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User manual – Siegert (English)

1. 77 6 9 Material NO QUL GO scc tute b n 77 6 92s Procedure mn 77 6 10 NO Sensor CaliDEablODI ossis anh bea ote Pu aae dupl Data deed 78 6 10 1 Material Requlred ex i oe tena OE Cet RS e ttu n RE px RN 78 6 10 2 cay ele Do iue quod 78 o SENSOR Ca l DES TO eas oe es tease rea 80 6 11 1 Material 80 PEOCOBQUI O oci Padum REI rn cm REN EN V A da vaa ud Lb du eR 80 CHAPTER MAINTENANCE KE ERA YE w a MEKE e e WA 82 0024 9473 Rev 4 5 PCA 3 Manual Ta Me OVET EW P nt 82 7 2 015 56 TU UM 82 72 1 TOOS REQUE Ik ned SEE RR een noi D RR 82 72 2 7 POC OU S aeon 82 7 3 Emptying the Water Trap Chamber eese 87 7 4 Replacing the Filter Element xa xr wey ka j nenn s 87 7 4 1 87 a 87 L5 5 es 88 7 6 Nitric Oxide NO Sensor Battery 90 7 6 1 Material 90 50j OC AUIS cuc nde
2. aeo Repo suene eoa Nu EN CE oe ee Se e Este 66 D Io gt E e N AN Ke DO ecc 66 6 2 Starting a Calibr ratio 66 6 3 B Smart Sensor Replacement and 67 6 4 Pressure Sensor Calibration nen iren 68 6 4 1 Material Required Hel eb net ed eu e event cai eg ou Fede una 68 oT 2 PCO CCU Geistes bulo eM 68 6 5 gt aeu A 69 6 5 1 Maternal Redquileg erit eet x e 70 6 5 2 TS Zero ProCedUt PA kane D ae 70 6 5 3 TO Spn Procedi tono Geo f 71 6 6 TAT CID ION oes anan 71 6 6 Material REGUINGO 71 6 6 2 gt TA Zero PLOCGOQU IR ete tb Esto atus ed 71 6 6 3 TA Span kk kek kek K k KAKE KAK KA 73 6 7 CO Sensor Gali DTAL OT 73 6 7 1 Material Required a En W We KRE N Aw E W 73 657 22 Procede y s sen yada k en dan yek Nay xek Edad de xeni Wek n Ka eden dan k AN 74 6 8 50 Sehsor CallDFat Olla cud vestro Nl 76 6 8 1L Material Requit ed iret ev d eraut 76 0 0 2 PROCEOUIG inei LC M DE 76 6 9 NO Sensor raul OM
3. 90 Fe T Cleaning the PEODO ao DoD a dI 91 Tola le GO si una lodo 91 PAYAN Dele e l ccm 91 CHAPTER 8 TROUBLESHOOTING isscssssccsvccvsnessnesczesauresiesnetnsstenecenscovecsavoanrs 92 OV IINOOIS PPE 92 8 2 Diagnostics and Status 5 5 92 8 3 Accessing the Diagnostic Menu 93 8 4 Accessing the Status enn ana ner 93 8 5 Error Messages After Warm uU D keke kek keke k 93 8 6 Replacement Droite netu s n NA 94 So der d n g a l gt ya E a ae 97 Analyzer xuy nes en ne W NEN wee ae ea 99 5 9 Service l PS esu ss bayi ye ber erka pe NUR pU ron EBE n PA ay ee ve NA 99 CHAPTER 9 DECLARATION OF 100 6 0024 9473 Rev 4 PCA 3 Manual CHAPTER 1 INTRODUCTION 1 1 About This Manual Thank you for investing in a Bacharach PCA 3 Combustion Analyzer To assure operator safety and the proper use of the PCA 3 please read the contents of this manual for important information on the operation and maintenance of the analyzer 1 2 Conventions WARNING warning statement denotes a potential hazard associated with the use of thi
4. 21 By ly HOVEIMICW 21 3 POWO eee tase Kewe en neki cet An ie oem nes suede nana nt S IE 21 3 3 Connecting the Probe and Hose Assembly 22 3 4 Preparing to Configure the BOA DE DD a 22 CHAPTER 4 CONFIGURATION PROCEDURES 24 4 1 iD taultOperatihg Paratetels oia ut e etes eti b apt eed 24 4 2 FuelsSelectiOllcs el ne KU d birak Ki ra Milay y Rana n k 24 4 3 Auto Manual CO Zero Select OfS E kek kek ke kk 26 4 4 Temperature Units Selection daniyan an n s kul y ken n na V n ka kek n 27 4 5 Pressure Units S l CEION yeki da b y mas 27 2 5 Pollution Units SeleetlODu K kulek Ek de P kan a kul denn 28 neka o ae CEAIUL ESE E A E 29 0024 9473 Rev 4 3 PCA 3 Manual 24 8 Ol DetiVablVO tente tr nats 30 4 9 Boiler Temperature oos 30 410 T E 31 A EI oot tuts E 32 2 O5 5 es en ula A 32 4 13 Print Pressure Selection esce eee n aves eher ean oue gu a eee 33 4 14 Zoom Display Selection
5. O Sensor Oxygen sensor not installed Install oxygen sensor Refer to 0024 9473 Rev 4 93 PCA 3 Manual Missing Sensor Replacement on page 88 BAD Sensors The oxygen sensor s output is too low and can not be calibrated in the instrument signifying that the sensor is depleted and needs to be replaced Refer to Sensor Replacement on page 88 No B Smart There are no B Smart sensor s installed Refer to Sensor Sensors Installed Replacement on page 88 Low Sensors O CO ow NO or SO sensor output s were low but still usable Sensor s may need to be replaced in the near future Message will indicate which sensor s are in warning T STK The probe s thermocouple is not connected to the analyzer s Disconnected T STACK connector Plug the probe thermocouple plug into the T STACK connector at the bottom of the instrument Warm up Sensor NO NO or SO Gas sensor s were not zeroed Error at warm up because of high output Run instrument on fresh air then restart instrument to re zero sensor s If message persists sensor s may need to be replaced Message will indicate which sensor s are in error e Stack or Air temperature channel is measuring temperature outside the range of 20 to 100 C 4 to 212 F at startup Make sure that the Stack and Air thermocouples are sampling ambient room air within the temperature range at startup Message will indicate which channe
6. eese nennen 34 TET ON 35 4 16 Button Sound Selecto Meca ke r we ia 35 2 17 Test lil TON T a LOD bawk kelaya M 36 4 17 1 Entering or Editing a Test 10 keke 36 24 17 2 Selecthg 3 Tesb 37 4 17 3 Clearing Test ID InfottriatiOTi siio e vr ae E 37 LM PEU LIN a 8545 38 418 1 Ehtering a User 38 4 18 2 Clearing a User nnn Waa 39 WoL Os ES I ET 39 4 20 Calibration Reminder 40 4 21 RunzHold Screen Format evt eon 41 22 ANO Ol K 43 5 OPERATION 44 5 1 Operating Sha eani Sa eques 44 5 2 Turning On the Analyzer 45 5 3 HOW Battery AlI en WIN Kaka ta Ut Ii ade 45 5 4 Locating Sampling Points 46 5 5 Petforminig a Combustion POSE 47 5 6 Selecting a Pressure dete E PO K n K ke eka 50 5 7 Temperature Label Selection and Measurement 50 5 8 Performing
7. NOTE If the duration is set for more than 10 hours we recommend using the optional AC power adapter to power the analyzer 1 As soon as logging is turned ON see Logging Selection on page 35 the LOGGING INTERVAL screen appears 2 Usethe A V buttons to highlight the desired interval and then press ENT to make the selection and display the LOGGING DURATION screen In this example 1 minute has been selected 3 Use the A V buttons to highlight the desired duration and then press ENT to make the selection and display the LOGGING SUMMARY screen In this example 2 hours has been selected than is currently available the analyzer will automatically select the longest duration possible for the selected d NOTE If the selected duration requires more memory interval Logging Interval ak 1 second 5 seconds 10 seconds 1 minute Menu 56 Logging Duration minutes minutes 5 minutes 0 minutes 0024 9473 Rev 4 PCA 3 Manual Figure 5 17 Setting the Logging Interval 5 12 4 Starting the Data Logging Process After turning ON data logging and setting the interval and duration the analyzer will pause at the LOGGING SUMMARY screen where the currently selected interval and duration time periods are displayed Press ENT to start the combustion test and logging process At this time the Combustion Test LOG screen will appear indicating that the analyzer is now performing a combustion test and the
8. Individual memory locations in each memory bank can be recalled for viewing on the display or printed or the entire contents of each memory bank can be individually downloaded to a computer and viewed in a spreadsheet program for analysis These functions are explained in the sections that follow NOTE When displaying the contents of either memory bank the Operator can quickly page through the screens by pressing the PAGE F1 and PAGE F3 buttons Or move to the first or last memory location by pressing the lt b buttons respectively 5 13 2 Recalling Combustion Test Data Recall individual combustion test data records as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight MEMORY and then press ENT to display the MEMORY MENU 3 Use the A V buttons to highlight MEMORY DIRECTORY and then press ENT to display the MEMORY DIRECTORY screen 4 Use the A V buttons to highlight the desired memory location to be recalled Each memory location is identified by the date and time at which data was saved The word EMPTY signifies that the memory location does not contain data 5 Press ENT to display the data contained in the selected memory location NOTE The top line of the recalled combustion test data screen shows the memory location being viewed In this example MEM 1 is being displayed NOTE The recalled com
9. 3 Barbed Hose Connector e 5 4 Bellows 6 n 5 Manometer Figure 6 3 Pressure Sensor Calibration Equipment 6 5 T Stack Calibration This procedure first zeros and then spans the stack temperature channel to known temperature values 0024 9473 Rev 4 69 PCA 3 Manual The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures Alternatively containers of ice water and boiling water can be used 6 5 1 Material Required e Thermocouple Simulator K type Range 0 to 300 C Accuracy 0 3 C e Alternatively Ice Water Boiling Water Thermometer 6 5 2 TS Zero Procedure 1 Setthermocouple simulator to room temperature and plug its output into the T STACK connector located at the bottom of the analyzer Alternatively Plug the probe s thermocouple into the T STACK connector located at the bottom of the analyzer CAUTION DO NOT attach the probe s gas hose to the N analyzers GAS port or water will be drawn into the analyzer 2 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 3 Use the A V buttons to highlight T Stack and then press ENT to display the CALIBRATE TS ZERO screen NOTE Measured is the current temperature reading 9 while Applied is a known temperature that will be applied for calibration purposes 4 Set thermocouple simulator to 0 C 32 F a
10. The Measurable Difference Portable Combustion Analyzer Siegert Version Operation and Maintenance Manual Instruction 0024 9473 Rev 4 August 2014 Product Leadership e Training e Service e Reliability PCA 3 Manual WARRANTY POLICY Bacharach Inc warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc s applicable specifications Bacharach s liability and Buyer s remedy under this warranty are limited to the repair or replacement at Bacharach s option of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc s reasonable satisfaction to have been defective provided that written notice of the defect shall have been given by Buyer to Bacharach Inc within two 2 years after the date of delivery of this Product by Bacharach Inc Routine service and calibration are excluded from this warranty Bacharach Inc warrants to Buyer that it will convey good title to this Product Bacharach s liability and Buyer s remedy under this warranty of title are limited to the removal of any title defects or at the election of Bacharach to the replacement of this Product or parts thereof that are defective in title THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF I ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATI
11. if changes were made to one of the analyzer s operating parameters e g date time reference etc pressing this button confirms those changes and saves them in memory Starts and stops a combustion test when the Combustion Test screen is displayed Pressing this button in any other screen returns the analyzer to the Combustion Test HOLD screen Pressing this button during the 5 second turn off delay period will abort the turn off process and also return the analyzer to the Combustion Test HOLD screen Displays a previously viewed screen In addition if changes were made to one of the analyzer s operating parameters e g date time reference etc pressing this button aborts those changes restores the old values and then displays the previously viewed screen 0024 9473 Rev 4 17 PCA 3 Manual Note that a button may perform multiple functions depending on the current screen that is displayed For example the functions of the F1 F2 and F3 buttons are defined by labels appearing above them on the LCD The labels that appear depend on the functions that can be performed in the particular screen being displayed dimly lit areas Turn the keypad backlight ON and OFF by briefly o NOTE A keypad backlight enables a user to read the keypad in pressing the I O button NOTE When the analyzer is turned OFF there is a 5 second delay during which time an operator can keep the analyzer turned ON by pressing the RU
12. the battery contact is stamped with a symbol Re install the Smart Sensor assembly Before powering up and using the analyzer allow the nitric oxide sensor to stabilize as described below Note that recalibration of the nitric oxide sensor is not required after replacing its bias battery 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 the sensor is sufficiently stable after 4 hours for measurement purposes Bias Battery Stabilization Specifications for NO Sensor Bias Battery Removed for Stabilization Time Less than 15 minutes Less than 1 minute Less than 1 hour Less than 5 minutes Less than 2 days Less than 4 hours Greater than 2 days Up to 2 days 90 0024 9473 Rev 4 PCA 3 Manual 7 7 Cleaning the Probe The probe tube and gas sample hose will become dirty under normal use NOTE The water trap s filter element should prevent soot from reaching the analyzer s internal components If the probe is not kept 9 clean it could become clogged and restrict the flow of gas into the analyzer resulting in incorrect combustion test readings and calculations normally requires less frequent cleaning than an analyzer used for o NOTE An analyzer that is used to test natural gas furnaces testing coal or oil fired fur
13. 0024 7059 e Gas Cylinder 250 ppm NO in Nitrogen P N 0024 1156 6 9 2 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 2 Usethe A V buttons to highlight NO and then press ENT to display the CALIBRATE NO screen is a known NO level that will be applied for calibration 9 NOTE Measured is the current NO reading while Applied purposes 3 Attach a 250 ppm NO cylinder to the regulator of the calibration fixture shown in Figure 6 12 on page 80 4 Use the A V and lt gt buttons to enter an applied value that exactly equals the concentration stamped on the NO cylinder to calibrate outside this range will cause the message Bad NOTE The calibration range is from 9 to 900 ppm An attempt Calibration Wrong CAL Entry to appear in the following step 0024 9473 Rev 4 77 PCA 3 Manual Calibration Menu Calibrate ressure Measured 253 ppm Stack Applied 50 ppm Press ENTER O LO 01 09 10 11 58 28 Print Menu Figure 6 10 NO Sensor Calibration 5 Adjust regulator for a flow meter indication of approximately 2 SCFH Wait until the measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the NO Measured value to that of the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed NOTE If the sens
14. C between 250 and 400 C 8 F between 481 and 752 F Primary Ambient 8 1 C 2 F between 0 and 100 C 32 and 212 F 0 05 mB from 2 49 to 2 49 mB 0 02 inwc from 1 to 1 inwc Pressure Draft 2 of reading from 24 9 to 24 9 mB 42 from 10 to 10 inwc 3 of reading from 100 to 100 mB 3 from 40 to 40 inwc System Flow Rate 999 cc min minimum with Probe General Specification Description Dimensions H x W x D 22 9 x 7 6 x 6 3 cm 9 0 x 3 0 x 2 5 inches Weight Analyzer with Batteries 0 6 kg 1 4 Ib Probe Hose Assembly 0 5 kg 1 0 Ib e Natural Gas Biofuel e Coal KOKS e Oil 2 Propane e LEG LPG e Oil 6 e Butane 60 seconds Sensors checked and auto zeroed A AA Batteries Alkaline 10 hours of operation min Bewer Disposable NiMH Rechargeable Operating time varies AC Adapter i Optional 100 240 VAC 50 60 HZz Continuous use Analyzer 0 to 40 C 32 to 104 F Probe Tip soe v e Moenum 800 C 1 472 F Max Operating Humidity Analyzer 15 to 90 RH non condensing DB Atmospheric Fuels Available for Combustion Calculations Operating Temperature Operating Air Pressure Memory Interfaces 0024 9473 Rev 4 15 PCA 3 Manual C
15. CAL Reminder Period Date Format Press ENTER E CO Zero Setting Figure 4 3 Auto Manual Zero Selection other purposes an auto zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurement d NOTE The performs a zero function during warm up Among A manual zero detects background CO during startup Manual Zero When the CO channel is set to manual zero the analyzer does not zero the CO sensor to ambient conditions during start up In this mode the fresh air zero established during manual mode setup is stored in memory and used for the calculation of CO Auto Zero When the CO channel is set to auto zero the CO sensor is zeroed to the ambient CO level during start up Important When using this mode the analyzer must be turned ON in fresh air otherwise incorrect CO readings will occur 26 0024 9473 Rev 4 PCA 3 Manual Auto Zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurements Manual zero is used to detect CO that may be present during start up The auto manual zeroing option allows the operator to select the start up mode It is selectable from the CO Zero Setting of the Setup Menu down to establish a new zero The manual mode establishes a 9 NOTE Both methods take the user through a 60 second count fresh air zero and stores it for use during instrument startup 4 4 Temperature Un
16. ID Edit Test ID oom Clear Test ID Logging Menu Figure 4 17 Editing a Test ID 4 17 2 Selecting a Test ID 1 From the Test ID menu use the A V buttons to highlight SELECT TEST ID and then press ENT to display the SELECT TEST ID menu which displays the first line of each Test ID record Test ID Menu select Test ID Figure 4 18 Selecting a Test ID 2 Use the A V buttons to choose a pre entered Test ID or choose NO Test ID located at bottom of list to deselect a previously chosen record then press ENT to make the selection and return to the Test ID menu 3 Press ESC to end the procedure and return to the Setup Menu or press the RUN HOLD key to return to the Run Hold Screen 4 17 3 Clearing Test ID Information 1 From the Test ID menu use the A V buttons to highlight CLEAR TEST ID and then press ENT to display the CLEAR TEST ID menu 2 Doone ofthe following to clear Individual Records or All Records Individual Records Use the A V buttons to highlight Individual Records then press ENT to display the Clear Individual menu Again use the A V buttons to highlight the individual record to clear then press ENT to clear the record All Records Use the A V buttons to highlight All Records then press ENT to display the Clear All menu Again use the A V buttons to highlight Yes then press ENT to clear all records 0024 9473 Rev 4 37 PCA 3 Manual 3 Press ESC to end this procedure and return
17. If the problem persist contact your nearest Bacharach Service Center NOTE To save time B Smart codes can be entered using the Fyrite User Software 0024 9473 Rev 4 67 PCA 3 Manual Bacharach also offers a convenient exchange program that allows the customer to regularly send in old sensors and as scheduled receive calibrated replacements Contact Bacharach customer service for more details about the exchange program 6 4 Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value 6 4 1 Material Required e Bellows e Manometer Range 8 in of water column 20 mb Accuracy 0 01 in of water column 0 025 mb 6 4 2 Procedure NOTE The unit of measure for pressure is selected in the Pressure Units Selection section on page 27 In the following procedure inwc is selected but note that any unit of measure can be used for calibration purposes 1 Assemble the pressure sensor calibration equipment as shown in Figure 6 3 but DO NOT connect the analyzer to the calibration equipment at this time 2 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 3 Use the A V buttons to highlight Pressure and then press ENT to display the CALIBRATE PRESSURE screen NOTE Measured is the pressure value currently being detected by the pressure sensor while Applied is a known value of pressure that will
18. P N 0024 1155 Leave Top Port Open GAS Port d V COC Parts 1 Gas Cylinder 2 Regulator 3 3 16 1 0 Tubing 4 Tee 5 Flowmeter 6 Barbed Hose Connector Part of Calibration Kit 24 7059 Figure 6 12 Gas Sensor Calibration Equipment 6 11 2 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 2 Usethe A V buttons to highlight CO HI and then press ENT to display the CALIBRATE CO HI screen NOTE Measured is the current CO reading while Applied is a known CO level that will be applied for calibration purposes 3 Attach a 4 000 ppm CO cylinder to the regulator of the calibration fixture shown in Figure 6 12 4 Use the A V and lt gt buttons to enter an applied value that exactly equals the concentration on the CO cylinder 80 0024 9473 Rev 4 PCA 3 Manual An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in d NOTE The calibration range is from 250 to 11 000 ppm the following step Calibration Menu Calibrate CO HI Measured 3988 ppm Applied 4000 ppm Press ENTER Pressure T Stack 01 09 10 08 21 0 Figure 6 13 COnich Sensor Calibration 5 Adjust regulator for a flow meter indication of approximately 2 SCFH Wait until the measured reading stabilizes approximately 3 minutes and
19. Purge Pump Battery Connector on printed circuit board Gas Pump Purge Air In Hose Connector Plate GAS AP AP Pressure Figure 7 2 Inside View with Rear Case Removed 84 0024 9473 Rev 4 PCA 3 Manual PRESSURE SENSOR on printed circuit board AP Top AP Bottom PURGE PUMP To Sensors GAS PUMP Figure 7 3 Tubing Connections Main Model 225 Models 235 amp 245 P N 0024 7330 P Ns 0024 7331 amp 0024 7332 Model 255 Models 265 amp 275 P N 0024 7333 P Ns 0024 7334 amp 24 7335 Figure 7 4 Tubing Connections Sensors 0024 9473 Rev 4 85 PCA 3 Manual LCD Connector Sensor Connector opposite side of board typical 4 places Wire Routing Connectors Solder 2 Places Red dot on pump indicates positive red wire connection Solder Connections Figure 7 5 Wire Routing Connectors and Solder Connections 86 0024 9473 Rev 4 PCA 3 Manual 7 3 Emptying the Water Trap Chamber The water trap chamber should be emptied after every test or when the water condensate approaches the tip of the riser tube 1 Remove water trap chamber also see page 53 2 Pour out liquid condensate and then reassemble trap 7 4 Replacing the Filter Element Replace the filter element when it becomes visibly dirty or becomes saturated with water 7 4 1 Material Required e Filter Element P N 0007 1644 e Small Flat Blade Screwdriver 7 4
20. TUV SUD WE
21. batteries tubing connected to each sensor s gas cap being careful not to put o NOTE In Step 3 if the sensors are not being replaced leave the unnecessary strain on the tubing during the disassembly process 3 Pull off sensor retainer and then unplug all sensors Lay analyzer face down on a padded work surface and then using a medium Phillips screwdriver remove the unit s four rear case screws 5 Lift rear case from analyzer and set aside 6 Unplug electrical connectors J8 J9 and J14 from printed circuit board CAUTION In Step 7 note that there is tubing connected between the bottom hose connector plate and the pressure sensor on the printed circuit board Do not put unnecessary strain on this tubing during the disassembly process 7 Carefully lift battery and pump chassis along with the bottom hose connector plate from analyzer 8 Lift printed circuit board from analyzer 82 0024 9473 Rev 4 PCA 3 Manual Rear Case Screws typical 4 places Release and then remove battery cover by pushing latch up Figure 7 1 Removing the Rear Case Model Number and Corresponding Sensor aa 2 HH 0024 9473 Rev 4 83 PCA 3 Manual Sensors Type and position determined by model number Sensor Retainer Purge Pump Motor Connector Gas Pump Motor Connector Battery amp Pump Chassis Pressure Sensor _ on printed circuit board AP Top AP Bottom
22. be applied for calibration purposes 4 With both the AP and AP ports open to the atmosphere observe that the current Measured pressure reading should be 0 0 01 inwc If necessary zero the pressure sensor refer to Performing a Draft Pressure Measurement on page 51 and repeat Steps 2 thru 4 5 Connect the hose from the manometer to the AP port and apply a negative pressure to this port by adjusting the bellows for a manometer reading of 4 00 6 Use the A V and lt gt buttons to enter an applied value that exactly equals the manometer reading 68 0024 9473 Rev 4 PCA 3 Manual 5 mb An attempt to calibrate outside this range will cause the message Applied Value High or Low to d NOTE The calibration range is from 6 to 2 inwc 15 to appear at the bottom of the screen Calibration Menu Calibrate Pressure Pressure Measured 9 95mB Stack Applied 0 00 mB Air T Ref 31 08 10 07 34 19 Figure 6 2 Pressure Sensor Calibration Press ENTER 7 Wait until the measured reading stabilizes and then press ENT to calibrate the pressure sensor s Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed 8 Remove calibration equipment Ww MN AN 1 2 4 4 2 Parts 5 L4 1 3 16 1 0 Tubing y 2 Tee
23. data is being stored in memory NOTE At the top of the screen the memory location where the current log entry is being saved is displayed session will start to store data in the next available memory location NOTE At no time will new data overwrite old data Logging will NOTE If there were previously stored log entries each new logging 0 stop when available memory is filled Logging Summary Log 176 NGAS Interval 2 minutes Duration 2 hrs Press ENT to start 0 0020 ppm 208 C Figure 5 18 Starting the Data Logging Process 5 12 5 Ending the Data Logging Process Data logging will stop and the pump will turn OFF after the prescribed duration or after all 500 memory locations are filled To exit the Combustion Test LOG screen press the RUN HOLD button twice to display the Combustion Test HOLD screen button If the logging process was stopped by pressing ESC it NOTE To end the logging process at any time press the ESC cannot be resumed without first turning logging back ON 0024 9473 Rev 4 57 PCA 3 Manual 5 13 Memory Functions 5 13 1 Overview There are two memory banks each containing 500 memory locations The first bank is used to store combustion test data as described in Saving Test Data page 52 while the second bank is used to store logged combustion test data as described in Data Logging page 54 Each bank is independent of each other and cannot share data or be combined
24. highlight DIAGNOSTICS and then press ENT to display the DIAGNOSTICS MENU 3 Use the A V buttons to highlight the desired diagnostic topic and then press ENT to display the information under that topic 4 Press ESC key to exit back to the Diagnostic menu or the Menu F2 key to exit back to the Main Menu 8 4 Accessing the Status Menu The Status screen provides a quick reference to key items when troubleshooting 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight STATUS and then press ENT to display the DEVICE STATUS screen 3 Press ESC key to exit back to the Main Menu 8 5 Error Messages After Warm up If there were problems detected during warm up error messages that describe the nature of the problems are displayed immediately following the analyzer s 60 second warm up period If problems were detected the analyzer will not automatically switch to the Combustion Test HOLD screen after warm up The analyzer however can still be used to perform any test that does not depend on the sensor that is in error Press the RUN button to manually display the Combustion Test HOLD screen and then continue using the analyzer The following is a list of the error messages that may appear following warm up and their suggested remedies Description Low Battery Battery voltage is low Replace batteries page 21
25. in Nitrogen P N 0024 0794 0024 9473 Rev 4 73 PCA 3 Manual 6 7 2 Procedure 1 74 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 Use the A V buttons to highlight CO LO and then press ENT to display the CALIBRATE CO screen Applied is a known CO level that will be applied for NOTE Measured is the current CO reading while calibration purposes Attach a 500 ppm CO cylinder to the regulator of the calibration fixture shown in Figure 6 12 on page 80 Use the A V and lt gt buttons to enter an applied value that exactly equals the concentration stamped on the CO cylinder to calibrate outside this range causes the message Applied NOTE The calibration range is 9 to 1 500 ppm An attempt Value High or Low to appear at the bottom of the screen Calibration Menu Calibrate CO Measured 480 ppm T Stack Applied 500 ppm Press ENTER CO LO 07 23 10 04 15 49 PM Figure 6 7 CO ow Sensor Calibration Adjust the regulator for a flow meter indication of approximately 2 SCFH Wait until the measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the CO Measured value to that of the applied value The message Good Calibration should briefly appear followed by the TEST GAS screen the message Good Calibration WARNING Low Sensor will appear The sensor will now be marked a
26. level to go above tip of riser tube Stack Gas From Probe Figure 5 15 Emptying the Water Trap 5 12 Data Logging 5 12 1 Overview When the logging function is activated up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined duration The maximum duration that data can be collected is determined by the interval For example if the interval is set to 10 seconds then the maximum selectable length of time in which data can be collected to fill 500 memory locations would be 1 hour 500 x 10 seconds 5000 seconds or 83 minutes If the operator chooses a duration that is longer than possible for the interval chosen then the analyzer automatically selects the highest duration possible for the selected interval The stored logged data can either be viewed on the display using the analyzer s memory function see Memory Functions on page 58 or downloaded to a personal computer using the supplied Fyrite User Software and USB cable Downloaded data is stored on the computer s hard drive as a comma separated value ASCII text file with a CSV extension which can be opened by most spreadsheet programs for analysis 54 0024 9473 Rev 4 PCA 3 Manual Logging Intervals and Durations Logging Intervals Logging Durations 5 12 2 Turning On Data Logging IMPORTANT Before turning ON data logging and starting the data logging process the analyzer should already be set
27. lt buttons to enter an applied value that exactly equals the setting of the simulator Alternatively Submerge probe tip into a container of boiling water with a thermometer wait several minutes and then use the A V and buttons to enter an applied value that exactly equals the thermometer reading NOTE The calibration range is from 90 to 110 C 194 to 230 F An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the following step 2 Wait until the measured reading stabilizes and then press ENT to calibrate the TA Span Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed Calibrate TA Span Measured 99 6 C Applied 00 Press ENTER 01 09 10 10 33 10 Figure 6 6 T Air Span Procedure 6 7 CO ow Sensor Calibration NOTE The sensor also measures for the purpose of compensating the CO reading for the presence of H in the gas sample This procedure first spans the sensor and optionally spans the H2 part of the sensor to known gas levels The user has the option to perform a CO only calibration or a CO H calibration using the PCA 3 soft keys 6 7 1 Material Required e Calibration Kit P N 0024 7059 e Gas Cylinder 500 ppm CO in air P N 0024 0492 e Gas Cylinder 1 000 ppm CO and 1 000 ppm gt
28. or end this procedure by highlighting Edit Complete and pressing the ENT key to return to he Setup Menu 38 0024 9473 Rev 4 PCA 3 Manual 8 Press ESC to go to the Main Menu or the RUN HOLD key to return to the Run Hold screen Main Menu setup Menu Edit Username Fuel Sd 02 Reference Memory __ 5 F Memory etup Calibration Username Figure 4 20 Entering a User Name 4 18 2 Clearing a User Name 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight USERNAME and then press ENT to display all three lines of the EDIT USERNAME screen Periods identify empty lines 4 Use the A V buttons to choose which of the three Username lines to clear then press CLEAR F3 to clear that line 5 Atthis time either return to Step 4 to choose another line to clear or end this procedure by highlighting EDIT COMPLETE and pressing the ENT key to return tot he Setup Menu 6 Press ESC to go to the Main Menu or the RUN HOLD key to return to the Run Hold screen Main Menu setup Menu nm nm Fuel Os Reference Pressure Print Pressure Temperature Edit Username Logging Setup Test ID Calibration B Username Menu Menu Figure 4 21 Clearing a User Name Edit Complete 4 19 Language Information on the di
29. the data field of either the NO or sensor contains three stars then the NOx data field will also contain three stars Indicates sensor over range 8 2 Diagnostics and Status Screens Three stars appear in the data field of sensors that are not installed E defective or found to be in error during warm up and also in the data The DIAGNOSTICS menu provides information regarding the operation of the analyzer Information includes the following Diagnostic Description Time Meters Displays the run time of the analyzer sample pump and zara sal purge pump hours of Time Meters operation Figure 8 1 Time Meters Main Lists the current status of the Stack and Air Thermocouple channels Diagnostics Reference Temperature channel Pressure channel and Battery Sensor Life Displays the approximate remaining life of the Oxygen sensor B Smart Displays the current status of all B Smart sensors installed Sensors Fresh Air Fresh air diagnostics will cycle the instrument through the 60 second Diagnostics warm up to check on the status of all sensors The probe must be in fresh air to perform a valid check 92 0024 9473 Rev 4 PCA 3 Manual 8 3 Accessing the Diagnostic Menu 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 Main Menu Calibration Diagnostics Figure 8 2 Accessing the Diagnostics Menu 2 Usethe A V buttons to
30. up to perform a combustion test see Performing a Combustion Test section on page 47 Turn ON data logging as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight LOGGING and then press ENT to display the LOGGING screen NOTE The amount of memory available for storing new data is displayed in the LOGGING screen maximum of 9 500 locations If previous logging sessions are stored and additional memory is needed clear the logging memory see Clearing Memory section on page 60 NOTE At no time will new logging data over write old data Logging will stop when available memory is filled 4 Use the V buttons to highlight YES turn logging ON 5 Press ENT to make the selection and display the LOGGING INTERVAL screen 0024 9473 Rev 4 55 PCA 3 Manual Main Menu setup Menu Confirm Logging est ID Temperature sername Yes un Hold Format Available Logging Setup anguage Selection Locations 500 Calibration V utton Sound 1 1 Figure 5 16 Turning On Data Logging 5 12 3 Setting the Logging Interval and Duration The logging interval is the length of time between measurements while the logging duration is the time allocated to the logging process Set the logging interval and duration as follows
31. when the measured 1 093 C 2 000 F 0024 9473 Rev 4 13 PCA 3 Manual Equations Some calculations vary by country CQ x 20 9 0598 AN 20 9 ETA 100 qA kg if Terg lt Tg 1 2 X Oz CO CO x 10 000 Definitions Measured oxygen Tsrk Measured stack temp in C T AIR Measured primary air temp in C CO Measured carbon monoxide in ppm Calculated carbon dioxide in ppm qA Calculated stack loss in Lambda Calculated excess air EFF Efficiency based on HHV in ETA Efficiency based on LHV in 2 Constant see table below A Constant see table below B Constant see table below Fuel Constants Some fuel constants vary by country FUEL CO max A B k Natural Gas s oee 000 se 96 Kos 02 0s oom Tez 42 _ LEG LPG Gm 0 007 34 oz oo 60 TI 14 0024 9473 Rev 4 PCA 3 Manual Reading Performance Accuracy 0 3 on practical concentrations of stack gas mix of CO and N3 Greater of 5 of reading or 10 ppm between 0 2 000 ppm 10 of reading between 2 001 and 4 000 ppm NO Greater of 5 of reading or 5 ppm between 0 and 2 000 ppm NO Greater of 5 of reading or 5 ppm between 0 500 ppm so 2 C 4 F between 0 and 124 C 32 and 255 F Flue Gas Temp 3 C between 125 and 249 C 6 F between 256 and 480 F 4
32. 07 AM Figure 4 6 Pollution Units Selection 28 0024 9473 Rev 4 PCA 3 Manual 4 7 Smoke Number Three smoke numbers as measured by the Bacharach True Spot Smoke Tester can be manually entered into the analyzer and their average automatically calculated The average Smoke Number will be displayed on the Run Hold screen Enter smoke numbers as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 Use the A V buttons to highlight SETUP and then press ENT to display the SETUP MENU Use the A V buttons to highlight smoke number and then press ENT to display the SMOKE NUMBER MENU Use the A V buttons to highlight Smoke Number 1 2 or 3 Then use the 4 buttons to enter a smoke number from 0 to 9 Repeat Step 3 to enter values for the second and third smoke number Press ENT to save and display the average of the three smoke numbers that were entered Press ENT to return to the Setup Menu or ESC to return to the Smoke Number menu The average Smoke Number will be displayed in the Run Hold screen Setup Menu Smoke Number Smoke Number Temperature Units Smoke No 1 Pollution Units Smoke No 2 Smoke Number Smoke No 3 Average Smoke No 0 Oil Derivative Press ENTER Boiler Temperature v Figure 4 7 Entering Smoke Numbers Manually 0024 9473 Rev 4 29 PCA 3 Manual 4 8 Oil Derivative This scr
33. 2 Procedure Remove water trap chamber also see page 53 2 Pry apart filter chamber using a small flat blade screwdriver Remove and discard old filter 3 Install new filter and reassemble filter chamber making sure that surfaces A and B contact each other 4 Reassemble trap Pry apart O RING FILTER filter chamber CHAMBER using a small lt flat blade screwdriver T Pull apart inserted into using a notch twisting When reassem motion bling filter chamber make sure surfaces FILTER Ahn ELEM N contaci rock back and forth O RING a lt Figure 7 6 Disassembling the Water Trap Filter Assembly 0024 9473 Rev 4 87 PCA 3 Manual 7 5 Sensor Replacement All sensors are replaced in a similar manner Do the following to replace either the O2 NO NO or SO sensor Refer to Replacement Parts on page 94 for a list of sensors and part numbers E GE es 10 11 sensors is 2 years Typical life expectancy of the CO NOTE The typical life expectancy of the SO NO and NO sensors is 3 years Turn OFF the analyzer Remove the battery cover Remove the sensor retainer Remove the tubing from the gas cup of sensor being replaced Unplug the sensor along with its printed circuit board from the analyzer s main board Remove the sensor s gas cup by twisting its bayonet fitting counterclockwise and t
34. 3 Rev 4 61 PCA 3 Manual Minimum Computer Requirements for Fyrite User Software Minimum Requirement Operating System Windows XP or higher Drive CD ROM drive Access Port USB port USB 1 1 2 0 or 3 0 Software 205 MB for the Fyrite User Software Hard Drive S SN aaa alae Data Additional 350 KB for each downloaded file 5 15 Importing Saved Data into a Spreadsheet Data that was recovered and saved as an ASCII text file with a CSV extension as described above can easily be opened for viewing in most spreadsheet programs by simply double clicking the filename For example double clicking the filename Customer XYZ csv should automatically open the spreadsheet program and display the contents of the file If the spreadsheet program does not recognize the CSV file extension then refer to the spreadsheets documentation for information on how to manually import comma delimited text files The table below contains information about the 32 data fields that are downloaded with each data record For sensors that are not installed all related data fields for those sensors will be marked as For example if the analyzer does not contain an SO sensor then will appear in data fields 23 and 24 Downloaded Data Fields Field Column Data Name or Value 6 re 8 co Carbon Monoxide Level see feas 9 ppmco o Carbon Monoxide Level referenced to
35. ALIBRATION PASSWORD screen 66 0024 9473 Rev 4 PCA 3 Manual 5 Before calibration can begin a 4 character alphanumeric password must be entered Use the A V and lt gt buttons to enter the password The default password is 1111 6 Press the ENT key to accept the password If the correct password was entered the CALIBRATION LIST Menu will be displayed 7 Use the A V buttons to highlight the sensor to be calibrated and then perform the calibration procedure for that sensor as described in the following sections Main Menu Calibration Password uel ressure emperature Enter Password emory etup Calibration Menu Figure 6 1 Starting a Calibration 6 3 B Smart Sensor Replacement and Calibration To replace a B Smart sensor and calibrate do the following 1 Enter the CALIBRATION MENU 2 Use the A V buttons to select BSSMART Press ENTER to display the B Smart code screen 3 Use the A V buttons to enter the 10 or 14 digit alphanumeric code supplied with the B Smart sensor Use the lt P buttons to move the cursor across the screen Press ENTER NOTE There are two B Smart sensor code lengths 10 digits for COnicH NO NO and SO and 14 digits for COLow NOTE If the correct code was entered the analyzer accepts it and returns to the CALIBRATION MENU If an incorrect code was o entered the screen will display Invalid Code Check to make sure the correct code has been entered
36. Combustion Test Ensure that the following items have been completed PCA 3 Manual Atmospheric Gravity Vented Boiler O2 CO Stack Temp Figure 5 7 Atmospheric Gravity Vented Boiler Boilers which have a bell shaped draft diverter on top should be tested directly below the diverter through a hole drilled in the vent connector Turn ON analyzer and allow it to warm up see page 45 Select fuel being burned see page 24 Inset probe into stack see page 46 If necessary insert the optional primary air thermocouple into the combustion air stream of the burners that use an outside source of combustion air Next proceed with the combustion test as described below 0024 9473 Rev 4 47 PCA 3 Manual 0 0020 ppm 208 C Figure 5 8 Performing a Combustion Test 1 Press the RUN HOLD button to start the test You should hear the pump start running and see the word RUN appear at the top of the Combustion Test screen Sensor Indicators The following indicators appear in the sensor s data field depending on certain conditions Sensor that is not calibrated or installed XXX Sensor over range The calculated data cannot be displayed because the measured data necessary to make the calculation is out of range i e oxygen level above 18 8 2 Usethe up and down arrow keys to scroll to the T STK reading Loosen the thumbscrew on the probe stop and move the probe in and ou
37. Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight RUN HOLD FORMAT and then press ENT to display Run Hold Format Menu 4 Use the A V buttons to highlight Edit Format and then press the ENT key to show the Edit Run Hold Format where the current order of combustion data is displayed 5 Change data shown for a particular location by first using the AV buttons to highlight the location Then press the ENT key to select the location the cursor will start to flash 6 Use the A V buttons to scroll through and select the desired data to appear at that location Press the ENT key to make the selection Change data displayed at other locations by repeating Steps 5 and 6 When finished use the W button to highlight Edit complete at the bottom of the list then press ENT to save the new display format and return to the Run Hold Format screen Setup Menu Run Hold Format Edit Run Hold Format CHACE Run Hold Format 2 CAL Reminder Period Date Format O CO2 y Figure 4 24 Changing the Order in Which Data Is Displayed Reset Display format back to factory default settings as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and th
38. ENTS INTRODUCTION ciaretta aaa aA aa EEE 7 EI ADOU This a uia tate dust a 7 CONVENTIONS a 7 1 4 General DESCENDO nd non ke yel kan I He eM RES 9 i5 Operation 9 1 5 1 Turning On the 9 1 5 2 The COMDUSTION Test 10 1 5 3 Turning Off the 3 10 1 6 Feat res and Benefits anes 10 1 7 Sales Combo and Model 12 1 5 SOE CIMCALIONS 13 CHAPTER 2 HARDWARE 16 2A OV CIVIC W soaks e 16 2 2 Front Panel 17 23 Bat KII DIS 18 24 Battery Compartment 18 2 5 AC Adapter Connector POWER eke kek kk 18 2 6 Probe Connectors Gas Pressure 19 2 7 Differential Pressure Connector AP ccseecccccesseeceeeeeseecesseeeeeceeeaeeeses 20 2 8 Primary Air Thermocouple Connector T AIR 20 2 9 Gommputer Interface USB a treated ds 20 2 10 Wireless Printer Port IrDA Dese ptio kk keke 20 CHAPTER S INITIAESETUP
39. HAPTER 2 HARDWARE 2 1 Overview IrDA Wireless printer communications port F1 F2 F3 Soft Menu Buttons whose functions are defined by labels appearing above them on the LCD Color LCD USB Computer communications LT connector ENT Selects a highlighted menu item or confirms the entry of data RUN HOLD Starts and stops a combustion efficiency test Pressing this button during the 5 second turn off period will keep the nalyzer turned ON Arrow Buttons A Moves cursor up the display or increments an alphanumerical value Moves cursor down the display or decrements an alphanumerical value Moves cursor left or moves to top of menu list Moves cursor right or moves to bottom of menu list ESC Displays previous menu or previously viewed screen Press from between 1 and 2 seconds to turn analyzer ON and OFF N 7 e With analyzer turned ON press briefly to turn keypad backlight ON and OFF T STACK Probe s stack gas thermocouple connector T AIR Primary ambient air thermocouple connector POWER AC power adapter connector GAS Probe s gas hose connector LAP Probe s draft pressure hose fitting hose fitting Figure 2 1 Front and Bottom Views Showing Key Components 0024 9472 Rev 2 16 PCA 3 Manual 2 2 Front Panel Buttons The PCA 3 is controlled by various buttons while a colo
40. N HOLD button Also note that if the measured emission levels are above predetermined limits at the time the instrument is turned OFF the pump is automatically started and purges the sensor compartment with fresh air until the gas levels inside the analyzer are reduced If desired the purging process can be aborted by again pressing the I O button though it is not recommended 2 3 Backlit Display A large backlit color graphic display shows multiple combustion test values simultaneously and includes a zoom capability that provides extra large text 4 0 96 195 ppm 1 23 9 5 96 11 8 96 0 0020 ppm 208 C Figure 2 2 Sample Display 2 4 Battery Compartment The PCA 3 is powered by either its four internal batteries or by an optional AC power adapter that operates from any convenient source of 100 240 VAC 50 60 Hz power Batteries may be either disposable alkaline or rechargeable NiMH 2 5 AC Adapter Connector POWER The AC power adapter P N 0024 1254 can be used as an external power supply to run the analyzer on a continuous basis It uses 100 240 VAC at 50 60 Hz 18 0024 9473 Rev 4 PCA 3 Manual or Sor TT I oT sc mnm Figure 2 3 Battery Compartment T STACK T AIR Figure 2 4 Bottom View Showing Connectors 2 6 Probe Connectors Gas Pressure T Stack The probe and hose assembly are connected to the analyzer by way
41. ON THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT 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 Register Your Warranty by Visiting www MyBacharach com NOTICE Product improvements and enhancements are continuous therefore the specifications and information contained in this document may change without notice Bacharach Inc shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Bacharach Inc Copyright 2014 Bacharach Inc all rights reserved BACHARACH PCA B SMART and FYRITE are registered trademarks of Bacharach Inc All other trademarks trade names service marks and logos referenced herein belong to their respective companies 2 0024 9473 Rev 4 PCA 3 Manual TABLE OF CONT
42. SO cylinder NOTE The calibration range is from 9 to 1 800 ppm An attempt to calibrate outside this range will cause the message Bad Calibration Wrong CAL Entry to appear in the following step Calibration Menu T Stack Calibrate STeP Measured 268 ppm Applied 270 ppm Press ENTER Os NO z 01 09 10 08 17 12 Figure 6 9 SO Sensor Calibration 5 Adjust regulator for a flow meter indication of approximately 2 SCFH Wait until the measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the 502 Measured value to that of the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed 76 0024 9473 Rev 4 PCA 3 Manual NOTE If the sensor s output is low but still usable then the message Good Calibration WARNING Low Sensor will appear The sensor will now be marked as being Low in the DIAGNOSTICS screen NOTE If the sensor s output is too low to be usable then the message Bad Calibration Sensor End of Life Entry Not 0 Saved will appear followed by the CALIBRATION LIST screen being re displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen 6 Turn OFF regulator and remove the gas cylinder 6 9 NO Sensor Calibration This procedure spans the optional nitric oxide sensor to a Known gas level 6 9 1 Material Required e Calibration Kit P N
43. See page 28 for pollution unit of measure selected 2 represents the selected oxygen reference level of between 0 and 15 see page 32 3 Only shown if selected in the Run Hold Format menu see page 41 A FF 2 NOTE Stars appear measurement and calculation fields of sensors that are not installed 0024 9473 Rev 4 49 PCA 3 Manual 5 6 Selecting a Pressure Label The pressure measurement can be labeled with types including differential across heat exchanger draft reading and differential pressure See page 51 for pressure and draft measurement procedures Label data as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight PRESSURE and then press ENT to display the PRESSURE MENU 3 Use the lt gt buttons to scroll through the available pressure label types The current label is used saved and printed with the record Main Menu Pressure mnm Fuel Pressure Measured r ka Type Diff Pressure Calibration Figure 5 9 Selecting a Pressure Label 5 7 Temperature Label Selection and Measurement The difference in temperature between two areas can be measured by using the analyzer s two temperature channels and the Temperature screen By using the T Air channel as a reference the temperature applied to the T Stack channel will be displayed on the Tem
44. Sektos kj Lambda _ ESENESAES eed eko yeker Ls fs TT Heating Values E em Le e Heating Values Carbon Dioxide CO tt Pt Pt tf No NS NO NO 7_j NO referenced to l J j i Ta J jo CO referenced to O NO reterencedto O NO referenced to EM ES SO referenced to O CO CO 12 0024 9473 Rev 4 PCA 3 Manual 1 8 Specifications Measurement Based on Installed Sensors Display Range Oxygen 0 1 to 20 9 Stack Temperature 20 to 1 200 C 4 to 2 192 F Primary Ambient Air Temperature 20 to 537 C 4 to 999 F Carbon Monoxide CO H5 compensated 0 to 4 000 ppm Pressure Draft 179 mb 72 inwc CO High Range 4 001 to 20 000 ppm Nitric Oxide NO 0 to 3 000 ppm Nitrogen Dioxide NO 0 to 500 ppm Sulfur Dioxide SO 0 to 5 000 ppm Calculated Value Based on Installed Sensors Display Range Stack Loss qA 0 1 to 100 Carbon Dioxide dry basis 0 0 to fuel dependent max in Lambda 1 to 9 55 EFF HHV 0 1 to 100 ETA LHV 0 1 to 112 fuel dependent 0 0001 to a fuel dependent Coe ate Approximately 8 000 CO referenced to 0 0 to 9 999 ppm NO referenced to 0 0 to 9 999 ppm NO referenced to 0 0 to 9 999 ppm NO referenced to O to 9 999 ppm SO referenced to 0 0 to 9 999 ppm oxygen level is below 18 8 and the stack temperature is below NOTE Calculations are performed only
45. a of see field 27 62 0024 9473 Rev 4 PCA 3 Manual Field Column Data Name or Value Nitric Oxide Level referenced to a of O see field 28 Nitrogen Oxides Level as referenced to a of O see field 28 1 0 reference as selected refer to O2 Reference Setup on page 32 2 Pressure units as selected refer to Pressure Units Selection on page 27 3 Pollution units as selected refer to Pollution Units Selection on page 28 5 16 Printing Test Data Combustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described below Data that is stored in memory can also be printed by first displaying the stored test data as described in Recalling Combustion Test Data section page 58 and Recalling Logged Test Data section page 59 In addition to printing combustion and pressure data the contents of any screen that shows the label PRINT above the F1 button can be printed For example the information shown in the DIAGNOSTIC screen can be printed 1 Turn ON printer Refer to the printer s instruction manual for detailed operating information If not already done set up the printer for 8 bit No parity 9600 baud IrDA is set to IIDA SIR DTR handshaking 2 Align the printer with the top of the analyzer as shown in Figure 5 23 3 Press the PRINT F1 button to begin printing 0024 9473 Rev 4 63 PCA 3 Manual 8 t
46. a Draft Pressure 51 5 9 SAVIN Test dept du Paula N neut Ma Qu 52 5 10 Ending a COMBUSTION EN ES 53 5 11 Emptying the Water 53 cn EM Data LOB INE errei 54 SM abs OVVIO E 54 5 12 2 TURNING ON Data LOPE INS 55 5 12 3 Setting the Logging Interval and Duration 56 5 12 4 Starting the Data Logging 57 5 12 5 Ending the Data Logging 57 9 13 M mol FUNCION S qe ESSE Uii 58 91341 OV TV Am X 58 4 0024 9473 Rev 4 PCA 3 Manual 5 13 2 Recalling Combustion Test 58 5 13 3 Recalling Logged Test 59 5 13 4 Clearing MenO sos odit ec pn T SEE Ro RU we NES 60 PEE ol 60 5 14 Downloading Stored Data to a 61 5 15 Importing Saved Data into a Spreadsheet 62 PIME Tes E tab e subidos he 63 5 17 Turning Off the Analyzer and 1 k 65 CHAPTER 6
47. ated and installed when needed Sensors can be moved from one analyzer to another The analyzer s diagnostics screen shows what sensors are installed and their current end of life condition Good Low Bad B Smart sensors should be calibrated by an authorized Bacharach Service Center see Service Centers on page 99 every 6 months to 1 year to assure that the analyzer continues to meet its published accuracy specifications B Smart sensors however can be calibrated in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in the following sections 6 2 Starting a Calibration Start any calibration procedure by doing the following 1 Place the probe in an area of fresh air turn ON the analyzer allowing it to cycle through its 60 second warm up period During warm up the analyzer s operation is checked and the sensors are set to the following ambient conditions e Oxygen sensor spanned to 20 9 e All gas sensors are zeroed e pressure sensor is zeroed 2 Any errors detected during warm up will be listed on the display immediately following warm up Correct any errors before proceeding Refer to page 93 Error Messages for a listing of error messages and their meaning 3 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 4 Usethe A V buttons to highlight CALIBRATION and then press ENT to display the C
48. bustion test data can be printed by pressing the PRINT F1 button Refer to Printing Test Data section on page 63 CES CS 58 0024 9473 Rev 4 PCA 3 Manual Memory Options Memory Directory Mem 2 NGAS Memory Directory 1 23 08 10 15 08 27 4 0 96 Logging Directory 2 31 08 10 07 30 12 139 ppm Clear Memory 3 31 08 10 07 30 14 Ms E Clear All 5 31 08 10 07 30 20 0 0015 ppm 6 31 08 10 07 30 22 Menu _Menu Figure 5 19 Recalling Combustion Test Data 5 13 3 Recalling Logged Test Data Clear Log 4 31 08 10 07 30 17 11 8 96 Recall individual logged combustion test data records as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight MEMORY and then press ENT to display the MEMORY MENU 3 Use the A V buttons to highlight LOGGING DIRECTORY and then press ENT to display the LOGGING DIRECTORY screen 4 Use the A V buttons to highlight the desired data logging location to be recalled Each logging location is identified by the date and time at which the data was saved The word EMPTY signifies that the logging location does not contain data 5 Press ENT to display the logging data contained in the selected memory location NOTE The top line of the log test data screen shows the log location being viewed In this example Log 1 is being displayed NOTE The recalled logged test data can be printed
49. by pressing the PRINT F1 button Refer to Printing Test Data section on page 63 Memory Options Logging Directory Memory Directory 1 07 23 10 02 49 04 PM Logging Directory 2 07 23 10 02 49 14 PM Clear Memory 3 07 23 10 02 49 24 PM Clear Log 4 07 23 10 02 49 34 PM Clear All 5 07 23 10 02 49 44 PM 6 07 23 10 02 49 54 PM Figure 5 20 Recalling Logged Test Data 0024 9473 Rev 4 59 PCA 3 Manual 5 13 4 Clearing Memory When all memory locations used to store individual combustion test records have been filled the next combustion test record saved will not overwrite the oldest When all logging memory locations in the logging directory are full they must be manually cleared in order to store new data At no time will the logging process overwrite older data Logging will stop when available memory is filled Each memory bank can be individually cleared or all memory locations in both banks can be cleared simultaneously Do the following to clear memory 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the A V buttons to highlight MEMORY and then press ENT to display the MEMORY MENU Main Menu Memory Options Clear Memory Memory Directory Logging Directory Clear Memory Memory Clear Log Clear All Calibration Figure 5 21 Clearing Memory 3 Use the A V buttons to highlight one of the following e CLEAR MEMORY DATA clears only t
50. cable and carrying case Refer to Figure 1 2 The PCA 3 can measure up to four gases simultaneously so it is the perfect tool for service technicians inspectors and boiler contractors who need to determine combustion efficiency excess air stack gas and CO levels stack temperature draft and differential pressure Figure 1 2 A Typical PCA 3 Kit The analyzer can also directly measure and display NO NO and 502 with the installation of the appropriate sensors Combustion efficiency calculations can be conducted for a variety of fuels see Specifications later in this chapter Combustion analysis is performed in accordance with EN50379 B Smart sensor technology allows a new sensor to be installed in the field without having to calibrate the analyzer with gas before use Advanced data storage and communication features allow the operator to store up to 500 individual combustion test records which can later be recalled for viewing printing or downloading to a personal computer In its data logging mode the analyzer can store an additional 500 data logged records The optional AC power adapter allows the analyzer to run for extended periods of time while data logging The optional sample conditioning probe is recommended when measuring NO and SO to ensure the highest degree of measurement accuracy A probe and hose assembly with an integral thermocouple and filter water trap connect to the bottom of the analyz
51. cause the message Bad Calibration Wrong CAL Entry to appear in d NOTE The calibration range is from 9 to 150 ppm An the following step Calibration Menu Calibrate Measured 93 ppm T Stack Applied Press ENTER NO 01 09 10 08 19 07 Figure 6 11 Sensor Calibration 5 Adjust regulator for a flow meter indication of approximately 2 SCFH Wait until the measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the measured value to that of the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed NOTE the sensor s output is low but still usable then the message Good Calibration WARNING Low Sensor will appear The sensor will now be marked as being Low in the DIAGNOSTICS screen NOTE If the sensor s output is too low to be usable then the message Bad Calibration Sensor End of Life Entry o Not Saved will appear followed by the CALIBRATION LIST screen being re displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen 6 Turn OFF regulator and remove the gas cylinder 0024 9473 Rev 4 79 PCA 3 Manual 6 11 Sensor Calibration This procedure spans the optional carbon monoxide high sensor 4 001 to 20 000 ppm to a known gas level 6 11 1 Material Required e Calibration Kit P N 0024 7059 e Gas Cylinder 4 000 ppm CO in Air
52. d by the main batteries the coin cell P N 0204 0020 every 5 years Main Menu Setup Menu Date Menu Pollution Units bate Oil Derivative Pee see SENE setup Boiler Temperature Calibration Date 30 08 10 16 09 09 Figure 4 10 Date Setup 0024 9473 Rev 4 31 PCA 3 Manual 4 11 Time Setup The time is stored in the format hh mmiss Its value is part of the date and time stamp that is saved along with each combustion test record Set the analyzer s internal clock to the current time as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight TIME and then press ENT to display the TIME MENU 4 First use the lt gt buttons to move the cursor across the screen until it is over the digit to be changed and then press the A buttons until the desired value is displayed 5 Repeat Step 4 until values for hour and minute are set NOTE The value for seconds cannot be entered but is displayed and stored as part of the combustion test record 6 Press ENT to save the displayed time values and re display the SETUP MENU or press ESC to abort and retain the old time values Main Menu Setup Menu Time Menu uel Pollution Units 5 ressure Smoke Number Tima IB 2 emperature Oil Derivative D Boiler Temperatu
53. d can be turned OFF and ON as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Use the A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the buttons to highlight BUTTON SOUND and then press ENT to display the BUTTON SOUND screen 4 Use the A V buttons to highlight either OFF or ON In the example shown OFF has been selected 5 Press ENT to save the selection and re display the SETUP MENU Main Menu setup Menu Button Sound Menu uel ressure Run Hold Format emperature Language Selection Button Sound setup CAL Reminder Period alibration Date Format 30 08 10 16 21 35 Menu Menu Figure 4 16 Button Sound Selection 0024 9473 Rev 4 35 PCA 3 Manual 4 17 Test ID Information Test records can be identified e g customers name burner number and location by manually entering up to three lines of text with each line containing a maximum of 20 alphanumeric characters When a Test ID is selected this information will be associated with all succeeding test records and will appear at the top of each test record when printed and in CSV files when records are downloaded to a PC The chosen Test ID remains in effect until it is deselected a new Test ID is selected or the instrument is turned off Up to 30 Test IDs can be pre entered for later retrieval NOTE To save time Test ID informa
54. d the PRESSURE screen By using the AP port as the reference the pressure applied to the AP port will be displayed on the PRESSURE screen as the differential pressure between the two ports Perform a draft pressure measurement as follows 1 Turn ON the analyzer and allow it to complete its warm up cycle see page 9 17 and 21 NOTE Refer to page 27 for information on selecting the pressure units of measure 2 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 3 Use the A V buttons to highlight PRESSURE and then press ENT to display the PRESSURE screen 4 Before taking a measurement the pressure sensor may need to be re zeroed if it is not already displaying zero with both pressure ports open to the atmosphere If necessary zero the pressure sensor as follows e Press the ZERO F2 button e Disconnect any hoses connected to the AP and AP ports and then press ENT to zero the pressure sensor e Reconnect any hoses When measuring draft simply leave the AP port open to the atmosphere and connect the probe s draft hose to the AP port see Figure 5 13 0024 9473 Rev 4 51 PCA 3 Manual Main Menu Pressure Pressure Zero uel Pressure Measured emperature 0 03 mB Disconnect hose emory Type Press ENTER etup Diff Pressure alibration Figure 5 11 Performing a Draft Pressure Measurement 5 Doone of the following to measure draft or d
55. d when the burner s primary air temperature is not the same as the room temperature 5 Inspect all hoses for cracks If any hose is found to be defective replace the entire probe and hose assembly Check that the water trap is empty and the filter is not dirty or saturated with water 3 4 Preparing to Configure the PCA 3 After initial setup is complete turn on the PCA 3 For detailed power up instructions refer to Turning On the PCA 3 on pages 9 and 45 You are now ready to configure your PCA 3 for your particular application and to your particular preferences Refer to Configuration Procedures on page 24 You configure the PCA 3 by navigating the menus and changing key parameter values It may be helpful to review Front Panel Buttons on page 17 in preparation for navigating the menu interface of the PCA 3 22 0024 9473 Rev 4 PCA 3 Manual Primary Ambient Air N Thermocouple T AIR Optional e AC Power DA em Adapter Jack POWER Differential Pressure Hose AP Optional Stack Gas eoe Draft Gas sample Thermocouple b d Hose Hose E Connector GAS T STACK Probe Tube E Probe Stop e Figure 3 2 Connecting the Probe to the Analyzer Water Trap Filter Assembly 0024 9473 Rev 4 23 PCA 3 Manual CHAPTER 4 CONFIGURATION PROCEDURES 4 1 Default Operating Parameters The PCA 3 is set up at the factory for the following operating parameters To change any of t
56. e properly zeroed during the warm up cycle Turn ON the analyzer by pressing the I O button for at least 1 second or until a single beep is heard Observe that the analyzer s firmware version model and serial numbers are briefly displayed followed by the Warm Up screen Wait for the analyzer to count down its 60 second warm up period after which the instrument will display the Combustion Test HOLD screen If problems were detected during warm up the message ERRORS DETECTED is displayed along with a list of those errors As an example the screen below shows that the battery is low Refer to Error Messages page 93 for a listing and possible remedy for the errors displayed NOTE f the sensors in error are not critical to the combustion test then press the RUN HOLD button to display the Combustion Test HOLD screen and proceed with the test Errors Detected 1 23 9 5 96 11 8 96 0 0020 ppm Warm Up 53 208 C Figure 5 1 Turning On the Analyzer and Warm up 5 3 Low Battery Alarm When the batteries are nearly depleted an empty battery icon appears in the upper right corner of the display and a short beep is sounded every 10 seconds 0024 9473 Rev 4 45 PCA 3 Manual Figure 5 2 Low Battery Indicator After a low battery alarm occurs the analyzer will continue to operate for only a few minutes The amount of operating time that remains depends on many factors e g pump and keypad backlight bein
57. e thermometer reading NOTE The calibration range is from 80 to 330 C 175 to 625 F An attempt to calibrate outside this range will 9 cause the message Applied Value High or Low to appear at the bottom of the screen 2 Wait until the measured reading stabilizes and then press ENT to calibrate the TS Span Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed 6 6 T Air Calibration This procedure first zeros and then spans the ambient temperature channel to known temperature values The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures Alternatively containers of ice water and boiling water can be used 6 6 1 Material Required e Thermocouple Simulator K type Range 0 to 300 C Accuracy 0 3 C e Alternatively Ice Water Boiling Water Thermometer 6 6 2 TA Zero Procedure 1 Set thermocouple simulator to room temperature and plug its output into the T AIR connector located at the bottom of the analyzer 0024 9473 Rev 4 71 PCA 3 Manual Alternatively Plug the probe s thermocouple into the T AIR connector located at the bottom of the analyzer DO NOT attach the probe s gas hose to the analyzer s GAS port otherwise water will be drawn into the analyzer 2 If not already done turn ON the analyzer and display t
58. een allows the user to manually enter YES or NO as to whether oil derivatives were present during the smoke test This setting will be displayed on the Run Hold screen 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 Use the A Wbuttons to highlight SETUP and then press ENT to display the SETUP MENU Use the A Wbuttons to highlight Oil Derivative and then press the ENT key to display the Oil Derivative Menu Use the A V buttons to highlight oil derivative YES or NO and th en press ENT to save and return to the SETUP MENU Main Menu Setup Menu Oil Derivative Temperature Units Pressure Pollution Units Setup Oil Derivative Calibration Boiler Temperature Figure 4 8 Configuring for the Presence of Oil Derivatives 4 9 Boiler Temperature This screen allows the user to manually enter a boiler temperature as measured by an external measuring device Boiler temperature will be displayed on the Run Hold screen 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 Use the A Wbuttons to highlight SETUP and then press ENT to display the SETUP MENU Use the A V buttons to highlight Boiler Temperature and then press the ENT key to display the Boiler Temperature screen Use the A V buttons to modify the highlighted number and the lt gt buttons to move the cursor across the input
59. en press ENT to display the SETUP MENU 3 Use the A V buttons to highlight RUN HOLD FORMAT and then press ENT to display Run Hold Format Menu 42 0024 9473 Rev 4 PCA 3 Manual 4 Use the A V buttons to highlight RESET FORMAT then press ENT to display the Reset Format screen 5 Usethe A V buttons to select YES then press ENT to reset the display and return to the Run Hold Format screen setup Menu Run Hold Format Edit Format Run Hold Format Reset Format Language Selection Reset Format Button Sound CAL Reminder Period Figure 4 25 Resetting Display Formats Back to Factory Defaults 4 22 NO Calculation NO is a combination of NO and The actual NO value on the PCA3 is the sum of both NO and NO readings NO NO NOz from the sensors in positions 4 and 3 respectively Analyzers having just the NO sensor in sensor position 4 can display a calculated NO approximation using just the NO sensor reading and a multiplier of 1 05 NOxxNO 1 05 This calculation is enabled by setting the NOx Calculation option in the Setup Menu to ON Setup Menu NOx Calculation Language Selection Off Button Sound On _ CAL Reminder Period Date Format NOx Calculation HB NOx Calculation Off On CO Zero Setting 02 10 12 09 23 57 AM 02 10 12 08 54 19 Figure 4 26 NOx Calculation Screens NOx Calculation NOx Calculation Off On NO NO x 1 05 Figure 4 27 Sensor Config
60. er providing the means of drawing in gas samples and for measuring stack temperature and draft 1 5 Operation Overview 1 5 1 Turning On the PCA 3 The PCA 3 is turned ON by pressing its red I O button A warm up period of 60 seconds then begins during which time the analyzer performs self diagnostics At the end of the warm up period if no errors were detected the instrument will display the Combustion Test HOLD screen If errors were detected the message 0024 9473 Rev 4 9 PCA 3 Manual ERRORS DETECTED is displayed along with a list of the errors These errors must be corrected before proceeding with the combustion test Before starting a test be sure to select the fuel being burned The default fuel selected is Natural Gas Note that the name of the fuel being burned is indicated at the top of the run hold screen 1 5 2 The Combustion Test To assure correct combustion efficiency calculations the analyzer must know the burners primary air temperature The analyzer normally uses its internal temperature sensor for the primary air temperature value but this method is only acceptable if the burner is using ambient room air If the burner is drawing in cold outside air we recommend that the optional T AIR thermocouple be used This thermocouple plugs into the bottom of the analyzer and is placed in the burner s primary air stream Begin the combustion test by first inserting the analyzer s probe tube into the stack
61. field to enter the boiler temperature Press ENT to save this information and return to the Setup Menu 30 0024 9473 Rev 4 PCA 3 Manual Main Menu Setup Menu Boiler Temperature Fuel id Temperature Units r Pollution Units Woo uel Smoke Number Press ENTER Setup Oil Derivative Calibration Boiler Temperature Figure 4 9 Configuring for Boiler Temperature 4 10 Date Setup The date is stored in the format DD MM YY Its value is part of the date and time stamp that is saved along with each combustion test record Set the analyzer s internal clock to the current date as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight DATE and then press ENT to display the DATE MENU 4 First use the lt gt buttons to move the cursor across the screen until it is over the digit to be changed and then press the A buttons until the desired value is displayed 5 Repeat Step 4 until the values for month day and year have been set 6 Press ENT to save the selection and re display the SETUP MENU or press ESC to abort this procedure and retain the old date values and is maintained by a coin cell battery on the Main PCB in the absence of batteries Bacharach recommends changing d NOTE The real time clock is powere
62. g ON or OFF and the type and condition of the batteries 5 4 Locating Sampling Points Forced Air Furnace Hot Water Tank O2 Undiluted Flue L 3100 Gas Sample Taken Stack Temp Under Draft Diverter in Top of Fire Tube Figure 5 3 Forced Air Furnace For atmospheric burner or gravity vented forced air heating equipment with a clam Figure 5 4 Hot Water Tank shell or sectional heat exchanger design test each of the exhaust ports at the top of U S made hot water tanks with the bell the heat exchanger The probe should be shaped draft diverter can be accurately inserted back into each of the exhaust tested by inserting the probe tip directly ports to obtain a flue gas sample before into the top of the fire tube below the any dilution air is mixed in diverter 46 0024 9473 Rev 4 90 Efficiency Condensing Furnace Combustion Air Sampling Point O2 CO Stack Temp Figure 5 5 90 Efficiency Condensing Furnace Condensing furnaces boilers can be tested through a hole drilled in the plastic vent pipe when allowed by the manufacturer or local authority of jurisdiction or taken from the exhaust termination 80 Efficiency Fan Assist or Power Vented Furnace Figure 5 6 80 Efficiency Fan Assist or Power Vented Furnace Combustion testing of fan assist or power vented furnaces boilers should be done through a hole drilled in the vent immediately above the inducer fan 5 5 Performing a
63. gas stream of the appliance under test and then pressing the RUN HOLD button to display the Combustion Test RUN screen The analyzer will begin to continuously monitor the stack temperature 02 and emission levels in the stack gas and then display measured and calculated values on its display The recommended time required to achieve a stable measurement is a minimum of 3 minutes During a test the sensor is protected from high CO levels by being automatically flushed with fresh air when the detected CO level exceeds 4 000 ppm The analyzer will automatically start using its optional sensor if installed at CO levels starting at 4 001 ppm thus providing continuous CO readings up to 20 000 ppm A keypad backlight enables a user to read the keypad in dimly lit areas Turn the keypad backlight ON and OFF by briefly pressing the I O button 1 5 3 Turning Off the PCA 3 The analyzer is turned OFF by pressing and holding down the I O button for at least 2 seconds Note that there is a 5 second delay before the analyzer actually turns OFF during which time the analyzer can be turned back ON by pressing the RUN HOLD button In addition there is a gas purge feature that keeps the analyzers pump running if the gas level inside the sensor chambers is abnormally high at shutdown With the probe removed from the stack and sampling fresh air the analyzer purges itself until the detected gas concentrations drop below predetermined le
64. gle Battery Clip Double Cable Assembly Tubing Vinyl 1 8 ID x 3 16 OD Tubing Silicon 1 16 ID x 1 8 OD Tubing Silicon 3 32 ID x 5 32 OD Tubing Silicon 1 8 ID x 3 16 OD Tubing 1 8 ID x 1 4 OD Elbow Bias Battery O Ring Kit all O rings included 0024 9473 Rev 4 95 PCA 3 Manual LO Main PCB Assembly Replacement Part Not Available Figure 8 3 Replacement Parts 96 0024 9473 Rev 4 PCA 3 Manual 15C r 15 16C 16D R 19C 16C JN 20 IN Bottom OUT Top 21 22 14 N c DI 5 2 N typical 2 places 2 typical 4 places ac Figure 8 3 Replacement Parts Continued 8 7 Accessories Standard Accessories Description Part No 1 Water Trap Filter w O Rings 0005 5122 and 0005 5117 2 Filter Element 3 pack 3 Probe Stop 4 5 Fyrite User Software USB Cable Instruction Manual 0024 9473 Rev 4 97 PCA 3 Manual O RING 0005 5117 O RING 0005 5122 Figure 8 4 Hose and Probe Assembly Parts Optional Accessories Description Calibration Kit includes hoses adapter flow meter does not include gas cylinders Gas Cylinder 500 ppm CO in air 103 Liter Gas Cylinder 1000 ppm CO amp 1000 ppm H in Nitrogen 103 Liter IrDA Printer Printer Paper 1 Roll Printer Paper 5 Pack Sample Conditioning Probe Compact recommended when measuri
65. haracters The operator can scroll through the complete list of measured and calculated data no matter what zoom level has been selected Select desired zoom level as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight ZOOM and then press ENT to display the ZOOM screen 4 Use the A V buttons to select the desired Zoom level Options include STANDARD 2X and 3X Standard will display seven lines of Combustion test data 2X will display five and 3X will display four 5 Press ENT to save the selection and re display the SETUP MENU setup Menu Zoom Menu Hold NGAS Standard Zoom Logging Test ID 30 08 10 16 18 48 Figure 4 14 Zoom Display Selection 34 0024 9473 Rev 4 PCA 3 Manual 4 15 Logging Selection When the logging function is activated up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined length of time Refer to Data Logging starting on page 54 for detailed information on how to select the logging function how to set the interval and duration time periods and how to view or download the stored data setup Menu ji Figure 4 15 Logging Selection 4 16 Button Sound Selection The audible sound used to signal when a button is presse
66. he CALIBRATION LIST screen refer to Calibration on page 66 3 Use the A V buttons to highlight T Air and then press ENT to display the CALIBRATE TA ZERO screen NOTE Measured is the current temperature reading o while Applied is a known temperature that will be applied for calibration purposes 4 Set thermocouple simulator to 0 C 32 F and then use the A V and lt gt buttons to enter an applied value that exactly equals the setting of the simulator Alternatively Submerge probe tip into an ice water bath with a thermometer wait several minutes and then use the A V and lt gt buttons to enter an applied value that exactly equals the thermometer reading NOTE The calibration range is from O to 5 C 32 to 41 F An attempt to calibrate outside this range will cause the message Applied Value High or Low to appear at the bottom of the screen o Wait until the measured reading stabilizes and then press ENT to calibrate the TA Zero Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CALIBRATE TA SPAN screen Calibration Menu Calibrate Measured _5 6 T Stack Applied 00 Press ENTER CO LO 09 09 10 10 03 08 Figure 6 5 T Air Zero Procedure 72 0024 9473 Rev 4 PCA 3 Manual 6 6 3 TA Span Procedure 1 Set thermocouple simulator to 100 C 212 F and then use the A V and
67. he individual saved combustion test records e CLEAR LOGGING DATA clears only the combustion test records that were saved during the logging process e CLEAR ALL MEMORY clears all memory locations in both memory banks 4 Press ENT to display the CLEAR MEMORY LOGGING or ALL DATA conformation screen Highlight YES to confirm that memory is to be cleared and then press ENT to actually clear memory as evidenced by the display of the WAIT Erasing memory screen 5 13 5 Print Average The PCA 3 will automatically calculate display and print the average of three consecutively saved combustion records Calculate display or print the average data as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight MEMORY and then press ENT to display the MEMORY MENU 60 0024 9473 Rev 4 PCA 3 Manual 3 Use the A V buttons to highlight PRINT AVERAGE press the ENT button to display a directory of stored test data Average calculation will be time and date coded Pressure and Temperature records will also be shown but can not be d NOTE Combustion records that can be used for the selected for the Average calculations 4 Usethe A V buttons to highlight any three consecutive combustion records then press ENT to display the calculated average for all data stored in the records NOTE If the highlighted records contain a Tempe
68. hen pulling the cup straight up Carefully remove the old sensor from the B Smart sensor PCB keeping in mind that there is an adhesive foam disk in between the PCB and sensor IMPORTANT When replacing the O2 sensor be sure that the sensor pin plugs into the PCB socket that is also marked O Also when replacing an NO sensor replace the bias battery Remove the replacement sensor from its plastic canister Note that the COi ow COnicH SO and NO sensors have a shorting spring installed between two of their pins Remove and discard this spring before installing the sensor Attach the gas cup to new sensor making sure that when the sensor assembly is plugged into the analyzer s main board the tubing connections on top of gas cup are aligned as shown in Figure 7 7 Plug the sensor into analyzer and then reattach tubing to gas cup Install the sensor retainer and battery cover 88 0024 9473 Rev 4 PCA 3 Manual Sensor Retainer ___ Twist gas DTE Gas Cup bayonet fitting counterclockwise to release Sensor a Adhesive in P d Printed So Circuit Board disk Sensor electrical connector mates with CAUTION sure to remove any pins on analyzer s main shorting spring from the board new sensor pins before installing There is no shorting spring on the O2 or NO sensors Figure 7 7 Sensor Assembly 12 Allow the sensor that was just installed time to stabili
69. hese parameters perform the associated procedure that follows Parameter Factory Default See SmkeNumer fo o o Oil Derivative 4 2 Fuel Selection To assure the accurate calculation of combustion efficiency select the fuel being burned as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight FUEL and then press ENT to display the FUEL MENU 3 Use the A V buttons to scroll through the list of available fuels until the desired fuel is highlighted In the example shown PROPANE has been selected If custom fuels are added they will be displayed at the bottom of the list 24 0024 9473 Rev 4 PCA 3 Manual NOTE Use the lt P buttons to quickly scroll to the bottom and top of the list NOTE In addition to the standard fuels programmed into the PCA 3 Bacharach can develop custom fuel codes based on the customer s specific needs The 3 can be programmed with 2 additional fuels which can be added to the instrument using the Fyrite User Software FUS Consult factory for price and delivery CES CES Main Menu Select Fuel Fuel Natural Gas a Pressure Calibration lo Menu Figure 4 1 Fuel Selection 4 Press ENT to save the selection and display the MAX screen 5 To accept the default CO Max value for the selected fuel use the A V buttons to highlight DEFAULT and press ENT t
70. ifferential pressure e measure draft simply insert the probe into the stack and observe the draft reading on the PRESSURE screen e measure differential pressure connect two sampling hoses to the AP and AP ports and place the open end of each hose into the areas being measured The differential pressure between the two areas is now displayed on the PRESSURE screen If the pressure at the AP port is higher than the AP port then the pressure reading will be positive If it is lower then the reading will be negative Pressure Zero e T STACK T AIR POWER Reconnect hose AP Pressure AP Pressure Reference Port Measurement Port Figure 5 12 Pressure Zero Screen Figure 5 13 Draft Pressure Measurement Hose Connections 5 9 Saving Test Data Up to 500 individual sets snap shots of combustion test pressure or temperature data can be saved in memory which can later be recalled for viewing from the Memory Directory see Recalling Combustion Test Data section on page 58 1 First display the screen that contains the data to be saved In the example below all data associated with the Combustion Test RUN screen will be saved 2 Press the SAVE F3 button to save the test data in the next available memory location 52 0024 9473 Rev 4 PCA 3 Manual saved until space is made available by clearing the data 9 NOTE When memory is full the next reading will not be see Clea
71. its Selection Select to display temperature in either F or C as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight TEMP UNITS and then press ENT to display the TEMP UNITS MENU 4 Use the A V buttons to highlight the desired temperature units In the example shown Fahrenheit has been selected 5 Press ENT to save the selection and re display the SETUP MENU Main Menu setup Menu Temp Units Menu Ful Temperature Units Celsius 5 emory etup Calibration Reference 30 08 10 16 05 45 Figure 4 4 Temperature Units Selection 4 5 Pressure Units Selection Select to display pressure in Inches of Water Column inwc millibar mb Pascals Pa or hectoPascals hPa as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight PRESSURE UNITS and then press ENT to display the PRESSURE UNITS MENU 0024 9473 Rev 4 27 PCA 3 Manual 4 Use the AVY buttons to highlight the desired pressure units In the example shown InchesWater has been selected 5 Press ENT to save the selection and re display the SETUP MENU Main Me
72. ity to keep the analyzer turned ON by pressing the RUN HOLD button If the PCA 3 was not purged with fresh air as described in Ending a Combustion Test on page 53 then the analyzer may remain ON with its pump running and display the message PURGING SENSORS as the result of combustion gases still being present inside the analyzer At this time the operator should ensure that the probe is removed from the stack allowing the analyzer to purge itself with fresh air The 5 second shutdown sequence will not begin until the gas levels inside the analyzer drop below predetermined levels NOTE Although not recommended the purging process can be bypassed by pressing the I O button a second time 0024 9473 Rev 4 65 PCA 3 Manual CHAPTER 6 CALIBRATION IMPORTANT Before performing any calibration procedure ensure i that new batteries are installed or use the optional AC power adapter Also ensure that the analyzer is at room temperature and will be sampling fresh air when turned ON 6 1 B Smart Sensors The PCA 3 uses Bacharach s B Smart Sensor technology for NO and 02 The B Smart Sensor is marked with a 10 or 14 digit calibration code that can be entered in the instrument s calibration screen via the keypad or with the Fyrite User Software Benefits of the B Smart Sensors include the following New sensors can be installed without applying gas for calibration Sensors can be pre calibr
73. l s are in error Pressure sensor is measuring pressure outside the range of 3 inches of water column at startup Ensure that the analyzer is sampling atmospheric pressure and restart The analyzer was turned on with the probe sampling flue gas Move the probe to fresh air and restart the analyzer 8 6 Replacement Parts Item Description Part No 6 Wndw 0041826 _ 8 Kepd 004 887 Te 00241388 14 Replacement Hose Connector Plate complete 0024 1480 assembly including O rings 94 0024 9473 Rev 4 PCA 3 Manual Part No 0105 5103 0105 5102 0024 1421 0024 1422 0024 1420 0024 0788 0024 1541 0024 1542 0024 1545 0024 1544 0024 1543 0024 0789 0024 0997 0024 0881 Item Description 14A O Ring Pressure Fitting 14B O Ring Gas Fitting 15A Gas Cup O SO NO 15B Gas Cup CO ow 15C Gas Cup 16A Sensor 16B Sensor B Smart CO ow 16C Sensor B Smart 16D Sensor B Smart NO 16E Sensor B Smart 16F B Smart Sensor SO 16G Sensor NOT calibrated CO ow 16H Sensor NOT calibrated CO 16J Sensor NOT calibrated NO 16K Sensor NOT calibrated NO 0024 1027 16L Sensor NOT calibrated SO 0024 0998 7 Screw 4 x 1 2 LG 0002 2144 18 0004 1434 19 0024 1433 20 0024 1521 2 0003 6104 22 0003 6372 23 0103 6101 24 0103 6102 25 0003 6105 26 0003 6170 0204 0020 0024 1471 Battery Clip Sin
74. ling flue gas keep the analyzer above the water trap and keep the trap in a vertical position This will maximize the effectiveness of the trap and keep liquid condensate from being drawn directly into the analyzer e When liquid condensate is seen inside the water trap empty the trap before it becomes full See Emptying the Water Trap on pages 53 and 87 e The analyzer should be purged after performing a combustion test After removing probe from the stack let the pump run for at least 10 minutes to remove any stack gases and dry any condensate from inside the sensor chamber and probe assembly If the analyzer is turned OFF with high levels of flue gas remaining in the analyzer then the pump will continue to run and the message PURGING SENSORS will appear on the display until all flue gas levels fall below predetermined levels e When storing the analyzer it s a good idea to empty the water trap and leave it open to further dry it out e Calibrate the analyzer every 6 months to 1 year to ensure its accuracy 44 0024 9473 Rev 4 PCA 3 Manual 5 2 Turning On the Analyzer 1 BACHARACH Connect the probe and hose assembly and make sure that the analyzer is properly set up according to Initial Setup page 21 and Configuration Procedures page 24 IMPORTANT DO NOT insert probe into stack before turning ON the analyzer Place the probe in an area that contains fresh air This ensures that the sensors will b
75. n additional 500 data logged records Wireless IrDA link for printing current and stored combustion records pressure records calibration data and diagnostic data USB connectivity for downloading data to personal computer Field replaceable sensors and thermocouple Two year warranty on analyzer and all gas sensors Language options including English French Spanish German Italian Danish Polish and Dutch Custom Display Formats Calibration Reminders PCA 3 can be set up to remind the user that calibration is past due Auto manual zeroing option allows the operator to select the start up mode Auto zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurements Also all sensing channels are automatically zeroed on ambient air when the analyzer is first turned ON Manual zero is used to detect CO that may be present during start up 0024 9473 Rev 4 11 PCA 3 Manual 1 7 Sales Combo and Model Configurations Sales Combo 0024 xxxx Sales Combo Kit 0024 xxxx Model Type PCA 3 Only Part Number 0024 xxxx Measurements ee Stack Temperature 7 74 44 _Primary Ambient Air Temperature e Carbon Monoxide Low COrow gt t titt PressureDrat T44 Carbon Monoxide High J t NmeOxde NO Tt Nitrogen Dioxide NO _ J J Jti o Sulfur Dioxide S0 Calculations
76. naces 7 7 1 Equipment Required Alcohol Aerosol Can of Automotive Carburetor Cleaner Clean Rag Source of Compressed Air optional 7 7 2 Procedure 1 Remove gas sample hose from top of water trap components Take precautions not to spray cleaner onto CAUTION Carburetor cleaner attacks plastic the probe handle or analyzer 2 Insert the plastic spray tube of the carburetor cleaner into the gas sample hose and then liberally spray carburetor cleaner through the hose and out the probe tube 3 After spraying remove all the residual cleaner by repeatedly flushing the gas hose and probe tube with alcohol Wipe off the surfaces of the probe and tubing with a clean rag Allow the parts to dry completely If available blow compressed air through the probe to expedite the drying process 6 Reconnect gas sample hose to top of water trap 0024 9473 Rev 4 91 PCA 3 Manual CHAPTER 8 TROUBLESHOOTING 8 1 Error Symbols Error symbols are shown in the data fields of the Combustion Test screens and on the printout to indicate the following Error Symbol Description Three hyphens or dashes indicates that the calculated data cannot be displayed because the measured data necessary to make the calculation is out of range For calculations to occur the oxygen level must be below 18 8 and the stack temperature must be below 2 000 F 1 093 C fields of that sensor s related calculated values For example if
77. nd then use the A V and b buttons to enter an applied value that exactly equals the setting of the simulator Alternatively Submerge probe tip into an ice water bath with a thermometer wait several minutes and then use the V and lt P buttons to enter an applied value that exactly equals the thermometer reading NOTE The calibration range is from O to 5 C 32 to 41 F Calibrating outside this range will cause the message Applied Value High or Low to appear at the bottom of the screen o Wait until the measured reading stabilizes and then press ENT to calibrate the TS Zero Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CALIBRATE TS SPAN screen 70 0024 9473 Rev 4 PCA 3 Manual Calibration Menu Calibrate 5 4 Calibrate TS Span ressure Measured 6 C Measured 302 T Stack Applied 0 00 Applied goo Air O LO Ref Smart 09 09 10 10 00 34 01 09 10 08 53 55 Figure 6 4 T Stack Zero and Span 6 5 3 TS Span Procedure 1 Set thermocouple simulator to 300 572 F and then use the A V and lt buttons to enter an applied value that exactly equals the setting of the simulator Press ENTER Press ENTER Alternatively Submerge probe tip into a container of boiling water with a thermometer wait several minutes and then use the and lt gt buttons to enter an applied value that exactly equals th
78. ng NO and SO 98 Part No 0024 1254 0104 1797 0104 1798 0104 1799 0024 1103 0024 7059 0024 0492 0024 0794 0024 1400 0006 8733 0024 1310 0024 7224 0024 9473 Rev 4 PCA 3 Manual 8 8 Analyzer Repair It is recommended that field repair of the PCA 3 be limited to Checks of printed circuit board connectors Replacing the probe assembly Replacing the filter element in the water trap filter assembly Replacing sensors Information on how to perform these repairs is provided on page 82 Maintenance All other repairs should be performed by an authorized Bacharach Service Center refer to Service Centers on page 99 Any repairs performed by an unauthorized service organization will void the analyzer s warranty and release Bacharach Inc of any implied or written product liability 8 9 Service Centers United States Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5723 Email help MyBacharach com Canada Bacharach of Canada Inc 20 Amber Street Unit 7 Markham Ontario L3R 5P4 Canada Phone 905 470 8985 Fax 905 470 8963 Email support BachCan ca 0024 9473 Rev 4 99 PCA 3 Manual CHAPTER 9 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer of the products Bacharach Inc covered by this declaration 621 Hunt Valley Circle New Kensington PA 15068 Year conformity is declared 2010 The under
79. nu setup Calibration B Setup Menu n Temperature Units Pressure Units Pollution Units Reference Pressure Units Menu lInchesWater hectoPascals 08 06 10 10 06 14 AM Figure 4 5 Pressure Units Selection 4 6 Pollution Units Selection The PCA 3 is capable of converting the measured ppm levels of CO NO and SO to various pollution units using CFR40 Part 60 emission factors Note that the pollution unit conversions for NO and NOx are based on the molecular weight of NO Configure the PCA 3 to display pollution units in parts per million ppm pounds of pollutant per million BTU Mbtu milligrams of pollutant per cubic meter of gas mg m or grams of pollutant per gigajoule g GJ as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight POLLUTION UNITS and then press ENT to display the POLLUTION UNITS MENU 4 Use theA V buttons to highlight the desired pollution units In th e example shown ppm has been selected 5 Press ENT to save the selection and re display the SETUP MENU Main Menu uel ressure emperature Memory setup Calibration setup Menu Pressure Units Pollution Units Reference Pollution Units ppm Ib MBtu g GJ 08 06 10 10 0
80. o 16 in 20 32 to 40 64 cm BACHARACH INC ppm ppm ppm ppm ppm ppm ppm ppm ppm PCA 3 SN TIME 13 00 00 DATE 24 06 10 FUEL NGAS O2 4 0 CO 195 LAMBDA 1 23 CO2 9 5 CO2MAX 11 8 CO CO2 0 0020 T STK 208 T AIR 24 4 qA 8 3 ETA 91 7 EFF 84 1 NO 18 NO2 6 NOX 24 SO2 xke CO 0 241 NO 0 22 NO2 0 7 NOX 0 29 SO2 0 AVG SMOKE OIL DERIVE KKK BOILER TEMP COMMENTS ppm C Figure 5 23 Printer Alignment and Sample Printout 64 0024 9473 Rev 4 PCA 3 Manual The printout shown in Figure 5 23 shows typical combustion test results of an analyzer containing O CO ow NO and NO sensors Note that since the SO sensor is not installed three stars appear in their data fields not calibrated or installed and in the data fields of that sensor s NOTE Three Stars appear the data field of sensors that are related calculated values data cannot be displayed because the measured data necessary to i NOTE Three hyphens or dashes indicate that the calculated make the calculation is out of range i e oxygen level above 16 o NOTE Three Xs i e X X X indicate the sensor is over range 5 17 Turning Off the Analyzer and Purging Turn OFF the analyzer by pressing the I O button for at least 2 seconds or until two beeps are heard The unit will count down 5 seconds before shutting down giving the operator an opportun
81. o return to the Hold screen 6 To enter a different CO2 Max value use the A V buttons to highlight ADJUST and press ENT to display the Adjust CO Max screen 7 Use the V buttons to set Max to a value between 8 0 and 23 0 96 then press ENT to save the new value in memory and return to the HOLD screen CO2Max Adjust CO2MAX Default 13 8 i CO2Max 11 0 Press ENTER to Save CO Max CO CO 0 0018 ppm T Stk 208 C Figure 4 2 Max Selection and HOLD Screen 0024 9473 Rev 4 25 PCA 3 Manual NOTE The Max value is returned to its default value when the analyzer is powered down 4 3 Auto Manual CO Zero Selections Select how the PCA 3 performs a zero function 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight CO Zero Setting and then press ENT to display the CO ZERO SETTING MENU 4 Use the A V buttons to highlight the desired zeroing option Manual or Auto Zero In the example shown Manual Zero has been selected 5 Place the instrument in fresh air to zero and press ENT to start a 60 second count down 6 Press ENT to save and re display the SETUP MENU Setup Menu CO Zero Setting Manual Zero Run Hold Format ji Language Selection Manual Zero Place instrument in Button Sound fresh air to zero
82. of the following connectors e Stack gas thermocouple to the analyzer s T STACK connector e Stack gas hose to the analyzer s GAS connector e Draft hose to the analyzer s AP connector Observe that the probe connectors are of different sizes and shapes which prevents incorrect connection to their associated connectors on the analyzer See Figure 2 5 0024 9473 Rev 4 19 PCA 3 Manual gt s Stack Gas M Probe Tub Thermocouple robe Tube ay KY Probe Stop T STACK Probe s SE Handle Water Trap Filter Assembly Draft Hose AP Gas Sample Hose GAS E TEE Figure 2 5 Probe Connectors GAS AP and T STACK 2 7 Differential Pressure Connector AP Draft is measured by connecting the probe s draft hose to the AP fitting while leaving the AP fitting open to the atmosphere See Figure 2 5 on page 20 In addition to measuring draft the and AP fittings can also be used to measure the differential pressure between two areas by first connecting a hose P N 0024 1103 to the AP fitting and then inserting the open end of this hose into the area being used as the reference pressure The analyzer s probe is then inserted into the area where differential pressure is to be measured 2 8 Primary Air Thermocouple Connector T AIR If thermocouple P N 0104 1797 10 feet long or Utility Wand P N 0104 1799 12 inch ridged probe wi
83. ons gt CAUTION When the instrument is used in an inefficient furnace or boiler application where there is a high emission of soot the probe s sample filter may become clogged Before every use check the filter to confirm that it is clean or replace it with a new filter To prevent this from occurring a smoke test should be performed before operating under such conditions This ensures that the furnace or boiler is burning at a level appropriate for the use of this Z N instrument When the level exceeds the allowable threshold a warning will appear prompting the user to consider performing a smoke test see Figure 1 1 This screen is removed by pressing the ENT button Once the warning is cleared it will not be displayed again for that particular test If a new test is started by pressing the HOLD button the warning will be displayed again if the limit has been exceeded High Need a smoke test Press ENT to clear Figure 1 1 High CO2 Warning 8 0024 9473 Rev 4 PCA 3 Manual 1 4 General Description The PCA 3 is a commercial grade hand held combustion and emissions analyzer designed for on demand sampling of light industrial institutional commercial and residential furnaces appliances and boilers The basic instrument is supplied with a probe and hose assembly instruction manual factory calibrated smart sensors 4 alkaline batteries boot Fyrite User Software USB
84. ors output is low but still usable then the message Good Calibration WARNING Low Sensor will appear The sensor will now be marked as being Low in the DIAGNOSTICS screen NOTE If the sensor s output is too low to be usable then the message Bad Calibration Sensor End of Life Entry o Not Saved will appear followed by the CALIBRATION LIST screen being re displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen 6 Turn OFF regulator and remove the gas cylinder 6 10 Sensor Calibration This procedure spans the optional nitrogen dioxide sensor to a known gas level 6 10 1 Material Required e Calibration Kit P N 0024 7059 e Gas Cylinder 100 ppm in Nitrogen P N 0024 1157 6 10 2 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 2 Use the A V buttons to highlight NO and then press ENT to display the CALIBRATE screen 78 0024 9473 Rev 4 PCA 3 Manual Applied is a known NO level that will be applied for 9 NOTE Measured is the current NO reading while calibration purposes 3 Attach a 100 ppm NO cylinder to the regulator of the calibration fixture shown in Figure 6 12 on page 80 4 Use the A V lt gt buttons to enter an applied value that exactly equals the concentration stamped on the NO cylinder attempt to calibrate outside this range will
85. perature Measurement screen as differential temperature between the two channels Additionally the temperature measurement can be labeled Label types include differential temperature across heat exchange or differential temperature Perform a differential temperature measurement as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight TEMPERATURE and then press ENT to display the TEMPERATURE MEASUREMENT screen Install thermocouples in both temperature channel connectors Before taking a measurement the temperature channels may need to be zeroed if not already displaying zero with both thermocouples exposed to the same condition Press ZERO F2 if needed 5 To label the data use the lt P buttons to scroll through the available temperature label types The current label will be used saved and printed with the record 6 Press ENT to save the selection and re display the TEMPERATURE MENU or ESC to exit back to the Main Menu 50 0024 9473 Rev 4 PCA 3 Manual Main Menu ak Fuel Pressure Measured Delta T Temperature 0 1 C Typ Diff Acrs HtEx Calibration Li Menu Figure 5 10 Performing a Temperature Measurement 5 8 Performing a Draft Pressure Measurement The difference in pressure AP between two areas can be measured by using the analyzer s two pressure ports an
86. r graphic LCD with automatic dimming feature is used to display all combustion and emission test data and analyzer parameters Descriptions of the front panel buttons are given below Transmits the data displayed on the screen to a printer through the IrDA communications port When viewing the Memory or Logging Directory each press of this button pages down through the directory Holding this button down speeds up the paging process Displays the Main Menu When viewing the Pressure screen this button zeros the pressure sensor to current atmospheric conditions When viewing the Temperature screen this button zeroes the temperature channel difference Saves the data currently displayed on the LCD in memory Up to 500 individual Combustion Test Temperature and Pressure records can be saved After 500 records have been saved the memory must be cleared to continue saving additional data The analyzer will not overwrite old data When viewing the Memory or Logging Directory each press of this button pages through the directory Holding this button speeds the paging process The arrow buttons move the cursor on the LCD In screens that require the entry of alphanumerical data use thed buttons to move cursor across the screen and then use V buttons to increment and decrement the data When viewing a menu use the lt P gt buttons to quickly move to the top and bottom of the menu Selects a highlighted item In addition
87. ration WARNING Low Sensor will appear The sensor will now be marked as being Low in the d NOTE If the sensor s output is low but still usable then the DIAGNOSTICS screen NOTE If the sensor s output is too low to be usable then the message Bad Calibration Sensor End of Life will appear 9 followed by the CALIBRATION LIST screen being re displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen 10 Turn OFF the regulator and remove the gas cylinder NOTE A CO only calibration can be done by pressing F3 in Step 5 instead of ENT 0024 9473 Rev 4 75 PCA 3 Manual 6 8 SO Sensor Calibration This procedure spans the optional sulfur dioxide sensor to a known gas level 6 8 1 Material Required e Calibration Kit P N 0024 7059 e Gas Cylinder 100 ppm SO in Nitrogen P N 0024 1158 6 8 2 Procedure 1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen refer to Calibration on page 66 2 Usethe A V buttons to highlight SO and then press ENT to display the CALIBRATE SO screen Applied is a known SO level that will be applied for NOTE Measured is the current SO reading while calibration purposes 3 Attach a 100 ppm SO cylinder to the regulator of the calibration fixture shown in Figure 6 12 on page 80 4 Use the A V and lt gt buttons to enter an applied value that exactly equals the concentration stamped on the
88. rature or Pressure record the calculation will not be performed 5 Press the print key F1 to print a copy of all three records and their average or ESC to return to the Print Average Screen Memory Options Print Average Avg 3 5 PROP Memory Directory 1 07 09 10 09 21 28 Logging Directory 2 09 09 10 08 58 42 Clear Memory 3 09 09 10 09 17 41 Clear Log 4 09 09 10 09 17 44 Clear All 9 09 09 10 09 17 46 Print Average 6 09 09 10 09 17 49 Figure 5 22 Print Average 5 14 Downloading Stored Data to a Computer The combustion test data that was stored in either the analyzers Memory Directory or Logging Directory see Memory Functions section on page 58 can be downloaded to a computer using the Fyrite User Software and USB cable that are supplied with the analyzer The downloaded data is stored on the computer s hard drive or removable media of the operator s choosing as a comma separated value ASCII text file with a CSV extension This type of file can be opened by most spreadsheet programs for analysis For information on the installation of the Fyrite User Software refer to the installation document provided in PDF format on the software disk The Fyrite User Software installation manual may also be downloaded from the PCA 3 page of the Bacharach website www MyBacharach com Refer to manual 0024 9465 Minimum computer requirements for installation and use of the Fyrite User Software are shown below 0024 947
89. re ref to O D ime O2 Reference 30 08 10 16 15 36 Figure 4 12 O2 Reference Setup 4 13 Print Pressure Selection Select whether to print or not print the pressure measurement on the combustion test printout as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight PRINT PRESSURE and then press ENT to display the PRINT PRESSURE screen 4 Use the A V buttons to highlight either No do not print pressure or Yes print pressure In the example shown Yes has been selected 5 Press ENT to save the selection and re display the SETUP MENU Main Menu setup Menu Print Pressure mn uel Os Reference ressure Print Pressure Yes emperature Zoom Logging setup Test ID Calibration E 30 08 10 16 16 18 0024 9473 Rev 4 33 PCA 3 Manual Figure 4 13 Print Pressure Selection 4 14 Zoom Display Selection Combustion test data in the Run Hold screen can be shown with enlarged characters to make viewing easier operator can set zoom levels to Standard 2X or The Standard zoom setting will display seven lines of combustion test data at one time 2X which will display five lines of combustion test data with enlarged characters and 3X which will display four lines of combustion test data with enlarged c
90. re Press ENTER to Save mm Date Calibration Time 30 08 10 16 12 55 Figure 4 11 Time Setup 4 12 O Reference Setup The measured values of CO NOx and SO can be individually referenced to a specific percentage of between 0 and 15 Individually set up the reference value for each of the above gases as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use theA V buttons to highlight O 2 REF and then press ENT to display the O2 REFERENCE screen 32 0024 9473 Rev 4 PCA 3 Manual 4 Use the A V buttons to highlight the desired measurement and then press ENT to display the REF TO screen for that measurement In the example shown CO has been selected 5 First use the lt P buttons to move the cursor across the screen until it is over the digit to be changed and then press the amp buttons until the desired value is displayed 6 Press ENT to save the displayed value and re display the REFERENCE screen or press ESC to abort this procedure and retain the old reference value T f the Oz reference value for more than one gas is being set repeat Steps 4 5 and 6 for each measurement Reference Menu setup Menu Set O2 Reference CO ref to Smoke Number B NOx ref to Oz Oil Derivative SO ref to Oz Boiler Temperatu
91. ring Memory section on page 60 4 0 96 195 ppm 1 23 9 5 96 11 8 96 0 0020 ppm 208 C Figure 5 14 Saving Test Data 5 10 Ending a Combustion Test from the stack Allow the probe to cool before handling about 5 WARNING Burn Hazard Do not touch the probe after removing it minutes Remove probe from stack 2 Allow the pump to run until all combustion gases have been flushed from the analyzer with fresh air as indicated by the reading returning to 20 9 5 11 Emptying the Water Trap The Water Trap Filter Assembly removes stack gas condensate and also prevents soot from contaminating the internal components of the analyzer position with the gas flow arrow pointing up as shown in the 9 IMPORTANT Use the Water Trap Filter Assembly in a vertical illustration below 1 Empty the water trap chamber after each combustion test or stop the test and empty the chamber if the liquid condensate level approaches the tip of the riser tube 2 To empty the trap first pull apart the two halves of the Water Trap using a slight twisting motion empty the water trap chamber and then reassemble the trap 3 After each combustion test check the Water Trap s filter element If it is dirty replace the filter see Replacing the Filter Element on page 87 0024 9473 Rev 4 53 PCA 3 Manual To Gas Port on Analyzer To empty water pull apart using a slight twisting motion Do not allow water
92. rs except Oxygen are recommended Set the calibration reminder period as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight CAL REMINDER PERIOD and then press ENT to display CAL Reminder Period Menu 4 Use the A V buttons to highlight the desired CAL reminder period and then press the ENT key to activate the selection and re display the Setup Menu NOTE The date and time settings must be correct to get accurate calibration reminders 40 0024 9473 Rev 4 PCA 3 Manual Main Menu setup Menu CAL Reminder Period 1 Run Hold Format Language Selection Button Sound 10 months CAL Reminder Period 12 months Calibration Date Format 15 months Figure 4 23 Selecting the Calibration Reminder Period 4 21 Run Hold Screen Format PCA 3 test data is located in the Run Hold screen By pressing the RUN HOLD key you should hear the pump running and see the word RUN at the upper left hand corner of the display The instrument is continuously measuring and calculating the data that is shown in the Run Hold screen Press the RUN HOLD key again the pump should stop running and the word HOLD should be shown at the upper left hand corner of the display The instrument will now show the last measured and calculated data
93. s being Low d NOTE the sensors output is low but still usable then in the DIAGNOSTICS screen the message Bad Calibration Sensor End of Life Entry Not Saved will appear The sensor will now be marked as d NOTE Ifthe sensor s output is too low to be usable then being BAD in the DIAGNOSTICS screen 0024 9473 Rev 4 PCA 3 Manual Turn OFF regulator of calibration fixture and remove the CO cylinder Attach a combination 1 000 ppm CO and 1 000 ppm cylinder to the regulator of the calibration fixture and then use the and 4 buttons to enter an applied value that exactly equals the CO concentration stamped on the cylinder Adjust the regulator for a flow meter indication of approximately 2 SCFH and then press ENT to display the CALIBRATE screen outside this range causes the message Bad Calibration NOTE The calibration range is 400 1 500 ppm Calibrating Wrong CAL Entry to appear in the next step Test Gas CO H2 Calibrate H2 Measured 1000 ppm Enter CO Value Applied j 000 ppm 000 ppm Press ENTER 01 09 10 08 34 35 01 09 10 08 46 07 Figure 6 8 CO ow Sensor Calibration Wait until the measured reading stabilizes approximately 3 minutes and then press ENT to calibrate the H2 Measured value to that of the applied value after which the message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed message Good Calib
94. s equipment Failure to follow this information could result in serious personal injury or death CAUTION A caution statement indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Caution statements may also be used to alert against unsafe practices IMPORTANT An important statement provides emphasis of an important feature operation etc Failure to follow this information could void your warranty result in improper operation or cause equipment damage NOTE A note statement provides emphasis of a feature operation practice etc Ge gt gt 1 3 Safety WARNING This analyzer is not intended to be used as a safety device WARNING When testing an appliance a full visual inspection of the appliance should be performed to ensure its safe operation CAUTION This analyzer is not intended to be used on a continuous basis gt gt 0024 9473 Rev 4 7 PCA 3 Manual CAUTION Do not store instrument or its sensors with solvents or products that contain solvents CAUTION Except for sensor and battery replacement this analyzer should only be opened and or serviced by authorized Bacharach personnel Failure to comply may void the warranty gt HAZARDOUS AREA WARNING This instrument has not been designed to be intrinsically safe for use in areas classified as hazardous locations For your safety DO NOT use it in hazardous classified locati
95. signed hereby declares that the above referenced products are in conformity with the provisions of the following standard s and is in accordance with the following directive s Standard s General Specifications for Portable Electrical Apparatus Requirements and Designed to Measure Combustion Flue Gas Test Methods Parameters of Heating Appliances EN 50379 2 Performance Performance Requirements for Apparatus Part 2 Requirements Used in Statutory Inspections and Assessments Electrical Apparatus for the Detection and Measurement of Combustible Gases Toxic Gases or Oxygen Radio Disturbance Limits and Methods of Measurements for EN 55011 Industrial Scientific and Medical ISM Radio Characteristics Frequency Equipment Directive s 2004 108 EC EMC Directive EN 50379 1 Part 1 EN 50270 Electromagnetic 2006 Compatibility Signature Doug Keeports Title VP of Product Development Date 18 October 2010 The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach Inc 100 0024 9473 Rev 4 PCA 3 Manual 0024 9473 Rev 4 101 PCA 3 Manual 102 0024 9473 Rev 4 PCA 3 Manual 0024 9473 Rev 4 103 World Headquarters 621 Hunt Valley Circle New Kensington Pennsylvania 15068 Phone 724 334 5000 Toll Free 1 800 736 4666 Fax 724 334 5001 Website www MyBacharach com E mail help MyBacharach com
96. splay screen can be shown in English French or Spanish Select the desired language as follows 0024 9473 Rev 4 39 PCA 3 Manual 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight LANGUAGE SELECTION and then press ENT to display The Language Selection Menu 4 Use the A V buttons to highlight the desired language then press ENT to activate the selection and re display the Setup Menu Main Menu Setup Menu Language Selection a english Run Hold Format Language Selection Button Sound 5 CAL Reminder Period emory etup 31 08 10 07 18 57 Mena Figure 4 22 Selecting a Language 4 20 Calibration Reminder Period The analyzer can be set to indicate a calibration reminder during the 60 second warm up period Calibration reminders can be preset to occur never 6 8 10 12 or 15 months after the last calibration When the preset period is exceeded the instrument will display the reminder and how long since the sensors were last calibrated The reminder will be displayed at the end of the 60 second warm up period If a calibration reminder is displayed the operator can press the RUN HOLD key to move to the Run Hold screen for normal operation Regular calibration periods of 6 months to a year for all gas senso
97. t of the stack until the stack s core temperature hot spot is located as indicated by the highest T STK reading then tighten the thumbscrew to prevent further probe movement Locating the highest stack temperature is very important for accurate efficiency calculations 3 You can now begin burner service procedures The analyzer readings will change quickly to show changes in burner performance CAUTION Position the water trap with its gas flow arrow pointing upward Do not let water condensate go above the tip of the riser tube The sensors could be damaged if water would enter the analyzer Empty the water trap after every combustion test See Emptying the Water Trap on pages 53 and 87 4 Pressing the RUN HOLD button holds all readings stops the pump and displays the Combustion Test HOLD screen Press the A V buttons to scroll through all test values Pressing RUN HOLD again restarts the pump and resumes testing 48 0024 9473 Rev 4 PCA 3 Manual List of Combustion Test Data Display Description of Measurement Calculation Excess Air PPM CO divided by PPM Primary Ambient Air Temperature as measured either T AIR internally or by an optional external thermocouple plugged into the analyzer s T AIR connector q A Stack Loss ET Efficiency referenced to lower heating value Efficiency referenced to higher heating value CO f Oxides of Nitrogen ppm level referenced to a of oxygen 1
98. taken before the instrument was placed in HOLD Use the up and down arrow keys to scroll through the complete list of measured and calculated values when the instrument is running or in the hold mode The default order in which data appears in the Run Hold screen is shown below 02 Oxygen CO J Carbon Monoxide Excess Air Carbon Dioxide _____ Carbon Dioxide in flue gas assuming perfect combustion PPM CO divided by PPM T STK Stack Temperature T AIR Ambient Primary Air Temperature Stack Loss Efficiency referenced to lower heating value Efficiency referenced to higher heating value Nitric Oxide Nitrogen Dioxide Oxides of Nitrogen NO and combined Sulfur Dioxide Carbon Monoxide content referenced to an Oxygen 96 Nitric Oxide content referenced to an Oxygen 96 NOxZ Nitrogen Dioxide content referenced to an Oxygen 96 Oxides of Nitrogen content referenced to an Oxygen 96 Sulfur Dioxide content referenced to an Oxygen 96 Average of 3 manually entered smoke numbers Oil derivative in fuel manually entered YES or NO Boiler Temp Boiler Temperature manually entered 0024 9473 Rev 4 41 2 X NO PCA 3 Manual NOTE A number sign denotes the current Reference selected Stars appear in measurement and calculation fields of sensors that are not installed Change the order in which data is displayed as follows 1
99. th handle and 5 foot coiled cable is to be used to measure the burners primary air temperature then connect either of these thermocouples to the analyzer s T AIR connector Refer to Figure 3 2 on page 23 2 9 Computer Interface USB Data stored in the analyzers memory can be downloaded to a personal computer by connecting USB data cable P N 0104 4032 between the USB ports of the computer and analyzer The PCA 3 s USB port is on its right side See Figure 2 1 on page 16 2 10 Wireless Printer Port IrDA Data that has been stored in the analyzers memory can be printed on a compatible IrDA Infrared data associated wireless printer by aligning their IrDA communication ports The IrDA port of the PCA 3 is located at the top of the device See Figure 2 1 on page 16 20 0024 9473 Rev 4 PCA 3 Manual CHAPTER 3 INITIAL SETUP 3 1 Overview Before configuring or using the PCA 3 you MUST e provide power e connect the probe and hose assembly 3 2 Power Three options are available to power the PCA 3 e disposable alkaline batteries e rechargeable NiMH batteries e AC power adapter If you are using either alkaline or NiMH rechargeable batteries to power the analyzer follow the instructions below to install or replace the batteries e Remove the battery cover from back of unit Figure 3 1 e Remove and properly dispose of any old batteries e Install a set of four AA alkaline or NiMH batteries per
100. the and markings inside the battery compartment e Replace the battery cover Release and then remove battery cover by pushing latch up R 1 _ fr I2 So ETILE Figure 3 1 Battery Cover and Compartment The AC power adapter is capable of powering the analyzer on a continuous basis The adapter plugs into an appropriate 100 240 VAC 50 60 Hz wall outlet and produces an output of 6 VDC The adapter s output connector plugs into the analyzer s POWER jack located on the bottom of the unit refer to Figure 3 2 on page 23 0024 9473 Rev 4 21 PCA 3 Manual NOTE The battery charging icon should appear fully green once the new batteries have been installed 3 3 Connecting the Probe and Hose Assembly To attach the probe and hose assembly to the analyzer follow the steps below and refer to Figure 3 2 on page 23 1 Push the gas sample hose connector the larger of the two connectors giving a slight twist onto the analyzer s GAS fitting 2 Push the draft hose connector the smaller connector giving a slight twist onto the analyzers AP fitting 3 Push the stack gas thermocouple connector into the T STACK jack connector fits in only one way 4 Push the optional primary ambient air thermocouple into the T AIR jack connector fits in only one way IMPORTANT To assure the accurate calculation of combustion efficiency the optional primary ambient air 9 thermocouple must be use
101. then press ENT to calibrate the CO Measured value to that of the applied value The message Good Calibration should briefly appear followed by the CALIBRATION LIST screen being re displayed NOTE If the sensor s output is low but still usable then the message Good Calibration WARNING Low Sensor will appear The sensor will now be marked as being Low in the DIAGNOSTICS screen If the sensor s output is too low to be usable then the message Bad Calibration Sensor End of Life Entry Not Saved will appear followed by the CALIBRATION LIST screen being re displayed The sensor will now be marked as being BAD in the DIAGNOSTICS screen 6 Turn OFF regulator and remove the gas cylinder 0024 9473 Rev 4 81 PCA 3 Manual CHAPTER 7 MAINTENANCE 7 1 Overview Customer maintenance of the PCA 3 is limited to the following Battery replacement see page 21 Sensor re calibration see page 66 Water trap filter assembly maintenance see pages 53 and 87 Sensor replacement see page 88 Cleaning the probe see page 91 All other maintenance should be performed by an authorized Bacharach Service Center Refer to Service Centers on page 99 7 2 PCA 3 Disassembly The following procedure describes and illustrates how to disassemble the analyzer 7 2 1 Tools Required e Medium Phillips Screwdriver 7 2 2 Procedure 1 Unplug all thermocouples from bottom of analyzer 2 Remove battery cover and then remove
102. tion can be entered using the Fyrite User Software 4 17 1 Entering or Editing a Test ID 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight TEST ID and then press ENT to display the TEST ID menu 4 Use the A V buttons to highlight EDIT TEST ID and then press ENT to display the EDIT TEST ID menu which displays the first line of each Test ID record 5 Use the A V buttons to select which Test ID to edit and then press ENT to display all three lines of that record Periods are used to identify empty lines 6 Usethe A V buttons to choose which of the three Test ID lines to edit and then press ENT to begin editing the chosen line 7 the A V buttons to enter the desired character and then move to the next character position by pressing the right arrow key Repeat this step until the line is complete A maximum of 20 characters can be entered Press ENT to accept the information 8 Atthis time either return to Step 6 to choose another line to edit or end this procedure by highlighting Edit Complete and pressing the ENT key to return to the Edit Test ID Menu 9 Press ESC to go to the Test ID Menu or the RUN HOLD key to return to the Run Hold screen 36 0024 9473 Rev 4 PCA 3 Manual setup Menu Test ID Menu 0 Select Test
103. to the Test ID menu or press the RUN HOLD key to return to the Run Hold screen Test ID Menu Edit Test ID Clear Test ID Figure 4 19 Clearing a Test ID 4 18 User Name The name of the user or owner of the analyzer e g company name address phone number can be stored in memory by manually entering up to three lines of text with each line containing up to 20 alphanumeric characters This information will appear at the top of each printout until new information is entered or cleared NOTE To save time user name information can be entered using the Fyrite User Software 4 18 1 Entering a User Name 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC until MENU appears above F2 2 Usethe A V buttons to highlight SETUP and then press ENT to display the SETUP MENU 3 Use the A V buttons to highlight USERNAME and then press ENT to display all three lines of the EDIT USERNAME screen Periods identify empty lines 4 Use the A V buttons to choose which of the three Username lines to edit then press ENT to begin editing the chosen line 5 Use the A V buttons to enter the desired character and then move to the next character position by pressing the right arrow key Repeat this step until the line is complete A maximum of 20 alphanumeric characters can be entered Press ENT to accept the entered information At this time either return to Step 4 to choose another line to edit
104. urations for Actual and Calculated NOx Values 0024 9473 Rev 4 43 PCA 3 Manual CHAPTER 5 OPERATION 5 1 Operating Tips e When an analyzer is brought in from a cold vehicle let it warm up slowly to minimize condensation Temperatures below freezing will not damage the analyzer CAUTION Although the analyzer itself is not damaged by an extremely cold environment the electrochemical sensors may be damaged The sensors electrolyte will freeze at approximately 29 C and the other sensors at approximately Z N 70 C If the analyzer is exposed to an extremely cold condition it is strongly suggested that the sensor housings be examined for hairline cracks Be aware that a leaking sensor can cause chemical burns to the skin and possibly damage the PCB assemblies e Ensure that the analyzer is sampling fresh air when turned ON Pulling a stack gas sample through the analyzer during its warm up period will not damage the analyzer but it will result in incorrect sensor readings and may result in sensor error messages appearing after the warm up cycle completes e Note that flue gas condensate is acidic and very corrosive It is important not to allow the analyzer s internal components to come in contact with condensate for long periods of time e Before each use inspect the filter element of the water trap filter assembly Replace the filter if it looks dirty See Replacing the Filter Element on page 87 e When samp
105. vels 1 6 Features and Benefits e Powered by 4 AA alkaline batteries or rechargeable batteries An optional AC adapter provides extended operation e and Hydrogen compensated measurements are standard Optional measurement of up to two additional gases including NO or 502 10 0024 9473 Rev 4 PCA 3 Manual With the appropriate sensors installed the analyzer optionally displays pollution conversions for CO NO and 02 Pollution conversions include ppm MBTU mg m and g GJ B Smart amp sensor technology allows pre calibrated sensors to be installed in the field Sensors are provided with data that can be entered through the PCA 3 software or instrument calibration menus for easy calibration Automatic flushing of the o sensor with fresh air if the CO level exceeds 4 000 ppm thus protecting the sensor from high CO levels To measure CO levels above 4 000 ppm the analyzer automatically switches to its sensor if installed Automatic purging of the gas sample system if the detected gas levels are abnormally high when the analyzer is turned OFF Displays temperatures in either C or F Displays pressure in either inwc mb Pa or hPa Backlit color graphic LCD with zoom capabilities Low battery alarm Stores 500 individual combustion records which can later be recalled for viewing printing or downloading to a personal computer Stores a
106. ze in the circuit before continuing with this procedure Stabilization time for all sensors except for the NO sensor is about 1 hour The NO sensor baseline technically requires several days to stabilize but should be sufficiently stabilized for use in approximately 4 hours 13 Turn ON the analyzer and confirm that no sensor errors occur during warm up NOTE Discard old sensors in accordance with local and federal hazardous waste disposal laws 14 Enter the B Smart calibration code or calibrate the new sensor s as explained earlier see Calibration on page 66 An exception is the sensor which does not require calibration 0024 9473 Rev 4 89 PCA 3 Manual 7 6 Nitric Oxide NO Sensor Battery Replacement A single lithium battery located on the NO Smart Sensor assembly applies a bias voltage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off The NO bias battery is expected to last at least the life of the NO sensor NOTE It is recommended that the bias battery be replaced whenever the NO sensor is replaced 7 6 1 Material Required e Bias battery refer to Replacement Parts on page 94 7 6 2 Procedure 1 Follow the instructions on page 82 PCA 3 Disassembly to remove the sensor assembly from sensor position 4 2 Remove the old battery from its holder on the nitric oxide printed circuit board 3 Insert the new battery with the positive side toward the sensor

User manual – Siegert (English)

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User manual &ndash; Siegert (English)

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User manual – Siegert (English)