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PCA2 User Manual - Bacharach, Inc.

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1. S R3 OON P7 pcs DEDE Figure 8 1 Parts 2 of 2 Instruction 24 9448 8 3 Parts amp Service x37 16G CO o NOT calibrated oo oooooooooooo ooo 24 0789 16H CO NOT calibrated 0 eee 24 0997 16J NO NOT calibrated o ooo ooooooooooomooo 24 0881 16K NO NOT calibrated ooo ooooooooooomooo 24 1027 16L SO NOT calibrated ooooooooooooorooo 24 0998 17 Screw 4 x V12LG o o ooooooooooooo ooo 02 2144 18 Battery Clip Single cuna iaa 04 1434 19 Battery Clip Double oo o ooooooooooo ooo 24 1433 20 Cable Assembly ooooooooooooooooooooo o 24 1410 21 Tubing Vinyl 1 8 ID x 3 16 OD 03 6104 22 Tubing Silicon 1 16 ID x 1 8 OD 03 6372 23 Tubing Silicon 3 32 ID x 5 22 OD 103 6101 24 Tubing Silicon 1 8 ID x 3 16 OD 103 6102 25 Tubing Silicon 1 8 ID x 1 4 OD o o o oo 03 6105 26 Il P 03 6170 Order tubing by the foot 15 150 16C 16D IN Bottom OUT Top PURGE AIR LD typical 2 places Figure 8 1 Parts 1 of 2 8 2 Instruction 24 9448 PRESSURE RY Introduction Sales Combo Sales Combo Kit Model Type PCA2 Only Part Number 248355 24 8354 24 6355 ass 265 zs Measurements Oxygen 0 u
2. 3 2 3 4 Operating Parameters 0 ccc ee 3 4 3 9 Fuel S lection 42 eder eae e s des e qe es 3 4 3 6 Temperature Units Selection ooooooooooooooo 3 5 3 7 Pressure Units Selection 0 000 ee eee 3 6 3 8 Pollution Units Selection 0 0 0000 ccc tunisia 3 7 3 9 Date Setups ses dee qu ia Aedes 3 8 3 10 Time Setup 0 ooo 3 9 3 11 O2 Reference Setup 3 10 3 12 Print Pressure Selection 00 0 cee eee eee 3 11 3 13 Zoom Display Selection 0 0 00 ccc ee eee 3 12 3 14 Battery Charger Selecti0M oooooooooooooom o ooo 3 13 3 15 Logging Selection o o oooooooooorr eee 3 14 3 16 Button Sound iic erae a CO Ea er RO au CEN DES 9 14 3 17 Test ID Information es AER ae Rer Y RE 3 15 3 18 Username 3 17 3 19 Language iee ol ad aia Ae Roast 3 19 3 20 Cal Reminder Period 0 000 ccc ee eee 3 20 Instruction 24 9448 i Contents FLY 3 21 Run Hold Screen Format o ooooooooooooro om 3 21 4 Operation oi sisi sss ia o ex Ex Eres e e 41 4 1 Operating Tips 4 1 4 2 Turning ON the Analyzer and Warm Up ss 4 2 4 3 Selecting a Fuel isis a arb ORG Qe CE a 4 3 4 4 Sampling Pom x reve auque gus uem Eg 4 4 4 5 Performing a Combustion Test o oo ooooooooomooo 4 5 4 6 Pressure Label Selection oo ooooooooooorooooooo 4 7 4 7 Temperature Measurement Label o ooooooo o 4 8 4 8 Making a Draft Press
3. Bacharach PCA 2 Data Recovery Program Recover Combustion Data Open Data File Enter Data File Name Recover Logging Data ter Log File Name csv gs E Records received 18 Records received Status Receiving Log files HARACH Instruction 24 9448 4 27 Operation 4 4 Sampling Point see ee FORCED AIR FURNACE For atmospheric burner or gravity vented forced air heating equipment with 0 0 a clamshell or sectional heat exchanger design test each of the exhaust ports at the top of the heat exchanger The probe should be inserted back into each of the exhaust ports to obtain a flue gas sample before any dilution air is mixed in EST HOT WATER TANK Domestic hot water tanks with the bell shaped draft diverter can be accurately tested by inserting the probe tip directly into the top of the fire tube below the diverter Forced Air Furnace Undiluted Flue Gas Sarrple Taken JN A 80 EFFICIENCY FAN ASSIST OR POWER VENTED i Under Draft H Diverter in Top Combustion testing of fan assist or power vented EAM a furnaces boilers should be done through a hole drilled o gt in the vent immediately above the inducer fan O 90 EFFICIENCY CONDENSING Condensing 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 exhaus
4. o oooooooooooooooo 5 2 5 4 T Stack Calibration 0 0 0 0 000 eh 5 4 5 5 T Air Calibration llis 5 6 5 6 CO LO Sensor Calibration o ooooooooooorooooo ooo 5 8 5 7 SO Sensor Calibration 0 0 0 0 ccc 5 10 5 8 NO Sensor Calibration oooooooooooroorr ees 5 11 li Instruction 24 9448 Notes Parts amp Service x32 8 3 Service Centers United States Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5723 Email help mybacharach com Canada Bacharach of Canada Inc 250 Shields Court Unit 3 Markham Ontario L3R 9W7 Canada Phone 905 470 8985 Fax 905 470 8963 Email bachcan idirect com M xico Bacharach de M xico Playa Regatas No 473 Tercer Piso Col Militar Marte Delegaci n Iztacalco 08830 M xico D F M xico Phones 52 555 634 7740 52 555 634 7741 Fax 52 555 634 7738 Email bacharachservicio bacharach com mx Website www bacharach mexico com Instruction 24 9448 E ay Contents 5 9 NO Sensor Calibration eee eee 5 12 5 10 CO HI Sensor Calibration 0 00000 cece nee 5 13 6 Maintenan e cc xa RE RERA4e aL 3XADA ER es 6 1 6 1 PCA 2 Disassembly 0 0 00 o 6 2 6 2 Water Trap Filter Maintenance llle 6 6 6 2 1 Emptying the Water Trap Chamber 6 6 6 2 2 Replacing the Filter Element o o o ooooo oo 6 6 6 3 Smart Sensor Re
5. 4 Click Next to accept the default destination folder or click Change to install to a different folder MES PCAZ InstallShield Wizard Destination Folder Click Next to install to this folder or click Change to install to a different folder Default 3 InstalPCA2 to Click to change Installation Folder em C Program Files PCA2 Ue installation folder Back Next gt N Cancel 4 22 Instruction 24 9448 RY Operation 4 16 Downloading Stored Data to a Computer The combustion test data that was stored in either the analyzer s Memory Directory Section 4 9 or Logging Directory Section 4 14 can be down loaded to a computer using the PCA 2 Data Recovery Program and USB cable that are supplied with the analyzer The following procedures assume that the operator is familiar with creat ing folders 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 for analysis Computer requirements Windows 98SE or higher CD ROM drive USB 1 1 or USB 2 0 port 12 MB of hard drive space for the PCA 2 data recovery program plus up to an addi
6. 5 Click Install to confirm the destination folder and user information A ISE PCAZ InstallShield Wizard Ready to Install the Program The wizard is ready to begin installation If you want to review or change any of your installation settings dick Back Click Cancel to exit the wizard Current Settings Setup Type Destination Folder C Program Files PCA2 User Information Name John Doe Company ABC Heating lt Back Install IN Cancel 6 Click Finish after all files have been copied into the destination folder UE PCAZ InstallShield Wizard E InstallShield Wizard Completed The InstallShield Wizard has successfully installed PCA2 Click Finish to exit the wizard 7 At this time the PCA2 Data Recovery Program icon should appear under Start All Programs menu PCA2 8 This completes the installation of the software Remove CD from drive Instruction 24 9448 4 23 Operation ESP 4 7 Temperature Measurement Label The difference in temperature between two areas can be measured by us ing the analyzer s two temperature channels and the Temperature screen By using the T Air channel as a reference the temperature applied to the T Stack channel will be displayed on the Temperature Measurement screen as differential temperature between the two channels Addition ally the temperature measurement can be labeled Label t
7. 5 6 Instruction 24 9448 ENG Initial Setup 3 17 Test ID Information Test records can be identified e g customer s name burner number and location by manually entering up to three lines of text with each line con taining a maximum of 20 alphanumeric characters When a Test ID is se lected this information will be associated with all succeeding test records and will appear at the top of each test record when printed and in Excel files when records are downloaded to a PC The chosen Test ID remains in effect until it is deselected a new Test ID is selected or the instrument is turned off Up to 30 Test ID s can be pre entered for later retrieval To enter or edit a Test ID 1 Display the MAIN MENU by press ing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight TEST ID and then press ENT to display the TEST ID menu 4 Use the AY buttons to highlight EDIT TEST ID and then press ENT to display the EDIT TEST ID menu which displays the first line of each Test ID record 5 Use the AY buttons to select which Test ID to edit and then press ENT to display all three lines of that record Periods are used to identify empty lines F1 F2 F3 6 Use the av buttons to choose which of the three Test ID lines to edit and then press ENT to begin editing the chosen
8. Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed Fi F2 F3 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 will appear followed by the CALIBRATION LIST screen being re displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen Instruction 24 9448 5 9 Calibration ray 5 6 CO LO Sensor Calibration Note that the CO LO sensor also measures H for the purpose of com pensating the CO reading for the presence of H in the gas sample This procedure first spans the CO LO sensor and optionally spans the H part of the sensor to known gas levels Material Required Calibration Kit P N 24 7059 Gas Cylinder 500 ppm CO in air P N 24 0492 Gas Cylinder 1 000 ppm CO amp 1 000 ppm H in Nitrogen P N 24 0794 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 2 Use the av buttons to highlight CO LO and then press ENT to display the CALIBRATE CO screen Measured is the current CO reading while Applied is a known CO level that will be applied for calibration purposes 3 Attach a 500 ppm CO cylinder to the regu lator of the calib
9. In the example shown InchesWater has been selected 5 Press ENT to save the selection and re display the SETUP MENU Instruction 24 9448 3 7 RY Maintenance 6 Maintenance Customer maintenance of the PCA 2 is limited to the following Battery replacement or charging using AC power 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 Instruction 24 9448 6 1 Calibration ECA this range will cause the message Bad Calibration Wrong CAL Entry to appear in the following step 5 Adjust regulator for a flowmeter indica tion of approximately 2 SCFH Wait until the Measured reading stabilizes approxi mately 3 minutes and then press ENT to calibrate the CO Measured value to that of the Applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed F1 F2 F3 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 displayed The sensor will now
10. The PCA2 must be 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 AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight BATTERY CHARGER and then press ENT to display the BATTERY CHARGER screen 4 Use the AY buttons to highlight either OFF turn charger OFF or ON turn charger ON In the example shown ON has been selected 5 Press ENT to save the selection and re display the SETUP MENU 3 14 Instruction 24 9448 ECA 3 15 Logging Selection When the logging function is activated up to 500 combustion test records will be automatically stored in memory at a preset interval over a pre determined length of time Refer to Section 4 14 for detailed information on how to select the logging function how to set the interval and duration time periods and how to view or download the stored data 3 16 Button Sound 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 button If necessary press ESC until MENU appears above F2 2 Use the av buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the av buttons to highlight BUTTON SOUND and then press ENT to display the BU
11. a slight twisting motion BLA Do not allow water level to go above tip of riser tube Stack Gas From Probe 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 shut Instruction 24 9448 4 11 Operation ESP 4 15 3 Clearing Memory When all memory snap shot locations used to store individual combustion test records have been filled the next combustion test record saved will overwrite the oldest When all logging memory locations in the logging directory are full they must be manually cleared in order to store new data At no time will the log ging process overwrite older data Each memory bank can be individually cleared or Fi F2 F3 all memory locations 1n both banks can be cleared simultaneously Do the following to clear memory 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the AY buttons to highlight MEMORY and then press ENT to display the MEMORY MENU 3 Use the AY 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 memo ry locations in both memory banks 4 Press ENT to display the CLEAR MEMORY LOGGING
12. regulator of the calibration fixture shown in Figure 5 2 on Page 5 14 4 Use the AY and 4 buttons to enter an Applied value that exactly equals the concen tration stamped on the NO cylinder F1 F2 F3 5 12 Instruction 24 9448 Initial Setup 3 10 Time Setup The time is stored in the format hh mm ss AM PM Its value is part of the date and time stamp that is saved along with each combustion test record Set the analyzer s internal clock to the current time 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 AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight TIME and then press ENT to display the TIME MENU 4 First use the lt gt buttons to move the cursor across the screen until it 1s over the digit to be changed and then press the av buttons until the desired value is displayed 5 Repeat Step 4 until the values for hour minute and meridiem have been set NOTE The value for seconds cannot be entered but are displayed and stored as part of the com bustion test record 6 Press ENT to save the displayed time values and re display the SETUP MENU or press ESC to abort this procedure and retain the old time values 3 10 Instruction 24 9448 ECA 3 11 O Reference Setup Initial Setup The measured values of CO NOx and SO can be indiv
13. 2 TIP The pressure units of measure is selected per Section 3 8 2 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 3 Use the AY buttons to highlight PRESSURE and then press ENT to display the PRESSURE 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 Sampling Hoses with quick connect fittings are available NR as an optional accessory Refer to Section 8 2 AP Pressure Reference Port AP Pressure Measurement Pol Figure 4 1 Draft Pressure Measurement Hose Connections Instruction 24 9448 4 9 Operation ESP 4 16 1 PCA 2 Data Recovery Program Installation The PCA 2 Data Recovery Program is supplied with the analyzer on a CD P N 24 1448 Install this program as follows 1 Insert the PCA 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 UE PCA2 InstallShield Wizard Welcome to the InstallShield Wizard for PCA2 The InstallShield R Wizard will allow you to modify repair or remove PCA2 To continue click Next
14. 3 9 Date Setup The date is stored in the format MM DD YY Its value is part of the date and time stamp that is saved along with each combustion test record Initial Setup Set the analyzer s internal clock to the current date 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 AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight DATE and then press ENT to display the DATE MENU 4 First use the lt gt buttons to move the cursor across the screen until it 1s over the digit to be changed and then press the av buttons until the desired value 1s displayed 5 Repeat Step 4 until the values 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 batteries and is main Fi F2 F3 tained by a supercap on the Main PCB for approximately 1 2 days in the absence of batteries The supercap is intended to maintain the real time clock when the batteries are changed when exhausted If the batteries are removed for extended periods of time such as when the PCA2 is not in use off season stor age simply reset the time and date after fresh batteries are installed when it is placed bach in service Inst
15. 5 8 NO Sensor Calibration This procedure spans the optional nitric oxide sensor to a known gas level Material Required Calibration Kit P N 24 7059 Gas Cylinder 250 ppm NO in Nitrogen P N 24 1156 Procedure 1 Use the AY buttons to highlight NO and Attach a 250 ppm NO cylinder to the regu Use the av and lt gt buttons to enter an If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 then press ENT to display the CALIBRATE NO screen Measured is the current NO reading while Applied is a known NO level that will be applied for calibration purposes lator of the calibration fixture shown in Figure 5 2 on Page 5 14 Applied value that exactly equals the concen tration stamped on the NO cylinder The calibration range is from 9 to 900 ppm An attempt to calibrate outside this range will cause the message Bad Calibration Wrong Fi F2 F3 CAL Entry to appear in the following step Adjust regulator for a flowmeter indication of approximately 2 SCFH Instruction 24 9448 5 11 Calibration ECA 5 7 SO Sensor Calibration This procedure spans the optional sulfur dioxide sensor to a known gas level Material Required Calibration Kit P N 24 7059 Gas Cylinder 100 ppm SO in Nitrogen P N 24 1158 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 2 Use the av
16. Calibrate the new sensor s per Section 5 except the O2 sensor which does not require calibration Instruction 24 9448 6 9 Maintenance RY Specifications 6 4 Sensor Only Replacement 1 an fF wh 10 11 All sensors are replaced in a similar manner Do the following to replace either the O2 CO LO CO HI NO NO2 or SO2 sensor Refer to Section 8 1 Replacement Parts for list of sensors and part numbers Turn OFF the analyzer Remove the battery cover Remove the sensor retainer Remove the tubing from the gas cup of sensor being replaced Unplug the sensor along with its printed circuit board from the analyz er s main board Remove the sensor s gas cup by twisting its bayonet fitting counter clockwise and then pulling the cup straight up Carefully remove the old sensor from the Smart sensor PCB keeping in mind that there is an adhesive foam disk in between the PCB and sensor Gently remove any adhesive from from the PCB Important When replacing the O2 sensor 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 Remove the replacement sensor from its plastic canister Note that the CO LO CO HI S02 Sensor Retainer and NO2 sensors have a Se shorting spring installed between two of their pins T Remove and discard this ad Gas Cup i bayonet fitting spring before installing counterc
17. Logging Data Recover Combustion Data Open Data File Status line ter Log File Name csv Enter Data File Name showing recovery Eml sar process has Records received 500 Records received finished Status Log files finished Click Exit to end the program Instruction 24 9448 4 3 4 28 Instruction 24 9448 Operation to Recove Logging Date Status line showing PCA 2 is successfully connected to the computer Select a pre existing folder or create a new folder to store the downloaded file Enter filename File type preset to cvs Location of downloaded file Click Start to begin the download process Total number of records received out of 512 total Status line showing files are currently being received Ea Bacharach PCA 2 Data Recovery Program Use this section Recover Logging Data Recover Combustion Data of window BpenLosrie E to Recover Combustion D Enter Log File Na ster Data File Name Data Ez Start the Records received 0 Records received download Status PCA2 connected process by clicking the desired Open r H Log Data File The ACHUASUC button Open rx Look in PCA2 Logging Data z e ef E Click here to r zm o create a new folder Click Open after File name Customer XYZ selecting a folder and entering a Files of type Logging File Setup csv y Cancel n ELM filename Open as read only
18. NOx referenced to 03 2 0 eens 0 to 9 999 ppm CO referenced to O9 0 eee eens 0 to 9 999 ppm NO reference to 9605 26 lisse ees 0 to 9 999 ppm NO reference to Oz3 o ooooooooommorronomooos 0 to 9 999 ppm SO reference to 9609 llle ee 0 to 9 999 ppm Fuels Available for Combustion Calculations Natural Gas Coal Oil 2 Wood Oil 4 Kerosene Oil 46 Bagasse Propane Digester Gas Instruction 24 9448 2 1 ESP Maintenance 6 6 Thermocouple Replacement Using the appropriate thermocouple replacement kit listed below replace the probe s thermocouple as follows Thermocouple Replacement Kits Part Number Replaces Thermocouple in a Probe with a Tube Length of 24 8413 6 inches 24 8414 12 inches 24 8415 24 inches 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 behind as much of the probe s thermocouple connector wire as possible Probe Handle Screws Figure 6 6 Probe Handle Disassembly Instruction 24 9448 6 11 Maintenance RY Specifications ERP 6 5 Nitric Oxide Sensor Battery
19. Replacement Normal Operating Conditions Temperature A single lithium battery located on the NO Smart Sensor assembly applies ep Analyzer ira ases od p Ra eR EE 32 to 104 F 0 to 40 a bias voltage to the NO sensor to prevent the sensor from destabilizing Probo Tip 1 p op m C M a when the analyzer is turned off The NO bias battery is expected to last at I least the life of the NO sensor Humidity Analyzer ss 15 to 90 Relative Humidity non condensing Note It is recommended that the bias battery be replaced whenever the NO sensor is replaced Air Pressure f Analyzer airada ob leta bo Atmospheric Material Reguired Probe 0 0 ceaiin 10 HO 25 mb draft max at probe tip Bias battery refer to Section 8 1 Replacement Parts Performance Procedure Accuracy 1 Follow the instructions in Section 6 3 Smart Sensor Replacement to Eid d A prastical aa remove the Smart Sensor assembly from position 4 ob atack gas ms of Os COs and Na CO toi vu ri a ad 5 of reading or 10 ppm 2 Remove the old battery from its holder on the Nitric Oxide printed whichever is greater between circuit board 0 2 000 ppm and 10 of reading 3 Insert the new battery with the positive side toward the sensor the between 2 001 20 000 ppm battery contact is stamped with a symbol NO ira a 5 of reading or 5 ppm whichever is greater between 4 Re nstall the Smart Sensor assembly 0 2 000
20. Use the AY buttons to highlight MEMORY DIRECTORY and then press ENT to display the MEMORY DIRECTORY screen 4 Use the AY buttons to highlight the desired memory location to be recalled Each memory location is identified by the date and time at which data was saved The word EMPTY signifies that the memory location does not contain data 5 Press ENT 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 F1 F2 F3 4 18 Instruction 24 9448 RY Operation Operation RY 4 14 4 Ending the Data Logging Process 4 14 1 Turning ON Data Logging Data logging will stop and the pump will turn OFF after the prescribed IMPORTANT Before turning ON data logging and starting the duration or after all 500 memory locations are filled data logging process the analyzer should already be set up to t perform a combustion test per Section 4 5 To exit the Combustion Test LOG screen press the RUN HOLD button wice to display the Com Turn ON data logging as follows bustion Test HOLD screen 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press E
21. av buttons to highlight RUN HOLD FORMAT and then press ENT to display Run Hold Format Menu 4 Use the av buttons to highlight Edit Format and then press the ENT key to show the Edit Run Hold Format where the current order of combustion data is displayed 5 Change data shown for a particular location by first using the av buttons to highlight the location Then press the ENT key to select the location the cursor will start to flash F1 F2 6 Use the AY buttons to scroll through and select the desired data to appear at that location Press the ENT key to make the selection 7 Change data displayed at other locations by repeating steps 5 amp 6 8 When finished use the v button to highlight F1 F2 Edit complete at the bottom of the list then press ENT to save the new display format and return to the Run Hold Format screen Operation RY BACHARACH INC PCA 2 SN XXXXXX TIME 01 00 00 PM DATE 10 06 06 FUEL NATURAL GAS O2 4 0 96 CO 12 ppm EFF 82 6 96 CO2 9 5 96 T STACK 374 F T AIR 68 0 F 8 to 16 in EA 21 20 32 to 40 64 cm NO 18 ppm NO Temp 70 5 F NO2 6 ppm NOX 24 ppm S02 ppm co 3 13 ppm F3 NO 3 19 ppm Optional NO2 3 6 ppm binarias MAN ao selected per SO2 3 appe Section 3 13 PRESSURE 0 25 inwc COMMENTS NOTES Three stars appear in the data field of sensors that are not calibrated or installed and in the data fields of that sensor s relat
22. buttons to highlight SO and C then press ENT to display the CALIBRATE LIEN SO screen Measured is the current SO reading while Applied is a known SO level that will be applied for calibration purposes F1 F2 F3 3 Attach a 100 ppm SO cylinder to the regu lator of the calibration fixture shown in Figure 5 2 on Page 5 14 4 Use the AY and lt gt buttons to enter an Applied value that exactly equals the concen tration stamped on the SO cylinder The calibration range is from 9 to 1 800 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 calibrate the SO Measured value to that of the Applied value The message Good Calibration should briefly appear followed by the CALIBRATION 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 5 10 Instruction 24 9448 Initial Setup 3 12 Print Pressure Selection Select whether to print or not print the pressure measurement on the combustion test printout 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 AY but
23. calibration 2 Use the AY buttons to highlight SETUP and equipment at this time then press ENT to display the SETUP MENU 2 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 3 Use the AY buttons to highlight USERNAME and then press ENT to display all three lines of the EDIT USERNAME screen Periods identify empty lines 3 Use the AY buttons to highlight Pressure and then press ENT to display the CALIBRATE PRESSURE screen Measured is the pressure value currently being detected by the pressure sensor while Applied is a known value of pressure that will be applied for calibration purposes 4 Use the AY buttons to choose which of the three Username lines to clear then press CLEAR F3 to clear that line 5 At this time either return to step 4 to choose another line to clear or end this procedure by highlighting EDIT COMPLETE and pressing the ENT key to return tot he Setup Menu F1 F2 F3 4 With both the AP and AP ports open to the atmosphere observe that the current Measured pressure reading should be 0 0 01 inwc If necessary zero the pressure sensor per Section 4 6 and repeating Steps 2 thru 4 6 Press ESC to go to the Main Menu or the RUN HOLD key to return to the Run Hold PEDE 5 Connect the hose from the manometer to the AP port and apply a negative pressure to this port by adjusting the bellows for a manom eter reading o
24. line 7 Use the AY buttons to enter the desired character and then move to the next character position by pressing the right arrow key Repeat this step until the line is complete A maximum of 20 alphanumeric char acters can be entered Press ENT to accept the information 8 At this time either return to step 6 to choose another line to edit or 3 16 Instruction 24 9448 ESP Initial Setup end this procedure by highlighting Edit Complete and pressing the ENT key to return to the Edit Test ID Menu 9 Press ESC to go to the Test ID Menu or the RUN HOLD key to return to the Run Hold screen Select a Test ID 1 From the Test ID menu use the AY buttons to highlight SELECT TEST ID and then press ENT to display the SELECT TEST ID menu which displays the first line of each Test ID record 2 Use the AY buttons to choose a pre entered Test ID or choose NO Test ID located at bottom of list to deselect a previously chosen record then press ENT to make the selection and return to the Test ID menu F1 F2 F3 3 Press ESC to end the procedure and return to the Setup Menu or press the RUN HOLD key to return to the Run Hold Screen Clear Test ID Information 1 From the Test ID menu use the AY buttons to highlight CLEAR TEST ID and then press ENT to display the CLEAR TEST ID menu 2 Do one of the following to clear Individual Records or All Records Individual Records Use the AY buttons to highlight Individual Re
25. lt 4 Moves cursor left or moves to top of menu list SZ I e With analyzer turned ON press briefly to turn backlight ON and OFF gt Moves cursor right or moves to bottom of menu list T STACK Probe s stack gas thermocouple connector OPT Option external measurement connector 4 f POWER AC power adap n T AIR Primary ambient air thermo couple connector connector GAS Probe s gas hose connector AP Reference AP Probe s draft pressure hose fitting hose fitting Figure 1 1 PCA 2 Components Instruction 0024 9448 1 7 Introduction EL 1 5 2 T AIR Primary Air Thermocouple If thermocouple P N 104 1797 10 feet long or Utility Wand P N 104 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 T AIR connector 1 5 3 POWER AC Adapter The AC power adapter P N 24 1404 can be used as an external power sup ply which will run the analyzer on a continuous basis When using rechargeable NiMH batteries the AC power adapter can also be used to charge the batteries while inside the analyzer The analyzer s rapid charger circuit however must first be turned ON per Section 3 16 The rapid charger will charge a set of depleted batteries in approximately 2 3 hours When disposable alkaline batteries are used the analyzer s battery
26. oxygen 2 NO Temp Nitric Oxide Sensor Temperature 8 Found New Hardware Wizard 1 Pollution unit of measure selected per Section 3 9 Completing the Found New Hardware Wizard The wizard has finished installing the software for 2 Bacharach PCA2 USB driver Click Finish to close the wizard 2 The letter O represents the oxygen reference level of between 0 and 15 as selected per section 3 12 3 Shown only on printout not on LCD display Note Stars appear in measurement and calculation fields of sensors that are not installed Instruction 24 9448 4 25 Instruction 24 9448 EL Operation 4 6 Pressure Label Selection The pressure measurement can be labeed with types including gas pres sure differential across heat exchanger draft reading and differential pressure See Section 4 6 of the PCA2 Instruction Manual 24 9448 for pressure and draft measurement procedures Label data as follows 1 Display the MAIN MENU by pressing the MENU F2 button If neces sary press ESC until MENU appears above F2 2 Use the AY buttons to highlight PRESSURE and then press ENT to display the PRESSURE MENU 3 Use the av buttons to scroll through the available pressure label types The current label will be used saved and printed with the record 4 Press ENT to save the selection and re display the PRESSURE MENU or ESC to exit back to the Main Menu Press ENT to save the s
27. should be performed by an authorized Bacharach Service Center refer to Section 8 3 Any repairs performed by an unauthorized service organization will void the analyzer s warranty and release Bacha rach 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 V ai mim 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 16 6 and the stack temperature must be below 2 000 F 1 093 C xx Three stars appear in the data field of sensors that are not installed defective or found to be in error during warm up and also in the data fields of that sensor s related calculated values For example if the data field of either the NO or NO sensor con tains three stars then the NOx data field will also contain Instruction 24 9448 7 1 Maintenance RY 6 8 Cleaning the Probe The probe tube and gas sample hose will become dirty under normal use Note that the water trap s filter element should prevent soot from reaching the analyzer s internal components If the probe is not kept clean it could become clogged and restrict the flow of gas into the analyzer resulting in incorrect combustion test readings and calculations NOTE An an
28. to keep the analyzer turned es Re ON by pressing the RUN HOLD button If the PCA 2 was not purged with fresh air as described in Section 4 8 then the analyzer may remain ON with its pump running and display the message PURGING SENSORS as the re sult of combustion gases still being present inside the analyzer At this time the operator should ensure that the probe is removed from the stack allowing the analyzer to purge itself with fresh air The 5 second shutdown sequence will not begin until the gas levels inside the analyzer drop below predetermined levels SHUTDOWN IN 5 sec TIP Although not recommended the purging process can be bypassed by pressing the MO button a second time PURGING SENSORS 4 13 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 beep is sounded every 10 seconds After a low battery alarm occurs the analyzer will continue to operate for only a few minutes The amount of operating time that remains depends on many factors e g pump and backlight being ON or OFF and the type and condition of the batteries Low Battery Alarm Empty Battery Icon 4 12 Instruction 24 9448 ELY Operation 4 14 Data Logging When the logging function is activated up to 500 combustion test records will be automatically stored in memory at a preset interval 1 5 10 15 30 seconds 1 2 5 10 minutes
29. 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 purging process can be aborted by again pressing the 1 0 button Instruction 0024 9448 FY 6 7 Pump Replacement Maintenance Parts amp Tools Required Replacement Pump Gas Pump P N 24 1393 Purge Pump P N 3015 1716 Soldering Iron and Solder Medium Phillips Screwdriver Small Flat Blade Screwdriver Procedure 1 Gain access to both the gas and purge pumps by removing the rear case Refer to Section 6 1 2 Unsolder the red and black wires from pump being replaced Note that during installation 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 P Top PURGE PUMP AP Baon pur To Sensors See Figure 6 3 GAS PUMP GAS PUMP LATCH Gas OUT Figure 6 8 Pump Tubing Connections Instruction 24 9448 6 13 Maintenance ELO RY Introduction 3 Pull old thermocouple from probe body and discard 1 7 Caution Possible Need for Smoke Test 4 The new thermocouple has been coiled for shipping purposes Straighten the thermocouple using your thumb and index finger CAUTION When the instr
30. will be properly zeroed during the warm up cycle men MODEL xxx SERIAL XXXXXXX button for at least 1 second or until a single beep is heard Observe that the analyzer s firmware version model and serial numbers are briefly displayed followed by the Warm EMCHARACH Up screen 4 Wait for the analyzer to count down its 60 sec ond warm up period after which the instru ment will display the Combustion Test HOLD Sere Warm Up 60 If problems were detected during warm up the message ERRORS DETECTED is dis played along with a list of those errors As an example the screen to the right shows that the battery is low Refer to Section 7 8 for a listing and possible remedy for the errors displayed TIP Jf the sensors in error are not critical to the combustion test then press the RUN HOLD button to display the Combustion Test HOLD screen and proceed with the test 4 2 Instruction 24 9448 ECA Operation Operation ERP 4 3 Selecting a Fuel The top line of the Combustion Test HOLD screen shows the fuel currently selected In the example shown the current fuel is NATURAL GAS If necessary change the fuel as follows 1 Display the MAIN MENU by pressing the MENU F2 button 2 Use the AY buttons to highlight FUEL and then press ENT to display the FUEL MENU 3 Use the AY buttons to scroll through the list of available fuels until the desired fuel is high lighted In the example shown PROPANE has b
31. 4BACHARACH 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 a BORM The Measurable Difference Portable Combustion Analyzer Instruction 0024 9448 Operation amp Maintenance Rev 6 September 2010 Product Leadership Training Service Reliability WARRANTY Bacharach Inc warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc s applicable specifications Bacharach s liability and Buyer s remedy under this warranty are limited to the repair or replacement at Bacharach s option of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc s reasonable satisfaction to have been defective provided that written notice of the defect shall have been given by Buyer to Bacharach Inc within two 2 years after the date of delivery of this Product by Bacharach Inc The Oxygen O sensor has a limited warranty of one 1 year Routine service and calibration are excluded from this warranty Bacharach Inc warrants to Buyer that it will convey good title to this Product Bacharach s liability and Buyer s remedy under this warranty of title are limited to the removal of any title defects or at the election of Bach
32. Id SJS Stack Temperature B ea Primary 7 Ambient Air Tomperatare v 7 Carbon Monoxide Law CO v 7 7 Pressure Draft SS Carbon Monoxide Hien COn T IweoxemOo 7 7 SINS SISTIS SJS Nitrogen Dioxide WO o Sulfur Dioxide SO Calculations Combustion Efficiency Excess Air Carbon Dioxide CO NOx NOx NO NOj NOx referenced to O CO referenced to 0 NO referenced to 960 NO referenced to 0 SO referenced to 0 Instruction 0024 9448 Introduction x32 RY Parts amp Service 1 3 Features amp Benefits 8 Parts amp Service Powered by 4 AA alkaline batteries or NiMH rechargeable batteries An optional AC power adapter provides continuous operation 8 1 Replaceme nt Parts Internal charging circuit allows rechargeable batteries to be charged Tieni inside the analyzer with the use of the optional AC power adapter Fig 8 1 Deseripiion Part No O and CO measurement standard Optional measurement of up to 1 Main PCB Assembly 0 0 00 cee ee eens 24 1442 two additional gases COpign NO NO or SO 2 EOD Moduler ETE TCR TE TO 24 1374 With the appropriate sensors installed the analyzer optionally dis 3 Rear Case sae dto dawns sake saad Gaede ee 24 1381 plays pollution conversions for CO NO NO and SO Pollution con 4 Top Case sedes bine ped a ed dp e 24 1382 versions include ppm MBTU mg m and g GJ 5 Battery C
33. Installation 6 After the ac Fin contact the hardware passed Windows Logo testing New Hardware Wizard has finished installing the soft ware click Finish to close the Wizards The software you are installing for this hardware Bacharach PCA2 USB driver has not passed Windows Logo testing to venfy its compatibility with Windows XP Tell me why this testing is important Continuing your installation of this software may impair or destabilize the either immediately or in the future Microsoft strongly correct operation of your system that you stop this installation now and vendor for software that has Name of new USB Sc Description of Measurement or Calculation hardware O Oxygen CO Carbon Monoxide 1 EFF Combustion Efficiency CO 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 CO O Carbon Monoxide ppm level referenced to a of oxygen 2 NO Nitric Oxide 1 NO Nitrogen Dioxide 1 NOx Oxides of Nitrogen NO and NO combined 1 SO Sulfur Dioxide 1 NO O Nitric Oxide ppm level referenced to a of oxygen 2 NO O Nitrogen Dioxide ppm level referenced to a of oxygen 2 NOx O Oxides of Nitrogen ppm level referenced to a of oxygen 2 SO O Sulfur Dioxide ppm level referenced to a of
34. Instruction 24 9448 RY Operation 4 17 Importing Saved Data Into a Spreadsheet Data that was recovered and saved as an ASCII text file with a CSV extension as described in Section 4 14 can easily be opened for viewing in most spreadsheet programs by simply double clicking the filename For example double clicking the filename Customer XYZ csv should automati cally open the spreadsheet 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 related data fields for those sensors will be marked as N A Not Applicable For example if the analyzer does not contain an SO sen sor then N A will appear in data fields 19 and 20 Instruction 24 9448 4 29 3 Turn ON the analyzer by pressing the I O Operation ERP 4 2 Turning ON the Analyzer and Warm Up 1 Connect the probe and hose assembly and make sure that the analyzer is properly set up per Section 3 Initial Setup IMPORTANT DO NOT insert probe into stack before turning ON the analyzer EXCHARACHD 2 Place the probe in an area that contains fresh PCA 2 FIRMWARE VERSION air This ensures that the sensors
35. RACH is a registered trademark of Bacharach Inc All other trademarks trade names service marks and logos referenced herein belong to their respective companies A Instruction 24 9448 RY Contents Contents 1 Introduction rocosas ads ais del 1 1 PCA 2 General Description 0 0 0 0 eee eee ee 1 1 1 2 Sales Combo amp Model Configurations oooooo o o oo 1 2 1 3 Features amp Benefits oooooooooooooooooo oo 1 4 1 4 Operational Overview eee 1 5 1 5 Connector Descripti0MS ooo 1 6 1 5 1 Probe Connections Gas Pressure T Stack 1 6 1 5 2 T AIR Primary Air Thermocouple 1 6 1 5 8 POWER AC Adapter 0 000 cece o 1 8 1 5 4 AP Differential Pressure oooooooooooooo o 1 8 1 5 5 USB Computer Interface o oooooooooooooo 1 8 1 5 6 IrDA Printer Interface oooooooooooooo o 1 8 L5 OPT Option cis ii ita Owe Sadie do 1 9 1 6 Front Panel Buttons 0 0 00 0 ccc ees 1 9 1 7 Caution Possible Need for Smoke Test 1 11 2 Specifications c eee ra s 2 1 3 Initial Selassie ROCHE ACCADE CAE ORE DL EOP Osa oda aorta door deed dab deed pedo ii qe e 3 1 9 2 POWER curia A e de Ye Se eae Os UPS Ds 3 1 3 2 1 Installing or Replacing Batteries o 3 1 3 2 2 Using the AC Power Adapter o o oooocooooooomoo 3 2 3 3 Connecting the Probe and Hose Assembly
36. SC until MENU appears above F2 Note the following To end the logging process at any time press the ESC button m 2 Use the AY buttons to highlight SETUP and At the end of the logging period or if the ES then press ENT to display the SETUP MENU ESC button was pressed the total number Where yy is the number of Ss of log entries that were stored during that log entries stored during the 3 Use the Av buttons to highlight LOGGING period appear at the bottom of the screen last logging session and then press ENT to display the LOGGING Screen If the logging process was stopped by pressing ESC it cannot be re sumed without first turning logging back ON per Section 4 12 1 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 4 15 Memory There are two memory banks each containing 500 memory locations The NOTE At no time will new logging data over first bank is used to store combustion test data as described in Section 4 7 write old data while the second bank is used to store logged combustion test data as E Ei F3 described in Section 4 12 Each bank is independent of each other and can 4 Use the av buttons to highlight YES turn log not share data or be combined ging ON Individual memory locations in each memory ba
37. TION PASSWORD screen Range 8 in of water column 3 Accuracy 0 01 in of water column 4 20 mb 0 025 mb 5 2 Instruction 24 9448 Initial Setup RY 3 19 Language Information on the display screen can be shown in English French or Spanish Select the desired language as follows 1 Display the MAIN MENU by press ing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight LANGUAGE SELECTION and then press ENT to display Fi F2 F3 The Language Selection Menu 4 Use the AY buttons to highlight the desired language then press ENT to activate the selection and re display the Setup Menu 3 20 Instruction 24 9448 ELY 3 20 Cal Reminder Period Initial Setup The analyzer can be set to indicate a calibration reminder during the 60 second warm up period Calibration reminders can be preset to occur 6 8 10 12 or 15 months after the last calibration When the preset period is exceeded the instrument 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 Ifa calibration reminder is displayed the operator can press the RUN HOLD key to move to the Run Hold screen for normal operation Regular calibration periods of 6 months to a year for all gas
38. TTON SOUND screen 4 Use the av 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 and re display the SETUP MENU TA Span Procedure 6 Set thermocouple simulator to 212 F Instruction 24 9448 RY Calibration The calibration range is from 32 to 41 F 0 to 5 C An attempt to calibrate outside this range will cause the message Applied Value High or Low to appear at the bottom of the screen Wait until the Measured reading stabilizes and then press ENT to calibrate the TA Zero Measured value to that of the Applied value after which the message Good Calibration should briefly appear fol lowed by the CALIBRATE TA SPAN screen 100 C and then use the av and 4 buttons to enter an Applied value that 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 AV and 4 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 Entry to appear in the following step Wait until the Measured reading stabilizes and then press ENT to calibrate the TA Span Measured value to that of the Applied value aft
39. Unplug the sensor along with its printed circuit board from the analyzer s main board 6 Remove the sensor s gas cup by twisting its bayonet fitting coun terclockwise and then pulling the cup straight up Twist gas cap CORTE Gas Cup bayonet fitting counterclockwise Sensor to release and Printed Pe Soui Board Sensor electrical connector mates with pins on analyzer s main board remove battery cover _ Y by pushing latch up T ll Figure 3 1 Installing Batteries Instruction 24 9448 7 Attach the gas cup to new sensor making sure that when the sensor is plugged into analyzer s main board the tubing connections on top of gas cup are aligned as shown in Figure 6 3 on page 6 4 8 Plug the sensor into analyzer and then reattach tubing to gas cup 9 Install the sensor retainer and battery cover 10 Turn ON the analyzer and confirm that no sensor errors occur during warm up Instruction 24 9448 6 7 Maintenance RY 6 2 Water Trap Filter Maintenance 6 2 1 Emptying the Water Trap Chamber The water trap chamber should 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 i
40. Use the av 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 7 4 Instruction 24 9448 ECA Language options including English French and Spanish Introduction Custom Display Formats Calibration Reminders PCA2 can be set up to remind the user that calibration is past due 1 4 Operational Overview The PCA 2 is powered by either its 4 internal batteries or by an optional AC power adapter that operates from any convenient source of 100 240 VAC 50 60 Hz power The type of batteries used can be either dispos able alkaline or rechargeable NiMH Note that rechargeable batteries can be charged inside the analyzer using the optional AC power adapter The PCA 2 is controlled by 11 front panel push buttons while a graphical LCD is used to display all combustion and emission test data and analyzer parameters A probe and hose assembly with an integral thermocouple and filter wa ter trap connect to the bottom of the analyzer thus providing the means of drawing in gas samples and for measuring stack temperature and draft The PCA 2 is turned ON by pressing its red I O button A warm up period of 60 seconds then begins during which time the analyzer performs self diagnostics At the end of the warm up period if no errors were detected the instrument will display the Combustion Test HOLD screen If errors were detected the messa
41. a control may perform multiple functions as determined by what screen is being displayed at the time rs hne functions of these buttons are defined by labels ap pearing above them on the LCD The labels that appear depend on the functions that can be performed in the particular screen being displayed PRINT F1 Transmits the data displayed on the screen to a printer through the IrDA communications port MENU F2 Displays the Main Menu SAVE F3 Saves the data currently displayed on the LCD in memory Up to 500 individual Combustion Test and Pressure records can be saved After 500 records have been saved the memory must be cleared to continue sav ing additional data The analyzer will not overwrite old data ZERO F2 When viewing the Pressure screen this but ton zeros the pressure sensor to current atmospheric conditions When viewing the Temperature screen this button zeroes the temperature channel difference 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 Instruction 0024 9448 1 9 Introduction ENG oo E e PAGE F3 When viewing the Memory or Logging Directory each press of this button pages up through the directory Holding this button down speeds up the paging process The arrow buttons move the cursor on the LCD in the di rection of the arrow In screens that re
42. aft ooooooooo ees 24 0878 PCA 2 Data Recovery Software 0 0 ccc eee eee 24 1425 USB Cable acotada tae don oki dei gob hee donent 104 4032 Instruction Manual se srsseri erimesi genia i a A A 24 9448 Quick Start Guide 2 0 0 retken ees 24 9449 Figure 8 2 Probe Hose and Water Trap Filter Assembly 8 4 Instruction 24 9448 RY 1 Introduction Introduction 1 1 PCA 2 General Description The PCA 2 is a commercial grade hand held combustion and emissions analyzer designed for on demand sampling of light industrial institu tional commercial and residential furnaces appliances and boilers The basic instrument is supplied with a probe and hose assembly instruction manual factory calibrated smart sensors 4 AA alkaline batteries Data Download Software with USB cable and carrying case Because of the PCA 2 s ability to measure up to four gases simultaneously it is the perfect tool for service technicians inspectors and boiler contrac tors who need to determine combustion efficiency excess air stack gas O and CO levels stack temperature draft and differential pressure The analyzer can also directly measure and display NO NO and SO with the installation of the appropriate sensors Combustion efficiency calculations can be conducted for the following fuels natural gas oil 2 oil 4 oil 6 propane coal wood kerosene bagasse and digest
43. alyzer that is used to test natural gas furnaces normally requires less frequent cleaning than an analyzer used for testing coal or oil fired furnaces Equipment Required Alcohol 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 Insert the plastic spray tube of the carburetor cleaner into the gas sample hose and then liberally spray carburetor cleaner through the hose and out the probe tube After spraying remove all the residual cleaner by repeatedly flushing the gas hose and probe tube with alcohol Wipe off the surfaces of the probe and tubing with a clean rag Allow the parts to dry completely If available blow compressed air through the probe to expedite the drying process Reconnect gas sample hose to top of water trap 6 14 Instruction 24 9448 RY Introduction 1 5 6 IrDA Printer Interface Data that has been stored in the analyzer s memory can be printed on a compatible IrDA wireless printer by aligning their IrDA communication ports Refer to Section 4 16 1 5 7 OPT Option The option connector is used for optional external measurement features 1 6 Front Panel Buttons Descriptions of the front panel buttons are given below Note that
44. and 3X Standard will display eight lines of Combustion test data 2X will display four and 3X will display 3 5 Press ENT to save the selection and re display the SETUP MENU Instruction 24 9448 3 13 EFF 82 6 Attach a combination 1 000 ppm CO and Adjust the regulator for a flowmeter indica Wait until the Measured reading stabilizes Y Calibration 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 The sen sor will now be marked as being BAD in the DIAGNOSTICS screen NOTE H calibration can be bypassed by pressing the ESC button after which the CALIBRATION LIST screen is re dis played Ship to Step 10 if the ESC button was pressed Turn OFF the regulator of calibration fixture and remove the CO cylinder 1 000 ppm H cylinder to the regula tor of the calibration fixture and then use the AY and 4 buttons to enter an Applied value that exactly equals the CO concentration stamped on the cylinder tion of approximately 2 SCFH and then press ENT to display the CALIBRATE H Screen The calibration range is from 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 approximately 3 minutes and then press ENT to calibrate the H Measured value to that of the Applied value after which the mes sage
45. arach to the replacement of this Product or parts thereof that are defective in title THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF I ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARIS ING FROM BACHARACH 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 including without limitation incidental or consequential damages No agreement varying or extending the foregoing warranties remedies or this limita tion will be binding upon Bacharach Inc unless in writing signed by a duly authorized officer of Bacharach Register Your Warranty by Visiting www MyBacharach com Notice Product improvements and enhancements are continuous therefore the specifications and information contained in this document may change without notice Bacharach Inc shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Bacharach Inc Copyright O 2006 Bacharach Inc all rights reserved BACHA
46. ard typical 4 places Factory Test Connector to J14 Lock Tabs both ends Solder Ribbon Cable Conection between LCD Assembly and Red dot on pump Printed Circuit Board indicates positive red wire connection Figure 6 4 Wiring Instruction 24 9448 6 5 Maintenance RY PRESSURE SENSOR on printed circuit board AP Top AP Bottom EE PURGE PUMP To Sensors GAS PUMP Model 225 Models 235 amp 245 P N 24 7301 P Ns 24 7302 amp 24 7303 Model 255 Models 265 amp 275 P N 24 7304 P Ns 24 7305 amp 24 7306 Figure 6 3 Tubing Connections Initial Setup RY 6 4 Instruction 24 9448 3 4 Operating Parameters The PCA 2 is set up at the factory for the following operating parameters AAA EE E Natural Gas Temperature Units F Pressure Units Inches of Water Column inwc Pollution Units ppm Date E v IER Current MM DD YY TIME uua te e En Current EST HH MM AM PM O Reference 096 Print Pressure No LOOM cera ita No Battery Charger OFF Logsing iv v LER 3 No Button Sound ON To change any of these parameters perform the associated procedure pro vided in Sections 3 5 thru 3 22 3 5 Fuel Selection To assure the accurate calculation of combustion efficiency select the fuel being burned as follows 1 Display the MAIN MENU by pressing the MENU F2 button If nec
47. ata Recovery Program Mie window should appear Observe that the window is divided into two sections The left hand sec tion 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 pro cedure can be used to recover combustion data using the right hand section of the window 2 Select where the downloaded file containing the recovered data will be located and give it a filename by clicking the Open Log File button The following example screens show that the downloaded file will be placed into a pre existing PCA2 Logging Data folder and given the filename Customer XYZ 4 26 Instruction 24 9448 ECA Operation Operation 4 Select Install the software automatically Recommended and click Next 5 At the Hardware Installation window click Continue Anyway Found New Hardware Wizard This wizard helps you install software for Bacharach PCA2 USB driver If your hardw E or floppy disk insert it now What do you want the wizard to do O Install the software automatically Recommended O Install fom a list orspecfic location Advanced L Select Advanced Click Next to continue 1 are came with an installation CD i lt Back J Nes p Canca TABLE 4 1 LIST OF COMBUSTION TEST DATA Hardware
48. be marked as being BAD in the DIAGNOSTICS screen 6 Turn OFF regulator and remove gas cylinder Leave Top Port Open GAS Port E Po CO Y d Parts 1 Gas Cylinder 2 Regulator 3 3 16 1 D Tubing 4 Tee 5 Flowmeter 6 Barbed Hose Connector Part of Calibration Kit 24 7059 Figure 5 2 Gas Sensor Calibration Equipment 5 14 Instruction 24 9448 ESAS Initial Setup 3 8 Pollution Units Selection The PCA 2 is capable of converting the measured ppm levels of CO NO NO and SO to various pollution units using CFR40 Part 60 emission factors Note that the pollution unit conversions for NO NO and NOx are based on the molecular weight of NO Select to display pollution units in parts per million ppm pounds of pol lutant per million BTU Mbtu milligrams of pollutant per cubic meter of gas mg m or grams of pollutant per gigajoule g GJ 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 av buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the av buttons to highlight POLLUTION UNITS and then press ENT to display the POLLUTION UNITS MENU 4 Use the av buttons to highlight the desired pol lution units In the example shown ppm has been selected 5 Press ENT to save the selection and re display the SETUP MENU 3 8 Instruction 24 9448 332
49. char ger circuit must be OFF to prevent the batteries from overheating As a precaution the charger circuit is automatically toggled back to its OFF state when the analyzer is turned OFF 1 5 4 P Differential Pressure Draft is measured by connecting the probe s draft hose to the AP fitting while leaving the AP fitting open to the atmosphere In addition to measuring draft the and AP fittings can also be used to measure the differential pressure between two areas by first connecting a hose P N 24 1108 to the AP 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 into the area where differential pressure is to be measured Refer to Section 4 6 1 5 5 USB Computer Interface Data that has been stored in the analyzer s memory can be downloaded to a personal computer by connecting USB data cable P N 104 4032 between the USB ports of the computer and analyzer Refer to Section 4 14 2 Instruction 0024 9448 x32 Troubleshooting 7 Troubleshooting 7 1 Analyzer Repair It is recommended that field repair of the PCA 2 be limited to Checks of printed circuit board connectors Replacing the probe assembly Replacing the filter element in the water trap filter assembly Replacing sensors Replacing either the gas or purge pump Information on how to perform these repairs is provided in Section 6 All other repairs
50. cords then press ENT to display the Clear Individual menu Again use the Av buttons to highlight the individual record to clear then press ENT to clear the record All Records Use the AY buttons to highlight All Records then press ENT to display the Clear All menu Again use the av buttons to high light Yes then press ENT to clear all records 3 Press ESC to end this procedure and return to the Test ID menu or press the RUN HOLD key to return to the Run Hold screen Instruction 24 9448 3 17 Set thermocouple simulator to 32 F 0 C Wait until the Measured reading stabilizes RY Calibration known temperature that will be applied for calibration purposes and then use the av and 4 buttons to enter an Applied value that exactly equals the set ting of the simulator Alternatively Submerge probe tip into an ice water bath with a thermometer wait several minutes and then use the av and lt gt buttons to enter an Applied value that exactly equals the thermometer reading The calibration range is from 32 to 41 F 0 to 5 C An attempt to calibrate outside this range will cause the message Applied Value High or Low to appear at the bottom of the screen and then press ENT to calibrate the TS Zero Fi F2 F3 Measured value to that of the Applied value after which the message Good Calibration should briefly appear fol lowed by the CALIBRATE TS SPAN screen TS Span Procedu
51. d 15B CULO F 2 24 1429 for viewing printing or downloading to a personal computer Stores an i 01 ttt ttt tttm ettet tote i additional 500 data logged records a nd o9 o9 o9 o9 9 o9 o9 o9 o9 9 o9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 3 9 3 9 9 5 24 1420 ensors Wireless IrDA link used for printing current and stored combustion 16A o DE CCP 24 0788 records pressure records sensor calibration data and diagnostic data 16B CO smart pre calibrated 0 000005 24 1395 USB connectivity for downloading stored data to a personal computer e o a E A dasp4c NM ee usd smart pre calibrated ooooo Field replaceable sensors and thermocouple 16E NO smart pre calibrated ooooo 24 1399 16F SO smart pre calibrated o o ooooooo o 24 1398 Two year warranty on analyzer and all gas sensors except the O sen sor which has a one 1 year warranty 1 4 Instruction 0024 9448 Instruction 24 9448 8 1 Troubleshooting ECA 3 Use the av buttons to highlight the desired diagnostic topic and then press ENT to display the information under that topic 4 Press ESC key to exit back to the Diagnostic menu or the Menu F2 key to exit back to the Main Menu The Status screen provides a quick reference to key items when trouble shooting Access the Status menu as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2
52. e first zeros and then spans the stack temperature channel to known temperature values The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures Alternatively containers of ice water and boiling water can be used Material Required Thermocouple Simulator K ty pe Range 0 to 600 F Accuracy 0 5 F Alternatively Ice Water Boiling Water Ther mometer TS Zero Procedure 1 Set thermocouple simulator to room tempera ture and plug its output into the T STACK connector located at the bottom of the analyzer Alternatively Plug the probe s thermocouple into the T STACK con nector located at the bottom of the analyzer 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 5 4 Instruction 24 9448 Initial Setup 3 18 Username The name of the user or owner of the analyzer e g company name ad dress phone number can be stored in memory by manually entering up to three lines of text with each line containing up to 20 alphanumeric characters This information will appear at the top of each printout until such time as new information is entered or cleared Username Information can be entered as follows 1 Display the MAIN MENU by press ing the MENU F2 button If necessa
53. e next available memory location F1 F2 F3 NOTE When memory is full the next reading will not be saved until space is made available by clearing the 4 10 Instruction 24 9448 ENG Operation 4 10 Ending a Combustion Test WARNING Burn Hazard Do not touch the probe after removing it from the stack Allow the probe to cool before handling about 5 minutes 1 Remove probe from stack 2 Allow the pump to run until all combustion gases have been flushed from the analyzer as indicated by the O reading returning to 20 9 4 11 Emptying 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 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 approaches the tip of the riser tube To empty the trap first pull apart the two halves of the Water Trap us ing a slight twisting motion emp the water trap chamber and then reas semble the trap After each combustion test also check the Water Trap s filter element If it looks dirty replace the filter per Section 6 2 4 12 Turning OFF the Analyzer Purging To Gas Port on Analyzer To empty water pull apart using
54. e of different sizes and shapes which prevent incorrect connection to their associated connectors on the analyzer Instruction 0024 9448 ENS Pressure sensor is measuring pressure outside the range of 3 inches of water column at startup Ensure that the analyzer is sampling atmospheric pressure and restart Troubleshooting The analyzer was turned on with the probe sampling flue gas Move the probe to fresh air and restart the analyzer UNCALIBRATED SENSORS COLO COHigh NO NO2 or SO2 sensor s do not have a calibration history stored on their printed circuit board Calibrate each of the sensors listed per Section 5 Message will indicate which sensor s are 1n error 7 4 Diagnostics and Status Screens The DIAGNOSTICS menu provides information regarding the operation of the analyzer Information includes the following Time Meters Displays the run time of the ana lyzer sample pump and purge pump in hours of operation Main Diagnostics Lists the current status of the Stack and Air Thermocouple channels Reference Temperature channel Pressure channel and Bat tery F1 F2 F3 O2 Sensor Life Displays the approximate remaining life of the Oxygen sensor Smart Sensors Displays the current status of all the smart gas sensors installed Fresh Air Diagnostics Fresh air diagnostics will cycle the instrument through the 60 second warm up to check on the status of all sensors The probe must be in
55. eading Loosen the thumbscrew on probe stop and move probe in and out of the stack until the stack s core temperature hot spot is located as indicated by the highest T STK reading then tighten thumbscrew to prevent further probe movement Locating the highest stack temperature is very important for accurate efficiency calculations 3 You can now begin burner service procedures The analyzer readings will change quickly to show changes in burner performance CAUTION Position the Water Trap with its gas flow arrow pointing upward Do not let water condensate go above the tip of the riser tube The sensors could be damaged if water would enter the analyzer Empty the Water Trap after every combustion test refer to Section 4 9 4 Pressing the RUN HOLD button freezes all readings stops the pump and displays the Combustion Test HOLD screen Press the ENT button to view all test values at the moment the RUN HOLD button was pressed Pressing RUN HOLD again restarts the pump and resumes testing Instruction 24 9448 4 5 Operation RY 4 16 3 Recovering Data Before data can be recovered from the analyzer install the PCA 2 Data Recovery Program USB cable and USB device driver as described in Sec tions 4 14 1 and 4 14 2 Recover either the logging or combustion data as follows 1 Start the program by either double clicking the PCA2 icon on the Windows desktop or clicking the PCA2 shortcut in H start menu The Bacharach PCA 2 D
56. eaking sensor can cause chemi cal burns to the skin and possibly damage the PCB assemblies Ensure that the analyzer is sampling fresh air when turned ON Pulling a stack gas sample through the analyzer during its warm up period will not damage the analyzer but it will result in incorrect sensor readings and may result in sensor error messages appearing after the warm up cycle completes Note that flue 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 position This will maximize the effectiveness of the trap and keep liquid condensate from being drawn directly into the analyzer When liquid condensate is seen inside the water trap empty the trap before it becomes full Refer to Section 4 9 The analyzer should be purged after performing a combustion test After removing probe from the stack let the pump run for at least 10 minutes to remove any stack gases and dry any condensate from inside the sensor chamber and probe assembly If the analyzer is turned OFF with high levels of flue gas remaining in the analyzer then the pump will continue to run and the message PURGING SENSORS wi
57. ed calculated values F3 Three hyphens or dashes indicate that the calculated data cannot be displayed because the measured data necessary to make the calculation is out of range i e oxygen level above 16 Three XXX indicate sensor over range Figure 4 3 Printer Alignment amp Sample Printout Instruction 24 9448 3 23 4 32 Instruction 24 9448 RY Operation 4 18 Printing Test Data Combustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described below Data that is stored in memory can also be printed by first displaying the stored test data as described in Sections 4 13 1 amp 4 13 2 In addition to printing combustion and pressure data the contents of any screen that shows the label PRINT above the F1 button 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 begin printing The printout shown in Figure 4 6 shows typical combustion test results of an analyzer containing O5 CO ow NO and NO sensors Note that since the COyj ay and SO sensors are not installed three s
58. ed for calibration purposes 3 Attach a 4 000 ppm CO cylinder to the regulator of the calibration fixture shown in Figure 5 2 on Page 5 14 4 Use the av and 4 buttons to enter an Applied value that exactly equals the concen Fi F2 F3 Instruction 24 9448 5 13 Calibration ESAS by the CALIBRATION 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 displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen 6 Turn OFF regulator and remove gas cylinder 5 9 NO Sensor Calibration This procedure spans the optional nitrogen dioxide sensor to a known gas level Material Required Calibration Kit P N 24 7059 Gas Cylinder 100 ppm NO 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 AY buttons to highlight NO and then press ENT to display the CALIBRATE NO screen Measured is the current NO reading while Applied is a known NO level that will be applied for calibration purposes 3 Attach a 100 ppm NO cylinder to the
59. een selected NOTE fcustom fuels were added to the instrument they will be located at the bottom of the list TIP Use the 4 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 NOTE The filename is automatically given a CSV Comma Separated Value extension allowing the file to be directly opened by most spreadsheet programs for analysis 3 After selecting a folder and entering the filename click Open and then click Start to begin the download process While recovering the stored data observe that the Records received line displays the total number of records currently downloaded And after all records have been received the Status line will read Log files finished The PCA 2 can download 500 combustion pressure and tempera ture records from memory and an additional 500 records from logged memory 4 This completes the process of recovering logging data Either click Exit to close the program or proceed to recover the combustion data by starting over at Step 2 but this time using the right hand section of the Bacharach PCA 2 Data Recovery Program window NOTE Once either the logging data or combustion data has been recovered that portion of the recovery program s window will turn gray Bacharach PCA 2 Data Recovery Program Recover
60. election and re display the PRESSURE MENU or ESC to exit back to the Main Menu Instruction 24 9448 4 7 Operation ES 2 4 16 2 Computer to PCA 2 Connection amp USB Device Driver Installation Connect the USB cable P N 104 4032 that was supplied with the PCA 2 and if necessary install the analyzer s USB device driver as follows 1 Insert the PCA 2 CD into the computer s CD ROM drive 2 With both the PCA 2 and computer turned ON connect the PCA 2 to the computer using the USB cable supplied with the instrument see Figure 4 2 in instruction manual 3 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 Found New Hardware Wizard NOTE The USB device driver SS ecc ias only needs to be installed once It does not requtre to be re installed each time the PCA 2 is con nected to the computer Windows will search for cument and updated software by looking on your computer on the hardware installation CD or on the Windows Update Web site with your permission Read our privac Can Windows connect to Windows Update to search for software O Yes this time on O Yes now and every time connect a device 9 No not this time Click Next to continue Figure 4 2 Computer to PCA 2 Connection 4 24 Instruction 24 9448 EL Operation
61. ent on battery type and condition An optional AC power adapter which runs from any convenient source of 100 240 VAC 50 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 communications Computer USB Dimensions 9H x 3W x 2 5D inches 22 9 x 7 6 x 6 3 em Weight Analyzer 1 4 Ib 0 6 kg w batteries Probe amp Hose Assembly 1 lb 0 5 kg Instruction 24 9448 2 8 12 13 14 15 16 RY Maintenance page 6 4 Plug the sensor into analyzer and then reattach tubing to gas cup Install the sensor retainer and battery cover Allow the sensor that was just installed time to stabilize in the circuit before continuing with this procedure Stabilization 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 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
62. er 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 Smart sensor technology allows a new sensor to be installed in the field without having to calibrate the analyzer before use New and innovative probe and analyzer designs allow the PCA 2 to be easily serviced thus lowering the cost of ownership Advanced data storage and communication features allow the operator to store up to 500 individual combustion test records which can later be recalled for viewing printing or downloading to a personal computer In its data logging mode the analyzer can store an additional 500 data logged records An optional AC power adapter allows the analyzer to run continuously for data logging purposes The optional sample conditioning probe is recommended when measuring NO and SO to ensure the highest degree of measurement accuracy Instruction 0024 9448 1 1 Introduction 3 2 1 2 Sales Combo amp Model Configurations 24 8351 24 8352 235 245 24 7301 24 7302 24 7303 xoxox nosso O Sd NOx referenced to 0 CO referenced to 0 Lo v P ip NO referenced to 09 NO referenced to 0 SO referenced to 6O Refer to Section 8 2 for a listing of standard and optional accessories Instruction 0024 9448 ERP Parts amp Service ite yf Ey N 1 is
63. er which the message Good Calibration should briefly appear fol lowed by the CALIBRATION LIST screen being re displayed Instruction 24 9448 5 7 Calibration ECA 5 5 T Air Calibration This procedure first zeros and then spans the ambient temperature chan nel to known temperature values The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures Alternatively containers of ice water and boiling water can be used Material Required Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F Alternatively Ice Water Boiling Water Thermometer TA Zero Procedure 1 Set thermocouple simulator to room temperature and plug its output into the T AIR connector located at the bot tom of the analyzer Alternatively Plug the probe s thermocouple into the T AIR connector located at the bot tom of the analyzer 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 AY 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 be applied for calibration purposes 4 Set thermocouple simulator to 32 F 0 C F1 re is
64. essary press ESC until MENU appears above F2 2 Use the AY buttons to highlight FUEL and then press ENT to display the FUEL MENU 3 Use the AY buttons to scroll through the list of Fi F2 F3 available fuels until the desired fuel is high lighted In the example shown PROPANE has been selected If custom fuels are added they will be displayed at the bottom of the list TIP Use the 4 buttons to quickly scroll to the bottom and top of the list 4 Press ENT to save the selection and display the Combustion Test HOLD screen Observe that the name of the selected fuel should now F1 F2 F3 3 4 Instruction 24 9448 ELO Initial Setup appear at the top of the screen Note In addition to the standard fuels programmed into the PCA2 Bacharach can develop custom fuel codes based on the customers specific needs The PCA2 can be programmed with 2 additional fuels which can be added to the instrument using the PC based software provided Consult factory for price and delivery 3 6 Temperature Units Selection Select to display temperature in either F or C 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 AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight TEMP UNITS and then press ENT to display the TEMP UNITS MENU 4 Use the AY buttons to highlight the desired temperat
65. f 4 00 6 Use the AY and lt gt buttons to enter an Applied value that exactly equals the manometer reading 1 3 16 1 D Tubing 2 Tee 3 Barbed Hose Connector 4 Bellows 5 Manometer Figure 5 1 Pressure Sensor Calibration Equipment Instruction 24 9448 3 19 Instruction 24 9448 5 3 Calibration Any errors detected during warm up will be listed on the display immediately fol lowing warm up For example the screen to the right shows that the battery 1s low Correct any errors before proceeding Refer to Section 7 3 for a listing of error messages and their meaning 2 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 uv 4 Before calibration can begin a 4 place alpha numeric password must be entered Use the AY and lt gt buttons to enter the password Note that the default password is 1111 5 Press the ENT key to accept the password If the correct password was entered the CALIBRATION Menu will be displayed 6 Use the av buttons to highlight the sensor to be calibrated and then perform the calibra tion procedure for that sensor as described in the following sections 5 3 Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value Material Required Bellows Manometer Use the AY buttons to highlight CALIBRATION and then press ENT to dis play the CALIBRA
66. f life condition Good Low Bad Each sensor stores its 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 Ser vice Center Section 8 3 every 6 months to 1 year to assure that the ana lyzer continues to meet its published accuracy specifications The smart sensors however can be calibrated in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in the following sections of this instruction manual 5 2 Starting a Calibration Start any calibration procedure by doing the following 1 Place the probe in an area of fresh air turn ON the analyzer allowing it to cycle through its 60 second warm up period During warm up Instruction 24 9448 5 1 Operation Instruction 24 9448 4 33 Initial Setup RY 3 21 Run Hold Screen Format PCA2 testdata is located in the Run Hold screen By pressing the Run Hold key you should hear the pump running and see the word RUN at the upper left hand corner of the display The instrument is continuously measuring and calculating the data that 1s shown in the Run Hold screen Press the RUN HOLD key again the pump should stop running and the word HOLD should be shown at the upper left hand corner of the di
67. fresh air to perform a valid check Access the Diagnostic menu as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 Instruction 24 9448 7 3 Troubleshooting ECA 7 3 Error Messages Displayed After Warm Up If there were problems detected during warm up error messages that describe the nature of the problems are displayed immediately following the analyzer s 60 second warm up period If problems were detected the analyzer will not automatically switch to the Combustion Test HOLD screen after warm up The analyzer however can still be used to perform any test that does not depend on the sensor that is in error Press the RUN button to manually display the Combustion Test HOLD screen and then continue using the analyzer The following is a list of the error messages that may appear following warm up and their suggested remedies Low Battery Battery voltage is low Replace or charge batteries per Section 3 2 O Sensor Missing Oxygen sensor not installed Install oxygen sensor per Figure 6 2 on Page 6 3 BAD Sensors The oxygen sensor s output is too low and can not be calibrated in the instrument signifying that the sensor is depleted and needs replaced Refer to Section 6 3 No Smart Sensors Installed There are no smart sensor s installed Install sensors per Section 6 3 Low Sensors O2 COLO COHigh NO NO2 or SO2 senso
68. g a slight twist onto the analyzer s AP fitting 3 Push the stack gas thermocouple connector into the T STACK jack connec tor fits in only one way NOTE The analyzer has a built in temperature sensor for mea suring ambient temperature Perform Step 4 only if the optional primary ambient air thermocouple is used 4 Push the optional primary ambient air thermocouple into the T AIR jack connector fits in only one way IMPORTANT 7o 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 temperature 5 Inspect all hoses for cracks If any hose is found to be defective replace the entire probe and hose assembly Check that the water trap is empty and that the filter is not dirty or saturated with water 3 2 Instruction 24 9448 ERP Initial Setup Option Connector Primary Optional External N e Air ermocouple Uc S T AIR Optional e AC Power DA em Adapter Jack POWER Differential Pressure Hose AP Optional Stack Gas Gas Sample Thermocouple Hose Connector GAS T STACK Probe Tube Water Trap Probe Sto p Filter Assembly SUN Probe Handle ke Figure 8 2 Connecting the Probe and Hose Assembly to the PCA 2 Instruction 24 9448 3 3 2 Places ESP Maintenance LCD Connector Sensor Connector opposite side of bo
69. ge ERRORS DETECTED is displayed along with a list of the errors These errors must be corrected before proceeding with the combustion 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 select FUEL from the menu then use the AV buttons to highlight the fuel being burned and finally press the green ENT button to select the highlighted fuel To assure correct combustion efficiency calculations the analyzer must know the burner s primary air temperature The analyzer normally uses its internal temperature sensor for the primary air temperature value but this method is only acceptable if the burner is using ambient room air If the burner is drawing in cold outside air we recommend that the optional T AIR thermocouple be used This thermocouple plugs into the bottom of the analyzer and is placed in the burner s primary air stream Instruction 0024 9448 1 5 Introduction ENS Begin the combustion test by first inserting the analyzer s probe tube into the stack gas stream of the appliance under test and then pressing the RUN HOLD button to display the Combustion Test RUN screen The ana lyzer will begin to continuously monitor the stack temperature 0 and emission levels in the stack gas and then display measured and calcula
70. his example 2 hours has been selected NOTE f the selected duration requires more memory than is currently available then the analyzer will automatically select the longest duration possible for the selected interval Instruction 24 9448 4 15 Operation RY 4 14 3 Starting the Data Logging Process After turning ON data logging and setting the interval and duration the analyzer will pause at the LOGGING SUMMARY screen where the currently selected interval and duration time periods are displayed Press ENT to start the combustion test and log ging process At this time the Combustion Test LOG screen will appear indicating that the ana lyzer is now performing a combustion test and the data is being stored in memory Note the following At the bottom of the screen the memory location where the current log entry 1s being saved is displayed If there were previously stored log entries each new logging session will start to store data 1n the next available memory location At no time will new data overwrite old data Fi F2 F3 The ENT button can be pressed while logging to view the other Com bustion Test screens 4 16 Instruction 24 9448
71. idually referenced to a specific O percentage of between 0 and 15 Individually set up the O reference value for each of the above gases 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 AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight O REF and then press ENT to display the O REFERENCE screen 4 Use the AY buttons to highlight the desired measurement and then press ENT to display the REF TO O 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 Av buttons until the desired value 1s displayed 6 Press ENT to save the displayed value and re display the O REFERENCE screen or press ESC to abort this procedure and retain the old O reference value 7 If the O reference value for more than one gas is being set then repeat Steps 4 5 and 6 for each measurement Instruction 24 9448 3 11 6 ENG Calibration 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 displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen Turn OFF regulator and remove gas cylinder
72. iv so duras tend elusreiupesiper ed 24 1383 Smart sensor technology allows pre calibrated sensors to be installed ii Ce LM D MCN SE des in the field TAMO r a oer O a Yo Poe O 3 WW a Automatic zero of all sensing channels on ambient air when the ana Poa B i amp P i ED T d Iyzon ie fitet tined ON P gt A Hd mp eese sur secl 2 Automatic flushing of the CO sensor with fresh air if the CO level 11 Replecement yim s e 1 e G e ONE PM RA 24 1437 exceeds 4 000 ppm thus protecting the CO sensor from high CO 19 Repl EP P P Soe ae er ee Se AUD 24 1439 levels To measure CO levels above 4 000 ppm the analyzer automati 3 ie cd i La M ML 45 cally switches to its COpign sensor if installed ensor HNeLtalnQY 463943 3 3o 9 9 ee ee ae ROS es E i 14 Repl tH tor Plat let 24 14 Automatic purging of the gas sample system if the detected gas levels 14A a S o Come Hoary 24 1 are abnormally high when the analyzer is turned OFF 14B in i po Aaa M M PN ME 24 1415 ressure FUESE 2222222229 cxx obe RR Pd Displays temperatures in either F or C 14C E Clip A 02 2886 Displays pressure in either inwc mb Pa or hPa 14D O Ring Gas Fitting ceo sed a pew a pacer dX neds 105 5102 Backlit graphic LCD with zoom capabilities 14E O Ring Pressure FittiM8 ooooo o 105 5103 Low battery alarm p p cd N I5A 05 507 NOs cia a RR ey e os 24 1421 Stores 500 individual combustion records which can later be recalle
73. ll appear on the dis play until all flue gas levels fall below predetermined levels When storing the analyzer it s a good idea to empty the water trap and leave it open to further dry it out Calibrate the analyzer every 6 months 1 year to assure its accuracy Instruction 24 9448 4 1 Operation ERP TABLE 4 2 DOWNLOADED DATA FIELDS Field CO Carbon Monoxide Level see field 26 ppm CO O2 Carbon Monoxide Level referenced to a of Os see field 21 96 Efficiency Combustion Efficiency 3 Q o 1 2 5 7 10 11 CO2 Carbon Dioxide Level 12 13 Primary Ambient Air Temperature 14 Nitric Oxide Level see field 26 ppm NO O2 Nitric Oxide Level referenced to a of O see field 22 Nitrogen Dioxide Level see field 26 ppm NO2 02 Nitrogen Dioxide Level referenced to a of O see field 22 NOx Nitrogen Oxides NO NO see field 26 21 Nitrogen Oxides Level referenced to a of Os see field 22 Sulfur Dioxide Level referenced to a of O see field 23 0 Reference for CO O Reference for NOx 0 Reference for SO 31 Nitric Oxide Sensor Temperature 4 1 0 reference as selected per Section 3 12 2 Pressure units as selected per Section 3 8 3 Pollution units as selected per Section 3 9 28 29 30 Field a NE 3 5 6 P p EN 12 MEM E 28 29 30 E 4 4 8hown only on printout not on LCD display
74. lockwise the sensor to release Place the adhesive disk L 44909 on the bottom of the new Adhesive lu Printed sensor and plug the new foam L 4 Circuit Board sensor into the sensor disk PCB Sensor electrical connector mates with Attach the gas cup to new Be sure to remove any pins on analyzer s main sensor making sure that oing spring from the board new sensor pins before when the sensor assem installing There is no bly is plugged into the shorting spring on the analyzer s main board the O2 or NO sensors 6 8 Notes Instruction 24 9448 2 4 Instruction 24 9448 ECA 3 Initial Setup 3 1 Scope Before using the PCA 2 Install batteries or plug in the optional AC power adapter Section 3 2 you MUST Connect the probe and hose assembly Section 3 3 Check and if necessary make changes to the analyzer s configuration Section 3 4 3 2 Power 3 2 1 Installing or Replacing Batteries Hither alkaline or NiMH rechargeable 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 RY Maintenance 6 3 Smart Sensor Replacement Bacharach s Smart sensor technology allows new sensors to be installed without needing
75. n Nitrogen 24 0794 Ie DA Printers ose esce red d ARG ei ate de Swe eRe 24 1400 Printer Paper PROUD iei oa gue Sade a quod Reed UR qe UNS bce BAR quae dor end 06 8733 D Roll Packs RR e UR ER AUS 24 1310 Probe Hose and Water Trap Filter Assemblies oun Probe bur A a exeat 24 3002 241n ProD s oes EY ey Vae a e x E 24 3021 96 i Probe esses dox aurei Reb s e Ra e gle qe ae 24 3022 Thermocouple Replacement Kits Of SU SG wee e Awe da ee eM V e eg aea ec seus 24 8413 TVLIA tieu a dep d trees e io Add ao 24 8414 DA id PI Ad 24 8415 DO ia A A coi 24 8416 Sample Conditioning Probes Recommended when measuring NO and SO Heavy Duty EPA ETV test verified performance 24 1223 Compactas acp Sane lsd ERU gr PUEDES oe OR CAS 24 7224 iv Instruction 24 9448 Instruction 24 9448 8 5 Parts amp Service 8 2 Accessories Standard Accessories Part No Carrying Case viana dotes och 4 doe ded eee debi 24 0865 Batteries AA Alkaline o ooooooooooooooro eA 204 0004 12 Probe Hose and Water Trap Filter Assembly Fig 8 2 24 3004 O Water Trap Filter o oooooooooooooooooo o 19 3265 O Filter Element 3 pack llle 07 1644 Thermocouple Replacement Kit 12 0 o o o ooooooo o 24 8414 Probe StoPumraioncrcona a o hrs 19 0580 O Thumb ScreW o oooooooooonroor Rh 102 0875 Connector Gas Sample anaana naaasar anra 24 0877 O Connector Dr
76. nk can be recalled for 5 Press ENT to make the selection and display viewing on the display or printed refer to Sections 4 13 1 amp 4 13 2 or the the LOGGING INTERVAL screen entire contents of each memory bank can be individually downloaded to a computer and viewed in a spreadsheet program for analysis refer to Sec tion 4 14 TIP When displaying the contents of either memory bank the operator can quickly page through the screens by pressing the PAGE F1 and PAGE F3 buttons Or move to the first or last memory location by pressing the 4 buttons respectively Instruction 24 9448 4 17 4 14 Instruction 24 9448 EL Operation 4 14 2 Setting the Logging Interval and Duration The logging interval is the length of time between measurements while the logging duration is the time allocated to the logging process Set the logging interval and duration as follows TIP Jf the duration is set for more than 10 hours we recom mend using the optional AC power adapter to power the analyzer 1 As soon as logging is turned ON as described in Section 4 12 1 the LOGGING INTERVAL Screen appears 2 Use the AY buttons to highlight the desired interval and then press ENT to make the selection and display the LOGGING DURATION screen In this example 1 min ute has been selected 3 Use the AY buttons to highlight the desired duration and then press ENT to make the selection and display the LOGGING SUMMARY screen In t
77. or ALL DATA conformation screen Highlight Y ES to confirm that memory 1s to be cleared and then press ENT to actually clear memory as evidenced by the display of the WAIT Erasing memory screen Fi F2 F3 4 20 Instruction 24 9448 EL Operation 4 15 2 Recalling Logged Test Data Recall individual logged combustion test data records 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 AY buttons to highlight MEMORY and then press ENT to display the MEMORY MENU 3 Use the AY buttons to highlight LOGGING DIRECTORY and then press ENT to display the LOGGING DIRECTORY screen 4 Use the AY 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 word EMPTY signifies that the logging location does not contain data 5 Press ENT to display the logging data contained F1 F2 F3 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 example 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 Instruction 24 9448 4 19 Operation RY ting down giving the operator an opportunity
78. over a predetermined duration 5 10 15 30 minutes 1 2 5 10 24 48 hours The maximum duration that data can be collected is determined by the in terval For example if the interval is set to 10 seconds then the maximum selectable length of time in which data can be collected to 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 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 PCA 2 data recovery software and USB cable refer to Section 4 14 Downloaded data is stored on the computer s hard drive as a comma separated value ASCII text file with a CSV extension which can be opened by most spreadsheet programs for analysis TIP The latest PCA 2 data recovery software can be downloaded from http www bacharach inc com downloads Instruction 24 9448 4 13 Operation ESP 4 15 1 Recalling Combustion Test Data Recall individual combustion test data records 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 AY buttons to highlight MEMORY and then press ENT to display the MEMORY MENU 3
79. placement 0 000 6 7 6 4 Sensor Only Replacement lees 6 8 6 5 Nitric Oxide Sensor Battery Replacement 6 10 6 6 Thermocouple Replacement o o ooooooooooooo ooo 6 11 6 7 Pump Replacement oo oooocooooroo ene 6 13 6 8 Cleaning the Probe 0 0 ccc eee 6 14 7 Troubleshooting eere eere 7 1 7 1 Analyzer Repair 0 llle 71 7 2 Error Symbols biie les e ido Gla aoe Peste io 71 7 3 Error Messages Displayed After Warm Up o o oooo 7 2 7 4 Diagnostics and Status Screens 0 0 cee eee 7 3 Parts amp Service coz honra aa RR e xs Sal 8 1 Replacement Parts lees 8 1 8 2 AGCeSSOFIOS 124394 E pue P OVTAOCeRGURRGO EG PA S SOR E ese s 8 4 8 8 Service Centers 0 0 ccc eee tenes 8 6 Instruction 24 9448 ili Contents ERP RY Parts amp Service Notes Optional Accessories Part No AC Power Adapter Input 100 240 VAC 50 60 Hz Output 9VDCO1A 24 1404 Ambient Air Thermocouples T AIR K Type TO UT 104 1797 Pinch c PRICE ats a E E O d aa 104 1798 Utility Wand 12 in ridged probe w 5 ft coiled cable 104 1799 Differential Pressure Hose Assembly 6 ft o 24 1103 Calibration Kit Includes hoses adapters flowmeter does not include gas cylinders 24 7059 Gas Cylinders 103 Liter 500 ppm COIN ATE eek e oett ne I RC aa ead d e 24 0492 1000 ppm CO amp 1000 ppm Hs i
80. ppm 5 Before powering up and using the analyzer allow the Nitric Oxide O TREES 5 of reading or 5 ppm sensor to stabilize as described below Note that recalibration of the whichever is greater between Nitric Oxide sensor is not required after replacing its bias battery 0 500 ppm Depending on how long the Nitric Oxide sensor was without bias SOS suriati ines ds 5 of reading or 10 ppm voltage the time required for the sensor to completely stabilize varies whichever is greater between from less than a minute to several days Typical stabilization times 0 2 000 ppm are shown below Generally however the sensor is sufficiently stable Stack Gas Temp 4 F between 32 and 255 F after 4 hours for measurement purposes 2 C between 0 and 124 C 6 F between 256 and 480 F 610 between 128 and 240 C E a 8 F between 481 and 752 F 4 C between 250 and 400 C Primary Ambient Air Temp 2 F between 32 and 212 F 21 C between 0 and 100 C O 5 iis Gooaler than days Pressure Draft e of reading or 0 02 H0O 0 05 mb whichever is greater System Flow Rate with Probe 200 cc min minimum 6 10 Instruction 24 9448 2 2 Instruction 24 9448 EL Specifications Power Requirements Four disposable AA alkaline batteries provide at least 15 hours of continu ous operation NiMH rechargeable batteries can also be used with the operating time depend
81. quire the entry of alphanumerical data use the 4 buttons to move cursor across the screen and then use the AY buttons to incre ment and decrement the data When viewing a menu use the 4 buttons to quickly move to the top and bottom of the menu Selects a highlighted menu In addition if changes were made to one of the analyzer s operating parameters e g date time O reference etc pressing this button con firms those changes and saves them in memory Starts and stops a combustion test when the Combus tion Test screen is displayed Pressing this button in any other screen returns the analyzer to the Combustion Test HOLD screen Pressing this button during the 5 second turn off delay period will abort the turn off process and also return the analyzer to the Combustion Test HOLD screen Displays a previously viewed screen In addition if changes were made to one of the analyzer s operating parameters e g date time O 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 which time an operator can keep the analyzer turned ON by pressing the RUN HOLD but ton Also note that if the measured emission levels are above predetermined limits at the time the instrument is
82. r output s were low but still usable Sensor s may need to be replaced in the near future Message will indicate which sensor s are in warning T STK Disconnected The probe s thermocouple is not connected to the analyzer s T STACK connector Plug the probe thermocouple plug into the T Stack connector at the bottom of the instrument Warmup Sensor Error COLO COHigh NO NO2 or SO2 Gas sensor s were not zeroed at warmup because of high output Run instrument on fresh air then restart instrument 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 Instruction 24 9448 Introduction ENS IrDA Wireless printer communications port LCD 160 x 160 graphic display ENT F1 F2 F3 Selects a highlighted menu item or confirms the entry of data VSB Computer communications RUN HOLD connector Starts and stops a combustion efficiency test Pressing this button during Arrow Buttons the 5 second turn off period will keep the analyzer turned ON A Moves cursor up the display or increments an ESC Displays previous menu alphanumerical value or previously viewed screen Y Moves cursor down the display or decrements an I O Press from between alphanumerical value 1 and 2 seconds to turn analyzer ON and OFF
83. ration fixture shown in Figure 5 2 on Page 5 14 4 Use the av and lt gt buttons to enter an Applied value that exactly equals the concen tration stamped on the CO cylinder The calibration range is from 9 to 1 500 ppm An attempt to calibrate outside this range will cause the message Applied Value High or Fl F2 F3 Low to appear at the bottom of the screen 5 Adjust the regulator for a flowmeter indication of approximately 2 SCFH Wait until the Measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the CO Measured value to that of the Applied value The message Good Calibration should briefly appear followed by the TEST GAS CO H screen If the sensor s output is low but still usable then the message Good Calibration WARNING Low Sensor will appear The sensor will now 5 8 Instruction 24 9448 Initial Setup 3 14 Battery Charger Selection When using rechargeable NiMH batteries the AC power adapter can be used to charge the batteries while inside the analyzer The analyzer s rapid charger circuit however must be first turned ON IMPORTANT When using disposable alkaline batteries the analyzer s battery charger circuit should be OFF to prevent the batteries from overheating As a precaution the charger circuit is automati cally toggled to its OFF state when the analyzer is turned OFF thus requiring the operator to turn the charger back ON when needed Note
84. re 6 Set thermocouple simulator to 572 F 300 C and then use the AY and lt gt buttons to enter an Applied value that exactly equals the setting of the simulator Alternatively Submerge probe tip into a container of boiling water with a thermometer wait several minutes and then use the AY and 4 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 Applied Value High or Low to appear at the bottom of the screen Wait until the Measured reading stabilizes and then press ENT to cali brate the TS Span Measured value to that of the Applied value after which the message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed Instruction 24 9448 5 5 Calibration ECA The calibration range is from 6 to 2 inwc 15 to 5 mb An attempt to calibrate outside this range will cause the message Applied Value High or Low to appear at the bottom of the screen 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 Calibration should briefly appear fol lowed by the CALIBRATION LIST screen being re displayed 8 Remove calibration equipment 5 4 T Stack Calibration This procedur
85. replaced leave the tubing connected to each sensor s gas cap being careful not to put unneces sary strain on the tubing during the disassembly process Figure 6 1 Removing Rear Case 3 Pull off sensor retainer 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 be tween the bottom hose connector plate and the pressure sensor on the printed circuit board Do not put unnecessary strain on this tubing during the disassembly process 7 Carefully lift battery and pump chassis along with the bottom hose connector plate from analyzer 6 2 Instruction 24 9448 3 6 Instruction 24 9448 ELO Initial Setup 3 7 Pressure Units Selection Select to display pressure in Inches of Water Column inwo millibar mb Pascals Pa or hectoPascals hPa 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 AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight PRESSURE UNITS and then press ENT to display the PRESSURE UNITS MENU 4 Use the AY buttons to highlight the desired pressure units
86. ruction 24 9448 3 9 ECA Calibration 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 calibrate the NO Measured value to that of the Applied value The message Good Calibration should briefly appear followed by the CALIBRATION 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 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 4 000 ppm CO in Air P N 24 1155 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 2 Use the av buttons to highlight CO HI and then press ENT to display the CALIBRATE CO HI screen Measured is the current CO reading while Applied is a known CO level that will be appli
87. ry press ESC until MENU appears above F2 2 Use the AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight USERNAME and then press ENT to display all three lines of the EDIT USERNAME screen Periods identify empty lines 4 Use the AY buttons to choose which of the three Username lines to edit then press ENT to begin editing the chosen line 5 Use the AY buttons to enter the desired charac ter and then move to the next character posi Fi F2 F3 tion by pressing the right arrow key Repeat this step until the line is complete A maximum of 20 alphanumeric characters can be entered 6 Press ENT to accept the entered information 7 At this time either return to step 4 to choose another line to edit or end this procedure by highlighting Edit Complete and pressing the ENT key to return tot he Setup Menu 8 Press ESC to go to the Main Menu or the RUN HOLD key to return to the Run Hold screen 3 18 Instruction 24 9448 ESP Initial Setup ERP Calibration To Clear a Username proceed as follows Section 3 8 In the following procedure inwc is selected but note that any unit of measure 1 Display the MAIN MENU by press can be used for calibration purposes ing the MENU F2 button If necessary press ESC until MENU appears above F2 1 Assemble the pressure sensor calibration equipment as shown in Figure 5 1 but DO NOT connect the analyzer to the
88. sensors except Oxygen are recommended Set the calibration reminder period as follows 1 Display the MAIN MENU by press ing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight CAL REMINDER PERIOD and then press ENT to display CAL Reminder Period Menu 4 Use the AY buttons to highlight the desired CAL reminder period and then press the ENT key to activate the selection and re dis play the Setup Menu Note The date and time settings must be correct to get accurate cal reminders Instruction 24 9448 3 21 RY 5 Calibration Calibration IMPORTANT Before performing any calibration procedure ensure that fresh batteries are installed or use the optional AC power adapter Also ensure that the analyzer is at room temper ature and will be sampling fresh air when turned ON 5 1 Smart Sensors The PCA 2 uses Bacharach s new Smart Sensor technology meaning that the calibration data for each sensor is stored in nonvolatile memory on the sensor s printed circuit board Benefits of Smart Sensors New sensors can be installed without needing to be calibrated Sensors can be pre calibrated and installed when needed Sensors can be moved from one analyzer to another The analyzer s diagnostics screen shows what sensors are installed and their current end o
89. splay The instrument will now show the last measured and calculated data taken before the instrument was placed in HOLD Use the up and down arrow keys to scroll through the complete list of measured and calculated values when the instrument is running or in the hold mode The order in which data appears in the Run Hold screen is as follows Os Oxygen CO Carbon Monoxide EFF Combustion Efficiency CO Carbon Dioxide T STK Stack Temperature T AIR Ambient Primary Air Temperature EA Excess Air CO O Carbon Monoxide content referenced to an Oxygen percentage NO Nitric Oxide NO Nitrogen Dioxide NOx Oxides of Nitrogen NO and NO combined SO Sulfur Dioxide NO O Nitric Oxide content referenced ro an Oxygen percentage NO O Nitrogen Dioxide content referenced to an Oxygen percentage NOx O Oxides of Nitrogen content referenced to an Oxygen percentage SO O Sulfur Dioxide content referenced to an Oxygen percentage Note O denotes the current O Reference selected Note Stars appear in measurement and calculation fields of sensors that are not installed 3 22 Instruction 24 9448 ray Initial Setup Change the order in which data is displayed as follows 1 Display the MAIN MENU by press ing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the av buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the
90. t becomes visibly dirty or becomes satu rated with water Material Required Filter Element P N 07 1644 8mall Flat Blade Screwdriver 1 Remove water trap chamber per Figure 6 5 2 Pry apart filter chamber using a small flat blade screwdriver Remove and discard old filter 3 Install new filter and reassemble filter chamber making sure that surfaces A and B contact each other 4 Reassemble trap Figure 6 5 Disassembling the Water Trap Filter Assembly Instruction 24 9448 Initial Setup ESP 3 2 2 Using the AC Power Adapter The AC power adapter is capable of powering the analyzer on a continuous basis The adapter plugs into an appropriate 100 240 VAC 50 60 Hz wall outlet and produces an output of 9 VDC The adapter s output connector plugs into the analyzer s POWER jack located on the bottom of the unit Figure 3 2 If NiMH rechargeable batteries are used the adapter can also rapid charge these batteries in approximately 2 3 hours while still inside the analyzer For the batteries to be charged however the analyzer s battery charger circuit must be turned ON per Section 3 16 3 3 Connecting the Probe and Hose Assembly Do the following to attach the probe and hose assembly to the analyzer Figure 3 2 1 Push the gas sample hose 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 givin
91. t termination ATMOSPHERIC OR GRAVITY VENTED BOILER Boilers which have a bell shaped draft diverter on top should be tested directly below the diverter through a hole drilled in the vent connector Hot Water Tank Combustion Air Sampling Poi O2 CO Stack Terrp 80 Eff Fan Assist or Power Vented 90 Eff Condensing Atmospheric or Gravity Vented Boiler 4 4 Instruction 24 9448 LY Operation 4 5 Performing a Combustion Test Ensure that the following has been completed and then proceed with the combustion test as described below Turn ON analyzer and allow it to warm up Section 4 2 Select fuel being burned Section 4 3 Inset probe into stack Section 4 4 If necessary insert optional primary air thermocouple into combustion air stream of burners that use an outside source of combustion air 1 Press the RUN HOLD button to start the test You should hear the pump start running and see the word RUN appear at the top of the Combustion Test screen Sensor Indicators The following indicators appear in the sensor s data field depending on certain conditions Sensor that is not calibrated or installed XXX Sensor overrange F1 F2 F3 The calculated data cannot be displayed because the measured data necessary to make the calculation is out of range i e oxygen level above 16 2 Use the up and down arrow keys to scroll to the T STK r
92. tars appear in their data fields Instruction 24 9448 4 31 Initial Setup RY Reset Display format back to factory default settings as follows 1 Display the MAIN MENU by press ing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight RUN HOLD FORMAT and then press ENT to display Run Hold Format Menu 4 Use the AY buttons to highlight RESET FORMAT then press ENT to display the Reset Format screen 5 Use the av buttons to select Y ES then press ENT to reset the display and return to the Run Hold Format screen Fi F2 F3 3 24 Instruction 24 9448 EL Operation 4 Operation 4 1 Operating Tips When an analyzer is brought in from a cold vehicle let it warm up slowly to minimize condensation Temperatures below freezing will not dam age the analyzer however bringing a cold analyzer into a warm humid environment may cause condensate to form inside the case CAUTION Although the analyzer itself is not damaged by an extremely cold environment the electrochemical sensors may be damaged The Os sensor s electrolyte will freeze at approximately 20 F and the other sen sors at approximately 94 F If the analyzer is exposed to an extremely cold condition it is strongly suggested that the sensor housings be exam ined for hairline cracks Be aware that a l
93. ted values on its LCD Values are listed in Section 2 Specifications During a test the CO sensor is protected from high CO levels by being automatically flushed with fresh air when the detected CO level exceeds 4 000 ppm The analyzer will automatically start using its optional CO High Sensor if installed at CO levels starting at 4 001 ppm thus providing continuous CO readings up to 20 000 ppm A backlight enables a user to read the display 1n dimly lit areas Turn the backlight ON and OFF by briefly pressing the I O button The analyzer is turned OFF by pressing and holding down the I O button for at least 2 seconds Note that there is a 5 second delay before the analyz er actually turns OFF during which time the analyzer can be turned back ON by pressing the 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 1s 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 Stack Attach the probe and hose assembly to the analyzer by connecting its 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 AP connector Observe that the probe connectors ar
94. tional 350 KB for each download Instruction 24 9448 4 21 Operation a Press the ZERO F2 button b Disconnect any hoses connected to the AP and AP ports and then press ENT to zero the pressure sensor c Reconnect any hoses When measuring draft simply leave the AP port open to the atmosphere and connect the probe s draft hose to the AP port see Figure 3 2 on Page 3 3 5 Do one of the following to measure draft or dif ferential pressure To measure draft simply insert the probe into the stack and observe the draft read ing on the PRESSURE screen To measure differential pressure con nect two sampling hoses to the AP and AP ports and place the open end of each hose into the areas being measured The differential pressure between the two areas is now displayed on the PRESSURE screen If the pressure at the AP port is higher than the AP port then the pressure reading will be positive If it is lower then the reading will be negative 4 9 Saving Test Data F1 F2 F3 Up to 500 individual sets snap shots of combustion test pressure or temperature 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 saved In the example to the right all data associated with the Combustion Test RUN screen will be saved 2 Press the SAVE F3 button to save the test data 1n th
95. to be calibrated inside the analyzer NOTE Sensors may be purchased with and without the Smart sensor technology PCB See Section 6 4 on how to change just the sensor itself Calibration must be performed if the sensor is purchased without the Smart technology PCB Refer to Section 8 1 Replacement Parts for list of sensors and part numbers of both types Replace the oxygen sensor when its automatic calibration fails and the ana lyzer displays an Os sensor error at the end of warm up Refer to Section 4 2 NOTE The O2 sensor and PCB is not Smart sensor technology Only the sen sor itself not the PCB needs to be purchased when the sensor needs replaced Replace a gas sensor when it can no longer be calibrated as evidenced by Bad Calibration Sensor End of Life being displayed during 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 Fig ure 6 2 on page 6 3 for sensor positions Do the following to replace a Smart sensor 1 Turn OFF the analyzer Sensor Retainer i Remove the battery cover 2 Remove and properly dispose of any old batteries 3 Install a set of four AA alkaline or NiMH batteries per the and markings inside the battery compartment 4 Replace battery cover Release and then 2 3 Remove the sensor retainer 4 Remove the tubing from the gas cup of sensor being replaced 5
96. tons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight PRINT PRESSURE and then press ENT to display the PRINT PRESSURE screen 4 Use the AY 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 3 12 Instruction 24 9448 ESP Initial Setup 3 13 Zoom Display Selection fold NGas Combustion test data in the Run Hold screen can be shown with enlarged characters to make view Oz 4 0 ing easier The operator can set zoom levels to Standard 2X or 3X The Standard zoom setting CO 19 ppm will display 8 lines of combustion test data at one time 2X which will display 4 lines of combustion test data with enlarged characters and 3X which will display 3 lines of combustion test data with en larged characters The operator 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 MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the AY buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the AY buttons to highlight ZOOM and then press ENT to display the ZOOM screen 4 Use the AY buttons to select the desired Zoom level Options include STANDARD 2X
97. ument is used in an inefficient furnace or boiler application where there is a high emission of soot filter may become clogged Check filter before every use to confirm that it is clean for use or replace with a new filter To prevent this from occurring a smoke test 6 Insert thermocouple into probe body until it bottoms out should be performed before operating under such conditions to ensure that the furnace is burning at a level appropriate for the use of this instrument 5 If not already done install supplied O Rings onto thermocouple 7 Strip 1 4 inch of insulation from each of the probe s thermocouple connector wires IMPORTANT Jn Step 8 the thermocouple wires must first be twisted together and then crimped 8 Twist both red thermocouple wires together insert them into the sup plied 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 together Cut away view of Thermocouple inserted into Probe Body gt Thermocouple Assembly CEL EA A Ensure end of Thermocouple is in front of plastic rib in handle ZA UL ZA ne miei O Rings zs NA O O z
98. ure Measurement 4 9 4 9 Saving Test Data oooooooooooorrr oro 4 10 4 10 Ending a Combustion Test oooooooooooooooo 4 11 4 11 Emptying the Water TraD o ooooooooorooooo oo 4 11 4 12 Turning OFF the Analyzer amp Purging ooooooo 4 12 4 13 Low Battery Alarm lsseeeee ee 4 12 414 Data Loggtiag iue a dd el 4 13 4 14 1 Turning ON Data Loggld8 oo ooooocooooo ooo 4 14 4 14 2 Setting the Logging Interval and Duration 4 15 4 14 3 Starting the Data Logging Process 4 16 4 14 4 Ending the Data Logging Process 4 17 41b Memory ems cra data Dae Cr ONU GaGa POE NUR 4 17 4 15 1 Recalling Combustion Test Data 4 18 4 15 2 Recalling Logged Test Data o ooooooooo oo 4 19 4 15 3 Clearing Memory sees 4 20 4 16 Downloading Stored Data to a Computer 4 21 4 16 1 PCA 2 Data Recovery Program Installation 4 22 4 16 2 Computer to PCA 2 Connection amp USB Device Driver Installation oooooooooooroom oo 4 24 4 16 3 Recovering Data ooooooooooo ees 4 26 4 17 Importing Saved Data Into a Spreadsheet 4 29 4 18 Printing Test Data 0 0 eens 4 31 5 Calbrati h i 9 o ER RR xx see e DL 5 1 Smart SensorsS nssw s D ERROR RR RR we de os 5 1 5 2 Starting a Calibration ee RE A xbv a abe Rex 5 1 5 3 Pressure Sensor Calibrati0OM
99. ure units In the example shown Fahrenheit has been selected 5 Press ENT to save the selection and re display the SETUP MENU Instruction 24 9448 3 5 ESP Maintenance Sensor Positions Model 225 235 245 255 265 275 Position 2o mE 24 1903 de 25 20 24 7306 1 Os lololol o 2 COLo 695 CO COLo COLo COL 3 SO NO SO 4 NO CO NO NO Sensors Type and position determined by model number Sensor Retainer Gas Pump Motor Connector Purge Pump Motor Connector Battery amp Pump Chassis Pressure Sensor on printed circuit board AP Top AP Bottom Purge Pump Battery Connector on printed circuit board Gas Pump Hose Connector Plate Purge Air In GAS AP AP Pressure Figure 6 2 Inside View with Rear Case Removed Instruction 24 9448 6 3 Maintenance ESP Initial Setup 6 1 PCA 2 Disassembly The following procedure describes how to disassemble the analyzer while Figures 6 1 thru 6 4 illustrate how the analyzer is put together Tools Required Medium Phillips Screwdriver Rear Case Screws Procedure typical 4 places 1 Unplug all thermocouples from bottom of analyzer Release and then remove battery cover by pushing 2 Remove battery cover and then latch up remove batteries TIP In Step 3 if the sensors are not being
100. x zx Red and Yellow Thermocouple Wires When reassembling probe handle ensure that the thermo couple wires do not become pinched around screw hole or edge of handle Wire Splice Connectors Figure 6 7 Thermocouple Installation and Wiring 6 12 Instruction 24 9448 Instruction 0024 9448 1 11 EL Specifications 2 Specifications The PCA 2 Directly Measures and Displays The gases displayed depend on the analyzer s model number Refer to Section 1 2 A spf aries EEE Giese APs oh Sosa eed ste eet 0 to 20 9 Stack Temperature ooo o 4 to 2 192 F 220 to 1 200 C Primary Ambient Air Temperature 4 to 999 F 20 to 537 C Carbon Monoxide CO H5 compensated 0 to 4 000 ppm Pressure Draft o o o ooooooommoommo o E12 H0 180 mb CO High Range munici dictada 4 001 to 20 000 ppm Nitric Oxide NO coso a DENS eee eee 0 to 3 000 ppm Nitrogen Dioxide NO3 0 0 0 ce siian 0 to 500 ppm Sulfur Dioxide S05 0 eee eee 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 1 098 C Combustion Efficiency 0 0 0 00 cee ene 0 1 to 100 Ecos Altice uten ve A e Reg ales and Aas 1 to 250 Carbon Dioxide dry basis 0 1 to fuel dependent maximum in NOx NOx NO NO 00 eens 0 to 3 500 ppm
101. ypes include differential temperature across heat exchange or differential temperature Perform a differential temperature measurement 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 AY buttons to highlight TEMPERATURE and then press ENT to dis play the TEMPERATURE MEASUREMENT screen 3 Install thermocouples in both temperature channel connectors 4 Before taking a measurement the temperature channels may need to be zeroed if not already displaying zero with both thermocouples exposed to the same condition Press ZERO F2 if needed 5 To label the data use the av buttons to scroll through the available temperature label types The current label will be used saved and printed with the record 6 Press ENT to save the selection and re display 2 the TEMPERATURE MENU or ESC to exit F1 F2 F3 back to the Main Menu 4 8 Instruction 24 9448 ESP Operation 4 8 Making a Draft Pressure Measurement The difference in pressure AP between two areas can be measured by using the analyzer s two pressure ports and the PRESSURE screen By using the AP port as the reference the pressure applied to the AP port will be displayed on the PRESSURE screen as the differential pressure between the two ports Perform a draft pressure measurement as follows 1 Turn ON the analyzer and allow it to complete lts warm up cycle Section 4

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