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PCA User Manual - Bacharach, Inc.

1. 6 6 Replacing the Oxygen Sensor Replace the Oxygen Sensor when it has expired when the analyzer s automatic O calibration fails and the unit displays the message O2 Sensor Error NOTE A 0O2 SENSOR ERROR displayed in the Sensor Status Screen does not necessarily mean that the sensor has expired Before replacing the sensor refer to Section 7 2 for other possible causes of the error Equipment Required e 1 3 Flat Blade Screw Driver e Oxygen Sensor Refer to Section 8 1 Procedure 1 2 Remove the analyzer s rear case and lay it aside refer to Section 6 2 Remove the Oxygen Sensor connector from the printed circuit board then carefully pull off the two wires connected to the pins of the sensor see Figure 6 2 Push in and turn the sensor counterclockwise watching the notch on top until it stops then pull the sensor out of its housing To install a new sensor push the sensor into the housing and turn it clockwise until it locks in place Connect the black and red wires which were removed from the old sensor in Step 2 to the pins of the new sensor Be sure to observe polarity as marked on the sensor Reinstall the sensor connector onto the printed circuit board Reassemble the analyzer Then allow the sensor to be connected in the circuit for at least 7 hour before continuing Place the analyzer in an area of fresh air and turn it ON After the warmup cyc
2. 3 Instruction 0024 9219 4 23 Operation PCA 4 18 Time Date Setup Screen SETUP TIME 03 12 45 pm DATE 02 24 01 The Time Date Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen Use this screen to enter the cur rent time and date as follows Use the st keys to move the cursor z in front of the TIME or DATE field to be changed and then press the Enter key to move the cursor inside the selected field Again press the enter key to select the field position to change after which use the st keys to increase or decrease the value of that field Continue using the enter and st keys until all values within the chosen field are correct then press run to save all field values and return the cursor to the left side of the screen Front Panel Key Functions Move cursor z up or Increase value in selected field position Move cursor z down or Decrease value in selected field position ENTER Select Time or Date field to be changed as selected by the cursor s position and then use to move the cursor through the field positions DAA RUN Go to the Combustion Test Screen or save the time and date values and return cursor to left side of screen MENU Go to Setup Printer Screen or return cursor to left side of screen g 4 24 Instruction 0024 9219 PCA Operation 4 19 Printer Setup Screen SETUP IR HP PRINTER IR IRDA
3. Display 20 character by 4 line alohanumeric LCD panel with a green backlight Accuracy referenced in practical flue gas concentrations mixtures of O CO and Nz 2 2 Instruction 0024 9219 PCA Technical Characteristics Power Requirements Four AA alkaline batteries Battery backup for the real time clock RAM and bias voltage for the Nitric Oxide sensor is provided by internal lithium batteries Optional AC Power Supplies 110 VAC amp 230 VAC are also available Operating Time A fresh set of batteries will provide at least 8 hours of continuous opera tion with the pump running and the backlight turned on Warm Up Time 60 seconds Printer Interface Infrared Communications refer to Section 4 24 Materials e High impact ABS plastic case e Polycarbonate window over the display e Nickel plated brass quick connect hose fitting e Stainless steel probe Dimensions Height 8 5 in 215 mm Width ee 3 8 in 96 mm at display 3 0 in 75 mm at controls Depth eeee 2 in 50 mm Weight With Batteries Approximately 1 5 lbs 0 7 Kg Instruction 0024 9219 2 3 Technical Characteristics PCA NOTES 2 4 Instruction 0024 9219 PCA Setup 3 0 SETTING UP THE PCA 3 1 Scope Before using the PCA you MUST e Check the batteries or plug in an Optional Power Supply Section 3 2 e Connect the probe to the analyzer Section 3 3 e Check the analyzer
4. e Differential Pressure in Millibars Pascals or Inches of Water Column For analyzers having a draft sensor The PCA will compute display and store the following data for any of the seven standard fuels e Combustion Efficiency in e Excess Air in e Flue Gas Carbon Dioxide Content in e Flue Gas Carbon Monoxide Content referenced to Oxygen in ppm For analyzers having a Carbon Monoxide sensor e Flue Gas Nitric Oxide Content referenced to Oxygen in ppm For analyzers having a Nitric Oxide sensor The seven standard types of fuels that can be selected are e Natural Gas e Oil 2 e Oil 4 e Oil 6 e Kerosene e Propane e Coal The PCA continuously monitors flue gas exhaust conditions and updates the above displayed values during a combustion test If the analyzer is equipped with an optional pressure sensor then draft measurements can be made simultaneously with the combustion test or made separately The analyzer has the capability of storing data that was collected during a combustion test or draft measurement The stored data can then ata later date be either viewed on the PCA s display printed using an op tional printer or downloaded to a computer 1 2 Instruction 0024 9219 PCA Introduction 1 3 PCA Model Configurations TABLE 1 1 PCA SENSOR CONFIGURATIONS PCA Models Sensors Installed Standard PCA Part No PCA Part No Stack Temp Mode 4 Mode 4 ir Temp amp 10 40 15 45 20 50 25 55 30 6
5. 9 10 35PM 2 24 1999 C2 co CF NX NF O2R EF EA DR MB PA WC 9 5 12 13 10 11 3 82 2 21 0 25 WC 0 25 WC Line 1 Column Headings Line 2 Typical Combustion Readings Line 3 Typical Draft Readings 4 16 Instruction 0024 9219 PCA Operation 4 12 ID Setup Screens For Advanced PCA Models 40 45 50 55 60 amp 65 SETUP ID 1 ID 2 ID 3 This initial ID Setup Screen is displayed by repeatedly pressing the menu key from the Combustion Test Screen Use this screen to edit three lines of customer information e g the customer s name location and burner reference number Each ID line can be up to 16 alphanumerical characters in length All three lines will appear at the top of each test record for the purpose of identifying individual tests Front Panel Key Functions for the Initial ID SETUP Screen Move cursor z upward Move cursor z downward ENTER Select ID Number that is next to the cursor for editing Go to Combustion Test Screen MENY Go to Temperature Setup Screen AHO To enter a line of text first use the st keys to position the cursor z in front of the desired ID line then press enter The selected ID Line Number Screen will then appear SETUP ID 1 lt lt Now press the st keys until the desired letter or number is displayed Available characters in
6. C Any attempt to calibrate outside this range will cause the analyzer to display the message BAD CALIBRATION ENTRY 5 4 Instruction 0024 9219 PCA Calibration 5 5 Calibrate TS Span Material Required e Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F Procedure 1 With the analyzer turned off first plug the simulator s K type connec tor into the T STACK jack Figure 3 2 then turn on the analyzer and wait for its warm up cycle to complete 2 Enter the Calibration Menu Screen per Section 5 3 then choose TS SPAN to span the analyzer s stack temperature channel 3 Set the simulator to 575 F 302 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and enter keys to enter an APPLIED value that equals 575 F 302 C Typical Calibrate TS Span Screen During Calibration Procedure CALIBRATE TS SPAN MEASURED 595 0 F APPLIED 0575 0 F 4 Press the run key to calibrate the analyzers MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The TS Span calibration range is 518 626 F 270 330 C Any attempt to calibrate outside this range will cause the analyzer to display the message BAD CALIBRATION ENTRY Instruction 0024 9219 5 5 Calibration PCA 5 6 Calibrate TA Zero Material Required e Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F P
7. Calibration PCA 5 2 Calibration Fixtures A gas and a draft fixture will be required to perform the various calibra tion procedures described in this manual Material Required e Calibration Kit Refer to Section 8 2 e Calibration Gas Cylinder Refer to Section 8 2 e Bellows e Micromanometer Procedure Assemble the appropriate fixture shown in Figure 5 1 as required by the calibration procedure being performed GAS Leave Top gt FIXTURE gt Ron Open E mT 1 Gas Cylinder 2 Regulator 3 Tubing 4 Tee 5 Flowmeter 6 Fitting Gas 7 Fitting Draft Contained in Calibration Kit DRAFT FIXTURE Bellows Micromanometer gt Figure 5 1 Calibration Fixtures 5 2 Instruction 0024 9219 PCA Calibration 5 3 Calibrate Menu Screen lt TS ZERO CALIBRATE TS SPAN NX TA ZERO CO TA SPAN DRAFT The Calibrate Menu Screen is displayed after entering either the correct password in the Calibration Password Screen for standard PCAs or the Maintenance Password Screen and selecting CALIBRATION from the Maintenance Screen for advanced PCAs refer to Sections 4 19 and 4 20 Use this screen to select the sensor to be calibrated Press the st keys until the cursor z is in front of the desired function and then press the enter key NOTE 7S is the stack temperature
8. RS232 The Printer Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen Use this screen to choose the type of connection and printer being used IR HP Infrared connection to a printer manufactured by Hewlett Packard which uses their proprietary infrared communica tions protocol IR IRDA Infrared connection to a printer that uses a standard IrDA protocol RS232 Cable connection between the PCA and any serial printer capable of 9600 baud operation Use the st keys to move the cursor z in front of the desired connection and printer and then press the enter key to make the selection and return to the Combustion Test Screen Front Panel Key Functions Move cursor z up Move cursor z down ENTER Select connection and printer next to cursor Go to Combustion Test Screen MENU Go to Calibration Maintenance Password Screen HHDIE Instruction 0024 9219 4 25 Operation PCA 4 20 Calibration Maintenance Password Screen PCA models 10 thru 35 PCA models 40 thru 65 CALIBRATION MAINTENANCE PASSWORD XXX PASSWORD XXX Where xxx Password number The Calibration Maintenance Password Screen is displayed by repeat edly pressing the menu key from the Combustion Test Screen From here a three digit password must be entered to access the PCA 10 thru 35 s Calibration Menu Screen Section 5 3 or a PCA 40 thru 65 s Mainte na
9. in front of the desired memory location then press the enter key The saved data is now displayed in either the Combustion Test Screen or Draft Screen depending on whether the chosen memory location contains combustion or draft information To print the saved data refer to Sec tion 4 23 After viewing or printing the saved data use the st keys to move the cursor z to the exit E function then press enter This will redisplay the memory directory Selecting the CLEAR MEMORY function displays the Clear Memory Screen from where all saved data can be erased refer to Section 4 24 Front Panel Key Functions Move cursor z up Move cursor z down DHH ENTER Display the data saved at the chosen memory location RUN Goto Combustion Test Screen MENY Goto Memory To PC Screen for Advanced analyzers or the Temperature Setup Screen for Basic analyzers Instruction 0024 9219 4 13 Operation PCA 4 11 Memory to PC Screen For Advanced PCA Models 40 45 50 55 60 amp 65 MEMORY TO PC TRANSMIT DATA CLEAR MEMORY The Memory To PC Screen is displayed by repeatedly pressing the menu key from the Combustion Test Screen Use this screen to either transmit all stored memory locations to a computer or clear a memory locations TRANSMIT DATA Before data can be transmitted to a personal computer the PCA s RS 232 output must first be connected to an unused c
10. 7 Reassemble the analyzer then allow the sensor to be connected in the circuit for at least 7 hour before continuing 8 Place the analyzer in an area of fresh air and turn it ON 9 Calibrate the analyzer per Section 5 0 6 10 Instruction 0024 9219 PCA Maintenance 6 8 1 Replacing the Carbon Monoxide Sensor Filter To increase the life of the Carbon Monoxide sensor it is recommended its red filter be replaced once a year Procedure 1 Remove the Carbon Monoxide sensor per Section 6 8 2 Pry the red filter from the Carbon Monoxide sensor and replace it with a new one 3 Reinstall the sensor Instruction 0024 9219 6 11 Maintenance PCA 6 9 Replacing the Pump Assembly Replace the Pump Assembly if it is found to be defective Equipment Required e 1 3 Flat Blade Screw Driver e No 1 Phillips Screw Driver e Pump Assembly Refer to Section 8 1 Procedure 1 Remove the analyzer s rear case and lay it aside refer to Section 6 2 2 Remove the two self tapping Phillips screws holding the Pump Assem bly See Figure 6 2 3 Unplug the pump connector from the printed circuit board slide off the two hoses from the pump noting their orientation then remove the entire assembly 4 Install the new assembly and reassemble the analyzer in the reverse order of disassembly 6 12 Instruction 0024 9219 PCA Troubleshooting 7 0 TROUBLESHOOTING 7 1 Analyzer Repair It is recommended that fie
11. Return to Maintenance Screen BB To enter text first use the st keys to position the cursor z in front of the desired line number then press Enter The selected User Name Line Number Screen will then appear USER NAME LINE 1 lt A Now press the st keys until the desired letter or number is displayed Available characters include space ABCDEFGHIJKLMNOPQRSTUVWXYZ0123456789 4 28 Instruction 0024 9219 PCA Operation Press EnTeR to save the selected character and advance to the next posi tion If you make a mistake press ENTER until the cursor is over the wrong character and make your correction by again using the st keys After all the desired characters have been selected press run to save the text line and return to the initial User Name Screen Front Panel Key Functions for Individual User Name Screens Increment character Y Decrement character Jr ENTER Select the displayed character and advance to the next character position RUN Save the text line and return to the initial User Name Screen MENU Abort any changes to the text line and return to the initial User Name Screen 4 23 Saving Test Data O2 4 0CO 12 HLD DRAFT C2 9 5NXK 15 NG DRAFT 0 25 WC TA 68 0 TS 374 P HOT SPOT 374 F P EF 82 6 EA 21 lt S S To save the data displayed in either the Combustion Test or Draft Screen first use the s t keys to move the
12. Toggle cursor z position Toggle cursor z position ENTER Select function next to cursor Dae RUN Goto Combustion Test Screen MENU Go to ID Setup Screen 3 Instruction 0024 9219 4 15 Operation PCA TABLE 4 1 COMMA DELIMITED FIELDS Field Data Name or Value Label in Column Headings 1 Instrument serial number SN 2 ID line 1 up to 16 characters ID1 3 ID line 2 up to 16 characters ID2 4 ID line 3 up to 16 characters ID3 5 Time of test hh mm ss TIME 6 Date of test dd mm yyyy DATE 71 Name of fuel up to 16 characters FUEL 81 Flue gas temperature TS 91 Air temperature TA 101 Temperature unit of measure F or C C F 111 O concentration in 02 121 CO concentration in C2 1312 CO concentration in ppm CO 1412 CO referenced to nn O in ppm CF 1513 NO concentration in ppm NX 1613 NO referenced to nn O in ppm NF 171 2 O Reference used in fields 14 and 16 O2R 181 Combustion efficiency in EF 191 Excess air in EA 20 Draft measurement DR 21 Draft unit of measure MB PA WC 1 Empty data field for draft tests 2 Empty data field for PCA Models 10 15 40 and 45 3 Empty data field for PCA Models 10 15 20 25 40 45 50 and 55 TABLE 4 2 TYPICAL SPREADSHEET FOR A PCA 65 SN ID1 ID2 ID3 TIME DATE FUEL TS TA C F 02 AX1020 ID LINE1 IDLINE2 IDLINE3 9 03 27PM 2 24 1999 NATGAS 374 68 F 4 AX1020 ID LINE1 IDLINE2 IDLINE3
13. cursor z in front of the save S function and then press the enter key The displayed data will be saved in memory and can be recalled at a later time for viewing from the Memory Directory Screen Section 4 10 NOTE Data will be automatically stored in the next free memory location After all memory locations are filled any additional data that is saved will start overwriting data starting at the first memory location Instruction 0024 9219 4 29 Operation PCA 4 24 Printing Test Data O2 4 0CO 12 HLD DRAFT C2 9 5NXK 15 NG DRAFT 0 25 WC TA 68 0 TS 374 P HOT SPOT 374 F P EF 82 6 EA 21 S S Before printing ensure that the correct connection and printer has been selected per Section 4 19 The Print function is available in either the z Combustion Test Screen or the Draft Screen NOTE The data which is stored in memory can also be printed First go to the Memory Directory Screen Section 4 10 and display the data to be printed then print the data as de scribed below D O When using an infrared printer 1 Place analyzer in line with the printer s IR input see Figure 4 5 2 Use the st keys to move the cursor z in front of the print P function 3 Press the enter key to start printing 4 3O 4 S 88 Figure 4 5 Aligning the Prin
14. of gas to the analyzer resulting in incorrect readings and calculations NOTE An analyzer that is used to sample natural gas furnaces normally requires less frequent cleaning than an analyzer used to sample oil or coal fired furnaces Equipment Required e Alcohol e Aerosol can of Automotive Carburetor Cleaner e Clean Rag e Source of Compressed Air optional Procedure 1 Remove the rubber tubing from the barbed fitting s on the probe handle Figure 3 2 CAUTION Carburetor cleaner attacks plastic components Take precau tions not to spray cleaner onto the probe handle or analyzer 2 Insert the plastic spray tube of the carburetor cleaner into the barbed fitting s of the probe handle then liberally spray carburetor cleaner through the probe 3 After spraying remove all the residual cleaner by repeatedly flushing the probe with alcohol 4 Wipe off the surfaces of the probe and tubing with a clean rag 5 Allow the parts to dry completely If available blow compressed air through the probe to expedite the drying process 6 Reassemble the parts of the probe assembly 6 4 Instruction 0024 9219 PCA Maintenance 6 4 Water Trap Filter Assembly Maintenance The Water Trap Filter Assembly removes water condensate from the gas sample and also prevents soot from contaminating the internal compo nents of the analyzer Drain the water condensate after every use Procedure 1 Pull off the end c
15. to 100 C 4 to 212 F Flue Gas thermocouple is not connected or is outside the range of 20 to 1200 C 4 to 2192 F Outside the range of 3 to 3 inches of water column 7 5 to 7 5 mb Battery voltage has dropped below 3 9 volts The instrument will shut off when battery voltage drops below 3 5 volts An attempt was made to enter a calibration value that was outside the analyzer s accept able limits Not calculated O above 16 or stack temperature above 1000 C 1832 F Sensor not installed or sensor error Overrange numeric 7 2 Instruction 0024 9219 PCA Troubleshooting 7 3 Troubleshooting Guide The following table lists the most common analyzer faults causes and remedies For help with any problem not discussed here please contact the nearest Bacharach Service Center per Section 8 3 TABLE 7 1 TROUBLESHOOTING GUIDE Fault Probable Cause amp Remedy Analyzer completely nonfunc tional won t turn on when the on orF key is pressed a Batteries dead Replace batteries per Section 3 2 b Loose battery connector Disas semble analyzer and ensure that the battery connector is attached to the printed circuit board c Microprocessor needs to be reset Press RESET button Fig 4 7 d Optional Power Supply defective Replace Power Supply e Analyzer defective Return to Bacharach for repair Display Screen is blank when analyzer is t
16. 0 35 65 PCA 10 amp 40 These basic instruments have the capability of measuring displaying and storing combustion tests They will also display flue gas Oxygen content flue gas Carbon Dioxide CO2 content air temperature flue gas temperature combustion efficiency excess air and the current fuel selected The standard PCA 10 stores up to 10 combustion tests while the advanced PCA 40 can store up to 100 tests PCA 15 amp 45 with Draft In addition to the features of the basic PCAs described above these instru ments have the added capability of measuring displaying and saving draft or differential pressure in either Millibars Pascals or Inches of Water Column PCA 20 amp 50 with Carbon Monoxide Measurement In addition to the features of the basic PCAs described above these instruments have the added capability of measuring displaying and saving Carbon Monoxide CO content as well as calculating a CO level that is referenced to Oxygen The standard PCA 20 calculates CO refer enced to 0 Oxygen while the advanced PCA 50 calculates CO refer enced to a user selected Oxygen level of between 0 15 PCA 25 amp 55 with Draft and CO Measurement These instruments combine the features of all the PCAs listed above Instruction 0024 9219 1 3 Introduction PCA PCA 30 amp 60 with CO and Nitric Oxide Measurement In addition to the features of the basic PCAs w
17. 15 NG C2 9 5 NX 10 NG TA 68 0 TS 374 P TA 68 0 TS 374 P EF 82 6 EA 21 S EF 82 6 EA 21 S OR This screen shows O2 n Oxygen content in flue gas O2 4 0 CF 15 HLD C2 aranan Carbon Dioxide content Ce 9 5 NF 12 NG present in flue gas TA 68 0 TS 374 P TA crescas Primary Ambient air temp F EF 82 6 EA 21 S EP seated Combustion efficiency COP peser Carbon Monoxide content in flue gas ppm CF oe Carbon Monoxide content referenced to a percentage of O2 ppm TS ponens Stack Flue gas temperature F EA eanna Excess air NX F rnanan Nitric Oxide content in flue gas ppm NF oo Nitric Oxide content referenced to a percentage of O2 ppm HLD RUN PCA on hold PCA running test NG 0 ee Fuel code for natural gas see Section 4 8 for other codes Pe senan Print Data O ireren Save Data For PCA models 30 35 60 and 65 you have the option of displaying either CO amp NX or CF amp NF Refer to Section 4 17 for setup instructions NOTE Refer to Section 7 3 if stars dashes or Xs xxxx appear in the display Front Panel Key Functions Move cursor z up Move cursor z down ENTER Save or print screen data fcc RUN Run test hold test MENU Go to Fuel Selection Screen 7 4 10 Instruction 0024 9219 PCA Operation 4 8 Fuel Selection Screen NATGAS FUEL OIL 2 KEROSENE OIL 4 PROPANE OIL 6 COAL This
18. 7 WC COMMENT Spanish Line 1 user name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data ID2 optional data ID3 optional data HORA 04 27 35 pm FECHA 02 24 1999 COMBUST GNATURL TEMP CHIM 374 F TEMP AMB 68 0 F 02 4 0 co2 9 5 co 12 ppm CO 0 O2 15 ppm NX 10 ppm NX 0 O2 12 ppm EFICIENCIA 82 6 EXCESO AIR 21 DRAFT 0 37 WC COMENTARIO Line 1 user name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data optional data ID3 optional data HORA 05 25 37 pm FECHA 02 24 99 DRAFT COMENTARIO Instruction 0024 9219 B 1 Appendix B PCA NOTES B 2 Instruction 0024 9219
19. ECTA USER NAME USER NAME NOMBRE DEL USUARIO LINE n LIGNE n LINEA n A 4 Instruction 0024 9219 PCA Appendix B APPENDIX B Printout Translations English Line 1 user name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data ID2 optional data IDS optional data TIME 04 27 35 pm DATE 02 24 1999 FUEL NATGAS STACK TEMP 374 F AMB TMP 68 0 F 02 4 0 co2 9 5 co 12 ppm CO 0 O2 15 ppm NX 10 ppm NX 0 O2 12 ppm EFFICIENCY 82 6 EX AIR 21 DRAFT 0 37 WC COMMENTS Line 1 user name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data ID2 optional data IDS optional data TIME 05 25 37 pm DATE 02 24 99 DRAFT DRAFT 0 37 MB COMMENTS French Combustion Test Data Line 1 user name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data ID2 optional data ID3 optional data HEURE 04 27 35 pm DATE 02 24 1999 COMBUST GAZNATU TEMP CHEMI 374 F TEMP AMBIA 68 0 F 02 4 0 cCoO2 9 5 co 12 ppm CO 0 O2 15 ppm NX 10 ppm NX 0 O2 12 ppm EFFICACITE 82 6 EX AIR 21 PRESSION 0 37 WC COMMENT Draft Only Line 1 user name Line 2 user name Line 3 user name BACHARACH INC PCA 65 SN xxxxxx ID1 optional data ID2 optional data IDS optional data HEURE 05 25 37 pm DATE 02 24 99 PRESSION PRESSION 0 3
20. ENTER No Action No Action MENU No Action LIGHT Toggle Backlight ON OFF Turn analyzer OFF aDOHOAE mn The tight button will always turn the backlight on and off while the ON OFF key will always turn the analyzer on and off These two keys will not be mentioned in the remainder of this section 4 Instruction 0024 9219 PCA Operation 4 6 Sensor Status Screen BACHARACH INC PCA xx WARMUP O zm Where xx Instrument Model Number z Sensor s in error If a problem with one or more of the sensors was detected during warmup the Sensor Status Screen will display an error code for those sensors at the bottom of the screen and wait for operator intervention Refer to Section 7 2 for a listing and explaination of the error codes Note that the analyzer will not automatically switch to the Combustion Test Screen if a sensor error was detected The analyzer however can still be used to perform any test that does not depend on the sensor that is in error Press the run key to manually enter the Combustion Test screen to continue using the analyzer Front Panel Key Functions No Action No Action ENTER No Action Go to Combustion Test Screen MENU No Action DADAE Instruction 0024 9219 4 9 Operation PCA 4 7 Combustion Test Screen PCA models 10 thru 25 40 thru 55 PCA models 30 35 60 amp 65 O2 4 0 CO 12 HLD O2 4 0 CO 12 HLD C2 9 5 CF
21. MP SETUP UNIDADES DRAFT SETUP REFERENCIA 02 SETUP PROGRAMME SETUP LANGUAGE LANGUE IDIOMA Display Mode Setup Screen SETUP PROGRAMME SETUP DISPLAY AFFICHER VISUALIZAR A 2 Instruction 0024 9219 PCA Appendix A English French Time Date Setup Screen SETUP PROGRAMME TIME HEURE DATE DATE Printer Setup Screen SETUP PRINTER PROGRAMME PRINTER IR HP IR HP IR IRDA IR IRDA RS232 RS232 Maintenance Password Screen MAINTENANCE MAINTENANCE PASSWORD MOT DE PASSE Maintenance Screen MAINTENANCE MAINTENANCE CALIBRATION CALIBRAGE USER NAME USER NAME Calibrate Menu Screen CALIBRATE CALBRAGE TS ZERO TS ZERO TS SPAN TS PTEE TA ZERO TA ZERO TA SPAN TA PTEE NX NX co co DRAFT PRESSION Calibrate TS Zero Screen CALIBRATE TS ZERO CALIBRER TS ZERO MEASURED MESUREE APPLIED APPLIQUEE BAD CALIBRATION ENTRY ERREUR D ETALONNAGE Calibrate TS Span Screen CALIBRATE TS SPAN CALIBRER TS PORTEE MEASURED MESUREE APPLIED APPLIQUEE BAD CALIBRATION ENTRY ERREUR D ETALONNAGE CalibrateTA Zero Screen CALIBRATE TA ZERO CALIBRER TA ZERO MEASURED MESUREE APPLIED APPLIQUEE BAD CALIBRATION ENTRY ERREUR D ETALONNAGE Spanish SETUP HORA FECHA SETUP PRINTER IR HP IR IRDA RS232 MANTENIMIENTO PASSWORD MANTENIMIENTO CALIBRACION NOMBRE DEL USUARIO CALIBRAR TS CERO TS SPAN TA CERO TA SPAN NX co DRAFT CALIBRAR TS CERO MEDIDO APLICADO CALIBRACION INCORRECTA CALIBRAR T
22. PTED IN LIEU OF I ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE AND Il ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARISING 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 limitation will be binding upon Bacharach Inc unless in writing signed by a duly authorized officer of Bacharach To Register Your Warranty Visit 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 BACHARACH is a registered trademark of Bacharach Inc All other trademarks are the property of their respective owners Copyright 2010 Bacharach Inc all rights reserved A Instruction 0024 9219 PCA Cont
23. S SPAN MEDIDO APLICADO CALIBRACION INCORRECTA CALIBRAR TA CERO MEDIDO APLICADO CALIBRACION INCORRECTA Instruction 0024 9219 A 3 Appendix A PCA English French Calibrate TA Span Screen CALIBRATE TA SPAN MEASURED APPLIED BAD CALIBRATION ENTRY Calibrate NX Screen CALIBRATE NX MEASURED APPLIED BAD CALIBRATION ENTRY Calibrate CO Screen CALIBRATE CO MEASURED APPLIED BAD CALIBRATION ENTRY Calibrate CO H2 Screen TEST GAS CO H2 CO VALUE ENTER CO VALUE BAD CALIBRATION ENTRY Calibrate H2 Screen CALIBRATE H2 MEASURED APPLIED BAD CALIBRATION ENTRY Calibrate DRAFT Screen CALIBRATE DRAFT MEASURED APPLIED BAD CALIBRATION ENTRY User Name Screen CALIBRER TA PORTEE MESUREE APPLIQUEE ERREUR D ETALONNAGE CALIBRER NX MESUREE APPLIQUEE ERREUR D ETALONNAGE CALIBRER CO MESUREE APPLIQUEE ERREUR D ETALONNAGE GAZ TEST CO H2 VALEUR CO ENTRER VALEUR CO ERREUR D ETALONNAGE CALIBRER H2 MESUREE APPLIQUEE ERREUR D ETALONNAGE CALIBRER PRESSION MESUREE APPLIQUEE ERREUR D ETALONNAGE Spanish CALIBRAR TA SPAN MEDIDO APLICADO CALIBRACION INCORRECTA CALIBRAR NX MEDIDO APLICADO CALIBRACION INCORRECTA CALIBRAR CO MEDIDO APLICADO CALIBRACION INCORRECTA GAS PRUEBA CO H2 VALOR DE CO ENTRAR VALOR CO CALIBRACION INCORRECTA CALIBRAR H2 MEDIDO APLICADO CALIBRACION INCORRECTA CALIBRAR DRAFT MEDIDO APLICADO CALIBRACION INCORR
24. SORIES Ambient Thermocouple 10 ft K type 0104 1797 Ambient Thermocouple 1 in K type 0104 1798 Bent Probe Tip 0024 8039 Calibration Kit 0024 7059 Differential Pressure Hose Assembly 0024 1103 Gas Cylinder 500 ppm CO in air 0024 0492 Gas Cylinder 1000 ppm CO amp 1000 ppm H in Nitrogen 0024 0794 Printer Infrared with Manual Batteries and Paper 120 VAC 0024 1229 230 VAC 0024 1230 Printer Paper 1 roll 0024 0887 Power Supply Adapter 110 VAC 0024 0885 Regulated Power Supply Adapter 230 VAC 0024 1209 Serial Communication Cable 0024 1073 8 2 Instruction 0024 9219 PCA Parts amp Service c MN f Figure 8 1 Replacement Parts 1 of 3 Instruction 0024 9219 8 3 Parts amp Service PCA 16 17 Figure 8 1 Replacement Parts 2 of 3 8 4 Instruction 0024 9219 PCA Parts amp Service Figure 8 1 Replacement Parts 3 of 3 Instruction 0024 9219 8 5 Parts amp Service PCA 8 3 Se
25. Spanish BACHARACH INC PCA nn CALENTAMIENTO nn NO ERROR DETECTADO BATERIA BAJA ERROR EN SENSOR 02 ERROR EN SENSOR CO ERROR EN SENSOR DRFT ERROR SENSOR T CHIM ERROR SENSOR T AIRE ERROR EN SENSOR NX ADAGADO EN n SEGS PURGANDO CO SENSOR GN A 2 A 4 A 6 KER GLP CAR COMBUST GNATURAL ACEITE 2 ACEITE 4 ACEITE 6 KEROSINA PROPANO CARBON DRAFT DESCONECTE MANGUERA DE ASPIRACION OPRIMA ENTER RECONECTE MANGUERA DE ASPIRACION HOT SPOT Instruction 0024 9219 Appendix A PCA English French Saving Memory Screen SAVING MEMORY GARDE LOCATION LOCATION nn MEMOIRE nn Memory Directory Screen MEMORY DIRECTORY LISTE MEMOIRE MEMORY EMPTY MEMOIRE VIDE CLEAR MEMORY EFFACER MEMOIRE Draft Memory Screen DRAFT MEM PRESSION MEM DRAFT PRESSION Clear Memory Screen CLEAR MEMORY EFFACER MEMOIRE Memory to PC Screen MEMORY TO PC MEMOROIRE A PC TRANSMIT DATA TRANSM DONNEES CLEAR MEMORY EFFACER MEMOIRE ID Setup Screen SETUP PROGRAMME IDn IDn Temperature Setup Screen SETUP PROGRAMME TEMPERATURE UNIT UNITE DE TEMP Draft Setup Screen SETUP PROGRAMME DRAFT UNIT UNITE DE PRESS O Reference Setup Screen SETUP PROGRAMME 02 REFERENCE REFERENCE A 02 Language Setup Screen Spanish SALVANDO EN MEMORIA LOCALIZACION nn DIRECTORIO MEM MEMORIA VACIA BORRAR MEMORIA MEMORIA DRAFT DRAFT BORRAR MEMORIA MEMORIA AL PC TRANSMITIR DATOS BORRAR MEMORIA SETUP IDn SETUP UNIDADES TE
26. The Measurable Difference Portable Combustion Analyzer PCA Instruction 0024 9219 Operation amp Maintenance Rev 10 May 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 year 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 or 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 Bacharach to the replacement of this Product or parts thereof that are defective in title THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCE
27. ap from the Inlet End of the Water Trap Filter Assembly Figure 6 3 2 Pour out all of the water condensate and replace the end cap Replace the filter element when it becomes excessively dirty Equipment Required e Filter Element Refer to Section 8 1 Procedure 1 Pull off the end cap from the Outlet End of the Water Trap Filter Assembly Figure 6 3 2 Remove and discard the old filter element 3 Install a new filter element and replace the end cap Figure 6 3 Water Trap Filter Assembly Instruction 0024 9219 6 5 Maintenance PCA 6 5 Replacing the Particulate Filter The internal particulate filter Figure 6 2 prevents small dust and dirt particles from entering and damaging the pump Depending on your environmental conditions it is recommended to change the particulate filter and fitting approximately every six months or sooner if it becomes clogged Equipment Required e Particulate Filter and Fitting Refer to Section 8 1 Procedure 1 Remove the analyzer s rear case and lay it aside refer to Section 6 2 2 Carefully pull off the 1 8 ID tubing from the filter and fitting Note the orientation of tubing and fitting before removing 3 Remove and discard the old filter and fitting and replace with new ones Be careful not to not pinch the tubing during reassembly 4 Reassemble the analyzer in the reverse order of disassembly 6 6 Instruction 0024 9219 PCA Maintenance
28. cceeeeseeeeeeteeeseneeeeees 4 5 4 3 5 Turning Off the Analyzer and Purging the CO Sensor 4 6 4 4 Differential Pressure Measurement cceeeeeceeeeeteeeeeneeeees 4 7 4 5 Warm Up Screen cccecceecceeceneeeeeeeeeceaeeeeaeeeseaeeeeseaeeeseaeeeeeaeeees 4 8 4 6 Sensor Status Screen cccecccce cee eeeeeeeeeeeeeeeeeeseaeeeeeeeeeseaeeeseaes 4 9 4 7 Combustion Test Screen ccccccceecceeseeeeeeeeeeeseaeeeeeeeessaeeeeenees 4 10 4 8 Fuel Selection Screen cccceeeeeceeeeeeeeeeeeeeeaeeeeeeeeeeeaeeeeneeeees 4 11 4 9 Draft SCre Ns arinina a a e aa paad a ia an 4 12 4 10 Memory Directory Screen sssssesseserssressrrersresrrrsrrrrsrressrens 4 13 4 11 Memory to PC Screen ssssesssessesssrsssesssirrssrrnesrnssrrnrensssnes 4 14 4 12 ID Setup Screens 0 eee cece eeeeeeeeeeeteeeeeeseaaeeeseneeesaeeseeneees 4 17 4 13 Temperature Setup SCreen eeceeeseeeceeeeeeeeeeeeeeeeeeeeeees 4 19 4 14 Draft Unit Setup Screen 0 eecee cc ee ceeeeceeceeeeeteeeeeteeeeeaeees 4 20 4 15 OzReference Setup Screen cccecceeeceeeeeeeeeeeeeeeeeeeeeeeeeees 4 21 4 16 Language Setup Screen ccecccceccceeeeeeeeeeeeeeeeeneeeesaeeeteneees 4 22 4 17 Display Mode Setup Screen 0 ccceeeeeeeeeeceeeeeeeeeeseeeeeeeeees 4 23 4 18 Time Date Setup SCreen ecccceccceeeeeeeeeeeeeeeeeeseeeeeeetaaeeee 4 24 4 19 Printer Setup Screen 0 eee eeeeee cee eeeeeeee cee eeeeeeeeeseaeeeeeeeeees 4 25 4 20 Calibration Maint
29. clude space ABCDEFGHIJKLMNOPQRSTUVWXYZ0123456789 Instruction 0024 9219 4 17 Operation PCA Press ENTER to save the selected character and advance to the next posi tion If you make a mistake press ENTER until the cursor is over the incorrect character and make your correction by again using the st keys After all the desired characters have been selected press the run key to save the text line and return to the initial ID SETUP Screen NOTE The entered ID information will be saved with all future test records until it is modified or deleted Front Panel Key Functions for the Individual ID SETUP Screens ENTER MENV 39 006 Increment character Decrement character Select the displayed character and advance to the next character position Save the text line and return to the initial ID SETUP Screen Abort any changes to the text line and return to the initial ID SETUP Screen 4 18 Instruction 0024 9219 PCA Operation 4 13 Temperature Setup Screen SETUP TEMPERATURE UNIT C CA The Temperature Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen Use this screen to setup the analyzer to display temperature in either C or F To select the temperature unit of measure first use the st keys to move the cursor z in front of C or F and then press the enter key Front Panel Key Functions Move cursor z up Mov
30. d causes the cursor to advance to the next field position in screens requiring multiple alphanumeric entries RUN Starts and stops a combustion test when the Combustion Test Screen is displayed Pressing this key in any other screen almost always returns the instrument to the Combustion Test Screen However there are four situations where this key behaves as an enter key 1 After entering a correct password in the Password Screen press the run key to display the first calibration screen 2 After entering an offset or span value in any of the Calibration Edit Screens press the run key to store the new values 3 After entering a time or date value in the Time Date Setup Screen press the run key to store the new values and return the cursor to the left side of the display 4 After entering text in either the ID Setup or User Name Screens press the run key to store the text MENU Advances the display to the next menu screen LIGHT Turns the screen s backlight ON and OFF Gt Instruction 0024 9219 4 1 Operation PCA 4 2 Sampling Hole Location The analyzer requires that a 1 2 diameter sampling hole be made in the furnace stack to accommodate the probe stop on the Probe and Hose Assembly Locate the sampling hole downstream from the last heat exchanger and upstream from any source of dilution such as a draft diverter Figure 4 1 Important As the distance between the last heat exchanger and sampling point increas
31. e NX sensor 2 At the conclusion of Step 1 the pump should start running 3 Using the Gas Fixture shown in Figure 5 1 attach the Nitric Oxide calibration gas cylinder to the analyzer s GAS inlet 4 Adjust the regulator of the calibration fixture for a flowmeter indica tion of approximately 2 SCFH 5 Wait until the MEASURED reading on the screen stabilizes approxi mately 3 minutes Then use the st and enter keys to enter an APPLIED value that equals the concentration that is stamped on the NX calibration gas cylinder Typical Calibrate NX Screen During Calibration Using 100 ppm Nitric Oxide Calibration Gas CALIBRATE NX MEASURED 092 PPM APPLIED 0100 PPM 6 Press the run key to calibrate the analyzer s MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The NX calibration range is 50 150 ppm Any attempt to calibrate outside range will cause the analyzer to display the message BAD CALIBRATION ENTRY 5 8 Instruction 0024 9219 PCA Calibration 5 9 Calibrate CO For PCA Models 20 25 30 35 50 55 60 amp 65 Material Required e Calibration Gas Fixture Section 5 2 e Gas Cylinder 500 ppm CO in air Refer to Section 8 2 e Gas Cylinder CO 1000 ppm and H 1000 ppm in Nitrogen Refer to Section 8 2 Procedure 1 Enter the Calibrate Menu Screen per Section 5 3 Then choose to calibrate the CO sensor Atthe concl
32. e analyzer off initiates a 5 second delay during which time the unit can be turned on again without any warm up time Press the Run key to turn the analyzer back on during this 5 second delay 4 6 Instruction 0024 9219 PCA Operation 4 4 Differential Pressure Measurement The difference in pressure AP between two areas can be measured by using the PCA s two pressure ports and DRAFT Screen By using Pres sure Port 2 as the reference the pressure applied to Port 1 will be displayed on the DRAFT Screen as the differential pressure between the two ports 1 Turn on the analyzer by pressing the on off key wait for the warm up cycle to complete then press the MENU key until the first DRAFT Screen is displayed refer to Section 4 9 If a TA SENSOR ERROR is displayed as the result of the probe s thermocouple not being plugged into the analyzer press the RUN key to acknowledge the error before pressing the MENU key 2 While the first DRAFT Screen is displayed remove any hoses con nected to Pressure Ports 1 and 2 then press the ENTER key to zero these ports to atmospheric pressure 3 Connect two sampling hoses to Pressure Ports 1 and 2 Figure 4 3 Then place the open end of each hose into the areas being measured 4 The differential pressure between the two areas is now displayed on DRAFT the third DRAFT Screen If the DRAFT 0 95 WC pressure at Port 1 is higher than HOT SPOT C P Port 2 then t
33. e analyzer per Section 5 0 Instruction 0024 9219 6 1 Maintenance PCA 6 2 Disassembly Perform the following when a maintenance procedure calls for removing the case printed circuit board pump or sensors 1 Remove the batteries Section 3 2 1 2 Place the analyzer face down on a work surface then remove the unit s four rear case screws 3 Carefully lift the rear case from the analyzer unplug the battery compartment wires then place the rear housing on a work surface see Figures 6 1 amp 6 2 4 2 g g G gpn na Cc C Ji C H Figure 6 1 Disassembling the Analyzer Instruction 0024 9219 PCA Maintenance TO BATTERY BIAS COMPARTMENT BATTERY NX PCB CARBON NITRIC MONOXIDE OXIDE SENSOR SENSOR OPTIONAL OPTIONAL PUMP MTG OXYGEN SCREWS SENSOR PUMP PARTICULATE FILTER DRAFT SENSOR OPTIONAL Figure 6 2 PCB and Sensors Instruction 0024 9219 6 3 Maintenance PCA 6 3 Cleaning the Probe The Probe Tube and the Probe Body will become dirty under normal use the water trap s filter element should prevent soot from reaching the analyzer s internal components If the probe assembly is not kept clean it could become clogged and restrict the flow
34. e cursor z down Select unit of measure next to cursor HDD RUN Go to Combustion Test Screen MENU Goto Draft Unit Setup Screen for PCAs with a pressure sensor or the O Reference Screen for Advanced PCAs that have an NX and or CO sensor or the Language Setup Screen for all other PCAs Instruction 0024 9219 4 19 Operation PCA 4 14 Draft Unit Setup Screen For PCA Models 15 25 35 45 55 amp 65 DRAFT UNIT MB The Draft Unit Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen Use this screen to setup the analyzer to display draft in either millibars MB Pascals PA or inches of water column WC To select the draft unit of measure first use the st keys to move the cursor z in front of MB PA or WC and then press the enter key Front Panel Key Functions Move cursor z up Move cursor z down ENTER Select unit of measure next to cursor Go to Combustion Test Screen Bene MENU Go to O Reference Setup Screen for Advanced PCAs that have an NX and or CO sensor or the Language Setup Screen for all other PCAs 4 20 Instruction 0024 9219 PCA Operation 4 15 O Reference Setup Screen For Advanced PCA Models 50 55 60 and 65 SETUP O2 REFERENCE O0 The O Reference SETUP Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Scr
35. e parameters however can be changed by following the instructions in their associated sections Function Parameters To Change Refer to Fuel Natural Gas Section 4 8 Temperature C Section 4 13 Draft WC Section 4 14 Oxygen Reference 0 Section 4 15 Language English Section 4 16 Display Mode CO amp NX Section 4 17 Time HR MIN SEC AM PM Section 4 18 Date MM DD YY Section 4 18 3 4 Instruction 0024 9219 PCA Operation 4 0 OPERATION 4 1 Key Pad Functions Descriptions of the key pad functions are given below Note that most of the front panel key pad buttons perform multiple functions as determined by what screen is being displayed at the time OFF delay that allows an operator to turn the instrument back ON by pressing the run key This feature prevents the accidental loss of test data if the analyzer is turned OFF by mistake Moves the cursor z in front of a menu item up through the displayed items This key also increases alphanumeric values in screens requiring a value change S Turns the analyzer ON and OFF Note that there is a 5 second OFF Moves the cursor z in front of a menu item down through the displayed items This key also decreases alphanumeric values in screens requiring a value change c gt Chooses the highlighted item the item with the cursor z in front e of it in all menus and screens This key also causes the cursor to enter the number field in the Password Screen an
36. e sensor is sufficiently stable after 4 hours for measurement purposes Bias removed for Stabilization time LessthantS min Lessthan Hnin Less than 1 hr Less than 5 min Less than 2 days Less than 4 hr Greater than 2 days Up to 2 days Instruction 0024 9219 6 9 Maintenance PCA 6 8 Replacing the Carbon Monoxide Sensor For PCA Models 20 25 30 35 50 55 60 amp 65 Replace the Carbon Monoxide sensor when it has expired can no longer be calibrated NOTE A CO SENSOR ERROR displayed in the Sensor Status Screen does not necessarily mean that the sensor has expired Before replacing the sensor refer to Section 7 2 for other possible causes of the error Equipment Required e 1 3 Flat Blade Screw Driver e Carbon Monoxide Sensor Refer to Section 8 1 e Carbon Monoxide Sensor Filter Refer to Section 8 1 Procedure 1 Remove the analyzer s rear case and lay it aside refer to Section 6 2 2 Carefully pull the printed circuit board off the rear of the Carbon Monoxide sensor see Figure 6 2 3 Push in and turn the sensor counterclockwise watching the notch on top until it stops then pull the sensor out of its housing 4 Remove the wire jumper from the pins of the new sensor 5 Install the new sensor by first pushing the sensor into its housing and then turning clockwise until it locks in place 6 Install the circuit board which was removed in Step 2 onto the rear of the sensor
37. een Use this screen to select the O reference level that the analyzer will use to calculate the CO and NX gas levels as referenced to Oxygen NOTE The O reference level for standard PCA models 20 25 30 and 35 is preset to 0 Oz and cannot be changed For PCAs with just a CO sensor the Combustion Test Screen can show both the measured level of CO and its calculated level referenced to Oxygen displayed as CF For PCAs with both CO and NX sensors the Combustion Test Screen can only show either the measured levels of CO and NX or their calculated levels referenced to Oxygen displayed as CF and NF respectively Refer to Section 4 17 for set up instructions To select the analyzer s Oxygen reference level press the st keys until the desired level is displayed and then press the ENTER key Front Panel Key Functions a Increment O Reference 15 max Y Decrement O Reference 0 min ENTER Select O Reference RUN Goto Combustion Test Screen Go to Language Setup Screen fs 4 Instruction 0024 9219 4 21 Operation PCA 4 16 Language Setup Screen SETUP LANGUAGE ENG ESP FRA The Language Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen Use this screen to select the language displayed on the analyzer The languages available for selection include English ENG Spanish ESP and French FRA To select a language first
38. ees 8 1 8 2 ACCOSSOMES i Avene cling tet cn Av td de en ee 8 2 8 3 Service Centers cceeecceeceeeeeeeneeeeecaeeeeaaeeeeeeeeesaaeeeeeeeeseaeeneneees 8 6 APPENDIX A Display Screen Translations sseceeseesseeeeeeees A 1 APPENDIX B Printout Translations cccsssseeeeeeseeeeeeeeeeeeeeees B 1 il Instruction 0024 9219 PCA Introduction 1 0 INTRODUCTION 1 1 The Portable Combustion Analyzer The Portable Combustion Analyzer PCA Figure 1 1 is a commercial grade hand held combustion efficiency analyzer that is designed for continuous on demand sampling of light industrial and residential furnaces appliances and boilers The basic instrument is supplied with a probe instruction manual batteries and carrying case Ulale B Figure 1 1 PCA Instruction 0024 9219 1 1 Introduction PCA 1 2 Displayed Data The PCA directly measures displays and stores the following data e Room Temperature in F or C Primary Air Ambient Temperature e Flue Gas Oxygen Content in e Flue Gas Temperature in F or C e Flue Gas Carbon Monoxide Content H Compensated in ppm For analyzers having a Carbon Monoxide sensor e Flue Gas Nitric Oxide content in ppm For analyzers having a Nitric Oxide sensor e Pressure Draft in Millibars Pascals or Inches of Water Column For analyzers having a draft sensor
39. enance Password Screen s 4 26 4 21 Maintenance Screen 00 ccecccceeeeeeeeeeeeeeeeeeeeaeeeteeeeesaaeeneneeees 4 27 Instruction 0024 9219 i Contents PCA 4 22 User Name Screens cccecccececeeeeeceeeeceeeeeeaeeeeeeeeseeaaeeneneeees 4 28 4 23 Saving Test Data eecccccceeeeeeeeeceeeeeeeeeeeeeaeeeseeeeeseeeeeenaeeees 4 29 4 24 Printing Test Data oo eee ee eeeeeeeeeeeaeeeeeeeeaeeeeeneaaes 4 30 4 25 Clear Memory Screen ccccceceececeeeeeeceeeeeeeeeeeeaeeseneeeeseaeenenes 4 32 4 26 Resetting the MicroproCeSSOl cccsceeeeeeeeeeeeeeesteeeeeeeeaaes 4 32 5 0 CALIBRATION i a a ieee cecccteveltg e rie aae dAdo traa taneb nikt iane Saaai 5 1 5 1 Sensor Check inceesni eaii ia ii adii aiaiai 5 1 5 2 Calibration Fixtures ssessssesesseessisssiissrnssrnssrrnssrnrernnserensrne 5 2 5 3 Calibrate Menu Screen cceecceceeceeeeeeeeeeneeeeeeeeeeeaaeeseeeeeeeeeeeeees 5 3 5 4 Calibrate TS Zero 2 eeeeccccccccceseeeeeeeeeeeeaaeseeeeeesaaeesseneeessaeeeeeneees 5 4 5 5 Calibrate TS Sparn ou cecccecccceceseeeceenceeeeeeeeeesaeeeeeeaeeseaaeeteneeennaas 5 5 5 6 Calibrate TA Zero ccccecccceccteeeeeeeeeeeeaeeeeeeeeseaeeeseaeeeseueeeeeaeeeeaes 5 6 5 7 Calibrate TA Span cccccccecceeeeeeseeeeeeeeeeeeeeseeeeeseaeesecaeeeeeeeeeeas 5 7 5 8 Calibrate NX oeer etaria raitinn ta ae Eea VELANA Eaa peta ATLE PA ARAE ne 5 8 59 Calibrate GOs iwiiia nine a ein Bap acide ees 5 9 5 10 Calibrate Draft 2 2 eccceceeceee
40. ensor 1 4 Instruction 0024 9219 PCA Technical Characteristics 2 0 TECHNICAL CHARACTERISTICS The PCA Directly Measures and Displays e Oxygen content in flue gas in the range of 0 1 to 20 9 O e Flue gas temperature in the range of 0 to 2192 F 18 to 1200 C e Primary air ambient temperature is in the range of 0 to 999 F 18 to 999 C Optional e Differential Pressure and Draft in the range of 28 H2O 70 0 mb e Carbon Monoxide content in flue gas in the range of 0 to 4000 ppm e Nitric Oxide content in flue gas in the range of 0 to 1000 ppm The PCA Computes and Displays When the measured oxygen level is not above 16 0 and the Stack Flue Gas temperature is not above 1832 F 1000 C e Efficiency in the range of 0 1 to 99 9 e Excess Air in the range of 1 to 250 e Carbon Dioxide content in flue gas from 0 1 to a fuel dependent maximum value in percent e Carbon Monoxide content referenced to a percentage of Oxygen in the range of 0 to 9 999 ppm on analyzers equipped with a CO sensor e Nitrix Oxide content referenced to a percenage of Oxygen in the range of 0 to 9 999 ppm on analyzers equipped with a NX sensor Standard Fuels Available for Combustion Calculations e Natural Gas e Oil 2 Oil 4 e Oil 6 e Kerosene e Propane e Coal For the PCA 30 35 60 amp 65 the display can be set up to show either measured values of Carbon Monoxide and Nitric Oxide CO amp NX or sh
41. ents Contents 10 INTRODUCTION 8c cticc e eere a ae pa ar Aora an raen ae e ae iradas audata daitek 1 1 1 1 The Portable Combustion Analyzer ccccccsseeeeereeeetteeeeeees 1 1 te Displayed Da r eee a e ae levees Re tA 1 2 1 3 PCA Model Configurations seeeeeseeeseeeseeseeerrieerirsrriesrrrsssns 1 3 2 0 TECHNICAL CHARACTERISTICS ccccsceeseseeeseeeeseseesesseeeenes 2 1 3 0 SETTING UP THE PCA iiss cn aievcccresecscecceteeeesecevsnncetvecearstuedetstcecntece 3 1 erate e10 0 ever erp Serre ere peer meyer rere ee eer cr rrr ce eee A rere 3 1 3 2 PCAIPOWEM seihattecstenthc Ps oaks h ale epera aeneae the eye aerae Tan aani 3 1 3 2 1 Checking and Replacing the Batteries ce 3 1 3 2 2 Using the Optional Power Supply cccceeeseeeee 3 2 3 3 Connecting the Probe eccccceeeeceeeeeeeeeeeeeeeeeeaeeeeeeeeeesaaeesenes 3 2 3 4 Configuring the POA tiekas feasan ernea Aaa raa Aeria iiaa 3 4 4 0 OPERATION o a aae aa r r aeaa o anaana na aaraa 4 1 4 1 Key Pad Functions v 20 cence cen Aone i a ee 4 1 4 2 Sampling Hole Location 0 c eee cee eeeeeeeeceeeeeeeeeeeseeeeeeaeeeeeas 4 2 4 3 Performing a Combustion Test cceceeeeeeeeeeeeeeeeeeetseeteeees 4 3 4 3 1 Analyzer Turn On and Warm Up eceeeeeeeteeesteeeees 4 3 4 3 2 Installing Probe in the Stack seses 4 4 4 3 3 Starting a Combustion Test cccccceeeeeteeeeeeeeeeeneees 4 5 4 3 4 Ending a Combustion Test cccccc
42. epair Analyzer will not calibrate prop erly a Wrong calibration gas or insuffi cient flow being applied to sensor Ensure your calibration setup is correct b Faulty sensor Replace sensor and recalibrate per Sections 5 0 and 6 0 c Analyzer defective Return to Bacharach for repair 7 6 Instruction 0024 9219 PCA Parts amp Service 8 0 PARTS amp SERVICE 8 1 Replacement Parts Item Description Part No Figure 8 1 1 Battery Cover 0024 0784 2 Screw Case Housing 0501 3824 3 Screw Pump Mounting 0501 3822 8 Oxygen Sensor 0024 0788 9 Carbon Monoxide Sensor 0024 0789 10 Nitric Oxide Sensor 0024 0881 11 Carbon Monoxide Sensor Filter 0024 0863 12 Nitric Oxide Sensor Filter 0024 0862 13 Pump Assembly 0024 3009 14 Fuse 1 25A 250V 0604 2605 15 Battery Nitric Oxide Sensor Bias 0204 0020 16 Particulate Filter 0007 1600 17 Fitting for Particulate Filter 0103 5267 18 O Ring 7mm OD x 1mm wall 0105 5103 19 O Ring 8mm OD x 1mm wall 0105 5102 24 Filter Element white 0007 1644 25 Draft Connector Probe 0024 0878 26 Gas Connector Probe 0024 0877 27 Filter Assembly complete 0024 1107 Instruction 0024 9219 8 1 Parts amp Service PCA 8 2 Accessories Description Part No STANDARD ACCESSORIES Battery AA Alkaline 0204 0004 Complete Probe and Hose Assembly Gas amp Draft 0024 3004 Instruction Manual 0024 9219 Plastic Carrying Case 0024 1078 OPTIONAL ACCES
43. es stack loss will falsely decrease due to heat loss by convection from the flue or stack For residential and light commercial combustion equipment applications the following recommendations are applicable e Oil Gun Burners Locate sampling hole at least 12 in 30 cm down stream from the furnace breaching and at least 6 in 15 cm upstream from the furnace side of the draft regulator e Gas Burners Locate sampling hole FLUE GAS FLOW at least 6 in 15 cm upstream from Downstream the furnace side of the draft diverter on gas converted units For gas designed equipment the probe may be inserted down into the flue through the draft diverter or hood DRAFT DIVERTER REGULATOR SAMPLE POINT Upstream FURNACE BREECHING Figure 4 1 Sampling Hole Location 4 2 Instruction 0024 9219 PCA Operation 4 3 Performing a Combustion Test Important Large rapid changes in the temperature of the analyzer can affect its accuracy This is important to know if the analyzer is stored in a cold place such as an unheated vehicle in the winter and then taken into a warm furnace area For the most accurate test results allow the analyzer to warm up to room temperature before use about 10 minutes 4 3 1 Analyzer Turn On and Warm Up Important Be sure the probe is at room temperature before performing the following steps 1 Make sure that the analyzer is properly set up per Section 3 0 2 Place pr
44. fective Return analyzer to Bacharach for repair T STACK OR T AIR SENSOR ERROR code appears in the Sensor Status Screen a Calibration was attempted while sampling combustion gases b Thermocouple not connected Connect thermocouple to ana lyzer per Section 3 3 c Thermocouple defective Re place probe assembly d Instrument was exposed to tem peratures outside it s allowable operating range BAD CALIBRATION ENTRY message appears during calibra tion Apply a calibration value that is within the range of the sensor as listed in the calibration procedure 7 4 Instruction 0024 9219 PCA Troubleshooting TABLE 7 1 TROUBLESHOOTING GUIDE Cont Fault Probable Cause amp Remedy ORRKEED appears in one or more value fields The field s associated sensor is not installed appears in one or more value fields of the Combustion Test Screen a The analyzer is not able to calcu late a numerical value based on measured combustion data The ig replaced with numerical values when the analyzer begins to detect valid combustion data b Sensor in error during warm up XXXX appears in one or more value fields Fhe tield s asseciated senseris de tecting a value that is outside the analyzer s detection range XXXX is replaced with numerical data when the analyzer detects values that fall within its range Microprocesso
45. he pressure differ lt lt S ence will be positive But if the pressure at Port 1 is lower then the pressure difference will be negative The reading shown in this example indicates that the pressure at Port 1 is 0 95 H O lower than the pressure at Port 2 Sampling Hoses with quick connect fittings are available as an optional accessory Refer to Section 8 2 Pressure Port 2 Pressure Port 1 Reference Figure 4 3 Differential Pressure Hose Connections Instruction 0024 9219 4 7 Operation PCA 4 5 Warm up Screen BACHARACH INC PCA xx WARMUP yy Where xx Instrument Model Number yy Counts down from 60 seconds As soon as the on off key is pressed the instrument s serial number and software version number are displayed for approximately 3 seconds To continuously display these items hold down the on off key at start up The warmup cycle continues after the on orF key is released The Warmup Screen is displayed during the analyzer s 60 second warmup cycle during which time the Warmup value yy counts down to zero After the warmup cycle is complete and if the unit is working correctly the instrument will flash NO ERRORS DETECTED and go directly to the Combustion Test Screen Section 4 7 If there is a problem however with one or more of the sensors the Sensor Status Screen Section 4 6 is displayed Front Panel Key Functions No Action No Action
46. ith CO measurement these instruments have the added capability of measuring displaying and saving Nitric Oxide NX content as well as calculating a NX level that is referenced to Oxygen The standard PCA 30 calculates NX referenced to 0 Oxygen while the advanced PCA 60 calculates NX referenced to a user selected Oxygen level of between 0 15 PCA 35 amp 65 with Draft CO amp NX These instruments are capable of measuring displaying and saving all measurements as previously described Printout Capability All PCAs have the ability to print the latest test data or any of the saved tests to an optional printer via an infrared link CO Sensor Purge On all PCAs that measure CO if the on orF key is pressed while the CO reading is 100 ppm or higher the analyzer will attempt to purge itself of CO before turning off Advanced PCA Model Features Advanced models of the PCA contain the following features that are in addition to the features of their corresponding standard units e 100 memory locations e RS232 output for transferring saved data to a personal computer e Ability to enter three lines of user identification information which is printed at the top of each printout e Ability to enter three lines of customer identification information which is printed with each test record e Ability to set the Oxygen reference level from 0 to 15 for CO and NX measurements on analyzers equipped with a CO or NX s
47. ld repair of the PCA be limited to e Simple checks of the printed circuit boards e Replacing the Probe Assembly e Replacing the filter element in the Water Trap Filter Assembly e Replacing the Particulate Filter e Replacing the Pump Assembly e Replacing Sensors and Sensor Filters e Replacing Batteries All other repairs should be performed by an authorized Bacharach Ser vice Center Any repairs performed by an unauthorized service organiza tion will void the analyzer s warranty and release Bacharach Inc of any implied or written product liability Before returning your analyzer for repair you may be able to determine and resolve a problem using the Troubleshooting Guide in Section 7 3 Instruction 0024 9219 7 1 Troubleshooting PCA 7 2 Error Codes If one of the following messages or symbols is displayed refer to Section 7 3 Troubleshooting Guide for information on how to correct the error O2 SENSOR ERROR CO SENSOR ERROR NX SENSOR ERROR TA SENSOR ERROR TS SENSOR ERROR DRAFT SENSOR ERROR LOW BATTERY BAD CALIBRATION ENTRY ok k k KD XXXX O Sensor not connected or is expired or was exposed to combustion gases during warmup Carbon Monoxide sensor is expired or was exposed to Carbon Monoxide during warmup Nitric Oxide sensor is expired or was exposed to Nitric Oxide during warm up or the bias battery is dead Room air thermocouple is outside the range of 20
48. le observe that the Sensor Status Screen should no longer show an O sensor error Instruction 0024 9219 6 7 Maintenance PCA 6 7 Replacing the Nitric Oxide Sensor For PCA Models 30 35 60 amp 65 Replace the Nitric Oxide sensor when it has expired can no longer be calibrated NOTE A NX SENSOR ERROR displayed in the Sensor Status Screen does not necessarily mean that the sensor has expired Before replacing the sensor refer to Section 7 2 for other possible causes of the error Equipment Required e 1 s Flat Blade Screw Driver e Nitric Oxide Sensor Refer to Section 8 1 e Nitric Oxide Sensor Filter Refer to Section 8 1 Procedure 1 Remove the analyzer s rear case and lay it aside refer to Section 6 2 2 Carefully pull the printed circuit board off the rear of the Nitric Oxide sensor see Figure 6 2 3 Push in and turn the sensor counterclockwise watching the notch on top until it stops then pull the sensor out of its housing 4 Install a new sensor by first pushing it into its housing and then turning it clockwise until it locks in place 5 Install the circuit board which was removed in Step 2 onto the rear of the sensor 6 Reassemble the analyzer and allow the sensor to be connected in the circuit for at least 4 hours before continuing 7 Place the analyzer in an area of fresh air and turn it ON 8 Calibrate the analyzer per Section 5 0 6 7 1 Replacing the Nitric Oxide Senso
49. linder Typical Test Gas CO H2 Screen During Calibration Procedure TEST GAS CO H2 CO VALUE XXXX ENTER CO VALUE 10 Press the run key to save the CO VALUE and display the Calibrate H2 Screen 11 After calibration gas has been applied for approximately 3 minutes to allow for stabilization use the st and enter keys to enter an APPLIED value that equals the H2 concentration which is stamped on the CO Hp calibration gas cylinder Typical CALIBRATE H2 Screen During Calibration Procedure CALIBRATE H2 MEASURED 1050 PPM APPLIED 1000 PPM 12 Press the run key to calibrate the analyzers MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The Ho calibration range is 500 1500 ppm any attempt to calibrate outside this range will cause the unit to display the message BAD CALIBRATION ENTRY 5 10 Instruction 0024 9219 PCA Calibration 5 10 Calibrate Draft For PCA Models 15 25 35 45 55 amp 65 Material Required e Calibration Fixture Section 5 2 e Bellows adjustable e Micromanometer Range 8 in HzO column 20 mb Accuracy 0 01 in HO column 0 025 mb Procedure Important n Step 1 do not connect the draft calibration fixture to the analyzer until the Calibrate Draft Screen has been selected and displayed 1 Enter the Calibrate Menu Screen per Section 5 3 Then choose to calibrate the draft sensor 2 With
50. n the Maintenance Password Screen Use this screen to either enter the analyzer s Calibration Menu Screen or User Name Screen To enter the Calibration Menu Screen Section 5 3 use the st keys to position the cursor z in front of CALIBRATION and then press the ENTER key To enter the User Name Screen Section 4 22 use the st keys to position the cursor z in front of USER NAME and then press the enter key Front Panel Key Functions Toggle cursor z position Toggle cursor z position Select function next to cursor HOG RUN Go to Combustion Test Screen MENY No action Instruction 0024 9219 4 27 Operation PCA 4 22 User Name Screens For PCA Models 40 45 50 55 60 amp 65 USER NAME LINE 1 LINE 2 LINE 3 This initial User Name Screen is displayed after selecting USER NAME from the Maintenance Screen Use this screen to either enter or edit three lines of user name information Each user name line can be up to 20 alphanumerical characters in length All three lines will appear at the top of each printout for the purpose of identifying the user or owner of the instrument i e your company s name and address Front Panel Key Functions for Initial User Name Screen Move cursor z upward Move cursor z downward ENTER Select Line Number next to the cursor for editing is RUN Go to Combustion Test Screen Sas MENY
51. nce Screen Section 4 21 The password is provided on the Portable Combustion Analyzer Calibration Password card that was supplied with the analyzer To enter the password first press the ENTER key to move the cursor z into the first number field next press the st keys until the first digit of the password is displayed then press ENTER to advance to the second number field In a similar manner enter the next two password digits Then press the run key after the correct password is entered to display either the Calibration Menu Screen or the Maintenance Screen Front Panel Key Functions A No action or increase value in password number field No action or decrease value in password number field NTER Move cursor z to next position in password number field RUN Go to Combustion Test Screen if cursor is on left side of ne screen or go to either the Calibration Menu or Maintenance Screen if the proper password was entered or return cursor to left side of screen if the wrong password was entered AE MENY Go to Combustion Test Screen if cursor is on left side of screen or return cursor to left side of screen if cursor is inside the password number field 4 26 Instruction 0024 9219 PCA Operation 4 21 Maintenance Screen For PCA Models 40 45 50 55 60 amp 65 MAINTENANCE CALIBRATION USER NAME The Maintenance Screen is displayed after entering the correct password i
52. ner s primary air temperature is not the same as the room temperature then be sure the Optional Room Air Primary Air Thermocouple is installed per Section 3 3 1 With the Combustion Test Screen Section 4 7 displayed and the probe installed in the stack press the run key to start a combustion test 2 Once all sensor readings are displayed A Loosen the thumbscrew on the probe stop B Move the probe in and out of the stack until the highest stack temperature TS reading is obtained C Tighten the thumbscrew to prevent further movement of the probe Alternately the highest stack temperature can be located by display ing the Draft Screen Section 4 9 and adjusting the probe for the highest HOT SPOT reading Note that locating the highest stack temperature is very important for accurate combustion calculations 3 You can now begin burner service procedures The readings on the analyzer change quickly to show changes in burner performance CAUTION With the Water Trap Filter Assembly stood up on its Outlet End do not let water condensate build up beyond the tip of the riser tube The sensors could be damaged if water would enter the analyzer Drain the water condensate after every combustion test refer to Section 6 4 4 Pressing the enter key will save the Combustion Test Screen readings while a test is in progress Moving the cursor z in front of the print P function using the s key and then pressing enter will
53. obe in an area of fresh ambient air then press the analyzer s on OFF key 3 Wait for the analyzer to countdown through its 60 second warm up period then perform one of the following e If no errors were detected during warm up the Combustion Test Screen will be displayed Skip Step 4 and go to Section 4 3 2 e If an error was detected during warm up proceed with Step 4 4 If one or more errors were detected by the analyzer s microprocessor during warm up these errors will be displayed at the bottom of the Sensor Status Screen Section 4 6 Address any problems now per Section 7 2 then repeat this procedure starting with Step 1 NOTE f the error detected is not critical to your test the instrument can still perform any test not using the function disabled by the error Instruction 0024 9219 4 3 Operation PCA 4 3 2 Installing Probe in the Stack 1 After making a sampling hole in the stack Section 4 2 and turning on the analyzer Section 4 3 1 screw the probe stop supplied with the Probe and Hose Assembly into the sampling hole Figure 4 2 2 Insert the probe through the hole in the probe stop then position the probe tip inside the stack near its center Tighten the thumbscrew on the probe stop to secure the probe PROBE STOP THUMBSCREW Figure 4 2 Installing the Probe 4 4 Instruction 0024 9219 PCA Operation 4 3 3 Starting a Combustion Test Important f the bur
54. ocouple into the T STACK jack connector fits in only one way NOTE The PCA has a built in room air thermocouple Perform Step 4 only if the Optional Room Air Primary Air Thermocouple is used 4 Push the Optional Room Air Primary Air Thermocouple into the T AIR jack connector fits in only one way NOTE n order for the PCA to correctly calculate combus tion efficiency when the burner s primary air temperature is not the same as room temperature the primary air tempera ture should be measured using the optional Primary Air Thermocouple Inspect all the hoses for cracks If any hose is defective replace the entire probe assembly Check that the water trap is empty and the filter is not dirty or saturated with water 3 2 Instruction 0024 9219 PCA Setup Power Supply 110V 60Hz 230V 50Hz Optional Flue Gas Thermocouple Flue Gas Hose Water Trap Filter Assembly Flue Gas Hose Reset Button _ Room Air Primary Air Thermocouple Optional Pressure Reference Port Used in the Measurement of Differential Pressure Draft Hose Present only on analyzers equipped with a pressure sensor Probe Tube Adjustable Probe Stop Figure 3 2 Connecting the Probe to the Analyzer Instruction 0024 9219 Setup PCA 3 4 Configuring the PCA The PCA is configured at the factory for the parameters shown below Thes
55. omputer COM port using serial data cable Part No 24 1073 see Figure 4 4 Also a communica tions program i e ProcommPlus Windows 3 x Terminal or Windows 9x Hyper Terminal must be installed and its communications parameters configured for 9600 baud 8 data bits 1 stop bit no parity and no handshaking Figure 4 4 Connecting the Serial Data Cable 4 14 Instruction 0024 9219 PCA Operation Data is transmitted to a computer in ASCII comma delimited format which can be captured as a text file and then opened in most commer cially available spreadsheet programs Note that each data record con sists of 20 fields some of which may be blank for different tests and PCA models as listed in Tables 4 1 amp 4 2 Use the communication software to capture and save the received data as an ASCII text file Consult the software s documentation for detailed instructions on how to perform this procedure To start transmitting data first use the st keys to position the cursor z in front of TRANSMIT DATA and then press the enter key Observe that as PCA downloads its data the word TRANSMITTING appears on the display CLEAR MEMORY To clear all memory locations first use the st keys to position the cursor z in front of CLEAR MEMORY and then press the enter key The Clear Memory Screen will then appear from where all saved data can be erased refer to Section 4 24 Front Panel Key Functions
56. oom air primary air temperature channel 3 Set the simulator to 212 F 100 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and enter keys to enter an APPLIED value that equals 212 F 100 C Typical Calibrate TA Span Screen During Calibration Procedure CALIBRATE TA SPAN MEASURED 209 0 F APPLIED 0212 0 F 4 Press the run key to calibrate the analyzers MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The TA Span calibration range is 194 230 F 90 110 C Any attempt to calibrate outside this range will cause the analyzer to display the message BAD CALIBRATION ENTRY Instruction 0024 9219 5 7 Calibration PCA 5 8 Calibrate NX For PCA Models 30 35 60 amp 65 The Nitric Oxide sensor needs to be spanned at regular intervals to determine if the analyzer still meets its accuracy specification Because of the toxicity of Nitric Oxide gas however unless your facility has the necessary gas cylinders and personnel trained in the handling of toxic gases we recommend that the Nitric Oxide sensor be spanned by an authorized Bacharach Service Center Material Required e Calibration Gas Fixture Section 5 2 e Gas Cylinder 50 to 150 ppm Nitric Oxide with an analytical accuracy of 1 customer supplied Procedure 1 Enter the Calibrate Menu Screen per Section 5 3 Then choose to calibrate th
57. ow the calculated values of these gases CF amp NF referenced to Oxygen In either case all values are listed on the printout of analzyers equipped with a printer Custom fuels available upon request Contact factory for details Instruction 0024 9219 2 1 Technical Characteristics PCA Normal Operating Conditions Temperature Analyzer cceeeeeees 32 to 104 F 0 to 40 C Probe Tip 0 1472 F 800 C Max Humidity Analyzer uo 15 to 90 Relative Humidity Non Condensing Air Pressure Analyzer asees Atmospheric Probe aen ieran 10 H2O 25 mb draft max at probe tip Performance Accuracy Oxygen oo 0 3 O Carbon Monoxide 5 of reading or 10 ppm whichever is greater between 0 2000 ppm and 10 of reading between 2001 4000 ppm Nitric Oxide 5 of reading or 5 ppm whichever is greater Flue Gas Temp 4 F between 32 and 255 F 2 C between 0 and 124 C 6 F between 256 and 480 F 3 C between 125 and 249 C 8 F between 481 and 752 F 4 C between 250 and 400 C Ambient Temp 2 F between 32 and 212 F 1 C between 0 and 100 C Pressure assise 2 of reading or 0 02 inches of Water Column 0 05 mb whichever is greater System Flow Rate With probe 200 cc min minimum Front Panel Controls Seven embossed pushbutton switches with tactile feedback refer to Section 4 3
58. print the current test information to an optional printer 4 3 4 Ending a Combustion Test 1 Press the run key to end a combustion test You should hear the pump stop running WARNING Burn hazard Allow a hot probe to cool before handling Instruction 0024 9219 4 5 Operation PCA CAUTION Do not place a hot probe inside the instrument s carrying case Allow the probe to cool before storage 2 Loosen the thumbscrew on the probe stop then remove the probe and probe stop from the stack 3 If data was saved during the combustion test you can turn off the analyzer and review or print the stored data at a later time as de scribed in Sections 4 10 and 4 23 4 3 5 Turning Off the Analyzer and Purging the CO Sensor Turn off the analyzer by pressing the on orF key If the on off key is pressed while the CO reading is 100 ppm or higher the pump will automatically turn on if not already running to purge the analyzer of CO Important The probe must be removed from the stack during the purging process to allow fresh air to be drawn through the analyzer The following message is displayed while the analyzer is being purged PURGING CO SENSOR As soon as the CO level falls below 100 ppm the pump turns off and the analyzer starts its normal 5 second turn off sequence To abort the purging process and immediately start the analyzer s turn off sequence press the on off key again NOTE Turning th
59. r Filter To increase the life of the Nitric Oxide sensor it is recommended its orange filter be replaced once a year Procedure 1 Remove the Nitric Oxide sensor per Section 6 7 2 Pry the orange filter from the Nitric Oxide sensor and replace it with a new one 3 Reinstall the sensor 6 8 Instruction 0024 9219 PCA Maintenance 6 7 2 Replacing the Nitric Oxide Sensor Bias Battery A single lithium battery located on the Nitric Oxide printed circuit board see Figure 6 2 applies a constant bias voltage to the Nitric Oxide sensor even while the instrument is turned off This battery has a life expectancy of at least 2 years Replace the Nitric Oxide bias battery toward the end of its expected life Equipment Required e Bias Battery See Section 8 1 Procedure 1 Remove the analyzer s rear case and lay it aside refer to Section 6 2 2 Remove old battery from its holder see Figure 6 2 3 Insert the new battery positive side facing upwards into its holder 4 Reassemble the analyzer 5 Before powering up and using the instrument allow the Nitric Oxide sensor to stabilize as described below Recalibration of the Nitric Oxide sensor is usually not required Depending on how long the Nitric Oxide sensor was without bias voltage the time required for the sensor to completely stabilize varies from less than a minute to several days Typical stabilization times are shown below Generally however th
60. r needs to be reset Press RESET button Fig 4 7 Analyzer won t respond when a panel key is pressed a Flow restricted Check that the Fl Pump motor sounds sluggish stalls or will not start Filter Assembly is clean and not saturated with water Fig 6 3 Also verify that the probe hose is not pinched b Flow restricted Check the Par ticulate Filter is clean and not blocked Fig 6 2 c Loose pump connection Disas semble analyzer and ensure that the pump connector is securely attached to the circuit board d Pump defective Replace pump assembly Instruction 0024 9219 7 5 Troubleshooting PCA TABLE 7 1 TROUBLESHOOTING GUIDE Cont Fault Probable Cause amp Remedy Backlight will not turn on Backlight LED burned out Return to Bacharach for repair Batteries do not last 10 hours Cold temperature is reducing bat tery capacity To obtain longer oper ating time keep analyzer warm Erratic Combustion Test Screen values a Faulty sensor s Check that the sensors are prop erly installed per Sections 6 6 through 6 8 Check sensor calibration per Section 5 0 Replace sensor s and recal ibrate per Sections 5 0 and 6 0 b Probe assembly leaking Check tightness of all hose connections and integrity of tubing c Pump defective Replace pump amp motor assembly d Analyzer defective Return to Bacharach for r
61. rocedure 1 With the analyzer turned off first plug the simulator s K type connec tor into the T AIR jack Figure 3 2 then turn on the analyzer and wait for its warm up cycle to complete 2 Enter the Calibration Menu Screen per Section 5 3 then choose TA ZERO to zero the analyzer s room air primary air temperature channel 3 Set the simulator to 32 F 0 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and enter keys to enter an APPLIED value that equals 32 F 0 C Typical Calibrate TA Zero Screen During Calibration Procedure CALIBRATE TA ZERO MEASURED 37 0 F APPLIED 0032 0 F 4 Press the run key to calibrate the analyzer s MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The TA Zero calibration range is 0 5 C 32 41 F Any attempt to calibrate outside this range will cause the analyzer to display the message BAD CALIBRATION ENTRY 5 6 Instruction 0024 9219 PCA Calibration 5 7 Calibrate TA Span Material Required e Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F Procedure 1 With the analyzer turned off first plug the simulator s K type connec tor into the T AIR jack Figure 3 2 then turn on the analyzer and wait for its warm up cycle to complete 2 Enter the Calibration Menu Screen per Section 5 3 then choose TA SPAN to span the analyzer s r
62. rvice Centers United States Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5728 Email help bacharach inc com Canada Bacharach of Canada Inc 20 Amber St Unit 7 Markham Ontario L3R SP4 Canada Phone 905 470 8985 Fax 905 470 8963 Email bachcan idirect com 8 6 Instruction 00 24 9219 PCA Appendix A APPENDIX A Display Screen Translations English Warm Up Screen BACHARACH INC PCA nn Warmup nn French BACHARACH INC PCA nn ECHAUFFEMENT nn Sensor Status Screen Errors NO ERRORS DETECTED LOW BATTERY 02 SENSOR ERROR CO SENSOR ERROR DRAFT SENSOR ERROR T STACK SENSOR ERROR T AIR SENSOR ERROR NX SENSOR ERROR Sign Off Screen OFF IN n SEC PURGING CO SENSOR PAS D D ERREUR RELEVEE BATTERIE FAIBLE ERREUR CELLULE 02 ERREUR CELLULE CO ERREUR CELLULE PRESS ERR CELLULE T CHEMI ERR CELLULE T AIR ERREUR CELLULE NX ARRET DANS n SEC PURGE DETECTEUR CO Combustion Test Screen Abbreviations NG O 2 O 4 O 6 KER LPG COL Fuel Selection Screen FUEL NATGAS OIL 2 OIL 4 OIL 6 KEROSENE PROPANE COAL Draft Screens DRAFT DISCONNECT DRAFT HOSE PRESS ENTER RECONNECT DRAFT HOSE HOT SPOT GNA H 2 H 4 H 6 KER PRO CAR COMBUST GAZ NATU HUILE 2 HUILE 4 HUILE 6 KEROSENE PROPANE CARBON PRESSION DEBRANCHER LE TUYAU DE TIRAGE APPUYER SUR ENTER REBRANCHER LE TUYAU DE TIRAGE PT CHAUD
63. s configuration Section 3 4 3 2 PCA Power 3 2 1 Checking and Replacing the Batteries A fresh set of batteries is supplied with the PCA Install the batteries as described below If a LOW BATTERY message is displayed when the analyzer is turned on replace the batteries 1 Remove the battery cover from the back of the PCA Figure 3 1 2 Remove and properly dispose of any old batteries 3 Insert a fresh set of four AA alkaline batteries making sure to install them per the and markings shown in the battery compart ment 4 Replace the battery cover L y S a 0 eS r eE Wo a el Figure 3 1 Battery Replacement Instruction 0024 9219 3 1 Setup PCA 3 2 2 Using the Optional Power Supply If an Optional Power Supply is to be used 1 Connect the output plug of the Optional Power Supply to the analyzer s power supply jack Figure 3 2 2 Plug the Optional Power Supply into an appropriate AC wall outlet The analyzer will now operate and function normally 3 3 Connecting the Probe To attach the probe to the analyzer Figure 3 2 1 Push the yellow banded quick connect Flue Gas Hose giving a slight twist onto the analyzer s GAS sample inlet fitting 2 Push the blue banded quick connect Draft Hose giving a slight twist onto the analyzer s DRAFT sample inlet fitting 3 Push the Flue Gas Therm
64. screen is displayed by pressing the menu key from the Combustion Test Screen and is used to select the fuel being burned To select a fuel first use the st keys to move the cursor z in front of the desired fuel and then press the ENTER key NOTE The fuel selected is saved as the default and re mains in memory after the PCA is turned off The fuel codes as displayed in the Combustion Test Screen NG Natural Gas KER Kerosene O 2 Oil 2 LPG Propane O 4 Oil 4 COL Coal O 6 Oil 6 Front Panel Key Functions Move cursor z up Move cursor z down ENTER Select Fuel Go to Combustion Test Screen meny Goto Draft Screen for PCAs with a pressure sensor or the Memory Directory Screen for PCAs without a pressure sensor DODGE Instruction 0024 9219 4 11 Operation PCA 4 9 Draft Screens For PCA Models 15 25 35 45 55 amp 65 The first Draft Screen is displayed by repeatedly pressing the menu key from the Combustion Test Screen To measure draft first zero the analyzer s pressure sensor to atmo spheric pressure by disconnecting the draft hose from the bottom of the instrument and then pressing the ENTER key Reconnect the draft hose after the second Draft Screen appears shown for 3 seconds The third screen shows the current values of draft and stack temperature as measured by the analyzer When using the analyzer to make a differential pressure measurement Sec
65. seeeeeeeeeeeeeeceeeeeeeaeeseeneeeseaeeesaees 5 11 6 0 MAINTENANCE ccccsccceseeeessteeeneeeeeseneeeeseeeeeseaesasneeeenseeeesseeeeneeeees 6 1 6 1 Routine Maintenance ier eeti nessie eeii aii NEARER ER SE 6 1 6 2 DISASSEMDLY irrar a aE EA EAA 6 2 6 3 Cleaning the Probe sistein aaa ea aaa aoi aaia enh 6 4 6 4 Water Trap Filter Assembly Maintenance seseeeeeen 6 5 6 5 Replacing the Particulate Filter asasssssesrecsessrressrrrrensrrrssses 6 6 6 6 Replacing the Oxygen Sensor cccccccssseeeeeeeeeeeeseeeeeeenaeeeeees 6 7 6 7 Replacing the Nitric Oxide Sensor s s 6 8 6 7 1 Replacing the Nitric Oxide Sensor Filter 008 6 8 6 7 2 Replacing the Nitric Oxide Sensor Bias Battery 6 9 6 8 Replacing the Carbon Monoxide Sensor c ee eeeeeeeee eres 6 10 6 8 1 Replacing the Carbon Monoxide Sensor Filter 6 11 6 9 Replacing the Pump Assembly eccccceeeeeseeeeeeeesteeeeeeeaaes 6 12 7 0 TROUBLESHOOTING cscccccceecsseeeeseeeeeeceeeeseeeeeseeeseeseeeeeeeeeeaneeneneees 7 1 7 1 Analyzer Repair oo eee eecceeeeeceeeeeeeeenaeeeeeeeeaeeeeeeeaaeeeeeeeaaeeeeeeeaaes 7 1 7 2 Error C0deS sorrisi hutiraa aaa aea Hale delat 7 2 7 3 Troubleshooting Guide ccccecccceeeceeeeeeeee esas eeeeeeeeseaeeeteeeees 7 3 8 0 PARTS amp SERVICE ccsccccsseessseeceeseeeeeeeesesneeeeenseseseeeeensnesessaeeensneees 8 1 8 1 Replacement Parts cccccccesccccceeeseecceeeeeeeeceeeeeseeaeeeeeeseeeeeenen
66. sensor while TA is the optional Room Air Primary Air temperature sensor NOTE f an optional sensor is not installed the user will not be able to enter the corresponding calibration screen Front Panel Key Functions Move cursor z up Move cursor z down oG ENTER Select sensor to be calibrated next to cursor RUN Go to Combustion Test Screen MENY Return to previous screen a Instruction 0024 9219 5 3 Calibration PCA 5 4 Calibrate TS Zero Material Required e Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F Procedure 1 With the analyzer turned off first plug the simulator s K type connec tor into the T STACK jack Figure 3 2 then turn on the analyzer and wait for its warm up cycle to complete 2 Enter the Calibration Menu Screen per Section 5 3 then choose TS ZERO to zero the analyzer s stack temperature channel 3 Adjust the simulator to 32 F 0 C 4 Wait until the MEASURED reading on the screen stabilizes Then use the st and enter keys to enter an APPLIED value that equals 32 F 0 C Typical Calibrate TS Zero Screen During Calibration Procedure CALIBRATE TS ZERO MEASURED 37 0 F APPLIED 0032 0 F 4 Press the run key to calibrate the analyzers MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The TS Zero calibration range is 32 41 F 0 5
67. ter s IR input to the Analyzer 4 30 Instruction 0024 9219 PCA Operation When using a serial printer 1 First connect the analyzer to the printer using the optional RS 232 cable see Figure 4 6 2 Set the printer s communication parameters to 9600 baud 8 data bits 1 stop bit no parity and no handshaking 3 Use the st keys to move the cursor z in front of the print P function 4 Press the enter key to start printing Figure 4 6 Connecting a Serial Printer to the Analyzer Instruction 0024 9219 4 31 Operation PCA 4 25 Clear Memory Screen CLEAR MEMORY C E The Clear Memory Screen is accessed from either the Memory Directory Screen Section 4 10 or the Memory to PC Screen Section 4 11 To clear ali memory locations use the st keys to move the cursor z in front of the clear C function and then press the ENTER key To return to the previous screen without clearing memory place the cursor z in front of the exit E function and press ENTER 4 26 Resetting the Microprocessor If the analyzer locks up and cannot be turned OFF reset the micropro cessor by pressing the RESET button Figure 4 7 The button can be activated using the end of a paper clip RESET BUTTON Figure 4 7 Reset Button 4 32 Instruction 0024 9219 PCA Calibration 5 0 CALIBRATION NOTE Bacharach recommends that the PCA be calibrated by your nearest Bacharach Service Cen
68. ter Calibration however can be performed in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in the sections that follow Important To prevent the loss of data during calibration perform the following procedures using fresh batteries or using an optional Power Supply see Section 3 2 Do not make calibration adjustments to the instru ment without applying calibration span gas Making adjustments without applying span gas could render the instrument inaccurate or unusable until re cali bration is performed correctly with span gas 5 1 Sensor Check Important Before turning on the analyzer or performing any of the calibration procedures ensure that the analyzer will be sampling fresh air and that the probe is at room temperature When the analyzer is first turned on and allowed to cycle through its 60 second warmup period and while sampling fresh air the sensors are checked read and calibrated set to the following ambient conditions e Oxygen sensor is spanned to 20 9 e Carbon Monoxide sensor if installed is zeroed e Nitric Oxide sensor if installed is zeroed e Pressure sensor if installed is zeroed If a sensor problem is detected by the analyzer s microprocessor during the warm up cycle an error message will be displayed at the bottom of the LCD display Refer to Section 7 2 for a listing of the error codes Instruction 0024 9219 5 1
69. the Calibrate Draft Screen displayed connect the hose from the calibration fixture to the analyzer s DRAFT port then adjust the bellows for a micromanometer reading of 4 H20 column 10 mb 3 Wait until the MEASURED reading on the screen stabilizes Then use the stand enter keys to enter an APPLIED reading which equals the Micromanometer reading Typical CALIBRATE DRAFT Screen During Calibration Procedure CALIBRATE DRAFT MEASURED 9 00 WC APPLIED 4 00 WC 4 Press the run key to calibrate the analyzers MEASURED value to that of the APPLIED value At this time the Calibrate Menu Screen is redisplayed The draft calibration range is from 2 to 6 inches of water column 5 to 15 mb any attempt to calibrate outside this range will cause the analyzer to display the message BAD CALIBRATION ENTRY Instruction 0024 9219 5 11 Calibration PCA NOTES 5 12 Instruction 0024 9219 PCA Maintenance 6 0 MAINTENANCE 6 1 Routine Maintenance Routine maintenance of the analyzer consists of replacing the batteries cleaning the probe draining the water trap replacing the water trap filter and performing periodic calibration checks to ensure that the analyzer is providing accurate readings e Replace the Batteries per Section 3 2 e Clean the Probe per Section 6 3 e Maintain the Water Trap Filter Assembly per Section 6 4 e Replace the Particulate Filter per Section 6 5 e Calibrate th
70. tion 4 4 the differential pressure value will appear on the third Draft Screen To save S or print P the screen data first use the st keys to move the cursor z in front of the desired function and then press the ENTER key Front Panel Key Functions Move cursor z up Move cursor z down DRAFT DISCONNECT DRAFT HOSE PRESS ENTER DRAFT RECONNECT DRAFT HOSE DRAFT DRAFT 0 25 KX HOT SPOT 190 C P S Where xx Unit of measure Default is inches of water column WC See Optional Draft SETUP Screen Section 4 14 for other choices Save or Print screen data Go to Combustion Test Screen ms lt Zz l men Go to Memory Directory Screen Instruction 0024 9219 PCA Operation 4 10 Memory Directory Screen Standard PCA Screen Advanced PCA Screen MEMORY DIRECTORY MEMORY DIRECTORY M8 2 24 01 3 45pm 98 2 24 01 3 45pm M9 MEMORY EMPTY 99 MEMORY EMPTY CLEAR MEMORY CLEAR MEMORY The Memory Directory Screen is displayed by repeatedly pressing the menu key from the Combustion Test Screen This screen is used to select a memory location which contains saved data that an operator can review NOTE A standard PCA has 10 memory locations num bered Mo thru M9 while an advanced PCA has 100 memory locations numbered 0 thru 99 To select a data memory location first use the st keys to move the cursor z
71. urned on but pump runs during warmup cycle a Microprocessor needs to be reset Press RESET button Fig 4 7 b Analyzer defective Return to Bacharach for repair LOW BATTERY message ap pears at bottom of display Batteries close to being discharged Analyzer will run for several min utes before the instrument shuts off Replace batteries per Section 3 2 1 O2 SENSOR ERROR code appears in the Sensor Status Screen a Calibration was attempted while sampling combustion gases b O sensor is either expired not wired correctly or not connected to the circuit board Replace or check wiring of sensor per Section 6 6 Instruction 0024 9219 7 3 Troubleshooting PCA TABLE 7 1 TROUBLESHOOTING GUIDE Cont Fault Probable Cause amp Remedy NX SENSOR ERROR code appears in the Sensor Status Screen a Calibration was attempted while sampling combustion gases b Nitric Oxide sensor is expired Replace sensor per Section 6 7 c Bias battery on the Nitric Oxide circuit board is dead Replace bat tery per Section 6 7 2 CO SENSOR ERROR code appears in the Sensor Status Screen a Calibration was attempted while sampling combustion gases b Carbon Monoxide sensor is ex pired Replace sensor per Sec tion 6 8 DRAFT SENSOR ERROR code appears in the Sensor Status Screen a Sensor was exposed to pressure outside of its detectable range b Sensor de
72. use the st keys to move the cursor z in front of ENG ESPor FRA and then press the enter key Front Panel Key Functions Move cursor z up Move cursor z down ENTER Select Language next to cursor Go to Combustion Test Screen Awe MENY Goto Display Mode Setup Screen for PCAs that have both a CO and NX sensor or the Time Date Setup Screen for all other PCAs 4 22 Instruction 0024 9219 PCA Operation 4 17 Display Mode Setup Screen For PCA Models 30 35 60 amp 65 SETUP DISPLAY CO NX CF NF The Display Setup Screen is displayed by repeatedly pressing the menu key from the Combustion Test Screen Use this screen to select whether the Combustion Test Screen will display the measured values of Carbon Monoxide and Nitric Oxide CO and NX or the calculated values of these gases CF and NF referenced to Oxygen NOTE The levels of CO NX CF and NF are always in cluded on the printout and in the downloaded data of each combustion test regardless of what is being displayed on the Combustion Test Screen To setup the display first use the st keys to move the cursor z in front of either CO NX measured values or CF NF calculated values and then press the enTER key Front Panel Key Functions Move cursor z up Move cursor z down ENTER Select Display Mode next to cursor Dae RUN Go to Combustion Test Screen MENU Go to Time Date Setup Screen
73. usion of Step 1 the pump should start running Using the Gas Fixture shown in Figure 5 1 attach the CO calibration gas cylinder to the analyzer s GAS inlet Adjust the regulator of the calibration fixture for a flowmeter indica tion of approximately 2 SCFH Wait until the MEASURED reading on the screen stabilizes approxi mately 3 minutes Then use the st and enter keys to enter an APPLIED value that equals the concentration which is stamped on the CO calibration gas cylinder Typical CALIBRATE CO Screen During Calibration Procedure Using 500 ppm CO Calibration Gas MEASURED 492 PPM APPLIED 0500 PPM CALIBRATE CO 6 Press the run key to calibrate the analyzers MEASURED value to that of the APPLIED value At this time the Test Gas CO H2 Screen is displayed The CO calibration range is 250 1500 ppm Any attempt to calibrate outside this range will cause the analyzer to display the message BAD CALIBRATION ENTRY Instruction 0024 9219 5 9 Calibration PCA 7 Turn off the flow of CO calibration gas then remove the calibration gas cylinder from the calibration fixture 8 Attach a CO H calibration gas cylinder to the calibration fixture then adjust the regulator of the calibration fixture for a flowmeter reading of approximately 2 SCFH 9 Use the st and enter keys to enter a CO VALUE that is the same as the CO concentration which is stamped on the CO Hp calibration gas cy

PCA User Manual - Bacharach, Inc.

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