Owner's Manual

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Portable Combustion Analyzer

Operation and Maintenance Manual

Instruction 0024-9472

Rev. 2 – August 2012

Product Leadership • Training • Service • Reliability

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Summary of content (100 pages)

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 Portable Combustion Analyzer Operation and Maintenance Manual Instruction 0024-9472 Rev.
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PCA3 Manual WARRANTY POLICY Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc.’s applicable specifications. Bacharach’s liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s option, of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc.
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PCA3 Manual TABLE OF CONTENTS CHAPTER 1. INTRODUCTION ........................................................................ 7 1.1. 1.2. 1.3. 1.4. 1.5. About This Manual ....................................................................................... 7 Conventions ................................................................................................. 7 Safety ...........................................................................................................
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PCA3 Manual 4.7. Date Setup.................................................................................................. 27 4.8. Time Setup ................................................................................................. 28 4.9. O2 Reference Setup .................................................................................... 29 4.10. Print Pressure Selection ........................................................................... 30 4.11. Zoom Display Selection ..............
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PCA3 Manual 5.14. 5.15. 5.16. 5.17. Downloading Stored Data to a Computer ................................................ 57 Importing Saved Data into a Spreadsheet ............................................... 57 Printing Test Data ..................................................................................... 59 Turning Off the Analyzer and Purging ...................................................... 61 CHAPTER 6. CALIBRATION .................................................................
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PCA3 Manual 7.3. Emptying the Water Trap Chamber ........................................................... 83 7.4. Replacing the Filter Element ...................................................................... 83 7.4.1. Material Required .......................................................................... 83 7.4.2. Procedure ...................................................................................... 83 7.5. Sensor Replacement .........................................................
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PCA3 Manual CHAPTER 1. INTRODUCTION 1.1. About This Manual Thank you for investing in a Bacharach PCA®3 Combustion Analyzer. To assure operator safety and the proper use of the PCA®3, please read the contents of this manual for important information on the operation and maintenance of the analyzer. 1.2. Conventions WARNING: A warning statement denotes a potential hazard associated with the use of this equipment. Failure to follow this information could result in serious personal injury or death.
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PCA3 Manual CAUTION: Do not store instrument or its sensors with solvents or products that contain solvents. CAUTION: Except for sensor and battery replacement, this analyzer should only be opened and/or serviced by authorized Bacharach personnel. Failure to comply may void the warranty. HAZARDOUS AREA WARNING: This instrument has not been designed to be intrinsically safe for use in areas classified as hazardous locations. For your safety, DO NOT use it in hazardous (classified) locations.
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PCA3 Manual 1.4. General Description The PCA®3 is a commercial-grade hand-held combustion and emissions analyzer designed for on-demand sampling of light industrial, institutional, commercial and residential furnaces, appliances, and boilers. The basic instrument is supplied with a probe and hose assembly, instruction manual, factory calibrated smart sensors, 4 ‘AA’ alkaline batteries, boot, Fyrite® User Software, USB cable, and carrying case. Refer to Figure 1-2.
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PCA3 Manual “ERRORS DETECTED” is displayed along with a list of the errors. These errors must be corrected before proceeding with the combustion test. Before starting a test be sure to select the fuel being burned. The default fuel selected is Natural Gas. Note that the name of the fuel being burned is indicated at the top of the run/hold screen. 1.5.2. The Combustion Test To assure correct combustion efficiency calculations, the analyzer must know the burner’s primary-air temperature.
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PCA3 Manual 1.6. Features and Benefits • • • • • • • • • • • • • • • • • • • Powered by 4 ‘AA’ alkaline batteries or NiMH rechargeable batteries. An optional AC adapter provides extended operation. O2 and COLOW measurement standard. Optional measurement of up to two additional gases, including COHIGH, NO, NO2, or SO2. With the appropriate sensors installed, the analyzer optionally displays pollution conversions for CO, NO, NO2, and SO2. Pollution conversions include ppm, #/MBTU, mg/m3, and g/GJ.
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PCA3 Manual 8453 285 7326 8446 8452 275 7325 8445 8451 265 7324 8444 8450 255 7323 8443 8449 245 7322 8442 8448 235 7321 8441 8447 225 7320 Sales Combo (0024-xxxx) 8440 1.7.
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PCA3 Manual 1.8. Specifications Measurement (Based on Installed Sensors) Oxygen Display Range 0.1 to 20.
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PCA3 Manual Reading Performance Accuracy O2 ±0.3% O2 on practical concentrations of stack gas (mix of O2, CO2, and N2) CO Greater of ±5% of reading or ±10 ppm, between 0-2,000 ppm, ±10% of reading between 2,001 and 20,000 ppm.
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PCA3 Manual CHAPTER 2. HARDWARE 2.1. Overview Figure 2-1.
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PCA3 Manual 2.2. Front Panel Buttons The PCA®3 is controlled by various buttons, while a color graphic LCD (with automatic dimming feature) is used to display all combustion and emission test data and analyzer parameters. Descriptions of the front panel buttons are given below. Note that a button may perform multiple functions depending on the current screen that is displayed. F1 PRINT Transmits the data displayed on the screen to a printer through the IrDA communications port.
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PCA3 Manual For example, the functions of the F1, F2, and F3 buttons are defined by labels appearing above them on the LCD. The labels that appear depend on the functions that can be performed in the particular screen being displayed. NOTE: A keypad backlight enables a user to read the keypad in dimly-lit areas. Turn the keypad backlight ON and OFF by briefly pressing the I/O button.
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PCA3 Manual Figure 2-3. Battery Compartment Figure 2-4. Bottom View Showing Connectors 2.6. Probe Connectors (Gas, Pressure, T-Stack) The probe and hose assembly are connected to the analyzer by way of the following connectors.
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PCA3 Manual Figure 2-5. Probe Connectors GAS, +∆P, and T-STACK 2.7. Differential Pressure Connector (∆P) Draft is measured by connecting the probe’s draft hose to the +∆P fitting, while leaving the -∆P fitting open to the atmosphere. See Figure 2-5.
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PCA3 Manual CHAPTER 3. INITIAL SETUP 3.1. Overview Before configuring or using the PCA®3, you MUST: • • provide power connect the probe and hose assembly. 3.2. Power Three options are available to power the PCA®3: • • • disposable alkaline batteries rechargeable NiMH batteries AC power adapter. If you are using either alkaline or NiMH rechargeable batteries to power the analyzer, follow the instructions below to install or replace the batteries.
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PCA3 Manual 3.3. Connecting the Probe and Hose Assembly To attach the probe and hose assembly to the analyzer follow the steps below and refer to Figure 3-2 on page 22. 1. 2. 3. 4. Push the gas sample hose connector, the larger of the two connectors (giving a slight twist), onto the analyzer’s GAS fitting. Push the draft hose connector, the smaller connector (giving a slight twist), onto the analyzers +∆P fitting.
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PCA3 Manual Figure 3-2.
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PCA3 Manual CHAPTER 4. CONFIGURATION PROCEDURES 4.1. Default Operating Parameters The PCA®3 is set up at the factory for the following operating parameters. To change any of these parameters, perform the associated procedure that follows.
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PCA3 Manual 4. Press ENT to save the selection and display the Combustion Test HOLD screen. Observe that the name of the selected fuel should now appear at the top of the screen. NOTE: In addition to the standard fuels programmed into the ® PCA 3, Bacharach can develop custom fuel codes based on the ® customers specific needs. The PCA 3 can be programmed with 2 additional fuels which can be added to the instrument using the Fyrite User Software (FUS). Consult factory for price and delivery. Figure 4-1.
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PCA3 Manual ® NOTE: The PCA 3 performs a zero function during warm-up. Among other purposes, an auto-zero determines the “zero reading” of the CO channel in fresh air and provides an offset for the CO measurement. A manual zero detects background CO during startup. Manual Zero: When the CO channel is set to manual zero, the analyzer does not zero the CO sensor to ambient conditions during start up.
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PCA3 Manual Figure 4-3. Temperature Units Selection 4.5. Pressure Units Selection Select to display pressure in Inches of Water Column (inwc), millibar (mb), Pascals (Pa), or hectoPascals (hPa) as follows. 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. 3.
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PCA3 Manual 4.6. Pollution Units Selection The PCA®3 is capable of converting the measured ppm levels of CO, NO, NO2, 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 NO2.
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PCA3 Manual 5. Repeat Step 4 until the values for month, day, and year have been set. 6. Press ENT to save the selection and re-display the SETUP MENU, or press ESC to abort this procedure and retain the old date values. NOTE: The real time clock is powered by the main batteries and is maintained by a coin cell battery on the Main PCB in the absence of batteries. Bacharach recommends changing the coin cell (P/N 0204-0020) every 5 years. Figure 4-6. Date Setup 4.8.
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PCA3 Manual Figure 4-7. Time Setup 4.9. O2 Reference Setup The measured values of CO, NOx, and SO2 can be individually referenced to a specific O2 percentage of between 0 and 15%. Individually set up the O2 reference value for each of the above gases as follows. 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. 3.
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PCA3 Manual 4.10. Print Pressure Selection Select whether to print or not print the pressure measurement on the combustion test printout as follows. 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. 3. Use the ▲▼ buttons to highlight PRINT PRESSURE, and then press ENT to display the PRINT PRESSURE screen. 4.
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PCA3 Manual Figure 4-10. Zoom Display Selection 4.12. Logging Selection When the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined length of time. Refer to Data Logging starting on page 50 for detailed information on how to select the logging function, how to set the interval and duration time periods, and how to view or download the stored data. Figure 4-11. Logging Selection 4.13.
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PCA3 Manual Figure 4-12. Button Sound Selection 4.14. Test ID Information Test records can be identified (e.g., customer’s name, burner number, and location) by manually entering up to three lines of text, with each line containing a maximum of 20 alphanumeric characters. When a Test ID is selected this information will be associated with all succeeding test records, and will appear at the top of each test record when printed, and in CSV files when records are downloaded to a PC.
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PCA3 Manual 8. At this time, either return to Step 6 to choose another line to edit, or end this procedure by highlighting Edit Complete and pressing the ENT key to return to the Edit Test ID Menu. 9. Press ESC to go to the Test ID Menu or the RUN/HOLD key to return to the Run/Hold screen. Figure 4-13. Editing a Test ID 4.14.2. Selecting a Test ID 1.
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PCA3 Manual All Records: Use the ▲▼ buttons to highlight All Records, then press ENT to display the Clear All menu. Again use the ▲▼ buttons to highlight Yes, then press ENT to clear all records. 3. Press ESC to end this procedure and return to the Test ID menu or press the RUN/HOLD key to return to the Run/Hold screen. Figure 4-15. Clearing a Test ID 4.15. User Name The name of the user or owner of the analyzer (e.g.
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PCA3 Manual 7. At this time, either return to Step 4 to choose another line to edit, or end this procedure by highlighting Edit Complete and pressing the ENT key to return to he Setup Menu. 8. Press ESC to go to the Main Menu or the RUN/HOLD key to return to the Run/Hold screen. Figure 4-16. Entering a User Name 4.15.2. Clearing a User Name 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2.
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PCA3 Manual 4.16. Language Information on the display screen can be shown in English, French, or Spanish. Select the desired language as follows. 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. 3. Use the ▲▼ buttons to highlight LANGUAGE SELECTION, and then press ENT to display The Language Selection Menu. 4.
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PCA3 Manual NOTE: The date and time settings must be correct to get accurate calibration reminders. Figure 4-19. Selecting the Calibration Reminder Period 4.18. Run/Hold Screen Format PCA®3 test data is located in the Run/Hold screen. By pressing the RUN/HOLD key, you should hear the pump running and see the word RUN at the upper left hand corner of the display. The instrument is continuously measuring and calculating the data that is shown in the Run/Hold screen.
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PCA3 Manual NOTE: A number sign (#) denotes the current O2 Reference selected. NOTE: Stars (***) appear in measurement and calculation fields of sensors that are not installed. Change the order in which data is displayed as follows. 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. 3.
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PCA3 Manual 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight SETUP, and then press ENT to display the SETUP MENU. 3. Use the ▲▼ buttons to highlight RUN/HOLD FORMAT, and then press ENT to display Run/Hold Format Menu. 4. Use the ▲▼ buttons to highlight RESET FORMAT, then press ENT to display the Reset Format screen. 5.
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PCA3 Manual CHAPTER 5. OPERATION 5.1. Operating Tips • When an analyzer is brought in from a cold vehicle, let it warm up slowly to minimize condensation. Temperatures below freezing will not damage the analyzer. CAUTION: Although the analyzer itself is not damaged by an extremely cold environment, the electrochemical sensors may be damaged. The O2 sensor’s electrolyte will freeze at approximately -20 ºF and the other sensors at approximately -94 ºF.
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PCA3 Manual 5.2. Turning On the Analyzer Connect the probe and hose assembly, and make sure that the analyzer is properly set up according to Initial Setup (page 20) and Configuration Procedures (page 23). IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer! 1. Place the probe in an area that contains fresh air. This ensures that the sensors will be properly zeroed during the warm-up cycle. 2.
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PCA3 Manual 5.3. Low Battery Alarm When the batteries are nearly depleted, an empty battery icon appears in the upper right corner of the display, and a short beep is sounded every 10 seconds. After a low battery alarm occurs, the analyzer will continue to operate for only a few minutes. The amount of operating time that remains depends on many factors (e.g., pump and keypad backlight being ON or OFF, and the type and condition of the batteries). 5.4.
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PCA3 Manual 90% Efficiency Condensing Furnace 80% Efficiency Fan Assist or Power Vented Furnace Atmospheric/Gravity Vented Boiler Figure 5-4. 90% Efficiency Condensing Furnace Figure 5-5. 80% Efficiency Fan Assist or Power Vented Furnace Figure 5-6. Atmospheric/Gravity Vented Boiler Condensing furnaces/boilers can be tested through a hole drilled in the plastic vent pipe (when allowed by the manufacturer or local authority of jurisdiction) or taken from the exhaust termination.
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PCA3 Manual Figure 5-7. Performing a Combustion Test 1. Press the RUN/HOLD button to start the test. You should hear the pump start running and see the word RUN appear at the top of the Combustion Test screen. Sensor Indicators: The following indicators appear in the sensor’s data field depending on certain conditions: (* * *) (XXX) (- - - ) Sensor that is not calibrated or installed.
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PCA3 Manual List of Combustion Test Data Display Name O2 CO Carbon Monoxide (1) EFF Combustion Efficiency CO2 % Carbon Dioxide T-STK Stack Temperature T-AIR Primary/Ambient Air Temperature as measured either internally or by an optional external thermocouple plugged into the analyzer’s T-AIR connector.
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PCA3 Manual Figure 5-8. Selecting a Pressure Label 5.7. Temperature Label Selection and Measurement The difference in temperature between two areas can be measured by using the analyzer’s two temperature channels and the Temperature screen. By using the T-Air channel as a reference, the temperature applied to the T-Stack channel will be displayed on the Temperature Measurement screen as differential temperature between the two channels. Additionally, the temperature measurement can be labeled.
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PCA3 Manual 5.8. Performing a Draft / Pressure Measurement The difference in pressure ∆ ( P) between two areas can be measured by using the analyzer’s two pressure ports and the PRESSURE screen. By using the –∆P port as the reference, the pressure applied to the + ∆P port will be displayed on the PRESSURE screen as the differential pressure between the two ports. Perform a draft / pressure measurement as follows. 1. Turn ON the analyzer and allow it to complete its warm-up cycle (see page 9, 16, and 20).
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PCA3 Manual differential pressure between the two areas is now displayed on the PRESSURE screen. If the pressure at the +∆P port is higher than the –∆P port, then the pressure reading will be positive. If it is lower, then the reading will be negative. Figure 5-11. Pressure Zero Screen Figure 5-12. Draft/Pressure Measurement Hose Connections 5.9.
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PCA3 Manual 5.10. Ending a Combustion Test WARNING: Burn Hazard. Do not touch the probe after removing it from the stack. Allow the probe to cool before handling (about 5 minutes). 1. Remove probe from stack. 2. Allow the pump to run until all combustion gases have been flushed from the analyzer with fresh air as indicated by the O2 reading returning to 20.9%. 5.11.
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PCA3 Manual Figure 5-14. Emptying the Water Trap 5.12. Data Logging 5.12.1. Overview When the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined duration. The maximum duration that data can be collected is determined by the interval.
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PCA3 Manual Logging Intervals and Durations Logging Intervals Logging Durations 1 second 5 minutes 5 second 10 minutes 10 second 15 minutes 15 second 30 minutes 30 second 1 hour 1 minute 2 hours 2 minutes 5 hours 5 minutes 10 hours 10 minutes 24 hours 48 hours 5.12.2.
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PCA3 Manual Figure 5-15. Turning On Data Logging 5.12.3. Setting the Logging Interval and Duration The logging interval is the length of time between measurements, while the logging duration is the time allocated to the logging process. Set the logging interval and duration as follows. NOTE: If the duration is set for more than 10 hours, we recommend using the optional AC power adapter to power the analyzer. 1.
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PCA3 Manual 5.12.4. Starting the Data Logging Process After turning ON data logging and setting the interval and duration, the analyzer will pause at the LOGGING SUMMARY screen, where the currently selected interval and duration time periods are displayed. Press ENT to start the combustion test and logging process. At this time the Combustion Test LOG screen will appear, indicating that the analyzer is now performing a combustion test and the data is being stored in memory.
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PCA3 Manual NOTE: If the logging process was stopped by pressing ESC, it cannot be resumed without first turning logging back ON. 5.13. Memory Functions 5.13.1. Overview There are two memory banks, each containing 500 memory locations. The first bank is used to store combustion test data as described in Saving Test Data (page 48), while the second bank is used to store logged combustion test data as described in Data Logging (page 50).
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PCA3 Manual NOTE: The recalled combustion test data can be printed by pressing the PRINT (F1) button. Refer to Printing Test Data on page 59. Figure 5-18. Recalling Combustion Test Data 5.13.3. Recalling Logged Test Data Recall individual logged combustion test data records as follows. 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight MEMORY, and then press ENT to display the MEMORY MENU. 3.
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PCA3 Manual Figure 5-19. Recalling Logged Test Data 5.13.4. Clearing Memory When all memory locations used to store individual combustion test records have been filled, the next combustion test record saved will not overwrite the oldest. When all logging memory locations in the logging directory are full, they must be manually cleared in order to store new data. At no time will the logging process overwrite older data. Logging will stop when available memory is filled.
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PCA3 Manual 5.14. Downloading Stored Data to a Computer The combustion test data that was stored in either the analyzer’s Memory Directory or Logging Directory (see Memory Functions on page 54), can be downloaded to a computer using the Fyrite® User Software and USB cable that are supplied with the analyzer. The downloaded data is stored on the computer’s hard drive – or removable media of the operator’s choosing – as a comma-separated-value ASCII text file with a CSV extension.
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PCA3 Manual Downloaded Data Fields Field 58 Data Name or Value 1 Date 2 Time Time of Test in 12 hour format (AM/PM) Test ID Information Input by User 6 Fuel Fuel Name 7 %O2 Oxygen Level 8 CO Carbon Monoxide Level (see field 30) Carbon Monoxide Level referenced to a % of O2 (see field 25) 3-5 (1) (2) (3) Column Name Date of Test in mm/dd/yy 9 ppm CO(O2) 10 % Efficiency Combustion Efficiency 11 % CO2 Carbon Dioxide Level 12 %EA Excess Air 13 TStk Stack Temperature 14 TAi
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PCA3 Manual 5.16. Printing Test Data Combustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described below. Data that is stored in memory can also be printed by first displaying the stored test data as described in the Recalling Combustion Test Data section (page 54) and the Recalling Logged Test Data section (page 55).
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PCA3 Manual Figure 5-21.
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PCA3 Manual 5.17. Turning Off the Analyzer and Purging Turn OFF the analyzer by pressing the I/O button for at least 2 seconds, or until two beeps are heard. The unit will count down 5 seconds before shutting down, giving the operator an opportunity to keep the analyzer turned ON by pressing the RUN/HOLD button.
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PCA3 Manual CHAPTER 6. CALIBRATION IMPORTANT: Before performing any calibration procedure ensure that new batteries are installed or use the optional AC power adapter. Also ensure that the analyzer is at room temperature and will be sampling fresh air when turned ON. 6.1. B-Smart Sensors The PCA®3 uses Bacharach’s B-Smart® Sensor technology for COLOW, COHIGH, NO, NO2, and SO2.
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PCA3 Manual 5. Before calibration can begin a 4-character alphanumeric password must be entered. Use the ▲▼ and ◄► buttons to enter the password. (The default password is 1111.) 6. Press the ENT key to accept the password. If the correct password was entered the CALIBRATION LIST Menu will be displayed. 7. Use the ▲▼ buttons to highlight the sensor to be calibrated, and then perform the calibration procedure for that sensor as described in the following sections. Figure 6-1.
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PCA3 Manual Bacharach also offers a convenient exchange program that allows the customer to regularly send in old sensors and, as scheduled, receive calibrated replacements. Contact Bacharach customer service for more details about the exchange program. 6.4. Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value. 6.4.1. Material Required • • Bellows Manometer: Range: Accuracy: ±8 in. of water column (±20 mb) ±0.01 in. of water column (±0.025 mb) 6.4.2.
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PCA3 Manual NOTE: The calibration range is from –6 to –2 inwc (–15 to -5 mb). An attempt to calibrate outside this range will cause the message “Applied Value High” (or Low) to appear at the bottom of the screen. Figure 6-2. Pressure Sensor Calibration 7.
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PCA3 Manual The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures. Alternatively, containers of ice water and boiling water can be used. 6.5.1. Material Required • • Thermocouple Simulator (K-type): Range: 0 to 600 °F Accuracy: ±0.5 °F (Alternatively) Ice Water, Boiling Water, Thermometer 6.5.2. TS-Zero Procedure 1.
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PCA3 Manual which the message “Good Calibration” should briefly appear followed by the CALIBRATE TS-SPAN screen. Figure 6-4. T-Stack Zero and Span 6.5.3. TS-Span Procedure 1. Set thermocouple simulator to 572 °F (300  °C), and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the setting of the simulator.
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PCA3 Manual 1. Set thermocouple simulator to room temperature and plug its output into the T-AIR connector located at the bottom of the analyzer. Alternatively: Plug the probe’s thermocouple into the T-AIR connector located at the bottom of the analyzer. DO NOT attach the probe’s gas hose to the analyzer’s GAS port; otherwise water will be drawn into the analyzer! 2. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to Calibration on page 62). 3.
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PCA3 Manual 6.6.3. TA-Span Procedure 1. Set thermocouple simulator to 212 °F (100  °C), and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the setting of the simulator. Alternatively: Submerge probe tip into a container of boiling water with a thermometer, wait several minutes, and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the thermometer reading. NOTE: The calibration range is from 194 to 230 °F (90 to 110 °C).
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PCA3 Manual 6.7.2. Procedure 1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to Calibration on page 62). 2. Use the ▲▼ buttons to highlight CO-LO, and then press ENT to display the CALIBRATE CO screen. NOTE: “Measured” is the current CO reading, while “Applied” is a known CO level that will be applied for calibration purposes. 3. Attach a 500 ppm CO cylinder to the regulator of the calibration fixture shown in Figure 6-12 on page 76. 4.
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PCA3 Manual NOTE: If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life, Entry Not Saved” will appear. The sensor will now be marked as being BAD in the DIAGNOSTICS screen. 6. Turn OFF regulator of calibration fixture and remove the CO cylinder. 7.
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PCA3 Manual NOTE: A CO-only calibration can be done by pressing F3 in Step 5 (instead of ENT). 6.8. SO2 Sensor Calibration This procedure spans the optional sulfur dioxide sensor to a known gas level. 6.8.1. Material Required • • Calibration Kit Gas Cylinder ( P/N 0024-7059) (100 ppm SO2 in Nitrogen, P/N 0024-1158) 6.8.2. Procedure 1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to Calibration on page 62). 2.
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PCA3 Manual and then press ENT to calibrate the SO2 Measured value to that of the applied value. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed. NOTE: If the sensor’s output is low, but still usable, then the message “Good Calibration WARNING Low Sensor” will appear. The sensor will now be marked as being Low in the DIAGNOSTICS screen.
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PCA3 Manual Figure 6-10. NO Sensor Calibration 5. Adjust regulator for a flow meter indication of approximately 2  SCFH. Wait until the measured reading stabilizes (approximately 3  minutes), and then press ENT to calibrate the NO Measured value to that of the applied value. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.
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PCA3 Manual NOTE: “Measured” is the current NO2 reading, while “Applied” is a known NO2 level that will be applied for calibration purposes. 3. Attach a 100 ppm NO2 cylinder to the regulator of the calibration fixture shown in Figure 6-12 on page 76. 4. Use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the concentration stamped on the NO2 cylinder. NOTE: The calibration range is from 9 to 150 ppm.
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PCA3 Manual 6.11. COHIGH Sensor Calibration This procedure spans the optional carbon monoxide high sensor (4,001 to 20,000 ppm) to a known gas level. 6.11.1. Material Required • • Calibration Kit Gas Cylinder (P/N 0024-7059) (4,000 ppm CO in Air, P/N 0024-1155) Figure 6-12. Gas Sensor Calibration Equipment 6.11.2. Procedure 1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to Calibration on page 62). 2.
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PCA3 Manual NOTE: The calibration range is from 250 to 11,000 ppm. An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. Figure 6-13. COHIGH Sensor Calibration 5. Adjust regulator for a flow meter indication of approximately 2  SCFH. Wait until the measured reading stabilizes (approximately 3  minutes), and then press ENT to calibrate the CO Measured value to that of the applied value.
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PCA3 Manual CHAPTER 7. MAINTENANCE 7.1. Overview Customer maintenance of the PCA®3 is limited to the following: • • • • • Battery replacement (see page 20) Sensor re-calibration (see page 62) Water trap / filter assembly maintenance (see pages 49 and 83) Sensor replacement (see page 84) Cleaning the probe (see page 87). All other maintenance should be performed by an authorized Bacharach Service Center. Refer to Service Centers on page 95. 7.2.
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PCA3 Manual Figure 7-1.
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PCA3 Manual Figure 7-2.
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PCA3 Manual Figure 7-3. Tubing Connections - Main Figure 7-4.
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PCA3 Manual Figure 7-5.
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PCA3 Manual 7.3. Emptying the Water Trap Chamber The water trap chamber should be emptied after every test, or when the water condensate approaches the tip of the riser tube. 1. Remove water trap chamber (also see page 49). 2. Pour out liquid condensate and then reassemble trap. 7.4. Replacing the Filter Element Replace the filter element when it becomes visibly dirty or becomes saturated with water. 7.4.1. Material Required • • Filter Element (P/N 0007-1644) Small Flat Blade Screwdriver 7.4.2.
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PCA3 Manual 7.5. Sensor Replacement All sensors are replaced in a similar manner. Do the following to replace either the O2, COLOW, COHIGH, NO, NO2, or SO2 sensor. Refer to Replacement Parts on page 90 for a list of sensors and part numbers. NOTE: The typical life expectancy of the O2, SO2 and NO2 sensors is 2 years. Typical life expectancy of the CO, COHIGH and NO sensors is 3 years. 1. Turn OFF the analyzer. 2. Remove the battery cover. 3. Remove the sensor retainer. 4.
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PCA3 Manual CAUTION: Figure 7-7. Sensor Assembly 12. 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. The NO sensor baseline technically requires several days to stabilize, but should be sufficiently stabilized for use in approximately 4 hours. 13. Turn ON the analyzer and confirm that no sensor errors occur during warm up.
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PCA3 Manual 7.6. Nitric Oxide (NO) Sensor Battery Replacement A single lithium battery, located on the NO Smart Sensor assembly, applies a bias voltage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off. The NO bias battery is expected to last at least the life of the NO sensor. NOTE: It is recommended that the bias battery be replaced whenever the NO sensor is replaced. 7.6.1. Material Required • Bias battery (refer to Replacement Parts on page 90) 7.6.2.
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PCA3 Manual 7.7. Cleaning the Probe The probe tube and gas sample hose will become dirty under normal use. NOTE: The water trap’s filter element should prevent soot from reaching the analyzer’s internal components. If the probe is not kept clean, it could become clogged and restrict the flow of gas into the analyzer, resulting in incorrect combustion test readings and calculations.
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PCA3 Manual CHAPTER 8. TROUBLESHOOTING 8.1. Error Symbols Error symbols are shown in the data fields of the Combustion Test screens and on the printout to indicate the following. Error Symbol Description - - - Three hyphens or dashes indicates that the calculated data cannot be displayed because the measured data necessary to make the calculation is out of range. For calculations to occur, the oxygen level must be below 16% and the stack temperature must be below 2,000 °F (1,093 °C).
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PCA3 Manual 8.3. Accessing the Diagnostic Menu 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. Figure 8-2. Accessing the Diagnostics Menu 2. Use the ▲▼ buttons to highlight DIAGNOSTICS and then press ENT to display the DIAGNOSTICS MENU. 3. Use the ▲▼ buttons to highlight the desired diagnostic topic, and then press ENT to display the information under that topic. 4.
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PCA3 Manual Error Message Low Battery O2 Sensor Missing BAD Sensors No B-Smart Sensors Installed Description Battery voltage is low. Replace batteries (page 20). Oxygen sensor not installed. Install oxygen sensor. Refer to Sensor Replacement on page 84. The oxygen sensor’s output is too low and can not be calibrated in the instrument, signifying that the sensor is depleted and needs to be replaced. Refer to Sensor Replacement on page 84. There are no B-Smart sensor(s) installed.
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PCA3 Manual Item Description Part No.
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PCA3 Manual Main PCB Assembly (Replacement Part Not Available) Figure 8-3.
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PCA3 Manual Figure 8-3. Replacement Parts (Continued) 8.7. Accessories Standard Accessories Description Part No.
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PCA3 Manual Figure 8-4. Hose and Probe Assembly (Parts) Optional Accessories Description Part No. AC Power Adapter: (Input: 100-240 VAC, 50/60 Hz; Output: 6 VDC @ 1 A) 0024-1254 Ambient Air Thermocouple (T-AIR), K-Type, 10 ft. 0104-1797 Ambient Air Thermocouple (T-AIR), K-Type, 1 inch. 0104-1798 Utility Wand (12 in. rigid probe w/ 5 ft. coiled cable) 0104-1799 Differential Pressure Hose Assembly, 6 ft.
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PCA3 Manual Description Part No. Thermocouple Replacement Kit, 24 in. 0024-8415 Thermocouple Replacement Kit, 36 in. 0024-8416 Sample Conditioning Probe, Compact (recommended when measuring NO2 and SO2) 0024-7224 8.8. Analyzer Repair It is recommended that field repair of the PCA®3 be limited to: • • • • Checks of printed circuit board connectors Replacing the probe assembly Replacing the filter element in the water trap / filter assembly Replacing sensors.
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PCA3 Manual CHAPTER 9. DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer of the products covered by this declaration: Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Year conformity is declared: 2010 Product(s): Combustion Analyzer Model(s): PCA3 (Domestic) The undersigned hereby declares that the above referenced products are in conformity with the provisions of the following standard(s) and is in accordance with the following directive(s).
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PCA3 Manual 0024-9472 Rev 2 97
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PCA3 Manual 98 0024-9472 Rev 2
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PCA3 Manual 0024-9472 Rev 2 99
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PCA3 Manual World Headquarters 621 Hunt Valley Circle, New Kensington, Pennsylvania 15068 Phone: 724-334-5000 • Toll Free: 1-800-736-4666 • Fax: 724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.