Home

Instruction Manual

1. P E E gt STORAGE COMPARTMENT 6 x 18 x 3 SENSOR COMPARTMENT NS EA SAA ASE PEN Y E a UNION YS SO a SALA PRINTER MS O OR SS SS IC CS E E ES E O O EZ LS O IS AA AS ES AM e E ER RS 232 CONNECTOR N a e o0 BATTERY CHARGER 2 AC ADAPTER CONNECTOR gt 0 o eer Doms VACUUM FLUORESCENT DISPLAY PANEL ma 4 Lines by 20 Characters 3 5 i Ee SHORTCUT MENU KEYS ee 300805 SET UP Displays Setup List screen Q z 9 Y EA Ch ETT CALIBRATE Displays Calibrate screen FUEL Displays Fuel screen PRESSURE Displays Pressure screen MEMORY Displays Memory screen 1 5 1 ESC Displays previous menu or previously viewed screen lt A V Moves cursor left Moves cursor up through screen or increments an alphanumerical value Moves cursor down through screen or decrements an alphanumerical value gt Moves cursor right ENTER Chooses a menu item that has been selected by the cursor s position GAS PRESSURE T STACK Probe AP REF Differential pressure reference hose
2. Procedure 1 Enter Calibration List screen then choose Pressure per Section 3 3 to display the PRESSURE CALIBRATE screen Instruction 0024 9400 51 Calibration ECA 450 2 With the Calibrate Pressure screen displayed and with the hose from the calibration fixture connected to the analyzer s PRESSURE port adjust the bellows for a micro manometer reading of 4 in H20 column 10 mb 3 Wait until the Measured reading on the screen stabilizes Then use the Av and lt gt keys to enter an Applied value that equals the micro manometer reading The calibration range is from 6 to 2 in H20 column 15 to 5 mb An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate Pressure Screen During Calibration 4 Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed 5 Remove calibration equipment 3 5 Calibrate T Stack Stack Temperature Channel The following procedure first zeros and then spans the stack temperature channel to known temperature values Material Required Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F TS Zero Procedure 1 Adjust simulator to 32 F 0 C The calibration range is from 82 to 41 F 0 to 5 C Any a
3. SO2 Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b SO2 sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor Pressure Sens Error message appears at bottom of display a Analyzer was turned on with probe measuring a pressure is that was outside the range of 3 inches of water 7 47 mb hPa 747 Pa Ensure probe is sampling atmospheric pressure and restart b Sensor defective Return to Bacharach for replacement Bad Calibration Entry message appears during calibration A calibration value was entered that is outside the allowable range for calibration Apply a calibration gas concentration or pressure value that is within the range of the sensor being calibrated as listed in the calibration procedure Instruction 0024 9400 ECA 450 Instruction 0024 9400 Parts amp Service Symptom Probable Cause Remedy Sensor Output Low message appears during calibration Sensor is nearing the end of its useful life Calibration is still good but the sensor should be replaced soon Sensor Not Calibrated message appears during calibration Sensor s output is too low to be calibrated Replace sensor per Section 4 4 appears in one or more of the d
4. The Measurable Difference Environmental Combustion Analyzer Model 450 Instruction 0024 9400 Operation amp Maintenance Rev 7 October 2014 gCA45 Product Leadership Training Service Reliability WARRANTY Bacharach Inc warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc s applicable specifications Bacharach s liability and Buyer s remedy under this warranty are limited to the repair or replacement at Bacharach s option of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc s reasonable satisfaction to have been defective provided that written notice of the defect shall have been given by Buyer to Bacharach Inc within one 1 year after the date of delivery of this Product by Bacharach Inc 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 LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II AN
5. 4 7 _ Resetting the Microprocessor 5 TROUDIESNOOTNG ia O CD A E E a 72 5 1 EIA RUN 72 5 2 Problem Messages Displayed After Warm Ubp ccccconcooononncncnononanonnconnonononnnnnonnnnnononnnnnnnconnnnnnnnnnnncaninnnnos 72 5 3 ErFoeSymbolSs ee ls i GT a GG CW GWRDD 5 4 Troubleshooting Guide O Parts amp SerVICE ni aia ai dL a add ad FT 79 6 1 Replacement Parts eu uu ni y Ted E GYD ED NG DC dd OT DOED IC Dd LYN ANN 79 6 2 SACCOSSONIES skeet y GG A a gd Cn GG A FC wnn 80 6 3 Service Centel Sui ue inicia naii 81 iV Instruction 0024 9400 ECA 450 Introduction 1 Introduction 1 1 General Description The Bacharach Environmental Combustion Analyzer Model 450 hereafter referred to as the ECA 450 is an industrial grade environmental and combustion efficiency analyzer that is designed for the testing of fuel burning combustion equipment This analyzer is for furnace and boiler technicians who need to determine combustion safety environmental compliance and efficiency of small to large commercial industrial heating systems 1 2 Features Instruction 0024 9400 Measures and displays O2 and CO in the flue gas pressure draft primary air temperature and stack temperature Calculates combustion efficiency excess air and CO Optionally measures and displays NO NO SO HC methane equivalent combustibles and CO in the high range of 4 000 to 80 000 ppm Optionally calculates NOx the combi
6. a Faulty sensor s Check that all sensors are properly installed and their wiring harnesses are correctly connected to the analyzer Refer to Section 4 4 Check sensor calibration per Section 3 Replace any sensor that does not calibrate and then recalibrate b Leak in gas path Check tightness of all hose connections on probe and tightness of all hose connections internal to the analyzer Sensor does not calibrate properly a Wrong calibration gas or insufficient flow being applied to sensor Ensure that the calibration setup is correct b Depleted sensor Replace sensor and recalibrate c If the NO sensor doesn t calibrate its bias battery may be dead Replace bias battery per Section 4 4 2 and recalibrate Instruction 0024 9400 ECA 450 Parts amp Service 6 Parts amp Service 6 1 Replacement Parts Complete ECA 450 Basic Configuration O2 CO Stack Temp Ambient Temp and Pressure measurement with sampling probe 12 in tube and hose assembly ccccseseseseseseresererees 0024 7221 AC Adapter Charger Uta de A DY DN tdi 0024 0985 Power Cord iu Gu FD A IT GN Ado 4998 8986 Battery Pack cocina GY YY AG A 0024 0977 Battery NO Sensor Bias Y YIII LIII LL Fin 0204 0020 Filter Particulate attached to inlet of gas pump 0007 1563 Instruction Mariali inosia E EA i aa EA AREE EEE 0024 9400 O Ring Kit 2 sets noe A AA EON 0024 1471 O Ring Sensor Blank
7. Data bits 8 Parity None Stop bits 1 Flow control None Then click OK to display HyperTerminal s main window e Click File click Save This creates a file with an ht extension in the folder C Program Files Accessories Hyper Terminal using the name that was entered in Step b 20 Instruction 0024 9400 ECA 450 Operation After HyperTerminal is running click Transfer click Capture Text then click Start to accept the default drive directory filename to which all received data will be stored as an ASCII text file Note By default the captured text file will be stored on the hard drive at C Program Files Accessories HyperTerminal CAPTURE TXT If desired click Browse to select a different drive directory and filename The next time data is captured it will be stored under the same location and filename Tip Changing the filename extension to CSV comma separated variable will allow the file to be directly opened in the spreadsheet program For example double clicking the filename CAPTURE CSV in Windows Explorer will automatically start Microsoft Excel and load the file Press analyzer s MEMORY key to display the Memory menu screen Use av keys to place cursor next to Transmit Memory then press ENTER to display the Transmit Memory screen Use av keys to select one of the following transmit options then press ENTER to choose that option What happens next depends
8. FAX 905 470 8963 E mail Support BachCan ca 81 BACHARACH Headquarters 621 Hunt Valley Circle New Kensington PA 15068 Ph 724 334 5000 Fax 724 334 5001 Toll Free 1 800 736 4666 Website www mybacharach com E mail help mybacharach com
9. Instruction 0024 9400 The following error symbols are shown in the Combustion Test Screen and on a printout to indicate 1 combustion test data that cannot be calculated 2 sensors that are in over range or 3 sensors that were detected as being in error during warm up _ ____ appears in the number fields of combustion test data that cannot be calculated because the current measurements will not provide a meaningful calculation For example if the Oxygen level is greater than 16 or the stack temperature is greater than 2000 F 1093 C or the ambient air temperature is greater than 999 9 F 537 8 C then the value for EFF combustion efficiency cannot be calculated x x x x indicates an over range condition and appears in the number fields of sensors that are being exposed to gas levels that are beyond the analyzer s detection range This symbol also appears in the number field of the HC sensor when there is not enough Oxygen present to measure the combustible gas level x x x is displayed in the number fields of sensors that were reported as being in error during warm up and also in the number fields of data that derive their values from the sensor in error For example if the NO or NO2 sensor was in error then the NOx data field will also contain stars 73 Parts amp Service 5 4 Troubleshooting Guide 74 ECA 450 The following table lists the causes and remedies for most of the problems
10. line of the Combustion Test RUN HOLD screen In the above example the current fuel is NGAS natural gas Fuel Codes NGAS Natural Gas OIL2 OilH2 OIL4 Oilf4 OIL5 Oil 5 OIL6 Oi1 6 PROP Propane COAL Coal WOOD Wood KERO Kerosene BGAS Bagasse To select a different fuel 1 Press FUEL key to display the Fuel menu screen 2 Use av keys to scroll through fuel list until cursor is next to desired fuel 3 Press ENTER key to store the fuel selection in memory The corresponding fuel code should now appear in the upper right hand corner of the Combustion Test HOLD screen 12 Instruction 0024 9400 ECA 450 Operation 2 4 Performing a Combustion Test Important When measuring nitrogen dioxide NO2 and sulfur dioxide SO it is recommended that a Sampler Conditioner Bacharach P N 0024 7224 be used to assure accurate readings 1 If not already done turn on analyzer Section 2 1 and select a fuel Section 2 3 See Figure 2 1 Make a inch sampling hole in stack to accommodate probe stop Locate this sampling hole before any draft diverter hood or barometric damper so that flue gasses are not diluted and stack temperature has not been decreased by surrounding air used to balance the draft Note that as the distance between the last heat exchanger and sampling point increases the calculated combustion efficiency will falsely increase due to heat loss by convection from the flue
11. appear if a thermocouple is plugged into the T AIR socket This thermocouple must be removed to continue this procedure 3 Use av keys to place cursor next to Measure then press ENTER to display the message Place probe in primary air stream then press ENTER 4 As instructed above place probe into primary air stream then press ENTER to display the probe s current temperature measurement Where XXX X the temperature being measured by the probe 28 Instruction 0024 9400 ECA 450 Operation 5 Wait until temperature display stabilizes then press ENTER to save the displayed temperature value in the analyzer s temperature memory buffer and return to the Setup List screen Note The temperature memory buffer is cleared when the analyzer is turned off or when the T AIR thermocouple is installed after the measured number is saved 2 143 Thermometer Method This method has an operator taking a one time primary alr temperature measurement using a thermometer and then manually entering the measurement into the analyzer s temperature memory buffer When viewing the T AIR value on the Combustion Test HOLD RUN screen the designation E will appear to the left of the temperature value The letter E signifies that the primary air temperature value was manually Entered Po z For example Measure the primary air temperature using a thermometer and manually ente
12. av keys to place cursor next to Print Pressure then press ENTER to display the Print Pressure screen 3 Use av keys to place cursor next to either No or Yes then press ENTER to make the selection and return to the Setup List screen 2 17 18 Information To display the analyzer s Serial Number Part Number Software Version and optional sensor s installed do the following 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Information then press ENTER to display the Information screen Note that the information displayed for your particular analyzer will vary from the one shown below 3 Press ESC to return to the Setup List screen 48 Instruction 0024 9400 ECA 450 Calibration 3 Calibration Bacharach recommends that the ECA 450 be calibrated by your nearest Bacharach Service Center refer to Section 6 3 The analyzer however can be calibrated in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in this section Important To prevent the loss of data during calibration perform the following procedures with a fully charged battery pack or with the AC adapter connected to the analyzer 3 1 Initial Sensor Check Important Before turning on the analyzer or performing any of the calibration procedures ensure that the analyzer will be sampling fresh air
13. downloading as described in Section 2 9 Recalling Test Data Stored in Memory Once all memory locations are filled an attempt to save additional data will cause the message Memory Full to be momentarily displayed To save additional data memory must first be cleared per Section 2 8 Clearing Memory Tip Before clearing memory its contents can be downloaded to a personal computer for permanent storage per Section 2 11 2 8 Clearing Memory Clear all memory locations as follows 1 Press MEMORY key to display the Memory menu screen 2 Use av keys to place cursor next to Clear Memory then press ENTER 3 Use av keys to place cursor next to Yes or No if you decide not to clear memory then press ENTER Observe that the message Clearing Memory appears as memory is being cleared 16 Instruction 0024 9400 ECA 450 Operation 2 9 Recalling Test Data Stored in Memory To recall the contents of a particular memory location containing either combustion test data or a pressure measurement do the following 1 Press MEMORY key to display the Memory menu screen 2 Use av keys to place cursor next to Memory Directory then press ENTER to show the directory of all stored test data 3 Use av keys to place cursor next to memory location that contains data to be recalled Note that memory locations are identified by the date and time the data was stored Also note that
14. hoses or analyzer Figure 4 5 Cleaning the Probe and Sampling Hoses GAS HOSE PRESSURE HOSE o WATER TRAP FILTER ASSEMBLY GAS HOSE Instruction 0024 9400 69 Maintenance ECA 450 3 Clean probe assembly by generously spraying carburetor cleaner through each of the barbed fittings of the probe handle while allowing the cleaner to flow out of the probe tip 4 After spraying with carburetor cleaner remove all the residual cleaner by repeatedly flushing the probe assembly with alcohol 5 Clean sampling hoses by first squirting a few drops of detergent into one end of each sampling hose Then force water through each hose until all detergent is removed a faucet adapter connected to a small piece of rubber hose can be used to supply a rapid flow of water through the sampling hose 6 Wipe off surfaces of probe and sampling hoses with a clean rag 7 Allow parts to dry completely If available blow compressed air through probe and hoses to expedite the drying process 8 Reassemble parts of probe assembly 4 7 Resetting the Microprocessor If the analyzer locks up and cannot be turned off or begins to operate in an erratic manner remove the analyzer s top panel and press the Reset button located on the main printed circuit board See Figure 4 6 Note Pressing the Reset button WILL NOT erase memory nor change the analyzer s calibration settings Figure 4 6 Res
15. memory locations that do not contain data are identified as Memory Empty Where nnnn memory location number mm dd yy month day year hh mm hour minute Instruction 0024 9400 17 Operation ECA 450 Press ENTER key to display the contents of chosen memory location Observe that MEM nnnn where nnnn denotes the memory location number appears in the top line signifying that the data being displayed was recalled from memory Also note that if any Test ID information was associated with the test data this information is displayed at the bottom of the screen Refer to Section 2 17 8 for additional information on Test ID Where nnnn memory location number xxxx test ID information Tip Use lt gt keys to quickly advance to the top and bottom of screen Press ESC to return to Memory Directory screen where another memory location can be viewed Or press ESC twice to return to Memory menu screen 18 Instruction 0024 9400 ECA 450 Operation 2 10 Printing Data By pressing the PRINT key the data which is currently being displayed in either the Combustion Test or Pressure screen is printed on the analyzer s internal printer Note that the contents of no other screen can be printed Data which has been stored in memory can also be printed by first displaying the contents of the desired memory location as described in Section 2 9 Recalling Test Data Stored in Memor
16. oononooncccnnncnnonononocnnonocnnnnnnonononnnnononnananonononoos 0105 5104 Probe Hose Assembly 12 probe Complete Assembly oooonooococcccncnoconononanononnononnnnonononnononannnnononcnnos 0024 3023 Hose Connector Gas ea oense a are aea aiaa aea aaas 0024 0877 Hose Connector Pressure YY iH 0024 0878 Filter Water Trap Assembly Complete Assembly i YHA II FFF 0024 1172 Filter Element package of 3 iin 0007 1644 Printer Paper box of 5 rolls YA II iH 0024 0980 Pump Gas ue A Fd FFA 0024 3009 Screw Phillips PH 6 32 x 1 2 Sensor Cover 4723 5860 Screw Phillips PH 6 32 x 9 16 Top Panel 0101 7672 Sensor Blank ues uy li DAW LON nw DN NUW UF 0024 0864 Sensors COMO oei ied i Cd GT GG a RD DYF YD 0024 0789 COS a Ti AF AN ARDDIO 0024 0997 H Cw a au dw E FY ON ds 0024 1055 NO GN LG PE FY UYD 0024 0881 NO nae ii YY ded Ud go Udd 0024 1027 A 0024 0788 SO side ii 0024 0998 Instruction 0024 9400 79 Parts amp Service ECA 450 6 2 Accessories Calibration Kit gas not supplied ieir LII Ynn 0024 7059 Flue Gas Sample Conditioning Unit Compact System Includes Peltier chiller probe assembly built in filter condensate pump and 15 ft hose assembly 0024 7224 Gas Cylinders CO DIO ppi 1n ait au FWG YO 0024 0492 CO H gt 1000 ppm CO amp 1000 ppm He in Nitrogen 0024 0794 CO 4000 ppm 1n alit ue Yg eee YC OY YF 0024 1155 NO 250 ppm in Nitrogen u
17. or stack If burner s primary air temperature is different from that of room air be sure to either immerse primary air thermocouple into primary air stream or take a primary air temperature measurement using either the probe s thermocouple or a thermometer Section 2 14 See Figure 2 2 Screw probe stop into sampling hole Next insert probe through probe stop positioning its tip near center of stack Secure probe by tightening the probe stop s thumbscrew Press RUN key You should hear the pump start running and see the word RUN appear in the upper left hand corner of the display The ECA 450 is now continuously measuring and calculating the values shown in the Combustion Test RUN screen Use av keys to scroll through the following typical set of data note that depending on which sensors are installed some of the data listed below may not be displayed Figure 2 1 Sampling Hole Location Figure 2 2 Installing the Probe FLUE GAS FLOW Downstream 2 Upstream SPPPPLLPLPSL LI gt FURNACE BREECHING SAMPLE PROBE STOP DRAFT DIVERTER REGULATOR _ THUMBSCREW HOLE Instruction 0024 9400 13 Operation ECA 450 7 10 11 Tip Use lt gt keys to quickly advance to the top and bottom of screen Also note that if x x x x or appear in a data field then data cannot be displayed for that measurement Refer to Section 5
18. period 3 Use av keys to select desired timeout period in 5 minute increments from Never no timeout to 60 minutes then press ENTER to make the selection and return to Setup List screen 2 17 10 Display Format The order in which data is displayed in the Combustion Test HOLD RUN screen can be rearranged to better suit an operator s needs The default order of this data is as follows Note Depending on what sensors are installed some of the data listed below may not be displayed ll ll ll ll 96 Oxygen Carbon Monoxide Combustion Efficiency Carbon Dioxide Stack Temperature Room Primary Air Temperature Excess Air Nitric Oxide Nitrogen Dioxide Oxides of Nitrogen combination of NO and NO Sulfur Dioxide Combustibles Methane based Carbon Monoxide content referenced to a percentage of Oxygen Nitric Oxide referenced to a percentage of Oxygen Nitrogen Dioxide referenced to a percentage of Oxygen Oxides of Nitrogen combination of NO and NO2 referenced to a percentage of Oxygen Sulfur Dioxide referenced to a percentage of Oxygen Instruction 0024 9400 43 Operation ECA 450 2 17 10 1 Changing Display Format Change the order in which the data is displayed in the Combustion Test HOLD RUN screen as follows Note Changing the order of the Combustion Test Data as displayed on the analyzer s front panel does not change the order in which the data is printed or downloa
19. s primary air temperature then connect either thermocouple to the analyzer s T AIR connector Refer to Section 2 14 Primary Air Temperature Measurement for alternate methods of measuring the burner s primary air temperature 1 5 3 POWER AC Adapter The analyzer s internal battery pack is charged by connecting the supplied AC adapter to any convenient source of 100 240 VAC 50 60 Hz power and then connecting the charger s output plug to the analyzer s POWER connector Refer to Section 4 1 Battery Charging The AC adapter can also be used as an external power supply to simulta neously charge and run the analyzer if its battery pack should become depleted during use 1 5 4 AP REF Differential Pressure The Differential pressure between two areas can be measured by first connecting pressure hose P N 0024 1108 to the analyzer s AP REF connector and 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 who s differential pressure is to be measured Refer to Section 2 15 Differential Pressure Measurement 1 5 5 RS232 Computer Interface Data that has been stored in analyzer s memory can be sent to a personal computer by connecting serial data cable P N 0104 4027 straight through 6 foot DB9 male to DB9 female between the computer s COM port and the analyzer s RS232 connector Refer to Section 2 11 Downloading Data to a Personal Co
20. to display the Pollution Units screen Pollution dirig Use av keys to place cursor next to either ppm Mbtu mg m or g GJ then press ENTER to make the selection and return to Setup List screen Information on the display screen can be shown in either English Spanish or French Select the desired language as follows 1 2 Press SETUP key to display the Setup List screen Use av keys to place cursor next to Language then press ENTER to display the Language screen Use av keys to place cursor next to either English Espa ol or Francais then press ENTER to activate selection and return to Setup List screen The date is stored in the format month day year MM DD YY Set the analyzer s internal clock to the current date as follows 1 2 Press SETUP key to display the Setup List screen Use av keys to place cursor next to Date then press ENTER to display the analyzer s current date setting Pigi m Press ENTER to stop clock and move cursor over first digit of date display Instruction 0024 9400 37 Operation ECA 450 2 17 6 Time Press gt key to place cursor on the month day or year digit to be changed then use av keys to set that digit to desired number Repeat this step until all digits are set correctly Press ENTER to save selections and start clock Then press ESC to return to Se
21. to stabilize Place analyzer in an area of fresh air and turn it ON After its warm up cycle completes observe that no sensor error messages should have appeared Calibrate the new sensor per Section 3 except the Oz sensor which does not require calibration 65 Maintenance ECA 450 4 4 2 Nitric Oxide Sensor Battery Replacement A single lithium battery located on top of the Nitric Oxide printed circuit board applies a bias voltage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off This battery has a life expectancy of at least 2 years Replace the Nitric Oxide bias battery toward the end of its life expectancy or when its voltage drops below 2 volts Tip Replace the bias battery whenever the NO sensor is replaced Material Required e Medium Phillips screwdriver Bias battery refer to Section 6 1 Procedure 1 Remove two screws from sensor cover plate and then remove plate to gain access to sensor compartment See Figure 4 3 2 Remove old battery from its holder on the Nitric Oxide printed circuit board 3 Insert new battery positive side facing upwards into holder 4 Install sensor cover plate that was removed in Step 1 5 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 Nitri
22. 17 1 Temperature Units 2 17 2 Pressure Units 2 17 3 Pollution Units LA pe E A TO 2 17 5 Di on A NN ZATLT O E RON A A TestlD oe E O TNA 2 17 8 1 Enter Edit Test ID Information ooconnncccninonaninaninaninanananononanc nano ALLN 39 2 17 8 2 Select Test ll mu Gi aTi NS Fi DN dia 40 2 17 8 3 Transmit TestilDi ce Gu O FY 41 2 17 8 4 Clearing Test ID Information cccoccooccnncnononononnnoncnnnnnonnnncnncnnonnononnnnncnncnnnnnononnos 42 BUT Display TIME UE Fd DY Fi 43 2 17 40 Display F rm t A A a a WG GY 43 2 17 10 1 Changing Display Formatsion ee ea aa a aeie aa a a A 44 Instruction 0024 9400 iii Contents ECA 450 2 17 10 2 Resetting Display Format Back to Factory Default ococononononononononononononoss 44 DURA Primary AIP el rd dd TY aa A dd AW dn 45 217 12 Data A OR EN 45 27I3 O RNE 45 2 17 14 Yser Name ica 45 2 17 14 1 Enter Edit User Name Information AL LLI 45 2 17 14 2 Clear User Name Informati0N ccconcooccnncconononannnoncnnnonennnnnoncnnnnnononnnnncnncnnnnnononnos 46 2 17 45 LS A RON 46 217 16 High Resolution NOX Enable edici 47 21717 Print Press re ni A a IA ara 48 217 18 NOR 48 3 Calibration iseiccinssecevecsacssccevscveuccotsseaenuesdennessacaceseusscuuetsbensssesweuuens ss aunses EEEE ERE EE REEE 49 3 1 InitialsSensor Cheka 49 3 2 Calipratio ME Cures Ri UC TG FU a a a e a a a ae 50 3 3 Starting and Ending a Calibration Procedure cccccessss
23. 3 Error Symbols for an explanation of these symbols and why data is not being displayed 02 Oxygen CO Carbon Monoxide EFF Combustion Efficiency CO2 Carbon Dioxide T STACK Stack Temperature T AIR Room Primary Air Temperature EA Excess Air NO Nitric Oxide NO2 Nitrogen Dioxide NOX Oxides of Nitrogen combination of NO and NO2 SO2 Sulfur Dioxide 0 3 HC Combustibles Methane based CO n Carbon Monoxide content referenced to a percentage of Oxygen 2 NO n Nitric Oxide referenced to a percentage of Oxygen NO2 n Nitrogen Dioxide referenced to a percentage of Oxygen 2 NOX n Oxides of Nitrogen combination of NO and NO2 referenced to a percentage of Oxygen amp SO2 n Sulfur Dioxide referenced to a percentage of Oxygen 0 Unit of measure is determined by the selected Pollution Units Refer to Section 2 17 3 The letter n represents the operator s selected Oxygen reference level of between 0 and 15 Refer to Section 2 17 7 3 The SOz sensor cannot be installed without the NO sensor also being installed e gt Use av keys to scroll to the T STACK reading Loosen thumbscrew on probe stop and move probe in and out of the stack until stack s core temperature hot spot is located then tighten thumbscrew to prevent further movement of probe Locating the highest stack temperature is very important in obtaining accurate efficiency cal
24. 4 C between 250 to 400 C Primary Air Ambient Temperature bF2 F between 32 and 212 F 1 C between 0 to 100 C Pressure 8 296 of reading or 20 05 mB 0 02 inches of H20 whichever is greater Introduction ECA 450 Front Panel Controls and Indicators Sixteen embossed push button switches with tactile feedback refer to Section 1 6 One POWER LED Display 2 x 8 20 character by 4 line alphanumeric vacuum fluorescent display panel Power Requirements Internal 7 2V battery pack or AC adapter 100 240 VAC 50 60 Hz Operating Time A fully charged battery pack will provide at least 8 hours of continuous operation with the pump running Unlimited operating time when using the AC adapter Warm Up Time 60 seconds Printer Internal 2 wide paper 20 characters Materials High impact ABS plastic briefcase with storage for the standard probe instruction manual and AC adapter Nickel plated brass quick connect hose fittings Stainless steel probe Dimensions Height 13 5 in 343 mm Width 18 5 in 470 mm Depth 9 in 229 mm Weight Approximately 25 lbs 11 34 kg Instruction 0024 9400 ECA 450 Introduction 1 4 Operation Overview Instruction 0024 9400 The ECA 450 is microprocessor controlled allowing it to be easily operated and configured to suit each operator s individual needs Using a system of menu
25. Ambient Temperature Channel The following procedure first zeros and then spans the ambient temperature channel to known temperature values Material Required Thermocouple Simulator K type Range 0 to 600 F Accuracy 0 5 F TA Zero Procedure 1 Adjust simulator to 32 F 0 C The calibration range is from 82 to 41 F 0 to 5 C Any attempt to calibrate outside this range will cause the message Bad Calibration Entry to appear Instruction 0024 9400 53 Calibration ECA 450 3 7 Plug simulator s K type connector into analyzer s T AIR jack see Figure 1 1 Enter Calibration List screen then choose T Air per Section 3 3 to display the CALIBRATE TA ZERO screen Wait until Measured reading on screen stabilizes Then use the Av and lt gt keys to enter an Applied value of 32 F 0 C Typical Calibrate TA Zero Screen During Calibration Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear followed by the CALIBRATE TA SPAN screen TA Span Procedure 6 Adjust simulator to 212 F 100 C The calibration range is from 194 to 230 F 90 to 110 C An applied value entry that is outside this range will cause the message Bad Calibration Entry to appear Wait until Measured reading on screen stabilizes Then use the nv and lt gt keys to enter an Applied of 212
26. An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate CO LO Screen During Calibration Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the Test Gas CO H2 screen is displayed Turn off regulator on CO calibration gas cylinder then remove gas cylinder from calibration fixture Attach a combination CO and Ha calibration gas cylinder to calibration fixture Use the nv and lt gt keys to enter a CO value that equals the CO concentration stamped on the gas cylinder Then press ENTER to display the Calibrate H2 screen Typical Testgas CO H2 Screen During Calibration Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the av and lt gt keys to enter an Applied value that equals the H2 concentration stamped on the gas cylinder The calibration range is from 400 to 1500 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate H2 Screen During Calibration 56 Instruction 0024 9400 ECA 450 Calibration 11 Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Cali
27. F 100 C Typical Calibrate TA Span Screen During Calibration Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed 9 Remove calibration equipment Calibrate HC Sensor The following procedure spans the optional combustibles sensor to a known gas level Material Required Calibration Gas Fixture Section 3 2 Gas Cylinder 2 5 CH 50 LEL Methane refer to Section 6 2 54 Instruction 0024 9400 ECA 450 Calibration Procedure 1 Enter Calibration List screen then choose HC per Section 3 3 to display the CALIBRATE HC screen At the conclusion of this step the pump should be running 2 Using the Gas Fixture shown in Figure 3 1 attach a CH calibration gas cylinder to the analyzer s GAS inlet port 3 Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH 4 Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the v and lt gt keys to enter an Applied value that equals the concentration stamped on the CHa gas cylinder The calibration range is from 1 to 3 An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate HC Screen During Calibration 5 Press ENTER to calibrate the analyzer s Meas
28. NO Test ID to deselect a previously chosen record then press ENTER to make the selection and return to the Test ID menu Note NO Test ID is automatically selected when the analyzer is turned on 5 Press ESC to end this procedure and return to Setup List screen 2 17 8 3 Transmit Test ID Before the Test ID information can be transmitted a personal computer must be connected to the analyzer and set up to receive the data refer to Section 2 11 Downloading Data to a Personal Computer Download all pre entered Test ID records to a personal computer as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Test ID then press ENTER to display the Test ID menu 3 Use av keys to place cursor next to Transmit Test ID then press ENTER to start transmitting At this time the analyzer displays Transmitting while also displaying the Test ID number that is currently being transmitted 4 Observe that the computer displays the data as it is being received After all data has been transmitted the analyzer re displays the Test ID menu Instruction 0024 9400 41 Operation ECA 450 5 The computer s communication program and the connection to the ECA 450 can now be closed 6 Press ESC to end this procedure and return to Setup List screen 2 17 8 4 Clearing Test ID Information Clear all or individual pre entered Test ID inf
29. NOX O2R 26 NO Concentration Referenced to O2 NO O2 27 NO2 Concentration Referenced to O2 NO2 02 28 NOx Concentration Referenced to O2 NOX O2 29 O2 Reference for SO in Field 30 SO2 O2R 30 SO Concentration Referenced to O2 SO2 02 31 Pressure Draft Measurement PRESSURE Instruction 0024 9400 25 Operation ECA 450 TABLE 2 TYPICAL SPREADSHEET FOR THE ECA 450 TESTID1 TESTID2 TESTID3 FUEL TEMP UNIT PRESS UNIT Customer Name Address Burner Number Natural Gas F inwc lt Customer Name Address Burner Number inwc POLL UNIT DATE TIME 02 co EFF CO2 TSTACK TAIR SOURCE lt ppm 01 14 00 2 45 30PM 4 12 82 2 9 5 374 T 2 TAIR EA NO NO2 NOX S02 HC CO O2R CO O2 i 68 21 18 6 24 1 0 01 3 13 lt NOX O2R NO O2 NO2 02 NOX O2 SO2 02R SO2 02 PRESSURE lt 3 19 6 25 3 1 0 25 0 25 Line 1 Column Headings Line 2 Typical Combustion Test Record with Pressure Line 3 Typical Pressure Only Measurement The following describes how to generate a spreadsheet from a comma delimited text file using Microsoft Excel 97 If you are using a different spreadsheet program then please refer to its instruction manual for information on how to import comma delimited text files Tip If the text file was saved with the filename extension CSV as described in Section 2 11 D
30. NTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed If the message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide 6 Turn off regulator then remove gas cylinder from calibration fixture Instruction 0024 9400 59 Calibration ECA 450 3 12 Calibrate CO HI Sensor This procedure spans the optional Carbon Monoxide High sensor 4 000 80 000 ppm CO to a known gas level Material Required Calibration Gas Fixture Section 3 2 Gas Cylinder 4 000 ppm CO in air refer to Section 6 2 Procedure 1 Enter Calibration List screen then choose CO HI per Section 3 3 to display the CALIBRATE CO HI screen At the conclusion of this step the pump should be running Using the Gas Fixture shown in Figure 3 1 attach a CO calibration gas cylinder to the analyzer s GAS inlet port Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the av and lt gt keys to enter an Applied value that equals the concentration stamped on the CO gas cylinder The calibration range is from 250 to 11 000 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appea
31. Y OBLIGA TION 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 Note The probe is considered a consumable item and is therefore not covered under the terms of this warranty HAZARDOUS AREA WARNING This instrument has not been designed to be intrinsically MA safe for use in areas classified as hazardous locations For your safety DO NOT use it in hazardous classified locations COMBUSTIBLE FLAMMABLE GAS WARNING This is NOT a safety device Some flue gases which this instrument can measure may be combustible flammable This instrument A should not be used to monitor combustible flue gases at or above their respective lower explosive limits LEL Immediately correct those conditions in the appliance e g boiler furnace causing unfired combustible gases before proceeding with the flue gas measurements Register Your Warranty By Visiting www mybacharach com Notice Product improvements and enhancements are continuous therefore the specifications and information contained in this document ma
32. and save it click Transfer click Capture Text click Stop 9 HyperTerminal and the connection to the ECA 450 can now be closed 2 12 Data Logging When the data logging function is turned on combustion test data is automatically stored at preset intervals over a predetermined length of time The test data can either be 1 sent to the analyzer s internal memory 2 sent to a personal computer as a comma delimited ASCII text file for storage on its hard drive or 3 sent to both the analyzer s internal memory and a PC 2 12 1 Turning Data Logging On Turn on data logging and begin the logging process as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Data Logging then press ENTER to display the Logging screen 3 Press v key to place cursor next to On then press ENTER to display the Logging menu screen yip 22 Instruction 0024 9400 ECA 450 Operation 4 Use av keys to place cursor next to one of the following three methods of storing test data Internal Stores test data in the analyzer s internal memory over 1000 data sets can be saved e PC Sends test data out the analyzer s RS232 port to a personal computer Before using this method however a personal computer must be connected to the analyzer and configured to store received data on its hard drive refer to Section 2 11 Downloading Data to a Pers
33. and the probe is at room temperature When the analyzer is first turned on and allowed to cycle through its 60 second warm up period and while sampling fresh air the sensors are checked read and calibrated set to the following ambient conditions Oxygen sensor spanned to 20 9 e All remaining gas sensors are zeroed e Pressure sensor zeroed If a sensor is found to be in error during warm up an error message will appear at the bottom of the screen describing the nature of the problem refer to Section 5 4 Troubleshooting Guide Correct any sensor errors before proceeding with these calibration procedures Instruction 0024 9400 49 Calibration ECA 450 3 2 Calibration Fixtures A gas and pressure fixture will be required to perform the various calibration procedures described in the sections that follow Parts Required Calibration Kit refer to Section 6 2 Calibration Gas refer to Section 6 2 Bellows e Micro manometer Procedure Assemble the appropriate fixture as required by the calibration procedure being performed See Figure 3 1 Figure 8 1 Calibration Fixtures GAS Leave Top El E Port Open E 2 NN FIXTURE i INLET PORT lt 1 3 e Parts Shown 1 Gas Cylinder t 2 Regulator Gr 3 Tubing 4 Tee 5 Flowmeter 6 Fitting Gas 7 Fitt
34. as been chosen by the position of the cursor In screens that require the a and v keys to be used to make a numerical or alphabetical selection i e Date Time O2 Reference Test 1D Display Timeout User Name and Calibrate screens the ENTER key is used to save those selections to memory Displays a previous menu or previously viewed screen Moves cursor in direction of arrow In screens that require an operator to enter alphanumerical data 1 e Date Time Oz Reference Test ID Display Timeout User Name and Calibrate screens the and v keys are used to scroll through the selections available for that screen Introduction ECA 450 Notes 10 Instruction 0024 9400 ECA 450 Operation 2 Operation 2 1 Turning On the Analyzer Important Prior to initially operating the analyzer be sure to first charge the battery per Section 4 1 Before turning on the analyzer connect the probe s gas hose pressure hose and thermocouple to the analyzer s GAS PRESSURE and T STACK connectors respectively refer to Section 1 5 1 Turn on the analyzer by pressing the I O key Observe that all display segments are briefly turned on to verify their operation The display then shows the following information as the analyzer performs its 60 second warm up sequence Where xx warm up time counting down from 60 seconds Note The software s version number is briefly displayed at the bottom of the screen prior to the s
35. astic canister then plug sensor into its printed circuit board 6 Install and secure the HC sensor s circuit board inside the sensor compartment using the screws removed in Step 3 7 Install sensor cover plate that was removed in Step 1 8 Place analyzer in an area of fresh air and turn it ON After the warm up cycle completes observe that no sensor error messages should have appeared 9 Calibrate the new sensor per Section 3 67 Maintenance ECA 450 4 5 Replacing Internal Particulate Filter An internal particulate filter is located at the inlet of the pump to protect the pump in the event dirt is drawn into the analyzer s GAS inlet Under normal operating conditions the probe s water trap filter assembly should catch all dirt particles large enough to damage the pump But if the probe s filter fails or is disconnected the internal particulate filter will provide backup protection Do the following to replace the internal particulate filter Material Required e Medium Phillips screwdriver Replacement Internal Particulate Filter refer to Section 6 1 Procedure 1 Turn off analyzer and remove screws from control panel 2 Lift up front of control panel to gain access to the particulate filter located on the right hand side of the analyzer See Figure 4 4 3 Remove tubing from old filter then discard filter 4 Install tubing onto new filter being sure to position the filter so that its flow arro
36. ata fields in the Combustion Test RUN screen The analyzer is not able to calculate a numerical value based on current measured data Numerical data will appear when the analyzer begins to detect valid data x x x x appears in a sensor s data field Sensor in over range The associated sensor is detecting a value that is outside the analyzer s detection range This symbol also appears in the number field of the HC sensor when there is not enough Oxygen present to accurately measure the combustible gas level sk appears in a sensor s data field The field s associated sensor was reported as being in error when the analyzer was turned on Gas pump motor sounds sluggish a Gas flow restricted somewhere between the probe tip and the T STACK connector Ensure that the probe tip is not plugged with dirt and that the Water Trap Filter Assembly is clean and not saturated with water Also verify that the probe s gas hose is not pinched b Internal particulate filter clogged Replace filter per Section 4 5 Gas pump motor does not start Loose pump connector Remove analyzer s top panel and ensure that the pump connector is securely attached to the printed circuit board Battery power does not last at least 8 hours Battery defective Replace TT Parts amp Service 78 ECA 450 Symptom Probable Cause amp Remedy Erratic combustion test screen data
37. b Carbon Monoxide content in flue gas in the range of 0 to 4 000 ppm CO corrected for the presence of Hydrogen mabe A Carbon Monomds in the range of 4 000 to 80 000 ppm CO Nitric Oxide in the range of 0 to 3 500 ppm NO Nitrogen Dioxide in the range of 0 to 500 ppm NOs Sulfur Dioxide in the range of 0 to 4 000 ppm SO Combustibles in the range of 0 to 5 gas The ECA 450 Calculates and Displays The following is true only when the measured Oxygen level is not above 16 0 Gnd the Stack Flue Gas temperature is not above 2192 F 1200 C Combustion efficiency in the range of 0 1 to 100 Excess Air in the range of 1 to 250 Carbon Dioxide content in flue gas in the range of 0 1 to a fuel dependent maximum CO value in percent Carbon Monoxide content referenced to a user defined percentage of Oxygen in the range of 0 to 99 999 ppm CO Differential pressure in the range of 27 7 inches of water column 69 mb Instruction 0024 9400 ECA 450 Instruction 0024 9400 Introduction Optionally NOx content in the range of 0 to 4 000 ppm NOx NOx content referenced to a user defined percentage of Oxygen in the range of 0 to 17 000 ppm NOx Nitric Oxide content referenced to a user defined percentage of Oxygen in the range of 0 to 14 900 ppm NO Nitrogen Dioxide content referenced to a user defined percentage of Oxygen in the range of 0 to 2 100 ppm NO Sulfur Dioxide content reference
38. bration List screen being redisplayed If the message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide 12 Turn off regulator then remove gas cylinder from calibration fixture 3 9 Calibrate SO Sensor This procedure spans the optional Sulfur Dioxide sensor to a known gas level Note The SO sensor cannot be installed without the NO2 sensor also being installed Material Required Calibration Gas Fixture Section 3 2 Gas Cylinder 100 ppm SO refer to Section 6 2 Procedure 1 Enter Calibration List screen then choose SO2 per Section 3 3 to display the CALIBRATE SO2 screen At the conclusion of this step the pump should be running Using the Gas Fixture shown in Figure 3 1 attach an SOz calibration gas cylinder to the analyzer s GAS inlet port Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the av and lt gt keys to enter an Applied value that equals the concentration stamped on the SO gas cylinder The calibration range is from 10 to 150 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate SO Screen During Calibration Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which th
39. c 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 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 66 Instruction 0024 9400 ECA 450 Maintenance 4 4 3 HC Sensor Replacement Instruction 0024 9400 Unlike the other sensors that are held in place by their associated bayonet holders the HC sensor is plugged into its printed circuit board which in turn is secured inside the sensor compartment with four screws Remove this board and replace the sensor as follows Material Required e Medium Phillips screwdriver Small flat blade screwdriver Replacement HC sensor refer to Section 6 1 Procedure 1 Gain access to sensor compartment by first removing two screws from the sensor cover plate and then removing plate see Figure 4 3 2 Unplug the HC sensor s printed circuit board from its connector jack 3 Remove the sensor s printed circuit board by first removing the board s four corner screws and then lifting the board with the HC sensor attached out from the sensor compartment 4 Unplug old sensor and discard 5 Remove replacement sensor from its pl
40. cally turned OFF and all statistical data is erased 34 Instruction 0024 9400 ECA 450 Operation 2 17 Setting Up the Analyzer The analyzer has been set up at the factory for the following defaults Temperature Units F Pressure Units Inches of Water Column inwc Pollution Units ppm Language English Date Y ydyn Current date Ten LY A Current Eastern Standard Time O Reference 096 for all gases Test Dyn onn ak blank Display Timeout Never no timeout Display Format e eenn Order of test data O2 CO EFF CO2 T STACK T AIR EA NO NO2 NOX SO2 HC CO 0 NO 0 NO2 0 NOX 0 SO2 0 Primary Air No preset Data LogglO8 cccnnncocococnnnnnnnnannnos Off Satale ey Y Hyd sed FN wn Off User Name blank Keypad Sound e eueeeueuen On High Resolution NOx Enable Off Print PressuTe coocococcnononnccninonnnoos Off Values for these parameters can be entered or changed by selecting the desired parameter from the Setup List screen which is displayed by pressing the SETUP key Instruction 0024 9400 35 Operation ECA 450 2 17 1 Temperature Units Select to display the temperature in either degrees centigrade C or Fahrenheit F as follows 1 Press SETUP key to display the Setup List screen 2 Use nv keys to place cursor next to Temperature Units then pr
41. ccccecsssessscecececeeseseseceesceesesesaeseeeeesseesaeseeseeseeeees 51 34 Calibrate Pressure SORA A 51 3 5 Calibrate T Stack Stack Temperature Channel cccccccccssssccessscecsessececsssseceesaeeecsessececseseceesaeeeessaaeees 52 3 6 Calibrate T Air Ambient Temperature Channel ccccccccsssccesssceceessececsssseceeaeeecsessececssseceeaeeecsssaeees 53 3 7 Calibrate HC Sensol rui TN A a AA A A GY cd 3 8 Calibrate CO LO Sensor E o RE E EUR SO A AN 310 CalibrateNO SE dai dis 3 11 Calibrate NO SEAS a dea aa irea FWY FYD YD 3 12 lt Calibrate CO HI SenSoI site Tu i Yd TF A Ng CD DF Ny 4 _ Maintenance 31 ii NO 4 1 Battery Charging 4 2 Water Trap Filter Assembly 4 3 lt PrinteniPaper heplacemeit i iMien ur Yd DDN yn dye DF SR UU DO FO DYD BA Sensorneplacementau eie YF GAED EF DY A E Gn Rd Cr DYF AG 4 4 1 Oz CO NO NO SO Sensor Replacement coooooooccnncncconononnnononccnnononnnnnoncnnnonenonnnnncnnanannnnnnnnos 65 4 4 2 Nitric Oxide Sensor Battery Replace Ment ccccccccccsssssssececccecsessseeseeececsesesaeseecescsesesaeeeeeesees 66 4 4 3 HESensor Replace Merci e a de aaa Enea ie 67 4 5 Replacing Internal Particulate Filter ccocconoconconcnonononoonnnnnnnnnnnnnnnonnnncnnnononnnnnnncnnnnnonnnnnnnccnnnnenonnnnncnnns 68 4 6 Cleaning the Probe and Sampling HOSES ccccccsccccccessessseecececesecesecececeesesesaeseeececsesesaeseeeescseesaeeeeeesees 69
42. cement Paper Roll refer to Section 6 1 Procedure 1 Open printer by pressing the printer s front panel latch See Figure 4 2 2 The paper roll carrier is mounted on the rear of the printer s front panel and will swing out when the printer is opened 3 Pinch in the two paper roll clips at end of paper carrier then remove paper retainer disk and empty roller from carrier 4 Install a new paper roll and the paper retainer disk onto the paper carrier 5 With analyzer turned on position paper at entry point of printer s feed mechanism The paper will be sensed by the mechanism and be automatically fed through the printer and into the proper position for printing Tip To correct for minor paper misalignment press the printer s front panel paper feed button until the paper self aligns Figure 4 2 Installing Printer Paper PAPER RETAINER PAPER FEED MECHANISM a FRONT PANEL LATCH y p PAPER CARRIER PAPER ROLL CLIPS Instruction 0024 9400 63 Maintenance ECA 450 4 4 Sensor Replacement The following sections described in detail how to replace the various sensors located in the analyzer s sensor compartment Refer to Figure 4 3 for the location and positioning of those sensors Note When a sensor error message appears at the bottom of the screen refer to Section 5 2 Problem Messages Displayed After Warm Up it does not necessarily mean that the s
43. connector GAS Probe s stack hose connector PRESSURE Probe s draft hose connector T AIR Primary air thermocouple connector T STACK Probe s Flue gas thermocouple connector OPT Option connector PRINT Prints contents of either the Combustion Test or Pressure screen on local printer SAVE Saves to memory the contents of the Combustion Test or Pressure screen Saved data can later be recalled for viewing on the display or downloaded to a personal computer MENU Steps display from the Combustion Test screen through the Setup List Calibrate Fuel Pressure and Memory menu screens Alternately a particular menu screen can be directly displayed by pressing its associated shortcut key 1 0 Turns analyzer ON and OFF RUN Starts and stops a combustion efficiency test Attach the supplied probe to the analyzer by connecting its flue gas thermocouple to the analyzer s T STACK connector flue gas hose yellow band to the analyzer s GAS connector draft hose blue band to the analyzer s PRESSURE connector Observe that the probe s connectors are of different sizes and shapes which prevent misconnection to their associated connectors on the analyzer Instruction 0024 9400 ECA 450 Introduction 1 5 2 T AIR Primary Air Thermocouple If thermocouple 0104 1797 10 feet long or Utility Wand 0104 1799 12 inch ridged probe with handle and 5 foot coiled cable is to be used to measure the burner
44. culation results Burner service procedures can now begin The readings on the analyzer will quickly change to show changes in burner performance If desired combustion test readings can be saved Refer to Section 2 7 Saving Test Data CAUTION The sensors could become damaged if water enters the analyzer Drain the water condensate in the Water Trap Filter Assembly as necessary during a combustion test as described in Step 10 During an efficiency test periodically check water level inside the probe s Water Trap Filter Assembly With this assembly stood up on its Outlet End do not let water condensate build up beyond tip of riser tube Drain water condensate after every combustion test For additional information on this subject refer to Section 4 2 Water Trap Filter Assembly 14 Instruction 0024 9400 ECA 450 Operation 2 5 Ending a Combustion Test 1 3 After performing a combustion test per Section 2 4 press RUN key to end the test You should hear the pump stop running WARNING Burn hazard Take all necessary precautions when handling a hot probe and probe stop CAUTION Allow a hot probe and probe stop to cool before storing them inside the analyzer s carrying case Loosen thumbscrew on probe stop then remove probe and probe stop from stack Note Jf data was saved during the combustion test the analyzer can be safely turned off without loosing the saved data which can be reviewed at a la
45. d to a user defined percentage of Oxygen in the range of 0 to 17 000 ppm SO Fuels Available for Combustion Calculations e Natural Gas e Propane Oil 2 Coal Oil 4 Wood Oil 5 Kerosene Oil 6 Bagasse Normal Operating Environment Temperature Analyzer 99 0 32 to 104 F 0 to 40 C Probe Tip 1472 F 800 C Max Humidity Analyzer ccc 15 to 90 Relative Humidity non condensing Air Pressure Analyzer e 09 0 9 6 Atmospheric Probe ie GG IW 10 H2O 25 mb negative pressure max at probe tip Accuracy OXY BOM cccccccnnoninnnancnncronaanana no 0 3 Ov on a practical concentration of flue gas mixtures of O2 CO and N Carbon Monoxide 5 of reading or 10 ppm whichever is greater between 0 and 2 000 ppm CO and 10 of reading between 2 001 and 40 000 ppm CO Nitric Oxide 8596 of reading or 5 ppm whichever is greater between 0 and 2 000 ppm NO Nitrogen Dioxide 8596 of reading or 5 ppm whichever is greater between 0 and 500 ppm NO Sulfur Dioxide 5 of reading or 10 ppm whichever is greater between 0 and 2 000 ppm SO2z Combustibles 5 of full scale Stack Temperature 4 F between 32 and 255 F 2 C between 0 to 124 C 6 F between 256 and 480 F 3 C between 125 to 249 C 8 F between 481 and 752 F
46. ded 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Display Format then press ENTER to show Display Format screen 3 Use av keys to place cursor next to Edit Format then press ENTER to show Edit Display Format screen where the current order of the Combustion Test Data is shown numbered from 0 to 23 Fwrgmmaoaft 4 Change data shown for a particular location by first using v keys to place cursor next to desired numbered location Next press ENTER to move cursor into that location s data field then use Av keys to choose desired data to appear at that location Finally press ENTER to make the selection and move cursor back to left of screen 5 Change data displayed at other numbered locations by repeating Step 4 6 When finished press ESC as necessary to return to Setup List screen 2 17 10 2 Resetting Display Format Back to Factory Default Return the display format back to its factory default order as follows 1 Press SETUP key to display the Setup List screen 2 Use nv keys to place cursor next to Display Format then press ENTER to show Display Format screen 3 Use v keys to place cursor next to Reset Format then press ENTER to show Reset Display Format screen 44 Instruction 0024 9400 ECA 450 Operation 4 Use av keys to choose Yes then press ENTER to reset the display and return
47. e message Good Calibration should appear along with the Calibration List screen being redisplayed If the message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide Turn off regulator then remove gas cylinder from calibration fixture Instruction 0024 9400 57 Calibration ECA 450 3 10 Calibrate NO Sensor The following procedure spans the optional Nitric Oxide sensor to a known gas level Material Required Calibration Gas Fixture Section 3 2 Gas Cylinder 250 ppm NO in Nitrogen refer to Section 6 2 Procedure 1 Enter Calibration List screen then choose NO per Section 3 3 to display the CALIBRATE NO screen At the conclusion of this step the pump should be running Using the Gas Fixture shown in Figure 3 1 attach an NO calibration gas cylinder to the analyzer s GAS inlet port Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the av and lt gt keys to enter an Applied value that equals the concentration stamped on the NO gas cylinder The calibration range is from 10 to 550 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate NO Screen During Calibration Press ENTER to calibrate the analyzer s Measured value
48. ective Return to Bacharach for replacement Instruction 0024 9400 ECA 450 Instruction 0024 9400 Parts amp Service Symptom Probable Cause Remedy Low Battery message appears at bottom of display accompanied by a beeping alert tone Battery close to being discharged Analyzer will run for only several minutes after this message first appears before turning itself off Recharge battery per Section 4 1 O2 Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b Oz sensor depleted Replace sensor per Section 4 4 1 TS Sensor Error message appears at bottom of display a The probe s stack thermocouple is not connected to the analyzer s T STACK connector Connect thermocouple per Section 1 5 1 b Analyzer was turned on with probe in stack Remove probe from stack allow it to cool to room temperature then restart c Temperature being measured during start up is outside the range of 4 to 212 F 20 to 100 C d Thermocouple defective Replace probe assembly TA Sensor Error message appears at bottom of display a Analyzer was turned on with its primary air thermocouple measuring a temperature that was outside the range of 4 to 212 F 220 to 100 C Ensure thermocouple is sampling ambient room temperature and restart b Thermocouple def
49. ective Replace NO2 Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b NO2 sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor HC Sensor Error message appears at bottom of display Combustibles sensor not plugged in or is defective Install or replace sensor per Section 4 4 3 75 Parts amp Service 76 ECA 450 Symptom Probable Cause amp Remedy NOXIDE Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b NO sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor CO LO Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b CO LO sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor CO HI Sensor Error message appears at bottom of display a Analyzer was turned on with probe sampling flue gas Remove probe from stack and restart b CO HI sensor not zeroed at start up Turn analyzer off and then on to re zero all sensors If error persists replace sensor
50. ensor has become depleted or is defective Before replacing a sensor refer to Section 5 4 Troubleshooting Guide for other possible causes of the error Caution Static damage When handling any printed circuit board be sure to follow all established industry procedures for the prevention of static buildup that when discharged may damage electrical components on the board Figure 4 3 Sensor Compartment O SENSOR NO SENSOR HC SENSOR OPTIONAL NO SENSOR SO SENSOR 8 PCB PCB amp LITHIUM amp PCB Sensor Blank amp PCB amp PCB BATTERY w O Ring shown SENSOR COVER J COVER SCREW 2 PLACES CO Lo SENSOR amp PCB CO Hi SENSOR amp PCB ee e E sees 8 J p o o om Optional NOTE FOR CLARITY THE WIRES BETWEEN THE SENSOR PRINTED CIRCUIT BOARDS AND THEIR ASSOCIATED CONNECTOR JACKS ARE NOT SHOWN 64 PCB CONNECTOR JACKS Instruction 0024 9400 ECA 450 Maintenance 4 4 1 O CO NO NO 8 SO Sensor Replacement Instruction 0024 9400 All sensors with the exception of the HC sensor are replaced in a similar manner Do the following to replace either the Oz CO LO CO HI NO NO or SO sensor Material Reguired Medium Phillips screwdriver Replacement sensor refer to Section 6 1 Procedu
51. ess ENTER to display the Temperature Units screen 3 Place cursor next to either C or F then press ENTER to make the selection and return to Setup List screen 2 17 2 Pressure Units Select to display pressure units in either inches of water column inwc millibars mb Pascals Pa or hecto Pascals hPa as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Pressure Units then press ENTER to display the Pressure Units screen 3 Use av keys to place cursor next to either inwc mb Pa or hPa then press ENTER to activate selection and return to Setup List screen 2 17 3 Pollution Units The analyzer is capable of converting the measured ppm levels of CO NO NO and SO2 to various pollution units using CFR40 Part 60 emission factors Note that the pollution unit conversions for NO NO2 and NOx are based on the molecular weight of NO Select to display the measured levels of CO NO NOz and SO in either parts per million ppm pounds of pollutant per million BTU Mbtu milligrams of pollutant per cubic meter of gas mg m3 or grams of pollutant per gigajoule g GJ as follows 4 Press SETUP key to display the Setup List screen 36 Instruction 0024 9400 ECA 450 Operation 2 17 4 Language 2 17 5 Date Use av keys to place cursor next to Pollution Units then press ENTER
52. est se Aaa 2 6 Performing a Draft Measurement ccccecssssesecececseseeaeeecececeeseaaesecececeeseseeseseesceeseseeaeseescessesesaeseeseseeegeea 24a Saving Test Datas A A a i a A a i a dn 2282 Cl MEM eO au uu TF YY GOD 2 9 Recalling Test Data Stored in MemMory ccconococonnnoncnonononnnnnnncnnnonnnnnnnncnncnnononnnnnnnnnnnnnnrnnnnnnnannnnnnnnnnnncnnannnnns 2410 Printing Data issue du Gyd dn CH did a Od dad dd e TF Fd GU FdA 2 11 Downloading Data to a Personal Computer 2 12 Data LOggin eu aiii GYHYRAU YAA s EEE ine ERES 2 12 1 Turning Data Logging On 2 12 2 Turning Data Logging Off 2 13 Importing Saved Data Into a Spreadsheet cccccccccesssssscesecececsesssecececeeseaesesececeeseeeeeseeecessesaeseesesesegees 2 14 Primary Air Temperature Measurement ccccoconoccnonononononononononononnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonononons 2 14 1 Thermocoupl Method ee GY ld tod eE 2 14 2 Probe Thermocouple Method ccccconococoonnoncnononennnnnonccnnnnonnnnnnncnnnnnonnnnnnncnnnnnnnnnnnnncnnannonnnnnnnos 214 3 Thermometer Method aiid ea iY e dias 2 14 4 Internal Temperature Sensor Method occccccncconooncnncnnnonennnononcnncononnnncnncnncnnnnnnnonnnnncnnnnnnnnnnos 30 2 15 Differential Pressure Measurement cccecsescecesseececeesaececeeeeecseaeeecseaeececaeeeceesueeeceeasececueeeceeueeeseeaaeens 31 2 10 sStatiStics oo EEE E A a iia 2 17 Setting Up The Analia A AAA A AA L r e eaaa 2
53. et Button a m 0 o oo00 nag 00 Fi al aga 000 0000 DE 0 0 E MW W o 70 Ed Co oog nu oo Do A RESET BUTTON Instruction 0024 9400 ECA 450 Maintenance Notes Instruction 0024 9400 71 Parts amp Service ECA 450 5 Troubleshooting 5 1 Analyzer Repair It is recommended that field repair of the ECA 450 be limited to Simple checks of printed circuit board connectors Replacing the Probe Assembly Replacing the filter element in the Water Trap Filter Assembly Replacing Sensors All other repairs should be performed by an authorized Bacharach Service Center 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 Before returning your analyzer for repair you may be able to determine and resolve a problem using the Troubleshooting Guide in Section 5 4 5 2 Problem Messages Displayed After Warm Up If there were problems detected during warm up messages that describe the nature of the problems are sequentially displayed at the bottom of the screen immediately following the analyzer s 60 second warm up period Note that the analyzer will not automatically switch to the Combustion Test HOLD screen if problems were detected The analyzer however can still be used to perform any test
54. eueueee eie Y Y LIII LLY Ynn 0024 1156 NO 100 ppm in Nitrogen eeuuuueenr nien III III FFIN 0024 1157 SO 100 ppm in Nitrogen euuuueeu inr III I II iH 0024 1158 Methane 2 596 CHa decine iini e e EAE E NR 0051 1121 Hose Extension 20 feet extends reach of prob eeenn 0024 1124 Probe and Hose Assemblies DATA A Ad a EESE a 0024 3024 MIA A A EA EN NR REN 0024 3025 Sensor Option Kits CO high 4 000 to 80 000 ppm CO ein 0024 3026 NO a 0024 3027 Combustibles cid E a dd asii 0024 3028 IN Ob ina la 0024 3029 SO requires NO2 Option ooooccconoccccconononononononcnnnnnnnc nono I I ocn 0024 3030 Serial Communications Cable DB 9M to DB 9F 0104 4027 Thermocouples for primary air measurement MOON A aia 0104 1797 True Spot Smoke Test Set ooooooocccncononononnnonocnnnnnnononononnononnananonononnos 0021 7006 Sensor Option Kits must be installed by an authorized Bacharach Service Center 80 Instruction 0024 9400 ECA 450 Parts amp Service 6 3 Service Centers Instruction 0024 9400 Service and replacement parts can be obtained by contacting a Bacharach Service Center at the following locations 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 St Unit 7 Markham Ontario L3R SP4 Canada Phone 905 470 8985
55. g and logging i iJ i This display shows that the analyzer is logging and currently saving data to internal memory location 25 Observe that the memory location number will increment as data is being saved Note that if all memory locations are used before the end of the logging duration then xxxx appears in place of the memory location number indicating a memory over range condition This display s being sent to only a personal computer Tip Logging can be stopped without loosing data that has already been collected by pressing the ESC key At the conclusion of the logging process the message Logging Complete will appear And if data was being stored in the analyzer s internal memory then the message Data in memory nnnn to nnnn will also appear where nnnn denotes the internal memory locations that contain the logged data Press ENTER to leave logging and display the Combustion Test HOLD screen 2 12 2 Turning Data Logging Off Data logging is automatically turned off at the end of the logging process when the ENTER key pressed if the logging process is interrupted by pressing the ESC key Note If the logging process is interrupted it cannot be resumed without first turning logging back on per Section 2 12 1 24 Instruction 0024 9400 ECA 450 Operation 2 13 Importing Saved Data Into a Spreadsheet A text file that was created as described in either Section 2 11 Download
56. gen reference 4 Use av keys to choose desired Oxygen reference value from 0 to 15 5 Press ENTER to make the selection and return to O2 Reference gas menu screen 6 Repeat Steps 3 thru 5 for remaining gases 7 After an Oxygen reference has been set for each gas press ESC to return to the Setup List screen Test records can be identified e g the customer s name burner number and location by manually entering up to three lines of text with each line containing a maximum of 20 alphanumerical characters This information will be associated with all succeeding test records and will appear at the top of each test record when printed and at the bottom of saved test records when viewed on the display The chosen Test ID remains in effect until such time as the Test ID is unselected a new Test ID is selected or the instrument is shut off Up to 32 Test IDs can be pre entered for later retrieval All pre entered Test IDs can be downloaded to a personal computer as an ASCII text file for storage and printing 2 17 8 1 Enter Edit Test ID Information Enter or edit Test ID information as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Test ID then press ENTER to display the Test ID menu Instruction 0024 9400 39 Operation ECA 450 3 Use av keys to place cursor next to Edit Test ID then press ENTER to display the Edit Test ID menu w
57. hich shows the first line of each Test ID record Note Five periods are used to identify empty lines 4 Use av keys to choose which Test ID record to edit then press ENTER to display all three lines of that record Eig bE prup 5 Use av keys to choose which of the three Test ID lines to edit then press ENTER to begin editing that line 6 Use av keys to display first desired character Then press gt key to move to next character position Repeat this step until line is complete maximum of 20 alphanumerical characters 7 When finished press ENTER to save information and move cursor back to left of screen 8 At this time either return to Step 5 to choose another line to edit or end this procedure by pressing the ESC key as necessary to return to the Setup List screen 2 17 8 2 Select Test ID Choose which pre entered Test ID to use as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place the cursor next to Test ID then press ENTER to display the Test ID menu 40 Instruction 0024 9400 ECA 450 Operation 3 Use av keys to place cursor next to Select Test ID then press ENTER to display the Select Test ID menu which shows the first line of each Test ID record Note Five periods are used to identify empty records 4 Use av keys to choose a pre entered Test ID or choose
58. ing Data to a Personal Computer or Section 2 12 Data Logging can be imported into spreadsheet programs that are capable of importing comma delimited files Note that each data record consists of 31 fields some of which may be blank for different tests and analyzer configurations TABLE 1 COMMA DELIMITED FIELDS Field Data Name or Value Label in Column Heading 1 Test ID Line 1 up to 20 characters TESTID1 2 Test ID Line 2 up to 20 characters TESTID2 3 Test ID Line 3 up to 20 characters TESTID3 4 Fuel Name FUEL 5 Temperature Unit of Measure used in fields 14 815 TEMP UNIT 6 Pressure Unit of Measure used in field 31 PRESS UNIT 7 Pollution Unit of Measure used in fields 11 18 thru 21 POLL UNIT 24 26 27 28 amp 30 8 Date of Test DATE 9 Time of Test TIME 10 O Concentration in 02 11 CO Concentration CO 12 Combustion Efficiency in EFF 13 CO Concentration in 96 CO2 14 Stack Temperature TSTACK 15 Primary Air Temperature Measurement Source TAIR SOURCE 16 Primary Air Temperature TAIR 17 Excess Air in EA 18 NO Concentration NO 19 NOz Concentration NO2 20 NOx Concentration NOX 21 SO Concentration S02 22 Hydrocarbon combustibles Level in Gas HC 23 O2 Reference for CO in Field 24 CO O2R 24 CO Concentration Referenced to O2 CO O2 25 O2 Reference for NO NO and NOx in Fields 26 27 amp 28
59. ing Pressure Contained in Calibration Kit PRESSURE PRESSURE FIXTURE INLET PORT Bellows Micro manometer 50 Instruction 0024 9400 ECA 450 Calibration 3 3 Starting and Ending a Calibration Procedure Start any calibration procedure by first pressing the CALIBRATE shortcut key Before calibration can begin however a 4 place alphanumerical password must be entered Enter the password by first pressing the ENTER key and then using the Av and lt gt keys until the correct password is displayed Note The calibration password is provided on a separate card supplied with the analyzer Again press the ENTER key If the correct password was entered the following Calibration List screen will appear Note Sensors that are not installed will not appear in the Calibration List Use av keys until cursor is in front of desired calibration function then press ENTER to display that function s corresponding Calibrate screen After the desired calibration procedures have been completed press the ESC key to return to the Combustion Test HOLD screen 3 4 Calibrate Pressure Sensor This procedure calibrates the pressure sensor to a known pressure value Material Required Calibration Pressure Fixture Section 3 2 Bellows adjustable e Micro manometer Range 8in H20 column 20 mb Accuracy 0 01 H20 column 0 025 mb
60. l Then insert the adapter s output plug into the analyzer s POWER connector Figure 1 1 A fully discharged battery pack should take approximately 11 hours to recharge Note that a protection circuit within the analyzer prevents the battery pack from being over charged If the battery pack becomes depleted while the analyzer is being used or if a continuous run time of over 8 hours is required then the AC adapter can be used to both run the analyzer and charge the battery pack at the same time 61 Maintenance ECA 450 4 2 Water Trap Filter Assembly The Water Trap Filter Assembly removes water condensate from the gas sample and also prevents soot from contaminating the internal components of the analyzer Figure 4 1 Water Trap Filter Assembly End Cap Filter Element Riser Tube End Cap Outlet Inlet a He 4 Hj d di Drain the water condensate after every use Procedure 1 Pull off end cap from inlet end of the Water Trap Filter Assembly 2 Pour out all of the water condensate then replace end cap Replace the filter element when it becomes excessively dirty Parts Required Filter Element refer to Section 6 1 Procedure 1 Pull off end cap from outlet end of Water Trap Filter Assembly 2 Remove and discard old filter element 3 Install a new filter element then replace end cap 62 Instruction 0024 9400 ECA 450 Maintenance 4 3 Printer Paper Replacement Parts Required e Repla
61. mputer 1 5 6 OPT Option Connector for future optional equipment Instruction 0024 9400 7 Introduction ECA 450 1 6 Front Panel Keypad Controls Descriptions of the front panel keypad controls are given below Note that a control may perform multiple functions as determined by what screen is being displayed at the time 1 0 e U AJ INT IU n gt lt m m Zz Cc n ic om rc P AP MEMORY SETUP U AJ m n n G AJ m Turns the analyzer ON and OFF Note that when the analyzer is turned OFF there is a 5 second off delay period that allows an operator to turn the analyzer back ON by pressing the RUN key Also note that if there are unsafe levels of gas present inside the analyzer when it is turned OFF the analyzer s pump 1s automatically started and purges the sensor compartment with fresh air The analyzer will turn OFF only after the gas levels have been reduced If desired the purging process can be aborted by again pressing the I O key Starts and stops a combustion efficiency test when the Com bustion Test RUN HOLD screen is displayed Pressing this key from any of the menu screens returns the analyzer to the Combustion Test HOLD screen Pressing this key during the 5 second turn off delay period or from the warm up screen whenever sensor errors are being displayed will also cause the Combustion Test HOLD screen to be displayed Prints the contents of either the Combusti
62. nation of NO and NO and calculates CO SOz2 and NOx individually referenced to a user defined Oxygen level of between 0 and 15 Automatically purges the low range CO sensor with fresh air if the CO level exceeds 4 000 ppm At this time the analyzer also automatically switches over to its optional high range CO sensor if installed Automatically zeros all sensing channels on ambient air when the analyzer is first turned on Displays temperature in either C or F Displays pressure in either inches of water column inwc millibars mb Pascals Pa or hecto Pascals hPa Optionally displays pollution conversions for CO NO NO and SO Pollution conversions include parts per million ppm pounds of pollutant per million BTU 4 MBTU milligrams of pollutant per cubic meter of gas mg m3 and grams of pollutant per gigajoule g GJ Low battery warning message Stores over 1000 individual combustion and or pressure test records which can later be recalled for viewing or printing Stored test records can be downloaded to a personal computer in comma delimited format which can be captured as a text file and then opened in a spreadsheet program Introduction ECA 450 Performs data logging A series of combustion tests can be automatically started at user defined intervals and the data saved for reviewing at the conclusion of the logging period The data can be stored in either the analyzer s internal memory sent
63. nel double click Add Remove Programs click Windows Setup double click Communications select the HyperTerminal check box click OK twice 1 Install serial data cable P N 0104 4027 straight through 6 foot DB9 male to DB9 female between the computer s COM port and the analyzer s RS232 connector For computers having a 25 pin COM port elther use a 25 pin to 9 pin adapter or use a serial cable with appropriate connectors on each end 2 Atthe computer start HyperTerminal by doing one of the following If HyperTerminal has already been set up to communicate with the ECA 450 then click Start point to Programs point to Accessories point to Communications click HyperTerminal and double click the file name or icon that has been associated with the ECA 450 If HyperTerminal has never been run in association with the ECA 450 then a new HyperTerminal connection needs to be made as follows a Click Start click Run In the Run box type hypertrm exe and click OK The New Connection dialog box should appear b Type in a New Connection Name such as ECA450 Click OK to select the default icon if desired select a different icon before clicking OK The Connect To dialog box should appear c Click the Connect using drop down menu and choose the COM port to which the analyzer is connected Then click OK to display the COM Properties dialog box for that COM port d Set Port Settings to Bits per second 19200
64. ng data Use av keys to select desired duration then press ENTER to make the selection and display the Statistics Summary screen Note The minimum and maximum duration values are dependent on the interval The duration can never be less than the interval and cannot record more than 120 readings The Statistics Summary screen shows both the interval and duration as chosen in Steps 4 and 5 For example if the interval was set to 10 seconds and the duration set for 5 minutes then emission data will be collected every 10 seconds over a 5 minute period for a total of 30 readings from which the average and standard deviation are calculated To change the value of either the interval or duration press ESC to redisplay the first Statistics screen and repeat Steps 3 4 and 5 With the analyzer set up per Section 2 4 Performing a Combustion Test press ENTER to begin collecting data for statistical analysis Before data 1s collected however the ECA 450 first waits 60 seconds to allow the sensor readings to stabilize After 60 seconds as elapsed the front panel now shows the data as it s being collected Use the av keys to scroll through the readings on the display In this example the top line of the display shows that the analyzer is in its statistics mode currently taking reading 10 with natural gas as the fuel Observe that the reading number increments as data is being collected at the cho
65. on Test or Pressure screen on the local printer This key is inactive in all other screens Saves the contents of the Combustion Test or Pressure screen to memory The saved data can then later be recalled for viewing on the display and printed or downloaded to a personal computer Cycles the display from the Combustion Test screen though the following menu screens Fuel Pressure Memory Setup List and Calibration List These menu screens can also be directly accessed by pressing their associated shortcut key Shortcut key to the Fuel menu screen where operators can choose which fuel is being burned Shortcut key to the Pressure menu screen where operators can view the pressure being sampled by the probe Pressing this key a second time allows an operator to zero the pressure sensor Shortcut key to the Memory menu screen where operators can choose to either view the Memory Directory screen transmit saved data out the analyzer s RS232 port or clear memory Shortcut key to the Setup List menu screen where operators can choose to change various operating parameters of the analyzer Instruction 0024 9400 ECA 450 Instruction 0024 9400 CALIBRATE m z 13 m a ESC EME Introduction Shortcut key to the Calibration List menu screen where operators can choose the sensor to be calibrated Note that a 4 place alphanumerical password must first be entered to begin calibration Selects a menu item that h
66. on the option chosen Last Immediately transmits the last memory location that contains data Observe that the analyzer displays Transmitting while also displaying the record number being transmitted Range When chosen the range select screen is displayed By default the range is from 0 to the last memory location that contains data To change the range first press ENTER to move the cursor into the From record data field Then use the a v lt and gt keys as necessary to enter the number of the first record to be transmitted Again press ENTER this time to save record number and move cursor back to left of screen Repeat this procedure to change the To record data field Start data transmission by moving cursor next to Transmit line and then pressing ENTER Observe that the analyzer displays Transmitting while also displaying the record number that is currently being transmitted All Immediately transmits all memory locations that contain data Observe that the analyzer displays Transmitting while also displaying the record number that is currently being transmitted Instruction 0024 9400 21 Operation ECA 450 7 Observe that HyperTerminal displays the data as it s being received After all data has been transmitted the analyzer re displays the Memory menu screen Tip The download process can be stopped by pressing the ESC key 8 Tostop capturing data
67. onal Computer e Both Stores test data in the analyzer s internal memory and also sends the test data out the analyzer s RS232 port After choosing the logging method press ENTER to make the selection and display the Logging Interval screen 5 The default interval the time period between measurements is 10 minutes To change this value use v keys to select either 1 5 10 15 30 seconds 1 2 5 10 15 30 minutes or 1 hour Then press ENTER to make the selection and display the Logging Duration screen 6 The logging duration is the length of time allocated to collecting data Use the av keys to select either 1 5 10 15 30 minutes 1 2 5 10 24 48 or 72 hours Then press ENTER to make the selection and display the Logging Summary screen Note The duration value can neuer be less than the interual 7 The Logging Summary screen shows both the logging interval and duration as chosen in Steps 5 and 6 For example if the interval was set to 10 minutes and the duration set for 2 hours then a combustion test will be conducted every 10 minutes over a 2 hour period for a total of 12 readings To change either the interval or duration value press ESC to abort the logging process and redisplay the first Logging screen Instruction 0024 9400 23 Operation ECA 450 With the analyzer set up per Section 2 4 Performing a Combustion Test press ENTER key to begin testin
68. ormation from memory as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Test ID then press ENTER to display the Test ID menu 3 Use av keys to place the cursor next to Clear Test ID then press ENTER to display the Clear Test ID menu 4 Doone of the following to either clear individual records or all records Individual Records Use v keys to place cursor next to Individual Records then press ENTER to display the Clear Individual menu Again use v keys this time to choose the record to clear then press ENTER to clear that record All Records Use av keys to place cursor next to All Records then press ENTER to display the Clear All menu Again use the av keys this time to choose Yes then press ENTER to clear all records Cigar s 5 Press ESC to end this procedure and return to Setup List screen 42 Instruction 0024 9400 ECA 450 Operation 2 17 9 Display Timeout To conserve battery life the vacuum fluorescent display panel can be configured to turn itself off after 5 to 60 minutes of keyboard inactivity Select the display s time delay off period as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Display Timeout then press ENTER to show the Display Timeout screen Where n current timeout
69. ownloading Data to a Personal Computer a spreadsheet will automatically be created when that file is opened in Microsoft Excel 97 1 2 Start Microsoft Excel 97 Click File then click Open to display the Open dialog box Change the Files of type to Text Files Then navigate to the directory containing the text file to be imported Double click the desired filename to display the Text Import Wizard Step 1 of 3 dialog box Select the Delimited radio button then click Next to display the Text Import Wizard Step 2 of 3 dialog box Under Delimiters select the Comma check box Then click Next to display the Text Import Wizard Step 3 of 3 dialog box Click Finish to create the spreadsheet 26 Instruction 0024 9400 ECA 450 Operation 2 14 Primary Air Temperature Measurement To properly calculate net stack temperature the analyzer must know the burner s primary air temperature The following sections describe four methods of measuring and supplying this temperature value to the analyzer 2 14 1 Thermocouple Method A thermocouple that is plugged into the T AIR connector see Figure 1 1 provides the analyzer with the most up to date primary air temperature information for combustion efficiency calculation purposes Refer to Section 1 5 2 T AIR If the burner s primary air supply is being drawn in from the room then simply place the thermocouple where it can sample room air If however the air
70. r Typical Calibrate CO HI Screen During Calibration Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed If the message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide Turn off regulator then remove gas cylinder from calibration fixture 60 Instruction 0024 9400 ECA 450 Maintenance 4 Maintenance Field maintenance of the ECA 450 is limited to the following Battery charging e Water Trap Filter replacement e Printer Paper replacement Sensor replacement Cleaning the probe Resetting the microprocessor Replacing the internal particulate filter All other maintenance should be performed by an authorized Bacharach Service Center Section 6 8 4 1 Battery Charging Instruction 0024 9400 A fully charged battery pack will power the analyzer for a minimum of 8 hours When the battery pack is just about depleted the message LOW BATTERY will appear at the bottom of the screen after which the analyzer will operate from 5 to 15 minutes before automatically shutting itself off Recharge the analyzer s internal battery pack by first plugging the supplied AC adapter in a source of 100 240 VAC 50 60 Hz power A green LED on the adapter should glow indicating that 1t 1s operationa
71. r that value as follows 1 Use a thermometer to measure the primary air temperature 2 Press SETUP key to display the Setup List screen 3 Use av keys to place cursor next to Primary Air then press ENTER to display the Primary Air screen Note The message Primary Air is measured by TC will appear if a thermocouple is plugged into the T AIR socket This thermocouple must be removed to continue this procedure Instruction 0024 9400 29 Operation ECA 450 2 14 4 Use av keys to place cursor next to Enter then press ENTER to display the Primary Air Temperature screen Press ENTER to move the cursor into the temperature data field then use the a v lt and gt keys as necessary to enter the temperature value that was measured in Step 1 Note that leading zeros should be entered as either a numerical 0 or a blank space For example a primary air temperature of 35 5 F should be entered as 035 5 in the display Press ENTER to save the displayed temperature value in the analyzer s temperature memory buffer and return to the Setup List screen Note The temperature memory buffer is cleared when the analyzer is turned off or when the T AIR thermocouple is installed after the entered number is saved Internal Temperature Sensor Method If a thermocouple is not plugged into the T AIR connector and there is no data stored in the temperature memory buffer then
72. re 10 Remove two screws from sensor cover plate and then remove plate to gain access to sensor compartment See Figure 4 3 Unplug the printed circuit board from the sensor being replaced by carefully pulling the board straight up Note position of sensor pins then release sensor from its bayonet type holder by turning the sensor counterclockwise Remove sensor by pulling it straight up Note Discard an old sensor in accordance with local and federal hazardous waste disposal laws Remove replacement sensor from its plastic canister Note that the CO LO CO HI SO2 and NO2 sensors have a shorting spring installed between two of their pins Remove and discard this spring before installing the sensor Insert sensor into its holder and turn clockwise to lock in place Ensure that the sensor pins are positioned as was noted in Step 3 Plug the circuit board which was removed in Step 2 into the top of the sensor Important When replacing the Oz sensor be sure that the sensor pin plugs into the circuit board socket that is also marked Polarity markings are located on the bottom of the printed circuit board and the sensor Install sensor cover plate that was removed in Step 1 Allow the sensor that was just installed time to stabilize in the circuit before continuing with this procedure Stabilization time for all sensors except for the NO sensor is about 1 hour An NO sensor requires approximately 4 hours
73. selections the operator is guided through the proper operation and set up procedures signaling the appropriate action and waiting until the correct steps are taken The analyzer is powered by either its internal battery pack or by an AC adapter that operates from any convenient source of 100 240 VAC 50 60 Hz power The analyzer s control panel consists of a bright and easy to read 2 x 8 blue vacuum fluorescent display sixteen pushbuttons and one POWER LED A sampling probe and hose assembly with an integral thermocouple and water filter trap provides the means of drawing in gas samples and for measuring stack temperature and pressure A burner s combustion efficiency is calculated by first entering the fuel being burned and then allowing the analyzer to measure the burner s primary air temperature stack temperature and percent Oxygen in the flue gas This information is processed by the analyzer resulting in the display of all the measured and calculated values that are listed in Section 1 3 Technical Data For analyzer models that are eguipped for environmental monitoring of combustion by products the gas sample that was drawn into the analyzer through its probe is applied to an array of electrochemical gas sensors The results of the analyzer s gas analyses are shown on the front panel display Introduction ECA 450 1 5 Front Panel Connections and Controls Figure 1 1 ECA 450 Components
74. sen interval and stored in memory Tip Press ESC to abort the statistical analysis process At this time the Statistics mode is turned OFF and the message Stats Interrupted is displayed Press ENTER to return to the Combustion Test HOLD screen Instruction 0024 9400 33 Operation ECA 450 10 At the conclusion of the data collection process the ECA 450 calculates the average and standard deviation values of the emissions data just recorded A Final Statistics screen then appears that shows the average and one standard deviation of each gas measured the number of readings taken and the duration of the test Use the av keys to scroll through the readings on the display If a sensor goes into over range or the calculated standard deviation exceeds 999 9 the display will show or xxxxx respectively for the average and standard deviation In this example the average oxygen reading was 14 5 with a one standard deviation of 0 3 meaning that there is a 68 chance the oxygen readings taken during the sampling duration were between 14 2 and 14 8 AVG 15D and a 95 chance the oxygen readings were between 13 9 and 15 1 AVG 25D If desired press PRINT to obtain a hard copy of the Final Statistics screen Note The data shown in the Final Statistics screen cannot be saved Press ENTER to display the Combustion Test HOLD screen At this time the Statistics mode is automati
75. step until the line is complete maximum of 20 characters When finished press ENTER key to save the information just entered and redisplay the User Name menu At this time either return to Step 4 to choose another line to edit or end this procedure by pressing ESC 2 17 14 2 Clear User Name Information Clear all User Name information as follows Press SETUP key to display the Setup List screen Use av keys to place cursor next to User Name then press ENTER to display the User Name menu Use av keys to place cursor next to Clear User Name then press ENTER to display the Clear User Name confirmation screen Use av keys to choose Yes then press ENTER to clear all information When finished press ESC to return to the Setup List screen 2 17 15 Keypad Sound The audible sound used to signal when a keypad button is pressed can be turned off and on as follows Press SETUP key to display the Setup List screen Use av keys to place cursor next to Keypad Sound then press ENTER to display the Keypad Sound menu screen Use av keys to place cursor next to either Off or On then press ENTER to make the selection and return to the Setup List screen 46 Instruction 0024 9400 ECA 450 Operation 2 17 16 High Resolution NOx Enable When High Resolution NOx Enable is turned ON the ECA 450 will display the values of NO NOz and NOx at a resol
76. supply is being drawn in from an outside source where the temperature is different from that of room air then immerse the thermocouple into the burner s primary air stream Note that when a thermocouple is plugged into the T AIR connector its temperature reading takes priority over all other methods of temperature measurement When viewing the T AIR value on the Combustion Test HOLD RUN screen the designation T will appear to the left of the temperature value The letter T signifies that a Thermocouple is being used to measure the primary air temperature For example 2 14 2 Probe Thermocouple Method This method has an operator taking a one time primary air temperature measurement using the probe s T STACK thermocouple and then storing the measurement in the analyzer s temperature memory buffer When viewing the T AIR value on the Combustion Test HOLD RUN screen the designation M will appear to the left of the temperature value The letter M signifies that the primary air temperature value was Measured For example i gl Measure the primary air temperature using the probe s thermocouple and store that measurement as follows 1 Press SETUP key to display the Setup List screen Instruction 0024 9400 27 Operation ECA 450 2 Use av keys to place cursor next to Primary Air then press ENTER to display the Primary Air screen Note The message Primary Air is measured by TC will
77. sure is to be measured The Pressure screen is now displaying the differential pressure between the two areas Positive readings indicate that the pressure of the area being measured is higher than the reference area while negative readings indicate the pressure is lower than the reference Instruction 0024 9400 31 Operation ECA 450 2 16 Statistics Mode The Statistics mode configures the ECA 450 to perform a statistical analysis of measured emissions data taken over a preset interval and duration At the end of the prescribed duration the average and standard deviation are calculated for each gas measured and shown on the front panel display Turn ON the Statistics mode and begin the statistical analysis process as follows 1 Press the SETUP key to display the Setup List screen 2 Use av keys to place cursor next to Statistics then press ENTER to display the Statistics screen 3 Press v key to place cursor next to On then press ENTER to display the Statistics Interval screen 4 The default interval the time period between measurements is 10 seconds To change this value use the v keys to select 1 5 10 15 30 seconds 1 2 5 10 15 30 minutes or 1 hour Then press ENTER to make the selection and display the Statistics Duration screen 32 Instruction 0024 9400 ECA 450 Operation The statistics duration is the length of time allocated to collecti
78. tart of the warm up sequence At the end of a normal warm up sequence the message No Problems Detected is briefly displayed followed by the display of the Combustion Test HOLD screen If however a problem was detected during warm up the analyzer will display the message Problem s Detected and sequentially display a list of those problems at the bottom of the screen and then wait for operator intervention Refer to Section 5 2 Troubleshooting Guide for a list of possible error messages and the recommended corrective action 2 2 Turning Off the Analyzer The analyzer is turned off by again pressing the I O key If there is any residual gas inside the sensor chamber the message Purging Sensors is displayed while the analyzer purges itself with fresh air The purging process continues until all gas concentrations inside the analyzer have reached safe levels Once the sensor chamber has been purged the analyzer enters its normal 5 second delay period after which the analyzer turns off Important The probe must be removed from the stack during the purging process to allow fresh air to be drawn through the sensor chamber Tips Pressing the I O key will abort the purging process During the off delay period the analyzer can be turned back on by pressing the RUN key Instruction 0024 9400 11 Operation ECA 450 2 3 Fuel Selection The fuel currently being used for combustion analysis is displayed in the top
79. ter time as described in Section 2 9 Recalling Test Data Stored in Memory Turn off analyzer per Section 2 2 Turning Off the Analyzer 2 6 Performing a Draft Measurement 1 If not already done turn on analyzer and place probe inside stack as previously described Sections 2 1 and 2 4 Press PRESSURE key to display the Pressure screen Where n nn current pressure reading xxxx pressure units refer to Section 2 17 2 If desired pressure sensor can be zeroed at this time as described below To skip the zeroing procedure proceed to Step 4 a With Pressure screen displayed again press PRESSURE key to display the Pressure Zero screen b Disconnect probe s pressure hose from analyzer s PRESSURE connector c Press ENTER to zero pressure sensor to atmospheric pressure after which reconnect probe hose that was removed in Step 3b The Pressure screen is now displaying the stack s draft value as a negative pressure Instruction 0024 9400 15 Operation ECA 450 2 7 Saving Test Data By pressing the SAVE key data that is currently being displayed in either the Combustion Test or Pressure screen is stored in one of the analyzer s over 1000 internal memory locations Observe that the following message appears when the SAVE key is pressed Where nnnn memory location number At a later time the stored data can be recalled for either viewing or
80. that does not depend on the sensor that is in error Press the RUN key to manually enter the Combustion Test HOLD screen to continue using the analyzer The following is a list of the problem messages that may appear after warm up completes 02 Sensor Error O sensor is depleted unplugged or the sensor was exposed to flue gas during warm up TS Sensor Error The probe s flue gas thermocouple not connected to analyzer or the temperature being measured by this thermocouple is outside the range of 4 to 212 F 20 to 100 C TA Sensor Error Primary air temperature as being measured by a thermocouple connected to the T AIR connector is outside the range of 4 to 212 F 20 to 100 C NO2 Sensor Error NOz sensor was exposed to flue gas during warm up HC Sensor Error HC sensor is defective or unplugged NOXIDE Sensor Error NO sensor was exposed to flue gas during warm up 72 Instruction 0024 9400 ECA 450 Parts amp Service CO HI Sensor Error CO HI sensor was exposed to flue gas during warm up CO LO Sensor Error CO sensor was exposed to flue gas during warm up Pressure Sens Error Pressure sensor is measuring a pressure that is outside the of range of 3 inches of water column during warm up SO2 Sensor Error SO sensor was exposed to flue gas during warm up Low Battery Battery voltage is low Only several minutes of operating time remain 5 3 Error Symbols
81. that may arise with the analyzer If the information in Table 5 1 does not solve the problem or for help with any problem that is not listed then please contact one of the Bacharach Service Centers listed in Section 6 3 TABLE 5 1 TROUBLESHOOTING GUIDE Symptom Probable Cause amp Remedy Analyzer completely nonfunctional won t turn on when the I O key is pressed a Battery pack dead Recharge battery pack per Section 4 1 b Loose battery connector Remove analyzer s top panel and ensure that the battery connector is securely attached to the printed circuit board c Microprocessor needs reset Remove analyzer s top panel and press the Reset button shown in Figure 4 5 Display screen is blank when analyzer is turned on but pump runs during warm up cycle a Microprocessor needs reset Remove analyzer s top panel and press the Reset button shown in Figure 4 6 b Loose display connector s Remove analyzer s top panel and ensure that all display panel connectors are properly attached to the printed circuit boards Display goes blank during operation The analyzer s display blanking function has been activated To change the display timeout interval refer to Section 2 17 9 Analyzer won t respond when a control panel key is pressed a Microprocessor needs reset Remove analyzer s top panel and press the Reset button shown in Figure 4 6 b Membrane switch def
82. the analyzer defaults to the instrument s internal temperature as measured on the main printed circuit board When viewing the T AIR value on the Combustion Test HOLD RUN screen the designation I will appear to the left of the temperature value The letter T signifies that the primary air temperature value was measured Internally For example 30 Instruction 0024 9400 ECA 450 Operation 2 15 Differential Pressure Measurement To measure the differential pressure between two confined areas do the following 1 Press PRESSURE key to display the Pressure screen Where n nn current pressure reading xxxx pressure units refer to Section 2 17 2 If desired the pressure sensor can be zeroed as described below To skip the zeroing procedure proceed to Step 3 a With Pressure screen displayed again press PRESSURE key to display the Pressure Zero screen b Disconnect all hoses from the AP REF and PRESSURE connectors This step ensures that both of these connectors are sampling the same pressure c Press ENTER to zero pressure sensor to atmospheric pressure after which reconnect probe hose that was removed in Step 3b Reconrecio He Connect pressure hose assembly P N 0024 1103 to analyzer s AP REF connector see Figure 1 1 Then insert open end of this hose into area being used as the reference pressure Insert probe into area whose pres
83. to a personal computer or both Utilizes four sources of primary air temperature information in the following priority 1 A thermocouple can be inserted into the primary air stream and plugged into the analyzer s front panel T AIR connector 2 A primary air temperature reading can be made with the probe s thermocouple and stored in memory 3 An external thermometer can be used to take a primary air temperature reading and then entered into memory using the analyzer s front panel keypad 4 If no other primary air temperature source is available the analyzer defaults to an internal case temperature that is measured the on printed circuit board Stores test identification that is manually entered by an operator This information is added to the test records as they are saved and appears within each test record when printed Stores user name information that is manually entered by the owner or user of the analyzer This information appears at the top of each printout Displays information in either English French or Spanish Can be set up to automatically turn off the front panel display to conserve battery life 1 3 Technical Data The ECA 450 Directly Measures and Displays Oxygen content in flue gas in the range of 0 1 to 20 9 Oz Stack gas temperature in the range of 4 to 2400 F 20 to 1315 C Primary air in the range of 4 to 999 F 20 to 999 C Pressure in the range of 27 7 inches of water column 69 m
84. to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed If the message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide Turn off regulator then remove gas cylinder from calibration fixture 58 Instruction 0024 9400 ECA 450 Calibration 3 11 Calibrate NO Sensor This screen is used to span the optional Nitrogen Dioxide sensor to a known gas level Material Required Calibration Gas Fixture Section 3 2 Gas Cylinder 100 ppm NO refer to Section 6 2 Procedure 1 Enter Calibration List screen then choose NO2 per Section 3 3 to display the CALIBRATE NO2 screen At the conclusion of this step the pump should be running 2 Using the Gas Fixture shown in Figure 3 1 attach an NO calibration gas cylinder to the analyzer s GAS inlet port 3 Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH 4 Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the av and lt gt keys to enter an Applied value that equals the concentration stamped on the NO gas cylinder The calibration range is from 10 to 150 ppm An applied value that is outside this range will cause the message Bad Calibration Entry to appear Typical Calibrate NO Screen During Calibration 5 Press E
85. to the Display Format screen 5 When finished press ESC to return to the Setup List screen 2 17 11 Primary Air Refer to Section 2 14 Primary Air Temperature Measurement 2 17 12 Data Logging Refer to Section 2 12 Data Logging 2 17 13 Statistics Refer to Section 2 16 Statistics Mode 2 17 14 User Name The name of the user or owner of the analyzer e g company name address and phone number can be stored in memory by manually entering up to three lines of text with each line containing up to 20 alphanumerical characters This information will appear at the top of each printout until such time as new information is entered 2 17 14 1 Enter Edit User Name Information Enter or edit a User Name as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to User Name then press ENTER to display the User Name menu 3 Use av keys to place cursor next to Edit User Name then press ENTER to display the Edit User Name menu which shows the three User Name lines that can be edited Note Five periods are used to identify blank lines Instruction 0024 9400 45 Operation ECA 450 Use av keys to choose which User Name line to edit then press ENTER to begin editing that line Use av keys to display the first desired character Then use the gt key to move cursor to the next character s position Repeat this
86. ttempt to calibrate outside this range will cause the message Bad Calibration Entry to appear 2 Plug simulator s K type connector into analyzer s T STACK jack see Figure 1 1 3 Enter Calibration List screen then choose T Stack per Section 3 3 to display the CALIBRATE TS ZERO screen 52 Instruction 0024 9400 ECA 450 Calibration 4 Wait until Measured reading on screen stabilizes Then use the av and lt gt keys to enter an Applied value of 32 F 0 C Typical Calibrate TS Zero Screen During Calibration 5 Press ENTER to calibrate the analyzer s Measured value to that of the Applied value after which the message Good Calibration should appear followed by the CALIBRATE TS SPAN screen TS Span Procedure 6 Adjust simulator to 572 F 300 C The calibration range is from 175 to 625 F 79 to 829 C Any attempt to calibrate outside this range will cause the message Bad Calibration Entry to appear 7 Wait until Measured reading on screen stabilizes Then use the v and lt gt keys to enter an Applied value of 572 F 300 C Typical Calibrate TS Span Screen During Calibration 8 Press ENTER to calibrate the analyzer s Measured value to that of the 9 Applied value after which the message Good Calibration should appear followed by the Calibration List screen being redisplayed Remove calibration equipment 3 6 Calibrate T Air
87. tup List screen Time is stored in the format HH MM SS am pm Set the analyzer s internal clock to the current time as follows Press SETUP key to display the Setup List screen Use av keys to place cursor next to Time then press ENTER to display the analyzer s current time setting Press ENTER to stop clock and move cursor over first digit of time display Press gt key to place cursor over the hour minute or second digit to be changed Then use Av keys to set that digit to the desired number Repeat this step until all digits are set correctly To change am pm setting first use the gt key to place cursor over first letter of am or pm Then use the av keys to select correct value Press ENTER to save selections and start clock Then press ESC to return to Setup List screen 2 17 7 O Reference The calculated values of CO NOx and SO can be individually referenced to a specific Oxygen percentage of between 0 and 15 Set up an Oxygen reference for each gas as follows Press SETUP key to display the Setup List screen Use av keys to place cursor next to O2 Reference then press ENTER to display the Oz Reference menu 38 Instruction 0024 9400 ECA 450 Operation 2 17 8 Test ID 3 Use av keys to place cursor next to the desired gas whose Oxygen reference is to be set then press ENTER to display the O2 Reference screen for that gas Where n Oxy
88. ured value to that of the Applied value after which the message Good Calibration should appear along with the Calibration List screen being redisplayed Ifthe message Sensor Output Low or Sensor Not Calibrated appears refer Section 5 4 Troubleshooting Guide 6 Turn off regulator then remove gas cylinder from calibration fixture 3 8 Calibrate CO LO Sensor This screen is used to span the Carbon Monoxide Low channel 0 4 000 ppm CO to a known gas level This procedure also includes Hz compensation Material Required Calibration Gas Fixture Section 3 2 Gas Cylinder 500 ppm CO in air refer to Section 6 2 Gas Cylinder 1000 ppm CO amp 1000 ppm Ha in Nitrogen refer to Section 6 2 Procedure 1 Enter Calibration List screen then choose CO LO per Section 3 3 to display the CALIBRATE CO LO screen At the conclusion of this step the pump should be running 2 Using the Gas Fixture shown in Figure 3 1 attach a CO only calibration gas cylinder to the analyzer s GAS inlet port Instruction 0024 9400 55 Calibration ECA 450 3 10 Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH Wait until Measured reading on screen stabilizes approximately 3 minutes Then use the av and lt gt keys to enter an Applied value that equals the concentration stamped on the CO gas cylinder The calibration range is from 10 to 1500 ppm
89. ution of 0 1 ppm when the values of these gases are lt 100 ppm When a gas value becomes gt 100 ppm the resolution for that gas switches to 1 ppm When High Resolution NOx Enable is turned OFF the display resolution for NO NO and NOx is always 1 ppm Turn High Resolution NOx Enable ON or OFF as follows 1 Press SETUP key to display the Setup List screen 2 Use av keys to place cursor next to High Res NOX Enabl then press ENTER to display the High Res NOX Enable screen 3 Use v keys to place cursor next to On or Off then press ENTER to make the selection and be returned to the Setup List screen 4 Press RUN to exit the Setup List screen and display the Combustion Test HOLD screen Combustion efficiency and emissions testing can now be performed as described in Section 2 4 Performing a Combustion Test Instruction 0024 9400 47 Operation ECA 450 5 When High Resolution NOx Enable is turned ON and when viewing the Combustion Test RUN screen observe in the example screens below that if the value of NO NO or NOx is lt 100 ppm then the resolution is 0 1 ppm but when a gas value is 2100 ppm the resolution becomes 1 ppm 2 17 17 Print Pressure To choose whether or not the pressure reading is printed on the combustion test printout refer to Section 2 10 Printing Data do the following 1 Press SETUP key to display the Setup List screen 2 Use
90. w points toward the pump Then reinstall control panel Figure 4 4 Replacing the Internal Particulate Filter PARTICULATE FILTER Install with arrow pointing toward inlet of pump 68 Instruction 0024 9400 ECA 450 Maintenance 4 6 Cleaning the Probe and Sampling Hoses If the combustion analyzer is used on either coal or oil fired burners particulates can accumulate within the probe and sampling hoses These particulates may in time build up and restrict the flow of gas into the analyzer Note that the probe s water trap s filter element should prevent soot from reaching the analyzer s internal components While using the combustion analyzer the type of fuels that cause the most dirt and how often the system needs to be cleaned will become evident Equipment Required Aerosol can of automotive carburetor cleaner Alcohol e Mild liquid detergent Method of forcing water through sampling hoses see text Clean rags Source of compressed air optional Procedure 1 If not already done disconnect the probe s gas and pressure fittings and its thermocouple connector from the analyzer 2 Remove gas and pressure hoses from barbed fittings on probe handle and gas hose from the water trap filter assembly Figure 4 5 CAUTION Carburetor cleaner attacks plastic and rubber components Take precautions not to spray carburetor cleaner onto the probe handle sampling
91. y Sample Printout yo Poe te a l User name information as ser ame 1ne User Name Line 3 entered in Section 2 17 14 BACHARACH INC ECA 450 SN XXXXXX TASE ID Liner l Test identification information Test ID Line 2 t d d Edad Test ID Line 3 as entere ana selected per Section 2 17 8 TIME 04 27 35 pm DATE 01 20 2000 FUEL Natural Gas 02 4 0 co 12 ppm EFF 82 2 3 co2 9 5 T STACK 374 F T AIR 68 F T EA 21 l Test data as measured and NO 18 ppm calculated by the analyzer NO2 6 ppm NOX 24 ppm S02 1 ppm HC 0 01 co 3 13 ppm NO 3 19 ppm NO2 3 6 ppm NOX 3 25 ppm so2 3 1 ppm PRESSURE 0 02 inwc Optional pressure printout as selected in Section 2 17 17 COMMENTS Instruction 0024 9400 19 Operation ECA 450 2 11 Downloading Data to a Personal Computer Test data that was stored in memory can be downloaded to a personal computer in ASCII text comma delimited format which can then be imported into most spreadsheet programs for analysis The following describes how to download data to a computer that is running Windows 95 98 using HyperTerminal as the communications program If a different operating system and or communications program is being used then consult the appropriate instruction manuals for those products Tip To install HyperTerminal first insert the Windows 95 98 CD then click Start point to Settings click Control Pa
92. y 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 2000 2014 Bacharach Inc all rights reserved BACHARACH is a registered trademark of Bacharach Inc All other trademarks trade names service marks and logos referenced herein belong to their respective owners ii Instruction 0024 9400 ECA 450 Contents Table of Contents 1 A O cseceseceaee 1 1 1 General Description 1 2 Features 1 3 Technical Data 1 4 Operation Overview 1 5 Front Panel Connections and Controls seereis anini a i a aa Naa aea 6 1 5 1 GAS PRESSURE T STACKAPTO DE viv atenas 6 1 5 2 T AIR Primary Air Thermocouple cccccccsscceesssceceessececesscececseseceesaececssseceesseeecsesaeeeeseseceees 7 1 5 3 POWERTAC Adapter RAREN EE EEE N EE Do Gr 1 5 4 AP REF Differential Pressure 1 5 5 RS232 Computer Interface onenen ii a i a FF Dd CYFOD YY 1 5 6 OPT Option a a a a WR a aiaia 1 6 Front Panel Keypad Control iii iia 8 E O SYNWYR dn FA ANO Er OSE TOCE EE eeri 2 1 Turning On the Analyzer 2 2 Turning Off the Analyzer A O NN 2 4 Performing a Combustion TeSt ee nieren e aa aea a a iia e a a eia 2 5 Endingia Combustion T

Instruction Manual

Contents

Download Pdf Manuals

Related Search

Related Contents