INSTRUCTION 24-9223 MODEL 300 COMBUSTION ANALYZER (Standard Efficiency Equations, Siegert Efficiency Equations, and NSX Version) Operation/Maintenance Rev. 2 – November 1999 Bacharach, Inc. 625 Alpha Drive, Pittsburgh, PA 15238 Phone: 412-963-2000 • FAX: 412-963-2091 • Web: www.bacharach-inc.com Printed in U.S.A.
MODEL 300 COMBUSTION ANALYZER 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.
MODEL 300 COMBUSTION ANALYZER WARNINGS! • Burn hazard. DO NOT touch the Model 300 Combustion Analyzer probe after it is removed from a stack. Allow the probe to cool before handling. • Burn hazard. When emptying filter/trap bowl and particulate trap, be aware that both traps may contain hot and mildly corrosive water. Take the necessary precautions to avoid being burned. • Burn hazard. All of the sensors contain corrosive chemicals. DO NOT puncture or take them apart.
MODEL 300 COMBUSTION ANALYZER TABLE OF CONTENTS 1 INTRODUCTION ................................................................................ 1-1 1.1 Scope of Manual .......................................................................... 1-1 1.2 Basic Features ............................................................................. 1-2 1.3 Optional Features ....................................................................... 1-3 1.4 Basic Panel Functions & Displays ............................
MODEL 300 COMBUSTION ANALYZER TABLE OF CONTENTS (Cont.) 4 CALIBRATION .................................................................................... 4-1 4.1 Sensor and/or Control Panel Removal ........................................ 4-3 4.2 Ambient Temperature Calibration - R24 ................................... 4-5 4.3 Toxic Gas Span Calibration ........................................................ 4-7 4.3.1 CO Span Calibration - R9 ................................................ 4-7 4.3.
MODEL 300 COMBUSTION ANALYZER SPECIFICATIONS GENERAL Size .................................... Carrying Case: 18" x 14" x 8" (45.7 x 35.6 x 20.3 cm) Standard Probe: 11.5" (29.2 cm)* Hose - 22' (6.7 m)* Weight ................................ 15 lbs. (6.8 kg) Materials ............................ HDPE Case, medium gray; polycarbonate membrane switch; stainless steel probe Calibration Interval ........... 60 seconds Storage Environment .........
MODEL 300 COMBUSTION ANALYZER ACCURACY (68°F [20°C], 45% RELATIVE HUMIDITY) Stack Temperature ........ ±1% full scale Oxygen ............................ ±0.6% O2 Carbon Monoxide ........... ±5% reading or ±10 ppm, whichever is greater NOX (Optional) ............... ±5% reading or ±10 ppm, whichever is greater SO2 (Optional) ................ ±5% reading or ±10 ppm, whichever is greater PROBE TEMPERATURE EXPOSURE LIMITS The time and temperature limits for the probe assembly (24-7131) are listed below.
MODEL 300 COMBUSTION ANALYZER FUNCTIONS (Cont.) Computes and Displays: • • • • Combustion Efficiency (1 to 99.9%) Stack Loss (1 to 99.
MODEL 300 COMBUSTION ANALYZER FUNCTIONS (Cont.) Additionally Displays (Cont.): • Analyzer errors or warnings Main Display OK W*CO E*O2 E*TC E*AM OR/A OR/T OR/C OR/O - No errors or warnings to report. CO channel warning. Oxygen channel error. Thermocouple channel error. Ambient temperature channel error. Ambient sensor overrange. Thermocouple overrange. CO sensor overrange. O2 sensor overrange. Auxiliary Display, NSX Units LOW BATT - NOX /SO2 sensor bias batteries low.
MODEL 300 COMBUSTION ANALYZER Figure A.
MODEL 300 COMBUSTION ANALYZER 1 INTRODUCTION The Model 300 Combustion Analyzer is an efficiency analyzer designed for medium to large, condensing and non-condensing, industrial burners. A microprocessor controls the analyzer’s operation along with calculating burner efficiency. 1.1 SCOPE OF MANUAL The following information is provided in this manual: 1. INTRODUCTION Describes the instrument, and its front panel controls 2. SET UP Describes how to prepare a new analyzer for operation. 3.
MODEL 300 COMBUSTION ANALYZER 1.2 BASIC FEATURES Three large LED readouts display the following information about both the combustion process being analyzed, and the instrument itself: • O2 Cell Output (mV) • Analyzer Errors • Stack Temperature (°F /°C) • CO Level in ppm • % Efficiency • % Excess Air • % Loss • % O2 • % CO2 Because the Model 300 Combustion Analyzer is a “smart” instrument, its operation is fast and virtually mistake-proof.
MODEL 300 COMBUSTION ANALYZER 1.3 OPTIONAL FEATURES • Printer, prints out a copy of the efficiency test results. The NSX version of the Model 300 Combustion Analyzer adds the following features (For information on upgrading to NOX and/or SO2, contact your distributor or the factory): • Real time clock, providing front panel hour and minute display of the time in either a 12 or 24 hour format. • Display of the NOX gas (oxides of nitrogen), present in sampled gas.
MODEL 300 COMBUSTION ANALYZER 1.4 BASIC PANEL FUNCTIONS & DISPLAYS 1.4.1 CAL, FUEL, and RUN Keys Press to start 60 second calibration cycle. When left display shows CAL, the CAL key must be pressed before the analyzer can continue its operation. Press to either select or show the type of fuel to be used in the combustion efficiency calculations. After the analyzer has completed its calibration sequence, the left display will show the word FUEL.
MODEL 300 COMBUSTION ANALYZER 1.4.2 Left Display and Select Key Figure 1-1. Left Display Press to show TEMP, CO (ppm), or ERROR information on the four-segment alphanumeric display. Also press with the FUEL key held down to change fuels after performing an efficiency test. The Display Mode Indicators identify what is being shown on the display. Display Mode Indicator Lit None Meaning of Display Indication CAL – Combustion Analyzer in calibration mode. Press CAL key to start 60 second calibration cycle.
MODEL 300 COMBUSTION ANALYZER Display Mode Indicator Lit Meaning of Display Indication Stack temperature detected by probe (°F or °C, see label inside case). Carbon Monoxide concentration as measured by the CO sensor. OK – No errors or warnings to report. W*CO – Warning, CO sensor bad or trip limit of +115 ppm was detected during calibration. E*O2 – Error, O2 cell bad or missing. Occurs at end of calibration cycle if output of O2 cell is either less than 15.1 mV or greater than 65.9 mV.
MODEL 300 COMBUSTION ANALYZER 1.4.3 Middle Display and Select Key Figure 1-3. Middle Display Press to show %O2, % EX AIR, or O2 CELL information on the three-segment numeric display. The Display Mode Indicators identify what is being shown on the display. Display Mode Indicator Lit Meaning of Display Indication Oxygen percentage as measured by the O2 sensor. Computed excess air percentage is based on the %O2 detected, the fuel selected, and on the amount of CO measured.
MODEL 300 COMBUSTION ANALYZER 1.4.4 Right Display and Select Key Figure 1-4. Right Display Press to show %EFF, %LOSS, or %CO2 information on the three-segment numeric display. The Display Mode Indicators identify what is being shown on the display. Display Mode Indicator Lit None Meaning of Display Indication Counts down 60 second calibration time. Combustion efficiency percentage. Computed value based on %O2 detected, CO detected, net stack temperature measured, and fuel selected.
MODEL 300 COMBUSTION ANALYZER 1.5 OPTIONAL AUXILIARY PANEL FUNCTIONS & DISPLAYS Functions of the three display windows on the auxiliary display panel are described in Sections 1.5.1 thru 1.5.3 below. NOTE: With or without an NOX (middle display) and/or SO2 (right display) sensor installed, each display shows warning, failure, and error messages (refer to Section 3.5) that pertain to the NSX portion of the analyzer. 1.5.
MODEL 300 COMBUSTION ANALYZER NOTES 1-10 Instruction 24-9223
MODEL 300 COMBUSTION ANALYZER 2 SET-UP The charts and procedures in this section describe how to set-up the Model 300 for combustion efficiency testing. If any difficulty is encountered while performing these procedures, please refer to Section 4 and/or 5 for assistance in resolving the problem.
MODEL 300 COMBUSTION ANALYZER 2.1 230 VAC PLUG INSTALLATION Due to the many different AC receptacles available for 230 VAC, a wall plug is not supplied on the instrument’s 230 VAC power supply. An IEC receptacle is provided for the input. An IEC 380 cord set must be obtained, with the proper type of AC wall outlet, for the country where the instrument is to be used. 2.
MODEL 300 COMBUSTION ANALYZER 2.4 PROBE CONNECTION See Fig. 2-2. To connect the probe, simply attach its air tubing to the filter/trap, and plug its thermocouple connector into the receptacle at the rear of analyzer’s control panel, noting the polarity of the connector. Figure 2-2.
MODEL 300 COMBUSTION ANALYZER 2.5 INITIAL START-UP AND ADJUSTMENT Flow Chart #2 INITIAL START-UP Section 2.5 & 4.3 Turn ON Unit Section 2.5, Step 1 At the End of the 60 Second CAL Cycle Section 2.5, Step 5 After 5 Seconds all displays light Section 2.5, Step 2 Left Display - (FUEL) Mid. & Rt. Displays - Blank Opt. Clock - Time Opt. Displays - (0) ppm Section 2.5, Step 5 Left Display - (CAL) All Other Displays - Dark Opt. Clock - Time Pump Starts Section 2.
MODEL 300 COMBUSTION ANALYZER Before using your Model 300 Combustion Analyzer in an actual efficiency test, verify that the analyzer indicates 20.9% oxygen in fresh air, and correctly measures ambient air temperature. 1. Turn on the analyzer by either plugging it in, or by setting its battery pack switch (see Fig. 3-9) to ON. 2.
MODEL 300 COMBUSTION ANALYZER 5. At the end of the calibration cycle, the left display should show FUEL, with the middle and right displays blank, the Optional clock will show the time, and Optional auxiliary panel middle and right displays will read 0 ppm. Now press the FUEL key until the left display shows your choice of any one of the analyzer’s seven programmed fuels. 6. Press RUN key to start pump. Allow pump to run for 30 seconds; after which, stop pump by again pressing the RUN key.
MODEL 300 COMBUSTION ANALYZER 2.6 SENSOR CHECKS Flow Chart #3 SENSOR CHECKS Section 2.6 & 4.3 Sensor Check Section 2.6 Qualified Test Personnel NO Span Calibration Section 4.3 Send to Bacharach Service Center R9-CO Span Section 4.3.1 Optional NO and/or SO NO Effic ie nc y Te s t S e c tio n 3 Flo w Chart #5 YES YES Optional NO & SO Span Calibration Section 4.3.2 Optional Clock & Analyzer Configuration Section 2.7 & 2.
MODEL 300 COMBUSTION ANALYZER Optional NOX and SO2 sensors are calibrated and installed at the factory and initially should not need a calibration check. Should you have reason to suspect the accuracy of either sensor, BACHARACH recommends that the unit be sent to a qualified Service Center (see the inside back cover) for calibration. If you have the qualified facilities and personnel to perform the calibration, see Section 4.3.2. 2.
MODEL 300 COMBUSTION ANALYZER 3. See Fig. 2.5. Using the end of a straightened paper clip, or similar object, press the clock’s MODE switch to cycle through the clock-mode settings. The following example shows what will be shown in the clock display after each depression of the MODE switch for: Sunday, the 9th of April, 1995, 3:58 PM. You may need to pause briefly after pressing the MODE switch, or any other clock switch, as the microprocessor may require a second or two to acknowledge your action.
MODEL 300 COMBUSTION ANALYZER If a setting is not changed, depressing the SET switch merely reconfirms that setting as it cycles you to the next setting – including exiting from that clock-set mode. If a change is made to the time format (CK:12 or CK:24), the hour of the day (PM:__ or HR:__) will also need to be reset. d. Repeat steps “a” thorough “c” until all clock modes are correct; then press the MODE switch until the clock display returns to the current time. Figure 2-5. Clock Display Switches 2.
MODEL 300 COMBUSTION ANALYZER 3 OPERATION This sections describes: • • • • • • • • • Performing an Efficiency Test Gas Sample Points Installing the Probe Printer Operation Error, Warning and Failure Displays Recalibration after an Efficiency Test Changing Fuels Combustion Analyzer Shutdown & Storage Changing the Battery Pack Instruction 24-9223 3-1
MODEL 300 COMBUSTION ANALYZER Flow Chart #5 EFFICIENCY TEST Section 3 Turn ON Analyzer Step 1 Press FUEL key to proper fuel Insert Probe in Stack Sample Hole See Sections 3.2 & 3.3 Step 6 Wait for Unit to go through Calibration Step 2 Furnace Draws Ambient Air Step 3 YES NO Press RUN Left - Stack Temp. or CO Level or Error Mid.
MODEL 300 COMBUSTION ANALYZER 3.1 PERFORMING AN EFFICIENCY TEST This procedure describes how to initially calibrate the Model 300 Combustion Analyzer and perform a combustion efficiency test. Each time the combustion analyzer is turned on, its microprocessor begins its initial start-up routine. This routine directs the operator to calibrate the analyzer and select the proper fuel.
MODEL 300 COMBUSTION ANALYZER 4. Press CAL key to start calibration cycle. The following should be seen: • Left display show CAL. • Middle display show millivolt output of O2 cell. Should the cell’s output fall outside acceptable limits, an E*O2 error will occur (Refer to Section 3.5). • Right display counts down the calibration time starting at 60 seconds. 5. At the end of the calibration cycle, the left display will either show FUEL, or flash an error code.
MODEL 300 COMBUSTION ANALYZER • Optional NOx and/or SO2 concentrations are displayed on the auxiliary panel. • Optional clock displays the current time. NOTE: It’s normal for the Display Mode Indicators to occasionally blink due to the complexity of the efficiency calculations. 8. During an efficiency test, periodically check the water level inside the panel-mounted filter/trap. WARNING! The liquid within the filter/trap bowl may be hot and mildly acidic.
MODEL 300 COMBUSTION ANALYZER 3.2 GAS SAMPLING POINTS The Model 300 Combustion Analyzer requires a 3/8" (9.5 mm) minimum diameter sampling hole to accommodate the analyzer’s probe-stop. Locate the sampling point downstream from the last heat exchanger, and upstream from any source of dilution. Important: As the distance between the heat exchanger and the sampling point increases, the calculated combustion efficiency will falsely increase due to heat loss in the flue or stack.
MODEL 300 COMBUSTION ANALYZER Figure 3-3. Installing the Probe 3.4 PRINTER OPERATION Press the PRINT switch (Fig. 3-4) to obtain a hard copy of the efficiency test results either during an efficiency test, or after its completion – the printer will not operate at any other time. Observe that the PRINT LED will glow as the printer operates. Fig. 3-5 shows a typical printout.
MODEL 300 COMBUSTION ANALYZER Figure 3-4. Printer Controls BACHARACH MODEL CA3ØØNSX ************ COMBUSTION ANALYZER BACHARACH MODEL 3ØØ ************ COMBUSTION ANALYZER ID: DATE: TIME: ________________ ________________ ________________ FUEL: PRIMRY TEMP : STACK TEMP : % OXYGEN: % EXCESS AIR: % CARBON DIOXIDE: PPM CARBON MONOXIDE: % EFFICIENCY: % STACK LOSS: ID: ________________ SER. NO: VD0511 DATE: 11/16/95 TIME: 09:02 FUEL: NAT.GAS 77 416 8.3 6Ø.Ø 7.1 Ø 88.4 11.
MODEL 300 COMBUSTION ANALYZER 3.5 ERROR, WARNING AND OVERRANGE DISPLAYS 3.5.1 Basic Error, Warning and Overrange Displays Three levels of problems are detected by the analyer’s microprocessor, and then identified on the left display in the form of E* (error), W* (warning) and OR (overrange) messages. Refer to Table 3-1 for a listing and description of these messages.
MODEL 300 COMBUSTION ANALYZER 2. If a recalibration cycle is started, allow the cycle to finish before proceeding. If RUN is displayed, press the RUN key to restart the efficiency test. If FUEL is displayed, press the FUEL key until the desired fuel is shown in the left display. Then press the RUN key to restart the efficiency test. 3.
MODEL 300 COMBUSTION ANALYZER TABLE 3-1. Basic Error, Warning and Overrange Displays Display Shows Display Meaning Remedy OK No errors, warnings or overranges to report. ----- W*CO Warning, CO level over 115 ppm after calibration. Remove and then reapply power to the analyzer. Allow pump to run 5 minutes (longer if necessary) while sampling fresh air to purge the instrument of CO. Then press CAL. Warning, CO span potentiometer R9 misadjusted. Adjust potentiometer R9. Refer to Section 4.3.
MODEL 300 COMBUSTION ANALYZER TABLE 3-1. Basic Error, Warning and Overrange Displays (Cont.) Display Shows E*TC Display Meaning Remedy Error, thermocouple temperature below – 100° or above 2300° F (–73° and 1260° C). Allow thermocouple to stabilize at room temperature and then recalibrate the analyzer. Error, thermocouple span potentiometer R19 misadjusted. Adjust potentiometer R19. Refer to Section 4.4. Error, thermocouple defective. Replace probe assembly, or replace just the thermocouple.
MODEL 300 COMBUSTION ANALYZER TABLE 3-2. Optional Error, Warning and Overrange Displays Left Display Middle Display Right Display LOW BATT Warning – sensor bias battery voltage getting low. This message is displayed at the conclusion of the calibration cycle, and once every 10 seconds during an efficiency test. The NOX and SO2 displays may be incorrect. BATT FAIL Failure – sensor bias batteries are dead. The NOX and SO2 displays are disabled.
MODEL 300 COMBUSTION ANALYZER 3.6 RECALIBRATION AFTER AN EFFICIENCY TEST If you are unsure about the calibration of the analyzer after performing an efficiency test, it can be recalibrated as follows: NOTE: Recalibration is essentially the same as the initial power-up calibration cycle, with the exception that the recalibration cycle can be aborted at any time by pressing the CAL key. 1. Remove probe from stack or flue. 2.
MODEL 300 COMBUSTION ANALYZER 3.7 CHANGING FUELS To change fuels after an efficiency test has been run, proceed as follows: 1. If not already stopped, stop the pump by pressing the RUN key. 2. Press and hold the FUEL key. The left display shows what fuel is presently being used in the combustion efficiency calculations. 3. While holding down the FUEL key, repeatedly press the left SELECT key until the desired fuel is shown in the left display. 3.
MODEL 300 COMBUSTION ANALYZER WARNING! Both traps may contain hot and mildly acidic water. Take the necessary precautions to avoid being burned. CAUTION: When emptying traps, be careful not to spill water into the combustion analyzer case. a. See Fig. 3-1. Remove filter/trap from control panel; then unscrew and empty its bowl. Replace bowl being sure its O-ring is in place; then store filter/trap in case. Figure 3-6. Particulate Trap Disassembly b. Remove knurled nut (see Fig.
MODEL 300 COMBUSTION ANALYZER 7. Coil up and store probe hose in the bottom part of the carrying case. To avoid crimping the hose when the case is closed, loop hose under strap per Fig. 3-7. 8. Flip down optional display. CAUTION: DO NOT store the Model 300 Combustion Analyzer at temperatures below – 4°F (– 20°C). Figure 3-7.
MODEL 300 COMBUSTION ANALYZER 3.9 CHARGING THE BATTERY PACK If the analyzer is powered by a battery pack, charge the pack as described below (also see Fig. 3-8). A fully charged battery pack will run the analyzer through at least 200 combustion efficiency tests (6 hours minimum); although, typical operating time is between 12–16 hours. When the battery pack becomes discharged, its BATTERY STATUS LED turns off.
MODEL 300 COMBUSTION ANALYZER 4 CALIBRATION NOTE: Analyzer calibration is available from authorized Bacharach Service Centers. This section describes how to check the combustion analyzer’s calibration, and how to adjust the three potentiometers.
MODEL 300 COMBUSTION ANALYZER Figure 4-1. Removing Sensor Cover Figure 4-2.
MODEL 300 COMBUSTION ANALYZER 4.1 SENSOR AND/OR CONTROL PANEL REMOVAL To adjust potentiometers R9, R19, R24, POT1 & POT2, or to replace the sensors, the sensor and/or control panels must first be removed from the case as follows: Equipment Needed • Medium Flat-Blade Screwdriver Procedure 1. Remove power from analyzer. If installed, fold down the Optional auxiliary display panel. Remove water trap by pressing the release tab and pulling on the trap (The water trap can remain attached to the air tubing).
MODEL 300 COMBUSTION ANALYZER Figure 4-3. Screw Locations Figure 4-4.
MODEL 300 COMBUSTION ANALYZER 4.2 AMBIENT TEMPERATURE CALIBRATION - R24 This procedure calibrates the combustion analyzer’s ambient temperature transducer (component D7, mounted on the printed circuit board) to room temperature, using the R24 potentioneter (see Fig. 4-6). Equipment Needed (See Section 6 for Part Numbers) • Thermometer, precision grade, 0 to 220°F (–20 to 150°C) • Potentiometer Adjustment Tool Procedure 1. Remove control panel per Section 4.1. 2.
MODEL 300 COMBUSTION ANALYZER 4. Power up the analyzer as follows: a. Turn on the analyzer by either plugging it in, or by setting its battery pack switch to ON. b. Press CAL key to start the 60 second calibration cycle. c. When the word FUEL appears on left display, press FUEL key to select any one of the seven fuels. d. Press RUN key to start analyzer. 5. Press the left SELECT key until TEMP indicator is lit. 6.
MODEL 300 COMBUSTION ANALYZER 4.3 TOXIC GAS SPAN CALIBRATION The following procedure calibrates the combustion analyzer’s sensors to a known concentration of gas. 4.3.1 CO Span Calibration - R9 Equipment Needed (See Section 6 for Part Numbers) • Calibration Kit • Potentiometer Adjustment Tool Procedure • Carbon Monoxide Gas Cylinder, 500 ppm WARNING! Perform this procedure in a well ventilated area. CO is toxic! 1. Remove control panel per Section 4.1. 2.
MODEL 300 COMBUSTION ANALYZER Figure 4-7. CO Sensor Calibration Setup 5. Press the left SELECT key until the CO (ppm) indicator is lit. 6. Connect calibration setup to the instrument. Then adjust regulator on gas cylinder for a flowmeter indication of 0.5 to 1 SCFH. 7. Allow gas to flow 2 minutes, then read CO concentration on the combustion analyzer’s left display. Compare this indication to the CO calibration concentration stamped on the gas cylinder. 8.
MODEL 300 COMBUSTION ANALYZER 4.3.2 Optional NOX & SO2 Span Calibration The optional NOX and SO2 sensors are calibrated and installed at the factory. Should you have reason to suspect the accuracy of either sensor, BACHARACH recommends that the unit be sent to a qualified Service Center (see the inside back cover) for calibration.
MODEL 300 COMBUSTION ANALYZER Equipment Needed (See Section 6 for Part Numbers) • Thermometer, precision grade, 0° to 220°F (–20° to 150°C) • Boiling Water Bath • Potentiometer Adjustment Tool Procedure 1. Remove filter/trap. Important: This step prevents boiling water from being sucked up through the probe. 2. Remove control panel per Section 4.1. 3. Power up the analyzer as follows: a. Turn on the analyzer by either plugging it in, or by setting its battery pack switch to ON. b.
MODEL 300 COMBUSTION ANALYZER 9. Replace filter/trap; then if no other calibration adjustments are to be made, replace control panel and printer (if applicable). Figure 4-8. Low-Temperature Range Thermocouple Calibration Setup 4.4.2 High-Range Thermocouple Calibration Up to 2000°F (1093°C) This procedure calibrates the probe’s thermocouple to be accurate up to a temperature of 2000°F (1093°C).
MODEL 300 COMBUSTION ANALYZER Procedure 1. Remove filter/trap and thermocouple plug from control panel. 2. Remove control panel per Section 4.1. 3. Power up the analyzer as follows: a. Turn on the analyzer by either plugging it in, or by setting its battery pack switch to ON. b. Press CAL key to start the 60 second calibration cycle. c. When the word FUEL appears on left display, press FUEL key to select any one of the seven fuels. d. Press RUN key to start analyzer. 4.
MODEL 300 COMBUSTION ANALYZER Figure 4-9. High-Temperature Range Thermocouple Calibration Setup TABLE 4-1. MV LEVEL VS. AMBIENT TEMPERATURE FOR THERMOCOUPLE CALIBRATION @ 1700°F (927°C) Ambient Temp °F (°C) 60 (16) 70 (21) 80 (27) 90 (32) 100 (38) Instruction 24-9223 mV Applied 37.8 37.5 37.3 37.1 36.
MODEL 300 COMBUSTION ANALYZER 4.5 OXYGEN SENSOR CALIBRATION The oxygen sensor does not require manual calibration. Automatic calibration to an oxygen level of 20.9% occurs each time the combustion analyzer runs through its calibration cycle – the microprocessor assumes fresh air is being sampled during calibration. During the calibration cycle, the middle display shows the millivolt output of the oxygen sensor.
MODEL 300 COMBUSTION ANALYZER 5 MAINTENANCE This section describes how to: • • • • • • • • • Remove the Sensor Cover Replace the Oxygen Sensor Replace the Toxic Sensors Replace the Filter/Trap Filter Element Clean the Gas-Sampling System Perform a Leak Test Replace the Printer Paper Replace the Optional Bias Batteries Configure the Analyzer Using its Optional Internal Switches Maintenance work, other than that noted above, should be performed by an authorized Bacharach Service Center.
MODEL 300 COMBUSTION ANALYZER 4. The new oxygen sensor is shipped in a foil envelope. Use scissors to cut open the envelope and remove the sensor. Figure 5-1. Oxygen Sensor Replacement 5. Look at the contacts on the oxygen sensor base. Three contacts have dimples and one has a hole. Line up the oxygen sensor (mesh end toward the base) so that its plastic screw is just to the right of the contact with the hole.
MODEL 300 COMBUSTION ANALYZER 5.2 TOXIC SENSOR REPLACEMENT Equipment Needed (See Section 6 for Part Numbers) • Nutdrivers, 4 mm (5/32"), & 8 mm (5/16") • CO Sensor, or Procedure •NOX Sensor, or •SO2 Sensor WARNING! Burn hazard. The carbon monoxide sensor contains corrosive chemicals. DO NOT puncture or take the sensor apart. 1. Remove sensor cover per Section 4.1. NOTE: The optional SO2 and NOX sensors are located directly beneath the O2 and CO sensors.
MODEL 300 COMBUSTION ANALYZER 7. Remove shorting wire from CO and/or SO2 sensor terminals R and S. 8. Loosen nuts on sensor terminals C, S and R; then connect wires from analyzer to the sensor as shown in Fig. 5-1. Tighten these connections with a nutdriver. DO NOT overtighten connections! 9. Replace sensor cover. 10.Calibrate the new Toxic sensor per Section 4.3 (See Table 5-1 for NOX stailization time prior to calibration). Figure 5-2.
MODEL 300 COMBUSTION ANALYZER 5.3 FILTER/TRAP FILTER REPLACEMENT The filter element within the panel mounted filter/trap should be replaced whenever it appears clogged, or becomes a restriction in the sampling system. Water soaked filters can be air dried, and do not necessarily require replacement. Equipment Needed (See Section 6 for Part Numbers) • Replacement Filter Procedure 1. If the analyzer’s pump is running, stop the pump by pressing the RUN key.
MODEL 300 COMBUSTION ANALYZER NOTE: Make sure that the open end of the shield is facing down. Figure 5-3.
MODEL 300 COMBUSTION ANALYZER 5.4 CLEANING THE GAS SAMPLING SYSTEM 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 cause a restriction in the gas sampling system. 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. 5.4.
MODEL 300 COMBUSTION ANALYZER d. Using an open-end wrench, loosen thermocouple nut from particulate trap. Then slide probe tube and particulate trap off thermocouple. e. Using an open-end wrench, loosen probe-tube retainer and remove probe tube from particulate trap. f. Unscrew knurl nut from bottom of particulate trap. Then use the particulate-trap wrench to unscrew the screw cap (Fig. 3-6 shows usage of wrench). 4. Clean probe tube by flushing it with a detergent and water solution.
MODEL 300 COMBUSTION ANALYZER d. Attach gas sampling hose to particulate trap. Dress the sampling hose and thermocouple wire neatly to prevent kinking the hose. e. Install particulate trap, probe tube, and roll pin in probe handle. Position particulate trap so that its tee fitting rests on top of the roll pin. f. Attach probe-tube retainer to probe handle using two Allen screws. If necessary, loosen bottom Allen screw and move retainer to align screw holes. 10.
MODEL 300 COMBUSTION ANALYZER 5.4.2 Cleaning the Analyzer’s Sampling System Equipment Needed • Screwdriver, 1/4" Flat-Blade • Pipe Cleaners • Jumper Wire with Alligator Clips • Water • Mild Detergent • Clean Rag Procedure 1. Turn off analyzer. 2. From rear of control panel, remove filter/trap from its quick-connect socket, and unplug thermocouple connector. 3. Remove the sensor cover (see Section 4.1), and remove the O2, and CO sensors.
MODEL 300 COMBUSTION ANALYZER 6. Disconnect sampling hoses from fittings marked in Fig. 5-5 and clean these fittings with a pipe cleaner soaked in a mild detergent. Remove detergent with another pipe cleaner soaked in water, and then dry the fittings with a dry pipe cleaner. 7. If sampling hoses look dirty, remove hoses from analyzer and swirl them around in a detergent and water solution. Thoroughly rinse and dry the hoses, and then reinstall them inside the analyzer. 8.
MODEL 300 COMBUSTION ANALYZER 5.5 LEAK TESTING After cleaning and reassembling the probe, it is good practice to ensure that no leaks have developed. A leak can draw air into the system, thus increasing the O2 indications for flue gases and diluting the flue gases for CO, NOX and SO2 measurements. A leak will also cause a lower than actual efficiency computation. Equipment Needed • Soap and Water Solution • Small Brush Procedure 1. Remove control panel (refer to Section 4.
MODEL 300 COMBUSTION ANALYZER 5.6 PRINTER PAPER REPLACEMENT Equipment Needed (See Section 6 for Part Numbers) • Replacement Paper Roll Procedure 1. Open the printer by pressing its spring-loaded latch on the left-hand side of the printer’s front panel. See Fig. 5-6. 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.
MODEL 300 COMBUSTION ANALYZER 5.7 OPTIONAL SENSOR BIAS BATTERY REPLACEMENT Four “AA” batteries mounted behind the control panel apply a constant bias voltage to the NOX and/or SO2 sensor(s). The batteries should last a minimum of 6 months, with a typical life expectancy of 9 months to more than 1 year. Replace the batteries when the LOW BATT message appears on the auxiliary display panel.
MODEL 300 COMBUSTION ANALYZER Table 5-1. Typical NOX Stabilization Times Bias removed* Stabilization Time Less than 15 min. Less than 1 hr. Less than 2 days Greater than 2 days Less than 1 min. Less than 5 min. Less than 4 hr. Up to 2 days * Due to dead or missing batteries. 4. Reinstall the control panel and the auxiliary-display panel. Figure 5-7. Optional Bias Battery Location 5.
MODEL 300 COMBUSTION ANALYZER 3. See Fig. 5-9. To enable or turn on a function, set its corresponding switch to ON. Note, however, the language and baud rate settings require the setting of two switches. 4. After setting switches, replace control panel. Figure 5-8. Optional DIP Switch Location Figure 5-9.
MODEL 300 COMBUSTION ANALYZER 6 REPLACEMENT PARTS, ACCESSORIES, AND DIAGRAMS This Section contains the following information: • • 6.1 Replacement Parts List Accessories List • Wiring Diagram REPLACEMENT PARTS LIST Item Part Number AC Power Supply: 120 VAC Input ....................................... 304-1706 240 VAC Input ......................................... 24-0508 Battery Pack .................................................. 24-0537 Battery Charger: 12 VDC Input .........................
MODEL 300 COMBUSTION ANALYZER 6.1 Item REPLACEMENT PARTS LIST (CONT.) Part Number Probe Assembly (Cont.) Thermocouple, K-Type ............................ 24-0613 Washer ..................................................... 05-6326 Wrench ..................................................... 21-0078 Pump and Motor Assembly ........................... 24-0500 Sensor Assemblies: Oxygen Sensor Assembly: Flange .................................................... 51-1206 Oxygen Cell Base ....................
MODEL 300 COMBUSTION ANALYZER 6.2 ACCESSORIES LIST Item Part Number CO Gas Cylinder, 100 ppm ........................... 51-1994 CO Gas Cylinder, 500 ppm ........................... 24-0492 K-Type Extended Hose Assy’:1 10 ft. .......................................................... 24-7127 20 ft. .......................................................... 24-7128 K-Type Extended Probe Assy’:2 24 in. ......................................................... 24-7126 36 in. ..............................
MODEL 300 COMBUSTION ANALYZER 6.3 WIRING DIAGRAM Figure 6-1A shows the wiring diagram of the Model 300 Combustion Analyzer. This diagram will be useful to an experienced technician when servicing the analyzer. Figure 6-1A.
MODEL 300 COMBUSTION ANALYZER Figure 6-1B.
MODEL 300 COMBUSTION ANALYZER J 2 B N S X D IS P L A Y J 1 B F ro m C o n tro l P a n e l C A 3 0 0 P C B J 1 J 6 J 3 J 4 J 2 P W R F ro m P u m T h e r (S e e O 2 & p M o to m o c o u F ig . 6 C O r, a p le -1 B C e lls , n d C o n n e c to r ) F ro m P o w e r S u p p ly J 1 A N S X P C B J 5 J 4 J 2 A J 7 1 1 J P 6 1 0 1 0 W H T C G R N O R N B L U P R IN T E R S S O 2 R C B L K R E D N O S R Figure 6-1C.
MODEL 300 COMBUSTION ANALYZER GLOSSARY OF TERMS AMBIENT AIR The atmosphere external to the furnace, appliance or process. CALIBRATION Comparison of an instrument of lesser accuracy with another standard of known accuracy (calibration gas) to detect, correct and adjust for instrument accuracy. CARBON DIOXIDE, (CO2) A colorless gas, heavier than air, formed by the complete combustion of carbon, and the Chemical symbol for Carbon Dioxide.
MODEL 300 COMBUSTION ANALYZER HEAT EXCHANGER A device that transfers heat from one system to another, such as in a warm air furnace. NON-CONDENSING FURNACE A standard furnace which does not recycle the heat of the vaporized water. OXIDES OF NITROGEN (NOX) The sum of NO (Nitric Oxide) and NO2 (Nitrogen Dioxide). PRIMARY AIR Air mixed with the fuel inside the burners. Primary Air Temperature can be greater or less than Ambient Air Temperature.
MODEL 300 COMBUSTION ANALYZER BACHARACH SERVICE CENTERS UNITED STATES INTERNATIONAL Bacharach S/S Center 625 Alpha Drive Pittsburgh, PA 15238 (412) 963-2164/2157 (412) 963-2640 Fax Bacharach of Canada 101 Amber Street, Unit #1 Markham, Ontario L3R 3B2 (905) 470-8985/8039 (905) 470-8963 Fax Bacharach S/S Center 8618 Louisiana Place Merrillville, IN 46410 (219) 736-6178 (219) 736-6269 Fax Bacharach Instruments Int'l 58 Kongensgade DK 6070 Christiansfeld Denmark 45 (74) 563171 45 (74) 563178 Fax Bachara
