 Nitrogen Oxides Level referenced to a of O2 see field 22 19 SO2 Sulfur Dioxide see field 26 20 ppm SO2 O2 Sulfur Dioxide Level referenced to a of O2 see field 23 21 CO_O2Ref O2 Reference for CO 1 22 NOx_O2Ref O2 Reference for NOx 1 23 SO2...

Page 64: ...on can be printed For example the information shown in the DIAGNOSTIC screen can be printed 1 Turn ON printer Refer to the printer s instruction manual for detailed operating information If not already done set up the printer for 8 bit No parity 9600 baud IrDA is set to IrDA SIR DTR handshaking 2 Align the printer with the top of the analyzer as shown in Figure 4 6 3 Press the PRINT F1 button to b...

Page 65: ...3 25 ppm SO2 3 ppm PRESSURE 0 25 inwc COMMENTS PRINT MENU SAVE 3 to 18 in 7 62 to 45 72 cm NOTES Three stars appear in the data field of sensors that are not calibrated or defective and in the data fields of that sensor s related calculated values Three hyphens or dashes indicate that the calculated data cannot be displayed because the measured data necessary to make the calculation is out of rang...

Page 66: ...Instruction 24 9448 4 32 Operation Notes ...

Page 67: ...calibration history and operating parameters which can be downloaded to a computer and analyzed This informa tion is useful in determining when the sensor was last calibrated and predicting its end of life The smart sensors should be calibrated by an authorized Bacharach Service Center Section 8 3 every 6 months to assure that the analyzer continues to meet its published accuracy specifications Th...

Page 68: ...wing sections 5 3 Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value Material Required Bellows Manometer Range 8 in of water column 20 mb Accuracy 0 01 in of water column 0 025 mb Procedure NOTE The unit of measure for pressure is selected per Section 3 7 In the following procedure inwc is selected but note that any unit of measure can be used for c...

Page 69: ...exactly equals the manometer reading The calibration range is from 6 to 2 inwc 15 to 5 mb An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the fol lowing step 7 Wait until the Measured reading stabilizes and then press ENT to cali brate the pressure sensor s Measured value to that of the Applied value after which the message Good Calibr...

Page 70: ...alyzer s GAS port otherwise water will be drawn into the analyzer 2 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 3 Use the buttons to highlight T Stack and then press ENT to display the CALIBRATE TS ZERO screen Measured is the current temperature read ing while Applied is a known temperature that will be applied for calibration purposes 4 Set the...

Page 71: ... wait several minutes and then use the and buttons to enter an Applied value that exactly equals the thermometer reading The calibration range is from 175 to 625 F 80 to 330 C An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the fol lowing step 7 Wait until the Measured reading stabilizes and then press ENT to cali brate the TS Span Mea...

Page 72: ...zer DO NOT attach the probe s gas hose to the analyzer s GAS port otherwise water will be drawn into the analyzer 2 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 3 Use the buttons to highlight T Air and then press ENT to display the CALIBRATE TA ZERO screen Measured is the current temperature read ing while Applied is a known temperature that will...

Page 73: ...t exactly equals the setting of the simulator Alternatively Submerge probe tip into a con tainer of boiling water with a thermometer wait several minutes and then use the and buttons to enter an Applied value that exactly equals the thermometer reading The calibration range is from 194 to 230 F 90 to 110 C An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL ...

Page 74: ... regu lator of the calibration fixture shown in Figure 5 2 on Page 5 14 4 Use the and buttons to enter an Applied value that exactly equals the concen tration stamped on the CO cylinder The calibration range is from 250 to 1 000 ppm An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the following step 5 Adjust the regulator for a flowmete...

Page 75: ...om 400 to 1 500 ppm An attempt to cali brate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the following step 9 Wait until the Measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the H2 Measured value to that of the Applied value after which the message Good Calibration should briefly appear followed by the CALIBRATION LIST s...

Page 76: ... that exactly equals the concen tration stamped on the SO2 cylinder The calibration range is from 9 to 150 ppm An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the following step 5 Adjust regulator for a flowmeter indication of approximately 2 SCFH Wait until the Measured reading stabilizes approximately 3 minutes and then press ENT to ...

Page 77: ...en Measured is the current NO reading while Applied is a known NO level that will be applied for calibration purposes 3 Attach a 250 ppm NO cylinder to the regu lator of the calibration fixture shown in Figure 5 2 on Page 5 14 4 Use the and buttons to enter an Applied value that exactly equals the concen tration stamped on the NO cylinder The calibration range is from 9 to 550 ppm An attempt to ca...

Page 78: ... gas level Material Required Calibration Kit P N 24 7059 Gas Cylinder 100 ppm NO2 in Nitrogen P N 24 1157 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 2 Use the buttons to highlight NO2 and then press ENT to display the CALIBRATE NO2 screen Measured is the current NO2 reading while Applied is a known NO2 level that will be applied for...

Page 79: ...ife 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 Turn OFF regulator and remove gas cylinder 5 10 CO HI Sensor Calibration This procedure spans the optional carbon monoxide high sensor 4 001 to 20 000 ppm to a known gas level Material Required Calibration Kit P N 24 7059 Gas Cylinder 4 0...

Page 80: ...TION LIST screen being re displayed 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 will appear followed by the CALIBRATION LIST screen being re display...

Page 81: ...er adapter Section 3 2 Sensor re calibration Section 5 Water trap filter assembly maintenance Section 6 2 Sensor replacement Section 6 3 Probe thermocouple replacement Section 6 6 Pump gas or purge replacement Section 6 7 Cleaning the probe Section 6 8 All other maintenance should be performed by an authorized Bacharach Service Center Refer to Section 8 3 ...

Page 82: ...r and then unplug all sensors 4 Lay analyzer face down on a padded work surface and then using a medium Phillips screwdriver remove the unit s four rear case screws 5 Lift rear case from analyzer and set aside 6 Unplug electrical connectors J8 J9 and J14 from printed circuit board CAUTION In Step 7 note that there is tubing connected between the bottom hose connector plate and the pressure sensor ...

Page 83: ...2 COLO COLO COLO COLO COLO COLO 3 SO2 NO2 SO2 4 NO COHI NO NO Model P N Position Sensor Retainer Purge Pump Gas Pump GAS Purge Air In Pressure P P Battery Pump Chassis Hose Connector Plate Purge Pump Motor Connector Gas Pump Motor Connector Sensors Type and position determined by model number Battery Connector on printed circuit board Pressure Sensor on printed circuit board P Top P Bottom ...

Page 84: ...ections Models 235 245 P Ns 24 7302 24 7303 Model 255 P N 24 7304 Models 265 275 P Ns 24 7305 24 7306 Model 225 P N 24 7301 PRESSURE SENSOR on printed circuit board P P P Bottom P Top PRESSURE PURGE AIR GAS Gas IN GAS PUMP PURGE PUMP Gas OUT OUT IN To Sensors ...

Page 85: ...re connection Battery to J14 Battery to J14 Gas Pump to J8 Purge Pump to J9 Sensor Connector typical 4 places Factory Test Connector LCD Connector opposite side of board Ribbon Cable Conection between LCD Assembly and Printed Circuit Board Lock Tabs both ends J8 J9 J14 Wire Routing Solder Connections Connectors ...

Page 86: ...d be emptied after every test or when the water condensate approaches the tip of the riser tube refer to Section 4 9 1 Remove water trap chamber per Figure 6 5 2 Pour out liquid condensate and then reassemble trap 6 2 2 Replacing the Filter Element Replace the filter element when it becomes visibly dirty or becomes satu rated with water Material Required Filter Element P N 07 1644 Small Flat Blade...

Page 87: ...g its calibration procedure Refer to Sections 5 6 thru 5 10 Refer to Section 8 1 for a listing of sensor part numbers Also see Figure 6 2 on page 6 3 for sensor positions Do the following to replace a Smart sensor 1 Turn OFF the analyzer 2 Remove the battery cover 3 Remove the sensor retainer 4 Remove the tubing from the gas cup of sensor being replaced 5 Unplug the sensor along with its printed c...

Page 88: ... be sure that the sensor pin plugs into the PCB socket that is also marked O2 When replacing an NO sensor also replace the bias battery 9 Remove the replacement sensor from its plastic canister Note that the CO LO CO HI SO2 and NO2 sensors have a shorting spring installed between two of their pins Remove and discard this spring before installing the sensor 10 Place the adhesive disk on the bottom ...

Page 89: ...ion time for all sen sors 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 13 Turn ON the analyzer and confirm that no sensor errors occur during warm up Note Discard an old sensor in accordance with local and federal haz ardous waste disposal laws 14 Calibrate the n...

Page 90: ...printed circuit board 3 Insert the new battery with the positive side facing away from the sensor the battery contact is stamped with a symbol 4 Re install the Smart Sensor assembly 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 replacing its bias battery Depending on...

Page 91: ...ches 24 8416 36 inches Each kit contains a thermocouple assembly two O rings and two wire splice connectors Tools Required Small Flat Blade Screwdriver Wire Cutter Wire Stripper Slip Joint Pliers Procedure 1 Gain access to the thermocouple connections by first removing three screws from probe handle and then separating the two handle pieces 2 Cut wires attached to old crimp connectors leaving behi...

Page 92: ...lied wire splice connector and then crimp the connector using a pair of pliers Repeat this step for the yellow thermocouple wires 9 Reassemble the probe handle being careful not to pinch the thermo couple wires between the handle pieces In addition ensure that the end of the thermocouple is in front of the rib molded into the bottom handle piece otherwise the handle pieces will not fit tightly tog...

Page 93: ...n of the new pump the red dot on the pump motor indicates the positive red wire connection 3 Do one of the following Gas Pump Removal Push pump latch toward bottom of analyzer and lift gas pump out from its mounting location Purge Pump Removal Insert a small flat blade screwdriver between the purge pump motor and the pump chassis and then pry the pump out from its mounting location 4 Remove tubing...

Page 94: ...lcohol Aerosol Can of Automotive Carburetor Cleaner Clean Rag Source of Compressed Air optional Procedure 1 Remove gas sample hose from top of water trap CAUTION Carburetor cleaner attacks plastic components Take precautions not to spray cleaner onto the probe handle or analyzer 2 Insert the plastic spray tube of the carburetor cleaner into the gas sample hose and then liberally spray carburetor c...

Page 95: ...Instruction 24 9448 6 15 Maintenance Notes ...

Page 96: ... Inc of any implied or written product liability 7 2 Error Symbols Error symbols are shown in the data fields of the Combustion Test screens and on the printout to indicate the following Three hyphens or dashes indicates that the calculated data can not be displayed because the measured data necessary to make the calculation is out of range For calculations to occur the oxy gen level must be below...

Page 97: ... 6 2 on Page 6 3 O2 BAD Sensor The oxygen sensor s output is below 24 mV signifying that the sensor is depleted and needs replaced Refer to Section 6 3 No Smart Sensors No gas sensors are installed Install sensors per Section 6 3 Pressure Overrange Pressure sensor measured a pressure that was outside the range of 3 inwc during warm up Ensure that probe tip is open to the atmosphere during warm up ...

Page 98: ...led and the O2 sensor status and mV output The STATUS screen provides a quick reference of key items when troubleshooting DIAGNOSTICS O2 Value 41mv Good Smart Sensors COLO cal Good Sensor F1 F2 F3 PRINT MENU STATUS Firmware Ver 1 00 Model 225 Serial LN1000 1 Smart Sensors Battery Volt 4 38 v Ref Temp 79 5 F No Errors 09 11 06 04 55 18 PM F1 F2 F3 PRINT MENU ...

Page 99: ...Instruction 24 9448 7 4 Troubleshooting Notes ...

Page 100: ...p 24 1388 10 Lens Infrared 24 1391 11 Pump Sample Gas 24 1393 12 Pump Purge 3015 1716 13 Sensor Retainer 24 1418 14 Hose Connector Plate complete assembly 24 1419 14A Gas Fitting 24 1416 14B Pressure Fitting 24 1415 14C Retaining ring 02 2886 15 O Ring Gas Fitting 105 5102 16 O Ring Pressure Fitting 105 5103 17 Gas Covers 17A O2 SO2 NO2 24 1421 17B CO H2 24 1422 17C NO COHI 24 1420 18 Smart Sensor...

Page 101: ...ry Clip Double 04 1433 22 Cable Assembly 24 1410 23 Tubing Vinyl 1 8 ID x 3 16 OD 03 6104 24 Tubing Silicon 1 16 ID x 1 8 OD 03 6372 25 Tubing Silicon 3 32 ID x 5 32 OD 103 6101 26 Tubing Silicon 1 8 ID x 3 16 OD 103 6102 A replacement O2 PCB is only required if it is damaged When replacing the NO sensor it is good practice to replace the bias battery at the same time Also see Section 6 4 for requ...

Page 102: ...22 P P P Bottom Pressure Sensor P Top PRESSURE PURGE AIR GAS IN Bottom OUT Top OUT IN 23 25 26 24 16 typical 4 places 15 typical 2 places 14B typical 2 places 14A 14C typical 3 places 23 14 11 12 17A 18A 17C 18C 17C 18D 17A 18E 17A 18F 17B 18B 25 OR OR O2 is not a Smart sensor ...

Page 103: ...Instruction 24 9448 8 4 Parts Service 4 10 7 6 2 1 9 18 17 13 3 5 8 19 12 14 20 21 11 19 Figure 8 1 Parts 2 of 2 ...

Page 104: ...ater Trap Filter Assembly Fig 8 2 24 3004 Water Trap Filter 19 3265 Filter Element 3 pack 07 1644 Thermocouple Replacement Kit 12 24 8414 Probe Stop with Thumb Screw 19 3037 Connector Gas Sample 24 0877 Connector Draft 24 0878 PCA 2 Data Recovery Software Disk 24 1425 USB Cable 104 4032 Instruction Manual 24 9448 Figure 8 2 Probe Hose and Water Trap Filter Assembly ...

Page 105: ... 24 0492 1000 ppm CO 1000 ppm H2 in Nitrogen 24 0794 4 000 ppm CO in air 24 1155 250 ppm NO in Nitrogen 24 1156 100 ppm NO2 in Nitrogen 24 1157 100 ppm SO2 in Nitrogen 24 1158 IrDA Printer 24 1400 Printer Paper 1 Roll 06 8733 5 Roll Pack 24 1310 Probe Hose and Water Trap Filter Assemblies 6 in Probe 24 3002 24 in Probe 24 3021 36 in Probe 24 3022 Thermocouple Replacement Kits 6 in 24 8413 12 in 24...

Page 106: ...5 470 8985 Fax 905 470 8963 Email bachcan idirect com México Bacharach de México Playa Regatas No 473 Tercer Piso Col Militar Marte Delegación Iztacalco 08830 México D F México Phones 52 555 634 7740 52 555 634 7741 Fax 52 555 634 7738 Email bacharachservicio bacharach com mx Website www bacharach mexico com Europe Bacharach Instruments Sovereign House Queensway Royal Leamington Spa Warwickshire C...

Page 107: ...Notes ...

Page 108: ...adquarters 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 ...

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