Bacharach Portable Combustion Analyzer, Instruction

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Parts & Service

8.2 Accessories

PCA

Description

Part No.

STANDARD ACCESSORIES:

Battery, “AA” Alkaline

0204-0004

Complete Probe and Hose Assembly (Gas & Draft) 0024-3004
Instruction Manual 0024-9219
Plastic Carrying Case 0024-1078

OPTIONAL ACCESSORIES:

Ambient Thermocouple, 10 ft. K-type

0104-1797

Ambient Thermocouple, 1 in. K-type

0104-1798

Bent Probe Tip 0024-8039
Calibration Kit 0024-7059
Differential Pressure Hose Assembly 0024-1103
Gas Cylinder, 500 ppm CO in air 0024-0492
Gas Cylinder, 1000 ppm CO & 1000 ppm H

2

in Nitrogen 0024-0794

Printer, Infrared (with Manual, Batteries, and Paper):

120 VAC 0024-1229
230 VAC 0024-1230

Printer Paper (1 roll) 0024-0887
Power Supply Adapter, 110 VAC 0024-0885
Regulated Power Supply Adapter, 230 VAC 0024-1209
Serial Communication Cable 0024-1073

8-2

Instruction 0024-9219

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Summary of Contents for Portable Combustion Analyzer

Page 1: ...Portable Combustion Analyzer PCA Instruction 0024 9219 Operation Maintenance Rev 10 May 2010 Product Leadership Training Service Reliability...

Page 2: ...AND ALL 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...

Page 3: ...he Stack 4 4 4 3 3 Starting a Combustion Test 4 5 4 3 4 Ending a Combustion Test 4 5 4 3 5 Turning Off the Analyzer and Purging the CO Sensor 4 6 4 4 Differential Pressure Measurement 4 7 4 5 Warm up...

Page 4: ...he Probe 6 4 6 4 Water Trap Filter Assembly Maintenance 6 5 6 5 Replacing the Particulate Filter 6 6 6 6 Replacing the Oxygen Sensor 6 7 6 7 Replacing the Nitric Oxide Sensor 6 8 6 7 1 Replacing the N...

Page 5: ...1 is a commercial grade hand held combustion efficiency analyzer that is designed for continuous on demand sampling of light industrial and residential furnaces appliances and boilers The basic instru...

Page 6: ...ess Air in Flue Gas Carbon Dioxide Content in Flue Gas Carbon Monoxide Content referenced to Oxygen in ppm For analyzers having a Carbon Monoxide sensor Flue Gas Nitric Oxide Content referenced to Oxy...

Page 7: ...tests while the advanced PCA 40 can store up to 100 tests PCA 15 45 with Draft In addition to the features of the basic PCAs described above these instru ments have the added capability of measuring d...

Page 8: ...any of the saved tests to an optional printer via an infrared link CO Sensor Purge On all PCAs that measure CO if the ON OFF key is pressed while the CO reading is 100 ppm or higher the analyzer will...

Page 9: ...99 9 Excess Air in the range of 1 to 250 Carbon Dioxide content in flue gas from 0 1 to a fuel dependent maximum value in percent Carbon Monoxide content referenced to a percentage of Oxygen in the r...

Page 10: ...ever is greater Flue Gas Temp 4 F between 32 and 255 F 2 C between 0 and 124 C 6 F between 256 and 480 F 3 C between 125 and 249 C 8 F between 481 and 752 F 4 C between 250 and 400 C Ambient Temp 2 F...

Page 11: ...rovide at least 8 hours of continuous opera tion with the pump running and the backlight turned on Warm Up Time 60 seconds Printer Interface Infrared Communications refer to Section 4 24 Materials Hig...

Page 12: ...Technical Characteristics NOTES PCA 2 4 Instruction 0024 9219...

Page 13: ...of batteries is supplied with the PCA Install the batteries as described below If a LOW BATTERY message is displayed when the analyzer is turned on replace the batteries 1 Remove the battery cover fro...

Page 14: ...DRAFT sample inlet fitting 3 Push the Flue Gas Thermocouple into the T STACK jack connector fits in only one way NOTE The PCA has a built in room air thermocouple Perform Step 4 only if the Optional...

Page 15: ...couple Draft Hose Pressure Reference Port Used in the Measurement of Differential Pressure Flue Gas Hose Present only on analyzers equipped with a pressure sensor Probe Tube Water Trap Filter Assembly...

Page 16: ...wing the instructions in their associated sections Function Parameters To Change Refer to Fuel Natural Gas Section 4 8 Temperature C Section 4 13 Draft WC Section 4 14 Oxygen Reference 0 Section 4 15...

Page 17: ...and screens This key also causes the cursor to enter the number field in the Password Screen and causes the cursor to advance to the next field position in screens requiring multiple alphanumeric ent...

Page 18: ...e or stack For residential and light commercial combustion equipment applications the following recommendations are applicable Oil Gun Burners Locate sampling hole at least 12 in 30 cm down stream fro...

Page 19: ...probe in an area of fresh ambient air then press the analyzer s ON OFF key 3 Wait for the analyzer to countdown through its 60 second warm up period then perform one of the following If no errors wer...

Page 20: ...rew the probe stop supplied with the Probe and Hose Assembly into the sampling hole Figure 4 2 2 Insert the probe through the hole in the probe stop then position the probe tip inside the stack near i...

Page 21: ...Note that locating the highest stack temperature is very important for accurate combustion calculations 3 You can now begin burner service procedures The readings on the analyzer change quickly to sh...

Page 22: ...pump will automatically turn on if not already running to purge the analyzer of CO Important The probe must be removed from the stack during the purging process to allow fresh air to be drawn through...

Page 23: ...een is displayed remove any hoses con nected to Pressure Ports 1 and 2 then press the ENTER key to zero these ports to atmospheric pressure 3 Connect two sampling hoses to Pressure Ports 1 and 2 Figur...

Page 24: ...ring which time the Warmup value yy counts down to zero After the warmup cycle is complete and if the unit is working correctly the instrument will flash NO ERRORS DETECTED and go directly to the Comb...

Page 25: ...rvention Refer to Section 7 2 for a listing and explaination of the error codes Note that the analyzer will not automatically switch to the Combustion Test Screen if a sensor error was detected The an...

Page 26: ...bon Monoxide content referenced to a percentage of O2 ppm TS Stack Flue gas temperature F EA Excess air NX Nitric Oxide content in flue gas ppm NF Nitric Oxide content referenced to a percentage of O2...

Page 27: ...d then press the ENTER key NOTE The fuel selected is saved as the default and re mains in memory after the PCA is turned off The fuel codes as displayed in the Combustion Test Screen NG Natural Gas KE...

Page 28: ...ed by the analyzer When using the analyzer to make a differential pressure measurement Section 4 4 the differential pressure value will appear on the third Draft Screen To save S or print P the screen...

Page 29: ...of the desired memory location then press the ENTER key The saved data is now displayed in either the Combustion Test Screen or Draft Screen depending on whether the chosen memory location contains co...

Page 30: ...memory locations TRANSMIT DATA Before data can be transmitted to a personal computer the PCA s RS 232 output must first be connected to an unused computer COM port using serial data cable Part No 24 1...

Page 31: ...on how to perform this procedure To start transmitting data first use the st keys to position the cursor z in front of TRANSMIT DATA and then press the ENTER key Observe that as PCA downloads its dat...

Page 32: ...tion in ppm NX 161 3 NO referenced to nn O2 in ppm NF 171 2 O2 Reference used in fields 14 and 16 O2R 181 Combustion efficiency in EF 191 Excess air in EA 20 Draft measurement DR 21 Draft unit of meas...

Page 33: ...each test record for the purpose of identifying individual tests Front Panel Key Functions for the Initial ID SETUP Screen Move cursor z upward Move cursor z downward Select ID Number that is next to...

Page 34: ...the text line and return to the initial ID SETUP Screen NOTE The entered ID information will be saved with all future test records until it is modified or deleted Front Panel Key Functions for the Ind...

Page 35: ...the temperature unit of measure first use the st keys to move the cursor z in front of C or F and then press the ENTER key Front Panel Key Functions Move cursor z up Move cursor z down Select unit of...

Page 36: ...r millibars MB Pascals PA or inches of water column WC To select the draft unit of measure first use the st keys to move the cursor z in front of MB PA or WC and then press the ENTER key Front Panel K...

Page 37: ...he Combustion Test Screen can show both the measured level of CO and its calculated level referenced to Oxygen displayed as CF For PCAs with both CO and NX sensors the Combustion Test Screen can only...

Page 38: ...lable for selection include English ENG Spanish ESP and French FRA To select a language first use the st keys to move the cursor z in front of ENG ESPor FRA and then press the ENTER key Front Panel Ke...

Page 39: ...ese gases CF and NF referenced to Oxygen NOTE The levels of CO NX CF and NF are always in cluded on the printout and in the downloaded data of each combustion test regardless of what is being displaye...

Page 40: ...se or decrease the value of that field Continue using the ENTER and st keys until all values within the chosen field are correct then press RUN to save all field values and return the cursor to the le...

Page 41: ...tions protocol IR IRDA Infrared connection to a printer that uses a standard IrDA protocol RS232 Cable connection between the PCA and any serial printer capable of 9600 baud operation Use the st keys...

Page 42: ...the st keys until the first digit of the password is displayed then press ENTER to advance to the second number field In a similar manner enter the next two password digits Then press the RUN key aft...

Page 43: ...creen or User Name Screen To enter the Calibration Menu Screen Section 5 3 use the st keys to position the cursor z in front of CALIBRATION and then press the ENTER key To enter the User Name Screen S...

Page 44: ...e user or owner of the instrument i e your company s name and address Front Panel Key Functions for Initial User Name Screen Move cursor z upward Move cursor z downward Select Line Number next to the...

Page 45: ...r Name Screen Abort any changes to the text line and return to the initial User Name Screen 4 23 Saving Test Data O2 4 0 CO 12 HLD DRAFT C2 9 5 NX 15 NG DRAFT 0 25 WC TA 68 0 TS 374 P HOT SPOT 374 F P...

Page 46: ...n or the Draft Screen NOTE The data which is stored in memory can also be printed First go to the Memory Directory Screen Section 4 10 and display the data to be printed then print the data as de scri...

Page 47: ...see Figure 4 6 2 Set the printer s communication parameters to 9600 baud 8 data bits 1 stop bit no parity and no handshaking 3 Use the st keys to move the cursor z in front of the print P function 4 P...

Page 48: ...front of the clear C function and then press the ENTER key To return to the previous screen without clearing memory place the cursor z in front of the exit E function and press ENTER 4 26 Resetting th...

Page 49: ...til re cali bration is performed correctly with span gas 5 1 Sensor Check Important Before turning on the analyzer or performing any of the calibration procedures ensure that the analyzer will be samp...

Page 50: ...fer to Section 8 2 Bellows Micromanometer Procedure Assemble the appropriate fixture shown in Figure 5 1 as required by the calibration procedure being performed GAS FIXTURE Leave Top Port Open 2 3 4...

Page 51: ...0 Use this screen to select the sensor to be calibrated Press the st keys until the cursor z is in front of the desired function and then press the ENTER key NOTE TS is the stack temperature sensor wh...

Page 52: ...nnel 3 Adjust the simulator to 32 F 0 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and ENTER keys to enter an APPLIED value that equals 32 F 0 C Typical Calibrate TS Ze...

Page 53: ...3 Set the simulator to 575 F 302 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and ENTER keys to enter an APPLIED value that equals 575 F 302 C Typical Calibrate TS Span...

Page 54: ...ture channel 3 Set the simulator to 32 F 0 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and ENTER keys to enter an APPLIED value that equals 32 F 0 C Typical Calibrate...

Page 55: ...hannel 3 Set the simulator to 212 F 100 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and ENTER keys to enter an APPLIED value that equals 212 F 100 C Typical Calibrate...

Page 56: ...ump should start running 3 Using the Gas Fixture shown in Figure 5 1 attach the Nitric Oxide calibration gas cylinder to the analyzer s GAS inlet 4 Adjust the regulator of the calibration fixture for...

Page 57: ...libration fixture for a flowmeter indica tion of approximately 2 SCFH 5 Wait until the MEASURED reading on the screen stabilizes approxi mately 3 minutes Then use the st and ENTER keys to enter an APP...

Page 58: ...10 Press the RUN key to save the CO VALUE and display the Calibrate H2 Screen 11 After calibration gas has been applied for approximately 3 minutes to allow for stabilization use the st and ENTER key...

Page 59: ...ion fixture to the analyzer s DRAFT port then adjust the bellows for a micromanometer reading of 4 H2O column 10 mb 3 Wait until the MEASURED reading on the screen stabilizes Then use the st and ENTER...

Page 60: ...Calibration PCA NOTES 5 12 Instruction 0024 9219...

Page 61: ...replacing the water trap filter and performing periodic calibration checks to ensure that the analyzer is providing accurate readings Replace the Batteries per Section 3 2 Clean the Probe per Section...

Page 62: ...ove the batteries Section 3 2 1 2 Place the analyzer face down on a work surface then remove the unit s four rear case screws 3 Carefully lift the rear case from the analyzer unplug the battery compar...

Page 63: ...BATTERY FUSE TO BATTERY COMPARTMENT CARBON MONOXIDE SENSOR OPTIONAL NITRIC OXIDE SENSOR OPTIONAL OXYGEN SENSOR RED PUMP MTG SCREWS PUMP BLACK PARTICULATE FILTER DRAFT SENSOR OPTIONAL Figure 6 2 PCB an...

Page 64: ...tor Cleaner Clean Rag Source of Compressed Air optional Procedure 1 Remove the rubber tubing from the barbed fitting s on the probe handle Figure 3 2 CAUTION Carburetor cleaner attacks plastic compone...

Page 65: ...nlet End of the Water Trap Filter Assembly Figure 6 3 2 Pour out all of the water condensate and replace the end cap Replace the filter element when it becomes excessively dirty Equipment Required Fil...

Page 66: ...f it becomes clogged Equipment Required Particulate Filter and Fitting Refer to Section 8 1 Procedure 1 Remove the analyzer s rear case and lay it aside refer to Section 6 2 2 Carefully pull off the 1...

Page 67: ...y pull off the two wires connected to the pins of the sensor see Figure 6 2 3 Push in and turn the sensor counterclockwise watching the notch on top until it stops then pull the sensor out of its hous...

Page 68: ...h in and turn the sensor counterclockwise watching the notch on top until it stops then pull the sensor out of its housing 4 Install a new sensor by first pushing it into its housing and then turning...

Page 69: ...3 Insert the new battery positive side facing upwards into its holder 4 Reassemble the analyzer 5 Before powering up and using the instrument allow the Nitric Oxide sensor to stabilize as described be...

Page 70: ...lay it aside refer to Section 6 2 2 Carefully pull the printed circuit board off the rear of the Carbon Monoxide sensor see Figure 6 2 3 Push in and turn the sensor counterclockwise watching the notc...

Page 71: ...fe of the Carbon Monoxide sensor it is recommended its red filter be replaced once a year Procedure 1 Remove the Carbon Monoxide sensor per Section 6 8 2 Pry the red filter from the Carbon Monoxide se...

Page 72: ...move the analyzer s rear case and lay it aside refer to Section 6 2 2 Remove the two self tapping Phillips screws holding the Pump Assem bly See Figure 6 2 3 Unplug the pump connector from the printed...

Page 73: ...acing the Pump Assembly Replacing Sensors and Sensor Filters Replacing Batteries All other repairs should be performed by an authorized Bacharach Ser vice Center Any repairs performed by an unauthoriz...

Page 74: ...ry is dead TA SENSOR ERROR Room air thermocouple is outside the range of 20 to 100 C 4 to 212 F TS SENSOR ERROR Flue Gas thermocouple is not connected or is outside the range of 20 to 1200 C 4 to 2192...

Page 75: ...ries dead Replace batteries per Section 3 2 b Loose battery connector Disas semble analyzer and ensure that the battery connector is attached to the printed circuit board c Microprocessor needs to be...

Page 76: ...ery on the Nitric Oxide circuit board is dead Replace bat tery per Section 6 7 2 a Calibration was attempted while sampling combustion gases b Carbon Monoxide sensor is ex pired Replace sensor per Sec...

Page 77: ...combustion data b Sensor in error during warm up The field s associated sensor is de tecting a value that is outside the analyzer s detection range XXXX is replaced with numerical data when the analy...

Page 78: ...sensors are prop erly installed per Sections 6 6 through 6 8 Check sensor calibration per Section 5 0 Replace sensor s and recal ibrate per Sections 5 0 and 6 0 b Probe assembly leaking Check tightnes...

Page 79: ...oxide Sensor Filter 0024 0863 12 Nitric Oxide Sensor Filter 0024 0862 13 Pump Assembly 0024 3009 14 Fuse 1 25A 250V 0604 2605 15 Battery Nitric Oxide Sensor Bias 0204 0020 16 Particulate Filter 0007 1...

Page 80: ...rmocouple 1 in K type 0104 1798 Bent Probe Tip 0024 8039 Calibration Kit 0024 7059 Differential Pressure Hose Assembly 0024 1103 Gas Cylinder 500 ppm CO in air 0024 0492 Gas Cylinder 1000 ppm CO 1000...

Page 81: ...PCA Parts Service Figure 8 1 Replacement Parts 1 of 3 Instruction 0024 9219 8 3...

Page 82: ...Parts Service PCA FUSE 14 15 9 10 11 12 8 13 RED BLACK 16 17 18 19 Figure 8 1 Replacement Parts 2 of 3 8 4 Instruction 0024 9219...

Page 83: ...PCA Parts Service Figure 8 1 Replacement Parts 3 of 3 Instruction 0024 9219 8 5...

Page 84: ...Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5723 Email help bacharach inc com Canada Bacharach of Canada Inc 20 Amber St Unit 7 Markham Ontario L3R SP4 Canada Phone 905 470 8...

Page 85: ...T AIRE NX SENSOR ERROR ERREUR CELLULE NX ERROR EN SENSOR NX Sign Off Screen OFF IN n SEC ARRET DANS n SEC ADAGADO EN n SEGS PURGING CO SENSOR PURGE DETECTEUR CO PURGANDO CO SENSOR Combustion Test Scre...

Page 86: ...emory to PC Screen MEMORY TO PC MEMOROIRE A PC MEMORIA AL PC TRANSMIT DATA TRANSM DONNEES TRANSMITIR DATOS CLEAR MEMORY EFFACER MEMOIRE BORRAR MEMORIA ID Setup Screen SETUP PROGRAMME SETUP ID n ID n I...

Page 87: ...ZERO TS CERO TS SPAN TS PTEE TS SPAN TA ZERO TA ZERO TA CERO TA SPAN TA PTEE TA SPAN NX NX NX CO CO CO DRAFT PRESSION DRAFT Calibrate TS Zero Screen CALIBRATE TS ZERO CALIBRER TS ZERO CALIBRAR TS CERO...

Page 88: ...ENTRY ERREUR D ETALONNAGE CALIBRACION INCORRECTA Calibrate CO H2 Screen TEST GAS CO H2 GAZ TEST CO H2 GAS PRUEBA CO H2 CO VALUE VALEUR CO VALOR DE CO ENTER CO VALUE ENTRER VALEUR CO ENTRAR VALOR CO B...

Page 89: ...ser name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data ID2 optional data ID3 optional data HORA 04 27 35 pm FECHA 02 24 1999 COMBUST GNATURL TEMP CHIM 374 F TEMP A...

Page 90: ...Appendix B PCA NOTES B 2 Instruction 0024 9219...

Page 91: ...World Headquarters 621 Hunt Valley Circle New Kensington PA 15068 Ph 724 334 5000 Fax 724 334 5001 Toll Free 800 736 4666 Website www mybacharach com E mail help mybacharach com Printed in U S A...

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