Bacharach 300 Instructions Manual Download

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INSTRUCTION 24-9223

MODEL 300

COMBUSTION ANALYZER

(Standard Efficiency Equations,

Siegert Efficiency Equations,

and NSX Version)

Operation/Maintenance

Rev. 2 – November 1999

Bacharach, Inc.

625 Alpha Drive, Pittsburgh, PA 15238

Phone: 412-963-2000 • FAX: 412-963-2091 • Web: www.bacharach-inc.com

Printed in U.S.A

® Registered Trademark

Summary of Contents for 300

Page 1: ...Efficiency Equations Siegert Efficiency Equations and NSX Version Operation Maintenance Rev 2 November 1999 Bacharach Inc 625 Alpha Drive Pittsburgh PA 15238 Phone 412 963 2000 FAX 412 963 2091 Web w...

Page 2: ...of Bacharach to the replacement of this Product or parts thereof that are defective in title The warranty set forth in paragraph 1 does not apply to parts the Operating Instructions designate as havi...

Page 3: ...DO NOT puncture or take them apart CAUTIONS To avoid damaging the probe assembly due to excessive heat remove probe from stack at or before the prescribed time listed below Allow probe to cool to roo...

Page 4: ...2 1 230 VAC Plug Installation 2 2 2 2 Printer Paper Installation 2 2 2 3 Filter Trap Installation 2 2 2 4 Probe Connection 2 3 2 5 Initial Start up and Adjustment 2 4 2 6 Sensor Checks 2 7 2 7 Optiona...

Page 5: ...bration 4 14 5 MAINTENANCE 5 1 5 1 Oxygen Sensor Replacement 5 1 5 2 Toxic Sensor Replacement 5 3 5 3 Filter Trap Filter Replacement 5 5 5 4 Cleaning the Gas Sampling System 5 7 5 4 1 Cleaning the Pro...

Page 6: ...ource Either 120 VAC 240 VAC or internal battery pack per sales order BATTERY PACK SPECIFICATIONS A battery powered unit may be run off the charger if required Output Voltage 5 VDC Charging Input Volt...

Page 7: ...24 7131 are listed below Stack Temperature Probe Exposure Time Limit 100 1000 F 38 538 C Unlimited 1000 1200 F 538 649 C 30 mins per exposure 1200 1400 F 649 760 C 10 mins per exposure NOTE The high t...

Page 8: ...andard Efficiency Equations NGAS Natural Gas OIL2 Number Two Fuel Oil OIL6 Number Six Fuel Oil LPG Liquid Propane COAL Coal WOOD Wood 17 Moisture BAGA Bagasse from vegetable matter Siegert Efficiency...

Page 9: ...ple overrange OR C CO sensor overrange OR O O2 sensor overrange Auxiliary Display NSX Units LOW BATT NOX SO2 sensor bias batteries low BATT FAIL NOX SO2 sensor bias batteries dead W NO NOX sensor out...

Page 10: ...MODEL 300 COMBUSTION ANALYZER Figure A Model 300 Combustion Analyzer Typical Configuration viii Instruction 24 9223...

Page 11: ...RODUCTION Describes the instrument and its front panel controls 2 SET UP Describes how to prepare a new analyzer for operation 3 OPERATION Describes how to perform a combustion efficiency test 4 MAINT...

Page 12: ...s microprocessor is programmed to compute percent efficiency percent excess air and percent carbon dioxide for the seven fuels described in Table 2 in the front of this manual In addition to the inst...

Page 13: ...ogen present in sampled gas Display of SO2 gas sulfur dioxide present in sampled gas Additional printout information Time and date of test Serial number of analyzer NOX level if NOX sensor is installe...

Page 14: ...lay will show the word FUEL At this time the FUEL key is pressed until the type of fuel being burned is shown in the left display See Table 2 in the front of this manual for a list of programmed fuels...

Page 15: ...cy test The Display Mode Indicators identify what is being shown on the display Display Mode Indicator Lit Meaning of Display Indication CAL Combustion Analyzer in calibration mode Press CAL key to st...

Page 16: ...or O2 cell bad or missing Occurs at end of calibration cycle if output of O2 cell is either less than 15 1 mV or greater than 65 9 mV E TC Error thermocouple temperature is below 100 or above 2300 F 1...

Page 17: ...eing shown on the display Display Mode Indicator Lit Meaning of Display Indication Oxygen percentage as measured by the O2 sensor Computed excess air percentage is based on the O2 detected the fuel se...

Page 18: ...Counts down 60 second calibration time Combustion efficiency percentage Computed value based on O2 detected CO detected net stack temperature measured and fuel selected Display shows three dashes if...

Page 19: ...o Section 3 5 that pertain to the NSX portion of the analyzer 1 5 1 Left Display Clock Shows current time in hours and minutes in either a 12 or 24 hour format Refer to Section 2 7 for information on...

Page 20: ...MODEL 300 COMBUSTION ANALYZER 1 10 Instruction 24 9223 NOTES...

Page 21: ...using the Model 300 preform all the following that apply AC Plug Installation Initial Start up and Alignment Printer Paper Installation Sensor Checks Filter Trap Installation Optional Clock Setting Pr...

Page 22: ...r the country where the instrument is to be used 2 2 PRINTER PAPER INSTALLATION Before turning on the analyzer ensure that the printer has a roll of printer paper installed Refer to Section 5 6 2 3 FI...

Page 23: ...ROBE CONNECTION See Fig 2 2 To connect the probe simply attach its air tubing to the filter trap and plug its thermocouple connector into the receptacle at the rear of analyzer s control panel noting...

Page 24: ...on 2 5 Step 5 At the End of the 60 Second CAL Cycle Section 2 5 Step 5 Press CAL Pump LED ON Left Display CAL Mid Display Oxygen Sensor Output Level Right Display Count Down Opt Clock Time Opt Display...

Page 25: ...display shows CAL the Optional clock display shows the correct time and the middle and right front and Optional auxiliary displays go dark Also note the pump starts and continues to run until the conc...

Page 26: ...N key to start pump Allow pump to run for 30 seconds after which stop pump by again pressing the RUN key Then check for the following Fig 2 4 Left display should show a temperature that is within 2 of...

Page 27: ...tion 4 3 CO Span Calibration however do not remove the control panel or make adjustments as instructed The control panel needs to be removed only if the CO calibration pot needs adjustment Send to Bac...

Page 28: ...date of an efficiency test to appear on the printout the clock on the NSX auxiliary display panel must be set as follows 1 Open the analyzer case and then flip up the auxiliary display panel 2 Apply p...

Page 29: ...mode or CK 12 12 hour format mode YR 95 Year MO 04 Month DY 09 Day of month DA SU Day of week HR 15 Hour shown in 24 hour format or PM 03 Hour shown in 12 hour format MN 58 Minute 3 58 or 15 58 curren...

Page 30: ...r of the day PM __ or HR __ will also need to be reset d Repeat steps a thorough c until all clock modes are correct then press the MODE switch until the clock display returns to the current time 2 8...

Page 31: ...N This sections describes Performing an Efficiency Test Gas Sample Points Installing the Probe Printer Operation Error Warning and Failure Displays Recalibration after an Efficiency Test Changing Fuel...

Page 32: ...ss FUEL key to proper fuel Insert Probe in Stack Sample Hole See Sections 3 2 3 3 Step 6 Press RUN Left Stack Temp or CO Level or Error Mid 2 or Excess Air or mV of O2 Cell Right Efficiency or Stack L...

Page 33: ...approved grounded extension cords Use of other cords may bring about a hazardous condition and voids the instrument s warranty Ungrounded extension cords may cause erratic display indications 2 During...

Page 34: ...sample point Sections 3 2 and 3 3 CAUTION To avoid damaging standard probe assembly due to excessive heat remove probe from stack at or before the prescribed time listed in Table 1 in the front of th...

Page 35: ...and mildly acidic If water begins to approach the trap s filter element press RUN key to stop test Remove filter trap and empty its bowl Fig 3 1 When replacing the bowl be sure its O ring is properly...

Page 36: ...ons are applicable Oil Burners Locate sampling hole at least 12 downstream from the furnace breeching and at least 6 upstream from the furnace side of the draft regulator Gas Burners Locate sampling h...

Page 37: ...splay shows three dashes while printing the numbers printed for efficiency stack loss and carbon dioxide are invalid After printing press and hold the PAPER ADVANCE switch to advance paper before tear...

Page 38: ...YGEN 2 9 EXCESS AIR 276 CARBON DIOXIDE PPM CARBON MONOXIDE PPM NOX 1 PPM SULFUR DIOXIDE 1 EFFICIENCY 99 9 STACK LOSS 1 TEST PERFORMED BY ________________________ COMMENTS BACHARACH MODEL 3 COMBUSTION...

Page 39: ...libration cycle If an overrange problem occurs during the CAL cycle the calibration cycle is immediately aborted the ERROR indicator starts flashing and an OR message appears If an error and or overra...

Page 40: ...ee attempts have been made to clear it correct the problem s displayed in Step 1 by following the suggested remedies listed in Table 3 1 3 5 2 Optional Error Warning and Overrange Displays The warning...

Page 41: ...nstru ment of O2 Then press CAL Replace O2 Cell Refer to Section 5 1 Allow analyzer to stabilize at a temperature between 32 and 122 F 0 and 5 C Adjust potentiometer R24 Refer to Section 4 2 TABLE 3 1...

Page 42: ...lyzer will then auto matically restart either its calibration or run sequence If a CO or O2 over range condition reoccurs after two attempts to clear it purge the analyzer s gas sampling system by rem...

Page 43: ...isplays may be incorrect BATT FAIL Failure sensor bias batteries are dead The NOX and SO2 displays are disabled W NO Warning NOX sensor out of calibration Four stars are printed on the NOX line of the...

Page 44: ...the furnace s primary air inlet If the furnace is drawing in ambient air you can sample room air for calibra tion purposes 5 Press CAL key to start recalibration cycle During recalibration you should...

Page 45: ...shut down and store your Model 300 Combustion Analyzer 1 If not already stopped press RUN key to stop the analyzer s pump WARNING Probe may be hot To avoid burns always handle the probe with heat pro...

Page 46: ...l panel then unscrew and empty its bowl Replace bowl being sure its O ring is in place then store filter trap in case b Remove knurled nut see Fig 3 6 located at the bottom of the particulate trap and...

Page 47: ...he bottom part of the carrying case To avoid crimping the hose when the case is closed loop hose under strap per Fig 3 7 8 Flip down optional display CAUTION DO NOT store the Model 300 Combustion Anal...

Page 48: ...down the analyzer to prevent a deep discharge of the pack s lead acid batteries Recharge the battery pack whenever its BATTERY STATUS LED no longer lights The pack however can be recharged at anytime...

Page 49: ...Calibration Oxygen Sensor Calibration The potentiometers should be adjusted whenever the analyzer is deter mined to be out of calibration using the procedures described in this section Calibration sh...

Page 50: ...MODEL 300 COMBUSTION ANALYZER 4 2 Instruction 24 9223 Figure 4 1 Removing Sensor Cover Figure 4 2 Printer Screw Location...

Page 51: ...g its three knurled screws NOTE Only two knurled screws are used with the battery powered analyzers At this point the O2 and CO sensors are accessible If a printer is installed remove the screw securi...

Page 52: ...MODEL 300 COMBUSTION ANALYZER 4 4 Instruction 24 9223 Figure 4 3 Screw Locations Figure 4 4 Accessing Control Panel Potentiometer Typical Configuration...

Page 53: ...e Fig 4 6 Equipment Needed See Section 6 for Part Numbers Thermometer precision grade 0 to 220 F 20 to 150 C Potentiometer Adjustment Tool Procedure 1 Remove control panel per Section 4 1 2 Remove the...

Page 54: ...is lit 6 The left display is now showing ambient room temperature as mea sured by the analyzer s ambient transducer Compare this reading to the temperature on a thermometer measuring room temperature...

Page 55: ...ve control panel per Section 4 1 2 Remove filter trap from the analyzer s Gas Inlet Port located on rear of control panel 3 Connect the Carbon Monoxide Gas Cylinder and the Calibration Kit together as...

Page 56: ...tion concentration stamped on the gas cylinder 8 Using a potentiometer adjustment tool adjust CO Span pot R9 Fig 4 6 until the analyzer s CO indication matches the gas cylinder s con centration value...

Page 57: ...andling of toxic gases otherwise these sensor s should be replaced and calibrated by an authorized Bacharach Service Center 4 4 THERMOCOUPLE SPAN CALIBRATION R19 Two thermocouple calibration procedure...

Page 58: ...alibration cycle c When the word FUEL appears on left display press FUEL key to select any one of the seven fuels d Press RUN key to start analyzer 4 Press left SELECT key until TEMP indicator is lit...

Page 59: ...to a temperature of 2000 F 1093 C NOTE The Ambient Temperature Calibration pot R24 must be adjusted to its correct setting before Thermocouple Span pot R19 can be adjusted Equipment Needed See Sectio...

Page 60: ...play press FUEL key to select any one of the seven fuels d Press RUN key to start analyzer 4 Press left SELECT key until TEMP indicator is lit 5 Connect temperature calibration device or mV source to...

Page 61: ...9223 4 13 Figure 4 9 High Temperature Range Thermocouple Calibration Setup TABLE 4 1 MV LEVEL VS AMBIENT TEMPERATURE FOR THERMOCOUPLE CALIBRATION 1700 F 927 C Ambient Temp mV F C Applied 60 16 37 8 7...

Page 62: ...he oxygen sensor If this output indication is below 18 the oxygen sensor is nearing the end of its useful life and should soon be replaced If the microprocessor senses that the oxygen sensor s output...

Page 63: ...rized service organization will void the instrument s warranty and release Bacharach Inc of any implied or written product liability 5 1 OXYGEN SENSOR REPLACEMENT Equipment Needed See Section 6 for Pa...

Page 64: ...ard the base so that its plastic screw is just to the right of the contact with the hole Rotate the sensor clockwise until its three stainless steel screwheads are seated in the dimples and its plasti...

Page 65: ...es connected to Toxic sensor terminals C S and R Fig 5 2 then remove the wires 3 Remove the 5 32 nuts that retain the Toxic sensor to its expansion chamber then remove and discard the old Toxic sensor...

Page 66: ...sensor terminals C S and R then connect wires from analyzer to the sensor as shown in Fig 5 1 Tighten these connections with a nutdriver DO NOT overtighten connections 9 Replace sensor cover 10 Calibr...

Page 67: ...ds before removing the filter trap assembly to allow the pressure within the assembly to equalize 2 Remove filter trap from control panel WARNING Water inside the filter trap may be hot and mildly aci...

Page 68: ...MODEL 300 COMBUSTION ANALYZER 5 6 Instruction 24 9223 NOTE Make sure that the open end of the shield is facing down Figure 5 3 Filter Trap Filter Replacement...

Page 69: ...ild Detergent Center Punch Pipe Cleaners Open End Wrench 1 2 Clean Rags Particulate Trap Key Wrench Method of forcing water through supplied with analyzer probe s sampling hose see text Gallon Bucket...

Page 70: ...alcohol and carefully wipe the thermocouple wire clean 7 With the sampling hose disconnected from the filter trap squirt a few drops of detergent into one end of the sampling hose Force water through...

Page 71: ...l pin in probe handle Position particulate trap so that its tee fitting rests on top of the roll pin f Attach probe tube retainer to probe handle using two Allen screws If necessary loosen bottom Alle...

Page 72: ...from the CO or the Optional SO2 sensors If the electrical connections are removed and then reconnected to these sensors a restabilization time period of up to several hours is required before the sen...

Page 73: ...look dirty remove hoses from analyzer and swirl them around in a detergent and water solution Thoroughly rinse and dry the hoses and then reinstall them inside the analyzer 8 After cleaning the analy...

Page 74: ...wer than actual efficiency computation Equipment Needed Soap and Water Solution Small Brush Procedure 1 Remove control panel refer to Section 4 1 and place it on a clean work surface 2 Reverse tubing...

Page 75: ...d will swing out when the printer is opened 3 Pinch in the two paper roll clips at the end of the paper carrier and then remove the empty roller from the carrier 4 Install a new paper roll onto the pa...

Page 76: ...ce the batteries as follows Equipment and Materials Needed Medium Flat Blade Screwdriver Four AA Alkaline Batteries Procedure 1 Remove control panel per Section 4 1 in this manual 2 Tilt the control p...

Page 77: ...TIONAL DIP SWITCH SETTINGS The settings of the analyzer s internal switches select which sensors are active when installed which language is used on the printout and which RS 232 port settings are in...

Page 78: ...able or turn on a function set its corresponding switch to ON Note however the language and baud rate settings require the setting of two switches 4 After setting switches replace control panel Figure...

Page 79: ...put 24 0508 Battery Pack 24 0537 Battery Charger 12 VDC Input 24 0527 240 VAC Input 24 0528 120 VAC Input 24 0529 Control Panel Screw 01 7276 Filter Trap Assembly Complete Assembly 24 0642 Filter Box...

Page 80: ...and Motor Assembly 24 0500 Sensor Assemblies Oxygen Sensor Assembly Flange 51 1206 Oxygen Cell Base 51 1207 Oxygen Sensor 24 0108 O Ring 05 5207 Screw 6 32 x 3 4 lg 01 6899 Toxic Sensor Assembly Carb...

Page 81: ...125 48 in 24 7124 Portable CO Calibration Kit NO Gas 24 7059 Potentiometer Adjustment Tool 06 9453 Thermocouple Plug 24 0204 True Spot Smoke Test Set 21 7006 Storage space is provided inside the combu...

Page 82: ...6 4 Instruction 24 9223 6 3 WIRING DIAGRAM Figure 6 1A shows the wiring diagram of the Model 300 Combustion Analyzer This diagram will be useful to an experienced technician when servicing the analyz...

Page 83: ...MODEL 300 COMBUSTION ANALYZER Instruction 24 9223 6 5 Figure 6 1B Wiring Diagram...

Page 84: ...3 0 0 P C B J 6 J 3 N S X P C B C S R W H T G R N O R N P R I N T E R J 1 A J 2 A J 4 J 5 C S R B L U B L K R E D P W R F r o m P o w e r S u p p l y F r o m C o n t r o l P a n e l J 1 F r o m O 2 C...

Page 85: ...the available fuel energy that the furnace turns into useful heat CONDENSING FURNACE A high efficiency furnace where water vapor generated by the combustion process is condensed and its latent heat o...

Page 86: ...ixed with the fuel inside the burners Primary Air Temperature can be greater or less than Ambient Air Temperature SECONDARY AIR Air for combustion supplied to the outside of the flame to supplement th...

Page 87: ...0 Bldg 22 Pennsauken NJ 08110 609 665 6176 609 665 6661 Fax Bacharach S S Center 5151 Mitchelldale B 4 Houston TX 77092 713 683 8141 713 683 9437 Fax Bacharach S S Center 7281 Garden Grove Blvd Suite...

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