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Portable Combustion Analyzer

(Siegert Version)

Operation and Maintenance Manual

Instruction 0024-9473

Rev. 3 – August 2012

Product Leadership

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Training

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Service

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Reliability

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Summary of Contents for PCA3

Page 1: ...Portable Combustion Analyzer Siegert Version Operation and Maintenance Manual Instruction 0024 9473 Rev 3 August 2012 Product Leadership Training Service Reliability...

Page 2: ...L OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY...

Page 3: ...tery Compartment 18 2 5 AC Adapter Connector POWER 18 2 6 Probe Connectors Gas Pressure T Stack 19 2 7 Differential Pressure Connector P 20 2 8 Primary Air Thermocouple Connector T AIR 20 2 9 Computer...

Page 4: ...39 4 20 Calibration Reminder Period 40 4 21 Run Hold Screen Format 41 CHAPTER 5 OPERATION 44 5 1 Operating Tips 44 5 2 Turning On the Analyzer 45 5 3 Low Battery Alarm 45 5 4 Locating Sampling Points...

Page 5: ...ion 68 6 4 1 Material Required 68 6 4 2 Procedure 68 6 5 T Stack Calibration 69 6 5 1 Material Required 70 6 5 2 TS Zero Procedure 70 6 5 3 TS Span Procedure 71 6 6 T Air Calibration 71 6 6 1 Material...

Page 6: ...e NO Sensor Battery Replacement 90 7 6 1 Material Required 90 7 6 2 Procedure 90 7 7 Cleaning the Probe 91 7 7 1 Equipment Required 91 7 7 2 Procedure 91 CHAPTER 8 TROUBLESHOOTING 92 8 1 Error Symbols...

Page 7: ...ment indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Caution statements may also be used to alert against unsafe practices IMPORTANT An importan...

Page 8: ...is a high emission of soot the probe s sample filter may become clogged Before every use check the filter to confirm that it is clean or replace it with a new filter To prevent this from occurring a s...

Page 9: ...ith EN50379 B Smart sensor technology allows a new sensor to be installed in the field without having to calibrate the analyzer with gas before use Advanced data storage and communication features all...

Page 10: ...display The recommended time required to achieve a stable measurement is a minimum of 3 minutes During a test the COLOW sensor is protected from high CO levels by being automatically flushed with fre...

Page 11: ...zoom capabilities Low battery alarm Stores 500 individual combustion records which can later be recalled for viewing printing or downloading to a personal computer Stores an additional 500 data logge...

Page 12: ...334 7335 7336 Measurements Oxygen O2 Stack Temperature Primary Ambient Air Temperature Carbon Monoxide Low COLOW Pressure Draft Carbon Monoxide High COHIGH Nitric Oxide NO Nitrogen Dioxide NO2 Sulfur...

Page 13: ...Dioxide SO2 0 to 5 000 ppm Calculated Value Based on Installed Sensors Display Range Stack Loss qA 0 1 to 100 Carbon Dioxide dry basis 0 0 to fuel dependent max in Lambda 1 to 9 55 EFF HHV 0 1 to 100...

Page 14: ...Calculated excess air EFF Efficiency based on HHV in ETA Efficiency based on LHV in CO2max Constant see table below A2 Constant see table below B Constant see table below Fuel Constants Some fuel cons...

Page 15: ...to 100 mB 3 from 40 to 40 inwc System Flow Rate with Probe 200 cc min minimum General Specification Description Dimensions H x W x D 22 9 x 7 6 x 6 3 cm 9 0 x 3 0 x 2 5 inches Weight Analyzer with Ba...

Page 16: ...PCA 3 Manual 0024 9472 Rev 2 16 CHAPTER 2 HARDWARE 2 1 Overview Figure 2 1 Front and Bottom Views Showing Key Components...

Page 17: ...Directory each press of this button pages through the directory Holding this button speeds the paging process The arrow buttons move the cursor on the LCD In screens that require the entry of alphanu...

Page 18: ...limits at the time the instrument is turned OFF the pump is automatically started and purges the sensor compartment with fresh air until the gas levels inside the analyzer are reduced If desired the...

Page 19: ...re connected to the analyzer by way of the following connectors Stack gas thermocouple to the analyzer s T STACK connector Stack gas hose to the analyzer s GAS connector Draft hose to the analyzer s P...

Page 20: ...Wand P N 0104 1799 12 inch ridged probe with handle and 5 foot coiled cable is to be used to measure the burner s primary air temperature then connect either of these thermocouples to the analyzer s...

Page 21: ...stall or replace the batteries Remove the battery cover from back of unit Figure 3 1 Remove and properly dispose of any old batteries Install a set of four AA alkaline or NiMH batteries per the and ma...

Page 22: ...To assure the accurate calculation of combustion efficiency the optional primary ambient air thermocouple must be used when the burner s primary air temperature is not the same as the room temperatur...

Page 23: ...PCA 3 Manual 0024 9473 Rev 3 23 Figure 3 2 Connecting the Probe to the Analyzer...

Page 24: ...rint Pressure Selection No Page 33 Zoom Display Selection Standard Page 34 Logging Selection No Page 35 Button Sound Selection On Page 35 Test ID Information blank Page 36 User Name blank Page 38 Lang...

Page 25: ...ult factory for price and delivery Figure 4 1 Fuel Selection 4 Press ENT to save the selection and display the CO2 MAX screen 5 To accept the default CO2 Max value for the selected fuel use the button...

Page 26: ...nd press ENT to start a 60 second count down 6 Press ENT to save and re display the SETUP MENU Figure 4 3 Auto Manual Zero Selection NOTE The PCA 3 performs a zero function during warm up Among other...

Page 27: ...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 TEMP UNITS and then press ENT...

Page 28: ...2 Configure the PCA 3 to display pollution units in parts per million ppm pounds of pollutant per million BTU Mbtu milligrams of pollutant per cubic meter of gas mg m3 or grams of pollutant per gigajo...

Page 29: ...ons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight smoke number and then press ENT to display the SMOKE NUMBER MENU 4 Use the buttons to highlight Smoke...

Page 30: ...save and return to the SETUP MENU Figure 4 8 Configuring for the Presence of Oil Derivatives 4 9 Boiler Temperature This screen allows the user to manually enter a boiler temperature as measured by a...

Page 31: ...3 Use the buttons to highlight DATE and then press ENT to display the DATE MENU 4 First use the buttons to move the cursor across the screen until it is over the digit to be changed and then press th...

Page 32: ...the desired value is displayed 5 Repeat Step 4 until values for hour and minute are set NOTE The value for seconds cannot be entered but is displayed and stored as part of the combustion test record...

Page 33: ...ence value for more than one gas is being set repeat Steps 4 5 and 6 for each measurement Figure 4 12 O2 Reference Setup 4 13 Print Pressure Selection Select whether to print or not print the pressure...

Page 34: ...perator can scroll through the complete list of measured and calculated data no matter what zoom level has been selected Select desired zoom level as follows 1 Display the MAIN MENU by pressing the ME...

Page 35: ...gure 4 15 Logging Selection 4 16 Button Sound Selection The audible sound used to signal when a button is pressed can be turned OFF and ON as follows 1 Display the MAIN MENU by pressing the MENU F2 bu...

Page 36: ...ight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight TEST ID and then press ENT to display the TEST ID menu 4 Use the buttons to highlight EDIT TEST ID and then press...

Page 37: ...the procedure and return to the Setup Menu or press the RUN HOLD key to return to the Run Hold Screen 4 17 3 Clearing Test ID Information 1 From the Test ID menu use the buttons to highlight CLEAR TES...

Page 38: ...sing 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 USERNAME and...

Page 39: ...ENT to display all three lines of the EDIT USERNAME screen Periods identify empty lines 4 Use the buttons to choose which of the three Username lines to clear then press CLEAR F3 to clear that line 5...

Page 40: ...ent will display the reminder and how long since the sensors were last calibrated The reminder will be displayed at the end of the 60 second warm up period If a calibration reminder is displayed the o...

Page 41: ...is running or in the hold mode The default order in which data appears in the Run Hold screen is shown below O2 Oxygen CO Carbon Monoxide Lambda Excess Air CO2 Carbon Dioxide CO2Max Carbon Dioxide in...

Page 42: ...cation by first using the buttons to highlight the location Then press the ENT key to select the location the cursor will start to flash 6 Use the buttons to scroll through and select the desired data...

Page 43: ...to highlight RESET FORMAT then press ENT to display the Reset Format screen 5 Use the buttons to select YES then press ENT to reset the display and return to the Run Hold Format screen Figure 4 25 Re...

Page 44: ...t 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 assembly Replace the filte...

Page 45: ...ed by the Warm Up screen 4 Wait for the analyzer to count down its 60 second warm up period after which the instrument will display the Combustion Test HOLD screen 5 If problems were detected during w...

Page 46: ...ce Hot Water Tank Figure 5 3 Forced Air Furnace For atmospheric burner or gravity vented forced air heating equipment with a clam shell or sectional heat exchanger design test each of the exhaust port...

Page 47: ...n testing of fan assist or power vented furnaces boilers should be done through a hole drilled in the vent immediately above the inducer fan Boilers which have a bell shaped draft diverter on top shou...

Page 48: ...il the stack s core temperature hot spot is located as indicated by the highest T STK reading then tighten the thumbscrew to prevent further probe movement Locating the highest stack temperature is ve...

Page 49: ...NOx Oxides of Nitrogen NO and NO2 combined 1 SO2 Sulfur Dioxide 1 CO Carbon Monoxide ppm level referenced to a of oxygen 2 NO Nitric Oxide ppm level referenced to a of oxygen 2 NO2 Nitrogen Dioxide pp...

Page 50: ...rature applied to the T Stack channel will be displayed on the Temperature Measurement screen as differential temperature between the two channels Additionally the temperature measurement can be label...

Page 51: ...Refer to page 27 for information on selecting the pressure units of measure 2 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 3 Use the buttons...

Page 52: ...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 Figure 5 12 Pressure Zero Screen Figure 5 13 Draft Pressure Measure...

Page 53: ...the Water Trap The Water Trap Filter Assembly removes stack gas condensate and also prevents soot from contaminating the internal components of the analyzer IMPORTANT Use the Water Trap Filter Assembl...

Page 54: ...fill 500 memory locations would be 1 hour 500 x 10 seconds 5000 seconds or 83 minutes If the operator chooses a duration that is longer than possible for the interval chosen then the analyzer automati...

Page 55: ...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 h...

Page 56: ...As soon as logging is turned ON see Logging Selection on page 35 the LOGGING INTERVAL screen appears 2 Use the buttons to highlight the desired interval and then press ENT to make the selection and d...

Page 57: ...e the current log entry is being saved is displayed NOTE If there were previously stored log entries each new logging session will start to store data in the next available memory location NOTE At no...

Page 58: ...ns Or move to the first or last memory location by pressing the buttons respectively 5 13 2 Recalling Combustion Test Data Recall individual combustion test data records as follows 1 Display the MAIN...

Page 59: ...y the LOGGING DIRECTORY screen 4 Use the buttons to highlight the desired data logging location to be recalled Each logging location is identified by the date and time at which the data was saved The...

Page 60: ...ay the MEMORY MENU Figure 5 21 Clearing Memory 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...

Page 61: ...Average 5 14 Downloading Stored Data to a Computer The combustion test data that was stored in either the analyzer s Memory Directory or Logging Directory see Memory Functions section on page 58 can...

Page 62: ...he spreadsheet s documentation for information on how to manually import comma delimited text files The table below contains information about the 32 data fields that are downloaded with each data rec...

Page 63: ...refer to O2 Reference Setup on page 32 2 Pressure units as selected refer to Pressure Units Selection on page 27 3 Pollution units as selected refer to Pollution Units Selection on page 28 5 16 Printi...

Page 64: ...PCA 3 Manual 64 0024 9473 Rev 3 Figure 5 23 Printer Alignment and Sample Printout...

Page 65: ...ging Turn OFF the analyzer by pressing the I O button for at least 2 seconds or until two beeps are heard The unit will count down 5 seconds before shutting down giving the operator an opportunity to...

Page 66: ...ch Service Center see Service Centers on page 99 every 6 months to 1 year to assure that the analyzer continues to meet its published accuracy specifications B Smart sensors however can be calibrated...

Page 67: ...d calibrate do the following 1 Enter the CALIBRATION MENU 2 Use the buttons to select B SMART Press ENTER to display the B Smart code screen 3 Use the buttons to enter the 10 or 14 digit alphanumeric...

Page 68: ...as shown in Figure 6 3 but DO NOT connect the analyzer to the calibration equipment at this time 2 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration...

Page 69: ...t until the measured reading stabilizes and then press ENT to calibrate the pressure sensor s Measured value to that of the applied value after which the message Good Calibration should briefly appear...

Page 70: ...een refer to Calibration on page 66 3 Use the buttons to highlight T Stack and then press ENT to display the CALIBRATE TS ZERO screen NOTE Measured is the current temperature reading while Applied is...

Page 71: ...he measured reading stabilizes and then press ENT to calibrate the TS Span Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CA...

Page 72: ...Set thermocouple simulator to 0 C 32 F and then use the and buttons to enter an applied value that exactly equals the setting of the simulator Alternatively Submerge probe tip into an ice water bath...

Page 73: ...he measured reading stabilizes and then press ENT to calibrate the TA Span Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CA...

Page 74: ...o calibrate outside this range causes the message Applied Value High or Low to appear at the bottom of the screen Figure 6 7 COLOW Sensor Calibration 5 Adjust the regulator for a flow meter indication...

Page 75: ...ration 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...

Page 76: ...urposes 3 Attach a 100 ppm SO2 cylinder to the regulator of the calibration fixture shown in Figure 6 12 on page 80 4 Use the and buttons to enter an applied value that exactly equals the concentratio...

Page 77: ...Material Required Calibration Kit P N 0024 7059 Gas Cylinder 250 ppm NO in Nitrogen P N 0024 1156 6 9 2 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen ref...

Page 78: ...DIAGNOSTICS screen NOTE If the sensor s output is too low to be usable then the message Bad Calibration Sensor End of Life Entry Not Saved will appear followed by the CALIBRATION LIST screen being re...

Page 79: ...for a flow meter indication of approximately 2 SCFH Wait until the measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the NO2 measured value to that of the applied val...

Page 80: ...If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 2 Use the buttons to highlight CO HI and then press ENT to display the CALIBRATE CO HI...

Page 81: ...d value to that of the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed NOTE If the sensor s output is low but still usable t...

Page 82: ...en remove batteries NOTE In Step 3 if the sensors are not being replaced leave the tubing connected to each sensor s gas cap being careful not to put unnecessary strain on the tubing during the disass...

Page 83: ...g the Rear Case Sensor Position Model Number and Corresponding Sensor Configuration 225 235 245 255 265 275 285 1 O2 O2 O2 O2 O2 O2 O2 2 COLOW COLOW COLOW COLOW COLOW COLOW COLOW 3 Empty Empty Empty S...

Page 84: ...PCA 3 Manual 84 0024 9473 Rev 3 Figure 7 2 Inside View with Rear Case Removed...

Page 85: ...PCA 3 Manual 0024 9473 Rev 3 85 Figure 7 3 Tubing Connections Main Figure 7 4 Tubing Connections Sensors...

Page 86: ...PCA 3 Manual 86 0024 9473 Rev 3 Figure 7 5 Wire Routing Connectors and Solder Connections...

Page 87: ...r Element Replace the filter element when it becomes visibly dirty or becomes saturated with water 7 4 1 Material Required Filter Element P N 0007 1644 Small Flat Blade Screwdriver 7 4 2 Procedure 1 R...

Page 88: ...kwise and then pulling the cup straight up 7 Carefully remove the old sensor from the B Smart sensor PCB keeping in mind that there is an adhesive foam disk in between the PCB and sensor IMPORTANT Whe...

Page 89: ...chnically 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...

Page 90: ...Insert the new battery with the positive side toward 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 th...

Page 91: ...Aerosol Can of Automotive Carburetor Cleaner Clean Rag Source of Compressed Air optional 7 7 2 Procedure 1 Remove gas sample hose from top of water trap CAUTION Carburetor cleaner attacks plastic com...

Page 92: ...her the NO or NO2 sensor contains three stars then the NOx data field will also contain three stars X X X Indicates sensor over range 8 2 Diagnostics and Status Screens The DIAGNOSTICS menu provides i...

Page 93: ...e the buttons to highlight STATUS and then press ENT to display the DEVICE STATUS screen 3 Press ESC key to exit back to the Main Menu 8 5 Error Messages After Warm up If there were problems detected...

Page 94: ...to re zero sensor s If message persists sensor s may need to be replaced Message will indicate which sensor s are in error Stack or Air temperature channel is measuring temperature outside the range o...

Page 95: ...nsor NOT calibrated COLOW 0024 0789 16H Sensor NOT calibrated COHIGH 0024 0997 16J Sensor NOT calibrated NO 0024 0881 16K Sensor NOT calibrated NO2 0024 1027 16L Sensor NOT calibrated SO2 0024 0998 17...

Page 96: ...PCA 3 Manual 96 0024 9473 Rev 3 Figure 8 3 Replacement Parts Main PCB Assembly Replacement Part Not Available...

Page 97: ...4 0865 Batteries AA Alkaline 0204 0004 12 Probe Hose and Water Trap Filter Assembly 0024 3053 1 Water Trap Filter 0019 3265 2 Filter Element 3 pack 0007 1644 3 Probe Stop 0019 0580 4 Thumb Screw 0102...

Page 98: ...8 Utility Wand 12 in rigid probe w 5 ft coiled cable 0104 1799 Differential Pressure Hose Assembly 6 ft 0024 1103 Calibration Kit includes hoses adapter flow meter does not include gas cylinders 0024...

Page 99: ...ould be performed by an authorized Bacharach Service Center refer to Service Centers on page 99 Any repairs performed by an unauthorized service organization will void the analyzer s warranty and rele...

Page 100: ...ns for Portable Electrical Apparatus Designed to Measure Combustion Flue Gas Parameters of Heating Appliances EN 50379 2 Part 2 Performance Requirements Performance Requirements for Apparatus Used in...

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Page 104: ...104 0024 9473 Rev 3 World Headquarters 621 Hunt Valley Circle New Kensington Pennsylvania 15068 Phone 724 334 5000 Toll Free 1 800 736 4666 Fax 724 334 5001 Website www MyBacharach com E mail help MyB...

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