Bacharach PCA 400 User Manual Download

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Combustion & Emissions

P/N: 0024-9551

| July 2018 Revision 1

Combustion Analyzer

for Commercial & Light Industrial Use

User

Manual

Summary of Contents for PCA 400

Page 1: ...Combustion Emissions P N 0024 9551 July 2018 Revision 1 Combustion Analyzer for Commercial Light Industrial Use User Manual...

Page 2: ...SERVICE POLICY Bacharach Inc maintains a service facility at the factory Some Bacharach distributors agents may also have repair facilities however Bacharach assumes no liability for service performe...

Page 3: ...Connections 13 2 1 5 Interfaces 14 2 1 6 Components 15 2 2 Sample Line Probe Assembly 16 2 3 Power Configurations 17 Operation 18 3 1 Setup 18 3 1 1 Operation Tips 18 3 1 2 Inspection Prerequisites 2...

Page 4: ...lution Mode 41 Care Maintenance 42 5 1 Emptying the Water Trap 42 5 2 Replacing the Filter Element 43 5 3 Cleaning the Probe Assembly 44 5 4 Sensor Replacement 45 5 5 B Smart Sensor Calibration 48 5 5...

Page 5: ...in Ireland ATTN Service Department Canada Phone 1 905 882 8985 Fax 1 905 882 8963 Email support bachcan ca Bacharach Inc 10 West Pearce Street Unit 4 Richmond Hill Ontario L4B 1B6 Canada ATTN Service...

Page 6: ...afety and the proper use of the PCA 400 please read the contents of this manual for important information on the operation and maintenance of the analyzer 1 2 Conventions 1 2 1 Short Form Instructions...

Page 7: ...roduct or environment It may also be used to alert against unsafe practices IMPORTANT Additional information on how to use the product 1 2 2 Iconography WARNING When testing an appliance a full visual...

Page 8: ...arry case filters USB cable PC Software digital download AC adapter and a rechargeable lithium ion battery pack The reporting kit version in addition to the base includes an IrDA Bluetooth printer and...

Page 9: ...l custom fuels Backlit display and resistive touch make operation simple and intuitive in the field View data in list tile or trending formats making it easier to interpret results Pre calibrated sens...

Page 10: ...ct ABS plastic with molded in magnets protects the analyzer and allows for hands free use LCD Touch Display 4 3 full color backlit liquid crystal display with resistive touch panel Interfaces USB T Ai...

Page 11: ...r on the display When viewing a directory use the buttons to open and close sub directories Enter Key Selects a highlighted item In addition if changes have been made to one of the analyzer s operatin...

Page 12: ...on Display Options Display table list format Display trending line graph format Display tile format Settings Display configuration parameters Memory Set file structure and naming conventions for data...

Page 13: ...to toggle RUN HOLD mode Print Touch to print data to IrDA Bluetooth printer Save Touch to save data to default selected folder Calibrate Touch to perform calibration functions Fig 2 4 Sample Line Conn...

Page 14: ...RTANT Interference can be caused by devices that are transmitting on the same frequency band Printer Interfaces The PCA 400 is capable of wirelessly transmitting data to compatible IrDA Infrared Data...

Page 15: ...ery replacement this analyzer should only be opened and or serviced by authorized Bacharach personnel Failure to comply may void the warranty 30 9 1 m Fig 2 7 Bluetooth Communication Range 60 max 4 to...

Page 16: ...ly Probe Tube available in multiple lengths Probe Stop Probe Handle Water Trap Filter Assembly Sample Line available in multiple lengths and construction types Quick Connector keyed to fit specific co...

Page 17: ...to charge batteries which are swollen or bulging IMPORTANT Operating the analyzer with the AC power adapter DOES NOT charge its rechargeable batteries To recharge the analyzer s batteries supply power...

Page 18: ...Tips 18 3 1 2 Inspection Prerequisites 20 3 1 3 Connecting Probe Assembly 21 3 2 Performing Combustion Test 22 3 2 1 Combustion User Preferences 22 3 2 2 Combustion Analysis 23 3 2 3 Additional Setti...

Page 19: ...r messages appearing after the warm up cycle completes Inspect Water Trap Filter Assembly Before each use inspect the filter element of the water trap filter assembly Replace the filter if it looks di...

Page 20: ...See Emptying the Water Trap Section 5 1 for more information Maintain Sensor Calibration Calibrate the analyzer every 6 months to 1 year to ensure its accuracy See Calibration Sections 5 5 and 5 6 fo...

Page 21: ...nnecting Probe Assembly 1 Connect Analyzer to Sample Line Firmly insert the gray quick connector into the base of the analyzer Users will hear a click once a secure connection has been made 2 Connect...

Page 22: ...ss the POWER button to begin a 60 second warm up period Users will hear the pump begin operation and splash screen should appear on the analyzer s display 3 2 Performing Combustion Test 3 2 1 Combusti...

Page 23: ...mory Location Main Menu Memory use navigation keys to highlight the desired folder Options select Target 2 Select Fuel Type f f To select Fuel Type Main Menu Fuel Menu select Natural Gas NGAS Oil 2 OI...

Page 24: ...Graph Settings O2 Reference Zoom NOx Calculation Save save combustion data to the selected folder memory location Print print combustion data to IrDA Bluetooth printer s IMPORTANT Printing via Bluetoo...

Page 25: ...he probe and sample line may become dirty during normal use and should be cleaned regularly to ensure proper function See Cleaning the Probe Assembly Section 5 3 for more information CAUTION The probe...

Page 26: ...der in which analysis results are displayed f f To update Run Hold Format Options Run Hold Format set prioritization via dropdown menu press Save Zoom List View Combustion test data can be shown with...

Page 27: ...30 seconds 1 minute 3 minutes 5 minutes and 15 minutes Save save Line Graph Settings and return to current combustion analysis results IMPORTANT Changes to this setting will not become the analyzer s...

Page 28: ...s the ability to organize their records in a folder structure for later viewing and downloads f f To change Folder Memory Location Main Menu Memory use navigation keys to highlight the desired folder...

Page 29: ...ng active data to the analyzer s onboard storage and or printing to the optional IrDA Bluetooth printer f f To save pressure readings report press Save f f To print pressure readings report press Prin...

Page 30: ...ture Units Main Menu Settings Temperature Units select Fahrenheit or Celsius 3 4 2 Temperature Analysis 1 Select Folder Memory Location User Discretion The PCA 400 gives users the ability to organize...

Page 31: ...ooth is diabled when the analyzer is connected to the PCA 400 App If you wish to print disconnect from the mobile app or enable IrDA communications 6 Save Print Readings The PCA 400 is capable of savi...

Page 32: ...an versions of the PCA 400 will display information in English French and Spanish Languages are chosen through software menu selections Changing Language Preference f f To change Language Selection Ma...

Page 33: ...time formats AM PM if 12 hour format is selected select AM or PM Save save changes to Date and Time and return to the Settings menu IMPORTANT Username information will appear at the top of each print...

Page 34: ...Timeout select None 20 minutes 30 minutes or 60 minutes 4 6 Post Purge Period Purge feature at shutdown if enabled specifies a duration time None 1 5 or 10 minutes during which the analyzer s pump wi...

Page 35: ...ition 1 Position 2 Position 3 Position 4 Auto Zero When the CO channel is set to Auto Zero the CO sensor is zeroed to the ambient CO level during start up Changing CO Zero Method Auto Zero determines...

Page 36: ...or in this position Position 3 the analyzer can optionally have None NO2 or a SO2 sensor in this position Position 4 the analyzer can optionally have either None or a NO sensor in this position Save s...

Page 37: ...s settings For more information about wireless communication ranges see Figures 2 6 and 2 7 Enabling Printing via IrDA The analyzer can communicate data via IrDA at a distance of up to 16 41 cm IrDA c...

Page 38: ...g records 4 11 Onboard Data Logging When the logging function is activated up to 500 combustion test records can be automatically stored in memory at a preset interval over a predetermined duration Lo...

Page 39: ...tings and return to the Combustion Test screen IMPORTANT The amount of memory available of storing new data is displayed in the LOGGING screen maximum of 500 locations If previous sessions are stored...

Page 40: ...hen viewing a directory users can the buttons to open and close sub directories Users may also use the Navigation Arrows Figure 4 6 on the touch interface to quickly scroll through saved records Clear...

Page 41: ...rs are not present 4 14 Sensor Protection Dilution Mode Sensor Protection Dilution Mode allows the instrument to dillute the gas sample in order to protect its sensors from over ranging during combust...

Page 42: ...2 5 6 1 Starting a Calibration 52 5 6 2 COLOW Sensor Calibration 53 5 6 3 SO2 Sensor Calibration 56 5 6 4 NO Sensor Calibration 57 5 6 5 NO2 Sensor Calibration 58 5 6 6 COHIGH Sensor Calibration 60 5...

Page 43: ...ashion and pull apart 5 2 Replacing the Filter Element Replace the filter element when it becomes visibly dirty or becomes saturated with water Materials Equipment Required Before cleaning the probe a...

Page 44: ...near an open flame 2 Open Filter Chamber Using a small flat blade screwdriver pry apart the Filter Chamber Remove and discard the old Water Trap Filter 3 Install New Filter Install new filter and rea...

Page 45: ...plugging vents where sensors are not present 2 Clean Sample Line with Carburetor Cleaner Insert the plastic spray tube of the carburetor cleaner into the sample line and liberally spray the cleaner t...

Page 46: ...the sensor assembly from the board Materials Equipment Required Before beginning the process of replacing sensors obtain the following items Phillips head Screwdriver Replacement Sensor 1 Turn OFF th...

Page 47: ...ould be sufficiently stabilized for use in approximately 4 hours 10 Turn ON the Analyzer Press the Power Key and ensure that no sensor errors occur during the 60 second warm up 6 Attach Sensor Cap Ass...

Page 48: ...gas for calibration Sensors can be pre calibrated and installed when needed Sensors can be moved from one analyzer to another and The analyzer s diagnostics screen shows which sensors have been insta...

Page 49: ...s touch screen or keypad to enter the 4 digit calibration password The calibration password can be changed and or disabled using the optional PCA Reporting Software f f To access the CALIBRATION MENU...

Page 50: ...nsor from Board Take care not to bend the connector pins on the base of the sensor when removing from the analyzer Disconnect sample tubing from the cap assembly and pull sensor from the board 6 Remov...

Page 51: ...ner supplied with the replacement B Smart sensor 2 Seal the plastic container in the pre paid shipping envelope and return it to Bacharach Inc at the following address ATTN B SMART SENSOR PROGRAM BACH...

Page 52: ...tion procedure by taking the following steps 1 Turn ON the Analyzer Turn the analyzer ON allowing it to cycle through its 60 second warm up period in fresh air During the warm up the analyzer s operat...

Page 53: ...he sensor to know gas levels Fig 5 7 Gas Sensor Calibration Equipment Leave Top Port Open Part of Calibration Kit P N 0024 7059 Regulator 3 16 I D Tubing Gas Cylinder Gas Connector Materials Equipment...

Page 54: ...rough the top of the flow meter Fig 5 8 Adjusting the Flow Rate Gas Flow Too Low Not enough to properly calibrate Gas Flow Optimal Ball in flow meter is in the sweet spot Gas Flow Too High Enough to c...

Page 55: ...an applied value which exactly equals the CO concentration stamped on the CO H2 cylinder 5 Allow Reading to Stabilize Waituntilthemeasuredreadingstabilizes approximately3minutes andpressSave tocalibra...

Page 56: ...efore manually calibrating the SO2 sensor obtain the following items Calibration Kit P N 0024 7059 Gas Cylinder 100 ppm SO2 in Nitrogen P N 0024 1158 1 Access the SO2 Calibration Menu f f To access th...

Page 57: ...ructed by the manufacturer or an authorized service provider DO NOT reset sensor gain during the calibration process 6 Remove Calibration Cylinder Turn OFF regulator and remove the 100 ppm SO2 cylinde...

Page 58: ...NO measured value to that of the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen 6 Remove Calibration Cylinder Turn OFF regulator and remove t...

Page 59: ...turer or an authorized service provider DO NOT reset sensor gain during the calibration process 5 Allow Reading to Stabilize Waituntilthemeasuredreadingstabilizes approximately3minutes andpressSave to...

Page 60: ...the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen 2 Apply 500 ppm CO to the Sensor Attach a 500 ppm CO cylinder to the regulator For more in...

Page 61: ...il it has stabilized Applied Value High or Low N A An attempt was made to calibrate a sensor outside its calibration range Warm up Sensor Error Error CO COHIGH NO NO2 or SO2 sensor s were not zeroed a...

Page 62: ...tatus Screens Device Status Displays the analyzer s status and any errors which should be addressed Section 5 7 1 f f To display Device Status Main Menu Status Device Status Device Info Displays the a...

Page 63: ...ime Displays the date and time Users can change the date and time by accessing the Settings Menu Section 4 2 f f To display Time and Date Main Menu Status Time and Date Bluetooth Link Displays the sta...

Page 64: ...54 kg Operating Conditions Temperature 23 to 113 F 0 to 45 C Humidity 15 to 90 RH non condensing Air Pressure 1 atmosphere 10 Storage Conditions Temperature 4 to 122 F 20 to 50 C Humidity 15 to 95 RH...

Page 65: ...m 0 to 50 5 51 to 500 T90 40 seconds SO2 0 to 5 000 ppm 1 ppm 10 ppm 0 to 200 5 reading 201 to 2 000 10 reading 2 001 to 5 000 T90 30 seconds Approval Description EN 50270 2015 EMC tested in accordanc...

Page 66: ...to 9 999 ppm 1 ppm North American SO2 Referenced to O2 0 to 9 999 ppm 1 ppm North American Excess Air 1 to 250 1 North American Measurement Range Resolution Accuracy Response Time Ambient Temperature...

Page 67: ...ch was stored in either the analyzer s Memory Directory can be downloaded to a computer using the PRS and USB cable that are supplied with the analyzer The downloaded data is stored on the computer s...

Page 68: ...Nitric Dioxide Level Referenced to a of O2 See Field 25 20 NOx Nitrogen Oxide NO NO2 See Field 27 21 ppm NOx O2 Nitrogen Oxide Level as Referenced to a of O2 See Field 25 22 SO2 Sulfur Dioxide See Fie...

Page 69: ...iOS 30mb for the application only 6 3 PCA 400 App To download the PCA 400 App visit www mybacharach com apps The companion smartphone application allows users to perform a variety of functions withou...

Page 70: ...to print reports directly from their analyzer without a wired connection P N 0024 1680 Printer Paper contains 5 rolls of paper P N 0024 1310 Tru Spot Smoke Tester Description The True Spot Smoke Teste...

Page 71: ...ton Sample Line Assembly with Water Trap 15 P N 0024 3237 Sensors O2 Sensor P N 0024 1652 CO Sensor B Smart Pre calibrated Sensor P N 0024 1687 CO Sensor Not Calibrated P N 0024 1660 COHIGH Sensor B S...

Page 72: ...001 Email help mybacharach com Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15068 USA ATTN Service Department Europe Phone 353 1 284 6388 Fax 353 1 284 6389 Email help mybacharach com Bachar...

Page 73: ...Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15068 USA Pittsburgh PA USA Dublin IRE Gloucester UK Stanardsville VA USA Toronto CAN www mybacharach com help mybacharach com...

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