Bacharach PCA 2, Instruction, Operating & Maintenance

Page 1: ...on Analyzer Instruction 0024 9448 Operation Maintenance Rev 6 September 2010 Headquarters 621 Hunt Valley Circle New Kensington PA 15068 Ph 724 334 5000 Fax 724 334 5001 Toll Free 800 736 4666 Website...

Page 2: ...XPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT...

Page 3: ...ible Need for Smoke Test 1 11 2 Specifications 2 1 3 Initial Setup 3 1 3 1 Scope 3 1 3 2 Power 3 1 3 2 1 Installing or Replacing Batteries 3 1 3 2 2 Using the AC Power Adapter 3 2 3 3 Connecting the P...

Page 4: ...ogging Interval and Duration 4 15 4 14 3 Starting the Data Logging Process 4 16 4 14 4 Ending the Data Logging Process 4 17 4 15 Memory 4 17 4 15 1 Recalling Combustion Test Data 4 18 4 15 2 Recalling...

Page 5: ...played After Warm Up 7 2 7 4 Diagnostics and Status Screens 7 3 8 Parts Service 8 1 8 1 Replacement Parts 8 1 8 2 Accessories 8 4 8 3 Service Centers 8 6 Instruction 24 9448 8 6 Parts Service 8 3 Serv...

Page 6: ...Kit Includes hoses adapters flowmeter does not include gas cylinders 24 7059 Gas Cylinders 103 Liter 500 ppm CO in air 24 0492 1000 ppm CO 1000 ppm H2 in Nitrogen 24 0794 IrDA Printer 24 1400 Printer...

Page 7: ...lity that provides an extra large display Smart sensor technology allows a new sensor to be installed in the field without having to calibrate the analyzer before use New and innovative probe and anal...

Page 8: ...Carbon Monoxide Low COLow Pressure Draft Carbon Monoxide High COHigh Nitric Oxide NO Nitrogen Dioxide NO2 Sulfur Dioxide SO2 Calculations Combustion Efficiency Excess Air Carbon Dioxide CO2 NOx NOx N...

Page 9: ...calibrated 24 0789 16H COHI NOT calibrated 24 0997 16J NO NOT calibrated 24 0881 16K NO2 NOT calibrated 24 1027 16L SO2 NOT calibrated 24 0998 17 Screw 4 x 1 2 LG 02 2144 18 Battery Clip Single 04 14...

Page 10: ...bilities Low battery alarm Stores 500 individual combustion records which can later be recalled for viewing printing or downloading to a personal computer Stores an additional 500 data logged records...

Page 11: ...select the fuel being burned The default fuel selected is Natural Gas Note that the name of the fuel being burned is indicated at the top of the display To change the fuel first press the MENU F2 but...

Page 12: ...connector stack gas hose to the analyzer s GAS connector draft hose to the analyzer s P connector Observe that the probe connectors are of different sizes and shapes which prevent incorrect connection...

Page 13: ...second warm up period If problems were detected the analyzer will not automatically switch to the Combustion Test HOLD screen after warm up The analyzer however can still be used to perform any test t...

Page 14: ...the area where differential pressure is to be measured Refer to Section 4 6 1 5 5 USB Computer Interface Data that has been stored in the analyzer s memory can be downloaded to a personal computer by...

Page 15: ...viewing the Memory or Logging Directory each press of this button pages down through the directory Holding this button down speeds up the paging process Instruction 24 9448 6 14 Maintenance 6 8 Clean...

Page 16: ...then displays the previously viewed screen Turns the analyzer ON and OFF and is also used to turn the backlight and button LEDs ON and OFF Note that when the analyzer is turned OFF there is a 5 second...

Page 17: ...bottoms out 7 Strip 1 4 inch of insulation from each of the probe s thermocouple connector wires IMPORTANT In Step 8 the thermocouple wires must first be twisted together and then crimped 8 Twist both...

Page 18: ...9 ppm NO reference to O2 0 to 9 999 ppm NO2 reference to O2 0 to 9 999 ppm SO2 reference to O2 0 to 9 999 ppm Fuels Available for Combustion Calculations Natural Gas Coal Oil 2 Wood Oil 4 Kerosene Oil...

Page 19: ...tage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off The NO bias battery is expected to last at least the life of the NO sensor Note It is recommended that th...

Page 20: ...communications Computer USB Dimensions 9H x 3W x 2 5D inches 22 9 x 7 6 x 6 3 cm Weight Analyzer 1 4 lb 0 6 kg w batteries Probe Hose Assembly 1 lb 0 5 kg Instruction 24 9448 6 9 Maintenance page 6 4...

Page 21: ...adhesive from from the PCB Important When replacing the O2 sensor be sure that the sensor pin plugs into the PCB socket that is also marked O2 When replacing an NO sensor also replace the bias battery...

Page 22: ...for list of sensors and part numbers of both types Replace the oxygen sensor when its automatic calibration fails and the ana lyzer displays an O2 sensor error at the end of warm up Refer to Section 4...

Page 23: ...ambient air thermocouple is used 4 Push the optional primary ambient air thermocouple into the T AIR jack connector fits in only one way IMPORTANT To assure the accurate calculation of combustion effi...

Page 24: ...ft Hose P Gas Sample Hose GAS Probe Tube Probe Stop Primary Ambient Air Thermocouple T AIR Optional Instruction 24 9448 6 5 Maintenance Figure 6 4 Wiring Solder 2 Places Red dot on pump indicates posi...

Page 25: ...to scroll through the list of available fuels until the desired fuel is high lighted In the example shown PROPANE has been selected If custom fuels are added they will be displayed at the bottom of t...

Page 26: ...n the example shown Fahrenheit has been selected 5 Press ENT to save the selection and re display the SETUP MENU SETUP MENU TEMP UNITS PRESSURE UNITS POLLUTION UNITS DATE TIME O2 REFERENCE PRINT PRESS...

Page 27: ...embly process 3 Pull off sensor retainer and then unplug all sensors 4 Lay analyzer face down on a padded work surface and then using a medium Phillips screwdriver remove the unit s four rear case scr...

Page 28: ...as been selected 5 Press ENT to save the selection and re display the SETUP MENU PRESSURE UNITS MENU InchesWater milliBar Pascals hectoPascals MENU F1 F2 F3 05 26 06 09 25 30 AM MAIN MENU FUEL PRESSUR...

Page 29: ...NU FUEL PRESSURE TEMPERATURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 MENU Instruction 24 9448 5 14 Calibration this range will cause the message Bad Calibration Wrong CAL Entry to appear...

Page 30: ...ION DIAGNOSTICS STATUS F1 F2 F3 MENU DATE MENU DATE 05 26 06 Press ENTER to Save 05 26 06 09 25 30 AM MENU F1 F2 F3 Instruction 24 9448 5 13 Calibration 5 Adjust regulator for a flowmeter indication o...

Page 31: ...M MENU F1 F2 F3 Instruction 24 9448 5 12 Calibration by the CALIBRATION LIST screen being re displayed If the sensor s output is low but still usable then the message Good Calibration WARNING Low Sens...

Page 32: ...ENCE PRINT PRESSURE more MENU F1 F2 F3 SET O2 REFERENCE CO REF TO O2 0 05 26 06 09 25 30 AM MENU F1 F2 F3 Instruction 24 9448 5 11 Calibration If the sensor s output is too low to be usable then the m...

Page 33: ...1 If not already done turn ON the analyzer and display the CALIBRATION LIST screen per Section 5 2 2 Use the buttons to highlight SO2 and then press ENT to display the CALIBRATE SO2 screen Measured is...

Page 34: ...ation Sensor End of Life Entry Not Saved will appear The sen sor will now be marked as being BAD in the DIAGNOSTICS screen NOTE H2 calibration can be bypassed by pressing the ESC button after which th...

Page 35: ...sensor also measures H2 for the purpose of com pensating the CO reading for the presence of H2 in the gas sample This procedure first spans the CO LO sensor and optionally spans the H2 part of the sen...

Page 36: ...LOGGING TEST ID USERNAME RUN HOLD FORMAT LANGUAGE SELECTION BUTTON SOUND CAL REMINDER PERIOD MENU F1 F2 F3 Instruction 24 9448 5 7 Calibration The calibration range is from 32 to 41 F 0 to 5 C An atte...

Page 37: ...omplete A maximum of 20 alphanumeric char acters can be entered Press ENT to accept the information 8 At this time either return to step 6 to choose another line to edit or MAIN MENU FUEL PRESSURE TEM...

Page 38: ...bration known temperature that will be applied for calibration purposes 4 Set thermocouple simulator to 32 F 0 C and then use the and buttons to enter an Applied value that exactly equals the set ting...

Page 39: ...TION DIAGNOSTICS STATUS F1 F2 F3 MENU SETUP MENU more LOGGING TEST ID USERNAME RUN HOLD FORMAT LANGUAGE SELECTION BUTTON SOUND CAL REMINDER PERIOD MENU F1 F2 F3 Instruction 24 9448 5 4 Calibration The...

Page 40: ...can be used for calibration purposes 1 Assemble the pressure sensor calibration equipment as shown in Figure 5 1 but DO NOT connect the analyzer to the calibration equipment at this time 2 If not alre...

Page 41: ...example the screen to the right shows that the battery is low Correct any errors before proceeding Refer to Section 7 3 for a listing of error messages and their meaning 2 Display the MAIN MENU by pre...

Page 42: ...nths 10 months 12 months 15 months MENU F1 F2 F3 Instruction 24 9448 5 1 Calibration 5 Calibration IMPORTANT Before performing any calibration procedure ensure that fresh batteries are installed or us...

Page 43: ...lculated values when the instrument is running or in the hold mode The order in which data appears in the Run Hold screen is as follows O2 Oxygen CO Carbon Monoxide EFF Combustion Efficiency CO2 Carbo...

Page 44: ...lay format and return to the Run Hold Format screen MAIN MENU FUEL PRESSURE TEMPERATURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 MENU SETUP MENU more Logging Test ID Username Run Hold Form...

Page 45: ...U F1 F2 F3 Instruction 24 9448 4 31 Operation 4 18 Printing Test Data Combustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described below Data...

Page 46: ...g a combustion test After removing probe from the stack let the pump run for at least 10 minutes to remove any stack gases and dry any condensate from inside the sensor chamber and probe assembly If t...

Page 47: ...e that the analyzer is properly set up per Section 3 Initial Setup IMPORTANT DO NOT insert probe into stack before turning ON the analyzer 2 Place the probe in an area that contains fresh air This ens...

Page 48: ...ppm EFF CO2 T STK 50 F T AIR 69 6 F EA CO O ppm PRINT MENU SAVE F1 F2 F3 HOLD PROP O2 20 9 CO 0 ppm EFF CO2 T STK 50 F T AIR 69 6 F EA CO O ppm PRINT MENU SAVE F1 F2 F3 NOTE The filename is automatica...

Page 49: ...nto each of the exhaust ports to obtain a flue gas sample before any dilution air is mixed in HOT WATER TANK Domestic hot water tanks with the bell shaped draft diverter can be accurately tested by in...

Page 50: ...with its gas flow arrow pointing upward Do not let water condensate go above the tip of the riser tube The sensors could be damaged if water would enter the analyzer Empty the Water Trap after every...

Page 51: ...by an optional external thermocouple plugged into the analyzer s T AIR connector CO O Carbon Monoxide ppm level referenced to a of oxygen 2 NO Nitric Oxide 1 NO2 Nitrogen Dioxide 1 NOx Oxides of Nitro...

Page 52: ...selection and re display the PRESSURE MENU or ESC to exit back to the Main Menu MAIN MENU FUEL PRESSURE TEMPERATURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 MENU Pressure Measured 6 00 inw...

Page 53: ...ude differential temperature across heat exchange or differential temperature Perform a differential temperature measurement as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necess...

Page 54: ...o with both pressure ports open to the atmosphere If necessary zero the pressure sensor as follows POWER P T STACK T AIR GAS P Pressure Reference Port P Pressure Measurement Por Sampling Hoses with qu...

Page 55: ...tmosphere and connect the probe s draft hose to the P port see Figure 3 2 on Page 3 3 5 Do one of the following to measure draft or dif ferential pressure To measure draft simply insert the probe into...

Page 56: ...of riser tube Stack Gas From Probe To empty water pull apart using a slight twisting motion 4 15 3 Clearing Memory When all memory snap shot locations used to store individual combustion test records...

Page 57: ...utton refer to Section 4 16 MAIN MENU FUEL PRESSURE TEMPERATURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS F1 F2 F3 MENU MEMORY MENU MEMORY DIRECTORY LOGGING DIRECTORY CLEAR MEMORY DATA CLEAR LOGGING...

Page 58: ...ach inc com downloads 4 15 1 Recalling Combustion Test Data Recall individual combustion test data records as follows 1 Display the MAIN MENU by pressing the MENU F2 button If necessary press ESC unti...

Page 59: ...ither memory bank the operator can quickly page through the screens by pressing the PAGE F1 and PAGE F3 buttons Or move to the first or last memory location by pressing the buttons respectively LOG NA...

Page 60: ...le for the selected interval LOGGING INTERVAL 1 sec 5 sec 10 sec 15 sec 30 sec 1 min 2 min more MENU F1 F2 F3 LOGGING DURATION 5 min 10 min 15 min 30 min 1 hr 2 hr 5 hr more MENU F1 F2 F3 4 14 3 Start...