Portable Combustion Analyzer (PCA) Instruction 0024-9219 Operation & Maintenance Rev.
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.
PCA Contents Contents 1.0 INTRODUCTION ............................................................................ 1-1 1.1 The Portable Combustion Analyzer ........................................... 1-1 1.2 Displayed Data ........................................................................... 1-2 1.3 PCA Model Configurations ......................................................... 1-3 2.0 TECHNICAL CHARACTERISTICS ............................................. 2-1 3.0 SETTING UP THE PCA ............
Contents 4.22 4.23 4.24 4.25 4.26 PCA User Name Screens ................................................................ 4-28 Saving Test Data .................................................................... 4-29 Printing Test Data .................................................................. 4-30 Clear Memory Screen ............................................................. 4-32 Resetting the Microprocessor ................................................. 4-32 5.0 CALIBRATION .............
PCA Introduction 1.0 INTRODUCTION 1.1 The Portable Combustion Analyzer The Portable Combustion Analyzer (PCA) (Figure 1-1) is a commercial grade, hand held, combustion efficiency analyzer that is designed for continuous (on demand) sampling of light industrial and residential furnaces, appliances, and boilers. The basic instrument is supplied with a probe, instruction manual, batteries, and carrying case. Figure 1-1.
Introduction PCA 1.
PCA Introduction 1.3 PCA Model Configurations TABLE 1-1. PCA SENSOR CONFIGURATIONS PCA Models Standard Advanced PCA Part No. PCA Part No. Model 10 15 20 25 30 35 248040 8041 8042 8043 8044 8045 Model 40 45 50 55 60 65 248140 8141 8142 8143 8144 8145 Sensors Installed Stack Temp., Air Temp. & O2 X X X X X X CO NX Draft (P) X X X X X X X X X PCA 10 & 40 These basic instruments have the capability of measuring, displaying, and storing combustion tests.
Introduction PCA PCA 30 & 60 with CO and Nitric Oxide Measurement In addition to the features of the basic PCAs with CO measurement, these instruments have the added capability of measuring, displaying, and saving Nitric Oxide (NX) content, as well as calculating a NX level that is referenced to Oxygen. The ‘standard’ PCA 30 calculates NX referenced to 0% Oxygen, while the ‘advanced’ PCA 60 calculates NX referenced to a user selected Oxygen level of between 0–15%.
PCA Technical Characteristics 2.0 TECHNICAL CHARACTERISTICS The PCA Directly Measures and Displays: • Oxygen content in flue gas in the range of 0.1 to 20.9 % O2 • Flue gas temperature in the range of 0 to 2192 ºF (–18 to 1200 ºC) • Primary-air / ambient temperature is in the range of 0 to 999 ºF (–18 to 999 ºC) Optional . . . • Differential Pressure and Draft in the range of ±28" H2O (±70.
Technical Characteristics PCA Normal Operating Conditions: Temperature: Analyzer ................... 32 to 104 ºF (0 to 40 ºC) Probe Tip .................. 1472 ºF (800 ºC) Max. Humidity: Analyzer ................... 15 to 90% Relative Humidity, Non-Condensing Air Pressure: Analyzer ................... Atmospheric Probe ......................... 10" H2O (25 mb) draft max at probe tip Performance: Accuracy: Oxygen* .................... ±0.3% O2 Carbon Monoxide .....
PCA Technical Characteristics Power Requirements: Four AA alkaline batteries. Battery backup for the real-time clock, RAM, and bias voltage for the Nitric Oxide sensor is provided by internal lithium batteries. Optional AC Power Supplies (110 VAC & 230 VAC) are also available. Operating Time: A fresh set of batteries will provide at least 8 hours of continuous operation with the pump running and the backlight turned on. Warm Up Time: 60 seconds.
Technical Characteristics PCA NOTES: 2-4 Instruction 0024-9219
PCA Setup 3.0 SETTING UP THE PCA 3.1 Scope Before using the PCA, you MUST: • Check the batteries or plug in an Optional Power Supply (Section 3.2) • Connect the probe to the analyzer (Section 3.3) • Check the analyzer’s configuration (Section 3.4) 3.2 PCA Power 3.2.1 Checking and Replacing the Batteries A fresh set of batteries is supplied with the PCA. Install the batteries as described below. If a LOW BATTERY message is displayed when the analyzer is turned on, replace the batteries. 1.
Setup PCA 3.2.2 Using the Optional Power Supply If an Optional Power Supply is to be used: 1. Connect the output plug of the Optional Power Supply to the analyzer’s power supply jack (Figure 3-2). 2. Plug the Optional Power Supply into an appropriate AC wall outlet. The analyzer will now operate and function normally. 3.3 Connecting the Probe To attach the probe to the analyzer (Figure 3-2): 1.
PCA Setup Reset Button Room Air / Primary Air Thermocouple (Optional) Power Supply 110V/60Hz 230V/50Hz (Optional) Pressure Reference Port* (Used in the Measurement of Differential Pressure) Draft Hose* Flue Gas Thermocouple *Present only on analyzers Flue Gas Hose equipped with a pressure sensor. Probe Tube Water Trap / Filter Assembly Flue Gas Hose Adjustable Probe Stop Probe Handle Figure 3-2.
Setup PCA 3.4 Configuring the PCA The PCA is configured at the factory for the parameters shown below. These parameters, however, can be changed by following the instructions in their associated sections. Function Parameters To Change, Refer to . . . Fuel Temperature Draft Oxygen Reference Language Display Mode Time Date Natural Gas ºC WC 0% English CO & NX HR:MIN:SEC AM/PM MM/DD/YY Section 4.8 Section 4.13 Section 4.14 Section 4.15 Section 4.16 Section 4.17 Section 4.18 Section 4.
PCA Operation 4.0 OPERATION 4.1 Key Pad Functions Descriptions of the key pad functions are given below. Note that most of the front panel key pad buttons perform multiple functions as determined by what screen is being displayed at the time. Turns the analyzer ON and OFF. Note that there is a 5 second OFF-delay that allows an operator to turn the instrument back ON by pressing the RUN key. This feature prevents the accidental loss of test data if the analyzer is turned OFF by mistake.
Operation PCA 4.2 Sampling Hole Location The analyzer requires that a ½" diameter sampling hole be made in the furnace stack to accommodate the probe stop on the Probe and Hose Assembly. Locate the sampling hole downstream from the last heat exchanger, and upstream from any source of dilution, such as a draft diverter (Figure 4-1). Important! As the distance between the last heat exchanger and sampling point increases, stack loss will falsely decrease due to heat loss by convection from the flue or stack.
PCA Operation 4.3 Performing a Combustion Test Important! Large rapid changes in the temperature of the analyzer can affect its accuracy. This is important to know if the analyzer is stored in a cold place (such as an unheated vehicle in the winter) and then taken into a warm furnace area. For the most accurate test results, allow the analyzer to warm up to room temperature before use (about 10 minutes). 4.3.
Operation PCA 4.3.2 Installing Probe in the Stack 1. After making a sampling hole in the stack (Section 4.2), and turning on the analyzer (Section 4.3.1), screw the probe stop supplied with the Probe and Hose Assembly into the sampling hole (Figure 4-2). 2. Insert the probe through the hole in the probe stop, then position the probe tip inside the stack, near its center. Tighten the thumbscrew on the probe stop to secure the probe. PROBE STOP THUMBSCREW Figure 4-2.
PCA Operation 4.3.3 Starting a Combustion Test Important! If the burner’s primary-air temperature is not the same as the room temperature, then be sure the Optional Room Air / Primary Air Thermocouple is installed per Section 3.3. 1. With the Combustion Test Screen (Section 4.7) displayed and the probe installed in the stack, press the RUN key to start a combustion test. 2. Once all sensor readings are displayed: A) Loosen the thumbscrew on the probe stop.
Operation PCA CAUTION: Do not place a hot probe inside the instrument’s carrying case. Allow the probe to cool before storage. 2. Loosen the thumbscrew on the probe stop; then remove the probe and probe stop from the stack. 3. If data was saved during the combustion test, you can turn off the analyzer and review or print the stored data at a later time as described in Sections 4.10 and 4.23. 4.3.5 Turning Off the Analyzer and Purging the CO Sensor Turn off the analyzer by pressing the ON/OFF key.
PCA Operation 4.4 Differential Pressure Measurement The difference in pressure (P) between two areas can be measured by using the PCA’s two pressure ports and DRAFT Screen. By using Pressure Port 2 (–) as the reference, the pressure applied to Port 1 (+) will be displayed on the DRAFT Screen as the differential pressure between the two ports. 1.
Operation PCA 4.5 Warm-up Screen BACHARACH, INC. PCA xx WARMUP yy Where: xx = Instrument Model Number yy = Counts down from 60 seconds As soon as the ON/OFF key is pressed, the instrument’s serial number and software version number are displayed for approximately 3 seconds. To continuously display these items, hold down the ON/OFF key at start-up. The warmup cycle continues after the ON/OFF key is released.
PCA Operation 4.6 Sensor Status Screen BACHARACH, INC. PCA xx WARMUP 0 z Where: xx = Instrument Model Number z = Sensor(s) in error If a problem with one or more of the sensors was detected during warmup, the Sensor Status Screen will display an error code for those sensors at the bottom of the screen and wait for operator intervention. Refer to Section 7.2 for a listing and explaination of the error codes.
Operation PCA 4.7 Combustion Test Screen PCA models 10 thru 25, 40 thru 55 O2 4.0 C2 9.5 TA 68.0 EF 82.6 CO 12 CF 15 TS 374 EA 21 HLD NG P «S This screen shows: PCA models 30, 35, 60, & 65 O2 4.0 C2 9.5 TA 68.0 EF 82.6 CO 12 NX 10 TS 374 EA 21 HLD NG P «S - OR - O2 4.0 CF 15 HLD O2 ............... Oxygen content in flue gas (%) C2 9.5 NF 12 NG C2 ............... Carbon Dioxide content TA 68.0 TS 374 P present in flue gas (%) EF 82.6 EA 21 « S TA ............... Primary/Ambient air temp. (°F) EF ..
PCA Operation 4.8 Fuel Selection Screen «NATGAS FUEL OIL #2 KEROSENE OIL #4 PROPANE OIL #6 COAL This screen is displayed by pressing the MENU key from the Combustion Test Screen, and is used to select the fuel being burned. To select a fuel, first use the st keys to move the cursor (z) in front of the desired fuel, and then press the ENTER key. NOTE: The fuel selected is saved as the default, and remains in memory after the PCA is turned off.
Operation PCA 4.9 Draft Screens (For PCA Models 15, 25, 35, 45, 55 & 65) The first Draft Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. To measure draft, first zero the analyzer’s pressure sensor to atmospheric pressure by disconnecting the draft hose from the bottom of the instrument, and then pressing the ENTER key. Reconnect the draft hose after the second Draft Screen appears (shown for 3 seconds).
PCA Operation 4.10 Memory Directory Screen ‘Standard’ PCA Screen MEMORY DIRECTORY «M8 2/24/01 3:45pm M9 MEMORY EMPTY CLEAR MEMORY ‘Advanced’ PCA Screen MEMORY DIRECTORY «98 2/24/01 3:45pm 99 MEMORY EMPTY CLEAR MEMORY The Memory Directory Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. This screen is used to select a memory location which contains saved data that an operator can review.
Operation PCA 4.11 Memory to PC Screen (For ‘Advanced’ PCA Models 40, 45, 50, 55, 60 & 65) MEMORY TO PC «TRANSMIT DATA CLEAR MEMORY The Memory To PC Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to either transmit all stored memory locations to a computer, or clear all memory locations.
PCA Operation Data is transmitted to a computer in ASCII comma-delimited format, which can be captured as a text file and then opened in most commercially available spreadsheet programs. Note that each data record consists of 20 fields, some of which may be blank for different tests and PCA models as listed in Tables 4-1 & 4-2. Use the communication software to capture and save the received data as an ASCII text file.
Operation PCA TABLE 4-1. COMMA-DELIMITED FIELDS Field Data Name or Value 1 2 3 4 5 6 71 81 91 101 111 121 131,2 141,2 151,3 161,3 171,2 181 191 20 21 Instrument serial number ID line 1 (up to 16 characters) ID line 2 (up to 16 characters) ID line 3 (up to 16 characters) Time of test (hh:mm:ss) Date of test (dd.mm.
PCA Operation 4.12 ID Setup Screens (For ‘Advanced’ PCA Models 40, 45, 50, 55, 60 & 65) SETUP «ID #1 ID #2 ID #3 This initial ID Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to edit three lines of customer information (e.g., the customer’s name, location, and burner reference number). Each ID line can be up to 16 alphanumerical characters in length.
Operation PCA Press ENTER to save the selected character and advance to the next position. If you make a mistake, press ENTER until the cursor is over the incorrect character and make your correction by again using the st keys. After all the desired characters have been selected, press the RUN key to save the text line and return to the initial ID SETUP Screen. NOTE: The entered ID information will be saved with all future test records until it is modified or deleted.
PCA Operation 4.13 Temperature Setup Screen SETUP TEMPERATURE UNIT «°C °F The Temperature Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to setup the analyzer to display temperature in either °C or °F. To select the temperature unit-of-measure, first use the st keys to move the cursor (z) in front of °C or °F, and then press the ENTER key.
Operation PCA 4.14 Draft Unit Setup Screen (For PCA Models 15, 25, 35, 45, 55 & 65) DRAFT UNIT SETUP MB PA «WC The Draft Unit Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to setup the analyzer to display draft in either millibars (MB), Pascals (PA), or inchesof-water column (WC). To select the draft unit-of-measure, first use the st keys to move the cursor (z) in front of MB, PA or WC, and then press the ENTER key.
PCA Operation 4.15 O2 Reference Setup Screen (For ‘Advanced’ PCA Models 50, 55, 60 and 65) SETUP O2 REFERENCE 0% The O2 Reference SETUP Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to select the O2 reference level that the analyzer will use to calculate the CO and NX gas levels as referenced to Oxygen. NOTE: The O2 reference level for ‘standard’ PCA models 20, 25, 30 and 35 is preset to 0% O2 and cannot be changed.
Operation PCA 4.16 Language Setup Screen LANGUAGE SETUP «ENG ESP FRA The Language Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to select the language displayed on the analyzer. The languages available for selection include English (ENG), Spanish (ESP), and French (FRA). To select a language, first use the st keys to move the cursor (z) in front of ENG, ESPor FRA, and then press the ENTER key.
PCA Operation 4.17 Display Mode Setup Screen (For PCA Models 30, 35, 60 & 65) DISPLAY SETUP «CO NX CF NF The Display Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to select whether the Combustion Test Screen will display the measured values of Carbon Monoxide and Nitric Oxide (CO and NX), or the calculated values of these gases (CF and NF) referenced to Oxygen.
Operation PCA 4.18 Time / Date Setup Screen «TIME DATE SETUP 03:12:45 pm 02/24/01 The Time/Date Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to enter the current time and date as follows: Use the st keys to move the cursor (z) in front of the TIME or DATE field to be changed, and then press the ENTER key to move the cursor inside the selected field.
PCA Operation 4.19 Printer Setup Screen SETUP «IR - HP PRINTER IR - IRDA RS232 The Printer Setup Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. Use this screen to choose the type of connection and printer being used.
Operation PCA 4.20 Calibration / Maintenance Password Screen PCA models 10 thru 35 PCA models 40 thru 65 CALIBRATION «PASSWORD XXX MAINTENANCE «PASSWORD XXX Where: xxx = Password number The Calibration / Maintenance Password Screen is displayed by repeatedly pressing the MENU key from the Combustion Test Screen. From here a three-digit password must be entered to access the PCA 10 thru 35’s Calibration Menu Screen (Section 5.3), or a PCA 40 thru 65’s Maintenance Screen (Section 4.21).
PCA Operation 4.21 Maintenance Screen (For PCA Models 40, 45, 50, 55, 60 & 65) MAINTENANCE «CALIBRATION USER NAME The Maintenance Screen is displayed after entering the correct password in the Maintenance Password Screen. Use this screen to either enter the analyzer’s Calibration Menu Screen or User Name Screen. To enter the Calibration Menu Screen (Section 5.3), use the st keys to position the cursor (z) in front of CALIBRATION, and then press the ENTER key. To enter the User Name Screen (Section 4.
Operation PCA 4.22 User Name Screens (For PCA Models 40, 45, 50, 55, 60 & 65) USER NAME «LINE 1 LINE 2 LINE 3 This initial User Name Screen is displayed after selecting USER NAME from the Maintenance Screen. Use this screen to either enter or edit three lines of user-name information. Each user-name line can be up to 20 alphanumerical characters in length. All three lines will appear at the top of each printout for the purpose of identifying the user or owner of the instrument (i.e.
PCA Operation Press ENTER to save the selected character and advance to the next position. If you make a mistake, press ENTER until the cursor is over the wrong character and make your correction by again using the st keys. After all the desired characters have been selected, press RUN to save the text line and return to the initial User Name Screen.
Operation PCA 4.24 Printing Test Data O2 4.0 CO 12 HLD C2 9.5 NX 15 NG TA 68.0 TS 374 «P EF 82.6 EA 21 S DRAFT DRAFT – 0.25 WC HOT SPOT 374 °F «P S Before printing, ensure that the correct connection and printer has been selected per Section 4.19. The Print function is available in either the Combustion Test Screen or the Draft Screen. NOTE: The data which is stored in memory can also be printed. First go to the Memory Directory Screen (Section 4.
PCA Operation When using a serial printer: 1. First connect the analyzer to the printer using the optional RS-232 cable (see Figure 4-6). 2. Set the printer’s communication parameters to 9600 baud, 8 data bits, 1 stop bit, no parity, and no handshaking. 3. Use the st keys to move the cursor (z) in front of the print (P) function. 4. Press the ENTER key to start printing. " "$ " ! " " # & "$ ' %$ ( )* Figure 4-6.
Operation PCA 4.25 Clear Memory Screen CLEAR MEMORY C «E The Clear Memory Screen is accessed from either the Memory Directory Screen (Section 4.10) or the Memory to PC Screen (Section 4.11). To clear all memory locations, use the st keys to move the cursor (z) in front of the clear (C) function, and then press the ENTER key. To return to the previous screen without clearing memory, place the cursor (z) in front of the exit (E) function and press ENTER. 4.
PCA Calibration 5.0 CALIBRATION NOTE: Bacharach recommends that the PCA be calibrated by your nearest Bacharach Service Center. Calibration, however, can be performed in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in the sections that follow. Important! To prevent the loss of data during calibration, perform the following procedures using fresh batteries, or using an optional Power Supply (see Section 3.2).
Calibration PCA 5.2 Calibration Fixtures A gas and a draft fixture will be required to perform the various calibration procedures described in this manual. Material Required: • Calibration Kit (Refer to Section 8.2) • Calibration Gas Cylinder (Refer to Section 8.2) • Bellows • Micromanometer Procedure: Assemble the appropriate fixture shown in Figure 5-1 as required by the calibration procedure being performed. GAS FIXTURE Leave Top Port Open 2 3 4 3 5 1 3 Parts Shown: 6 1. Gas Cylinder 2.
PCA Calibration 5.3 Calibrate Menu Screen «TS-ZERO TS-SPAN TA-ZERO TA-SPAN CALIBRATE NX CO DRAFT The Calibrate Menu Screen is displayed after entering either the correct password in the Calibration Password Screen for ‘standard’ PCAs, or the Maintenance Password Screen and selecting CALIBRATION from the Maintenance Screen for ‘advanced’ PCAs (refer to Sections 4.19 and 4.20). Use this screen to select the sensor to be calibrated.
Calibration PCA 5.4 Calibrate TS-Zero Material Required: • Thermocouple Simulator (K-type) Range: 0 to 600 °F Accuracy: ±0.5 °F Procedure: 1. With the analyzer turned off, first plug the simulator’s K-type connector into the T-STACK jack (Figure 3-2); then turn on the analyzer and wait for its warm-up cycle to complete. 2. Enter the Calibration Menu Screen per Section 5.3; then choose TS-ZERO to zero the analyzer’s stack temperature channel. 3. Adjust the simulator to 32 °F (0 °C).* 4.
PCA Calibration 5.5 Calibrate TS-Span Material Required: • Thermocouple Simulator (K-type) Range: 0 to 600 °F Accuracy: ±0.5 °F Procedure: 1. With the analyzer turned off, first plug the simulator’s K-type connector into the T-STACK jack (Figure 3-2); then turn on the analyzer and wait for its warm-up cycle to complete. 2. Enter the Calibration Menu Screen per Section 5.3; then choose TS-SPAN to span the analyzer’s stack temperature channel. 3. Set the simulator to 575 °F (302 °C).* 4.
Calibration PCA 5.6 Calibrate TA-Zero Material Required: • Thermocouple Simulator (K-type) Range: 0 to 600 °F Accuracy: ±0.5 °F Procedure: 1. With the analyzer turned off, first plug the simulator’s K-type connector into the T-AIR jack (Figure 3-2); then turn on the analyzer and wait for its warm-up cycle to complete. 2. Enter the Calibration Menu Screen per Section 5.3; then choose TA-ZERO to zero the analyzer’s room-air/primary-air temperature channel. 3. Set the simulator to 32 °F (0 °C).* 4.
PCA Calibration 5.7 Calibrate TA-Span Material Required: • Thermocouple Simulator (K-type) Range: 0 to 600 °F Accuracy: ±0.5 °F Procedure: 1. With the analyzer turned off, first plug the simulator’s K-type connector into the T-AIR jack (Figure 3-2); then turn on the analyzer and wait for its warm-up cycle to complete. 2. Enter the Calibration Menu Screen per Section 5.3; then choose TA-SPAN to span the analyzer’s room-air/primary-air temperature channel. 3. Set the simulator to 212 °F (100 °C).* 4.
Calibration PCA 5.8 Calibrate NX (For PCA Models 30, 35, 60 & 65) The Nitric Oxide sensor needs to be spanned at regular intervals to determine if the analyzer still meets its accuracy specification. Because of the toxicity of Nitric Oxide gas, however, unless your facility has the necessary gas cylinders and personnel trained in the handling of toxic gases, we recommend that the Nitric Oxide sensor be spanned by an authorized Bacharach Service Center.
PCA Calibration 5.9 Calibrate CO (For PCA Models 20, 25, 30, 35, 50, 55, 60 & 65) Material Required: • Calibration Gas Fixture (Section 5.2) • Gas Cylinder, 500 ppm CO in air (Refer to Section 8.2) • Gas Cylinder, CO (1000 ppm) and H2 (1000 ppm) in Nitrogen (Refer to Section 8.2) Procedure: 1. Enter the Calibrate Menu Screen per Section 5.3. Then choose to calibrate the CO sensor. 2. At the conclusion of Step 1 the pump should start running. 3.
Calibration PCA 7. Turn off the flow of CO calibration-gas; then remove the calibrationgas cylinder from the calibration fixture. 8. Attach a CO/H2 calibration-gas cylinder to the calibration fixture; then adjust the regulator of the calibration fixture for a flowmeter reading of approximately 2 SCFH. 9. Use the st and ENTER keys to enter a CO-VALUE that is the same as the CO concentration which is stamped on the CO/H2 calibration-gas cylinder.
Calibration PCA 5.10 Calibrate Draft (For PCA Models 15, 25, 35, 45, 55 & 65) Material Required: • Calibration Fixture (Section 5-2) • Bellows (adjustable) • Micromanometer Range: ±8 in. H2O column (±20 mb) Accuracy: ±0.01 in. H2O column (±0.025 mb) Procedure: Important! In Step 1, do not connect the draft calibration fixture to the analyzer until the Calibrate Draft Screen has been selected and displayed. 1. Enter the Calibrate Menu Screen per Section 5.3. Then choose to calibrate the draft sensor. 2.
Calibration PCA NOTES: 5-12 Instruction 0024-9219
PCA Maintenance 6.0 MAINTENANCE 6.1 Routine Maintenance Routine maintenance of the analyzer consists of: replacing the batteries, cleaning the probe, draining the water trap, replacing the water trap filter, and performing periodic calibration checks to ensure that the analyzer is providing accurate readings. • Replace the Batteries per Section 3.2 • Clean the Probe per Section 6.3 • Maintain the Water Trap/Filter Assembly per Section 6.4 • Replace the Particulate Filter per Section 6.
Maintenance PCA 6.2 Disassembly Perform the following when a maintenance procedure calls for removing the case, printed circuit board, pump, or sensors: 1. Remove the batteries (Section 3.2.1) 2. Place the analyzer face down on a work surface, then remove the unit’s four rear-case screws. 3. Carefully lift the rear case from the analyzer, unplug the battery compartment wires, then place the rear housing on a work surface (see Figures 6-1 & 6-2). 112 3 4 2 Figure 6-1.
PCA Maintenance BIAS BATTERY CO PCB TO BATTERY COMPARTMENT FUSE NX PCB CARBON MONOXIDE SENSOR (OPTIONAL) NITRIC OXIDE SENSOR (OPTIONAL) PUMP MTG. SCREWS OXYGEN SENSOR – + PUMP RED BLACK PARTICULATE FILTER DRAFT SENSOR (OPTIONAL) Figure 6-2.
Maintenance PCA 6.3 Cleaning the Probe The Probe Tube and the Probe Body will become dirty under normal use (the water trap’s filter element should prevent soot from reaching the analyzer’s internal components). If the probe assembly is not kept clean, it could become clogged and restrict the flow of gas to the analyzer, resulting in incorrect readings and calculations.
PCA Maintenance 6.4 Water Trap/Filter Assembly Maintenance The Water Trap / Filter Assembly removes water condensate from the gas sample, and also prevents soot from contaminating the internal components of the analyzer. Drain the water condensate after every use. Procedure: 1. Pull off the end-cap from the Inlet End of the Water Trap / Filter Assembly (Figure 6-3). 2. Pour out all of the water condensate, and replace the end-cap. Replace the filter element when it becomes excessively dirty.
Maintenance PCA 6.5 Replacing the Particulate Filter The internal particulate filter (Figure 6-2) prevents small dust and dirt particles from entering and damaging the pump. Depending on your environmental conditions, it is recommended to change the particulate filter and fitting approximately every six months, or sooner if it becomes clogged. Equipment Required: • Particulate Filter and Fitting (Refer to Section 8.1) Procedure: 1. Remove the analyzer’s rear case and lay it aside (refer to Section 6.2).
Maintenance PCA 6.6 Replacing the Oxygen Sensor Replace the Oxygen Sensor when it has expired (when the analyzer’s automatic O2 calibration fails and the unit displays the message “O2Sensor Error”). NOTE: A "O2-SENSOR ERROR" displayed in the Sensor Status Screen does not necessarily mean that the sensor has expired. Before replacing the sensor, refer to Section 7.2 for other possible causes of the error. Equipment Required: • 1/8" Flat Blade Screw Driver • Oxygen Sensor (Refer to Section 8.
Maintenance PCA 6.7 Replacing the Nitric Oxide Sensor (For PCA Models 30, 35, 60 & 65) Replace the Nitric Oxide sensor when it has expired (can no longer be calibrated). NOTE: A "NX-SENSOR ERROR" displayed in the Sensor Status Screen does not necessarily mean that the sensor has expired. Before replacing the sensor, refer to Section 7.2 for other possible causes of the error. Equipment Required: • 1/8" Flat Blade Screw Driver • Nitric Oxide Sensor (Refer to Section 8.
Maintenance PCA 6.7.2 Replacing the Nitric Oxide Sensor Bias Battery A single lithium battery, located on the Nitric Oxide printed circuit board (see Figure 6-2), applies a constant bias voltage to the Nitric Oxide sensor even while the instrument 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 expected life. Equipment Required: • Bias Battery (See Section 8.1) Procedure: 1.
PCA Maintenance 6.8 Replacing the Carbon Monoxide Sensor (For PCA Models 20, 25, 30, 35, 50, 55, 60 & 65) Replace the Carbon Monoxide sensor when it has expired (can no longer be calibrated). NOTE: A "CO-SENSOR ERROR" displayed in the Sensor Status Screen does not necessarily mean that the sensor has expired. Before replacing the sensor, refer to Section 7.2 for other possible causes of the error. Equipment Required: • 1/8" Flat Blade Screw Driver • Carbon Monoxide Sensor (Refer to Section 8.
PCA Maintenance 6.8.1 Replacing the Carbon Monoxide Sensor Filter To increase the life of the Carbon Monoxide sensor, it is recommended its red filter be replaced once a year . Procedure: 1. Remove the Carbon Monoxide sensor per Section 6.8. 2. Pry the red filter from the Carbon Monoxide sensor and replace it with a new one. 3. Reinstall the sensor.
Maintenance PCA 6.9 Replacing the Pump Assembly Replace the Pump Assembly if it is found to be defective. Equipment Required: • 1/8" Flat Blade Screw Driver • No. 1 Phillips Screw Driver • Pump Assembly (Refer to Section 8.1) Procedure: 1. Remove the analyzer’s rear case and lay it aside (refer to Section 6.2). 2. Remove the two self tapping Phillips screws holding the Pump Assembly (See Figure 6-2). 3.
PCA Troubleshooting 7.0 TROUBLESHOOTING 7.1 Analyzer Repair It is recommended that field repair of the PCA be limited to: • Simple checks of the printed circuit boards • Replacing the Probe Assembly • Replacing the filter element in the Water Trap / Filter Assembly • Replacing the Particulate Filter • Replacing the Pump Assembly • Replacing Sensors and Sensor Filters • Replacing Batteries All other repairs should be performed by an authorized Bacharach Service Center.
Troubleshooting PCA 7.2 Error Codes If one of the following messages or symbols is displayed, refer to Section 7.3 Troubleshooting Guide for information on how to correct the error. O2 - SENSOR ERROR O2 Sensor not connected, or is expired, or was exposed to combustion gases during warmup. CO - SENSOR ERROR Carbon Monoxide sensor is expired, or was exposed to Carbon Monoxide during warmup.
PCA Troubleshooting 7.3 Troubleshooting Guide The following table lists the most common analyzer faults, causes and remedies. For help with any problem not discussed here, please contact the nearest Bacharach Service Center per Section 8.3. TABLE 7-1. TROUBLESHOOTING GUIDE Fault Probable Cause & Remedy Analyzer completely nonfunctional; won’t turn on when the ON/ OFF key is pressed. a. Batteries dead. Replace batteries per Section 3.2. b. Loose battery connector.
Troubleshooting PCA TABLE 7-1. TROUBLESHOOTING GUIDE (Cont.) Fault NX-SENSOR ERROR code appears in the Sensor Status Screen. Probable Cause & Remedy a. Calibration was attempted while sampling combustion gases. b. Nitric Oxide sensor is expired. Replace sensor per Section 6.7. c. Bias battery on the Nitric Oxide circuit board is dead. Replace battery per Section 6.7.2. CO-SENSOR ERROR code appears in the Sensor Status Screen. a. Calibration was attempted while sampling combustion gases. b.
PCA Troubleshooting TABLE 7-1. TROUBLESHOOTING GUIDE (Cont.) Fault “****” appears in one or more value fields. Probable Cause & Remedy The field’s associated sensor is not installed. “- - - -” appears in one or more value a. The analyzer is not able to calcufields of the Combustion Test late a numerical value based on measured combustion data. The Screen. “- - - -” is replaced with numerical values when the analyzer begins to detect valid combustion data. “XXXX” appears in one or more value fields.
Troubleshooting PCA TABLE 7-1. TROUBLESHOOTING GUIDE (Cont.) Fault Probable Cause & Remedy Backlight will not turn on. Backlight LED burned out. Return to Bacharach for repair. Batteries do not last 10 hours. Cold temperature is reducing battery capacity. To obtain longer operating time, keep analyzer warm. Erratic Combustion Test Screen values. a. Faulty sensor(s): - Check that the sensors are properly installed per Sections 6.6 through 6.8. - Check sensor calibration per Section 5.0.
PCA Parts & Service 8.0 PARTS & SERVICE 8.1 Replacement Parts Item Description Part No. (Figure 8-1) 1 2 3 Battery Cover Screw, Case Housing Screw, Pump Mounting 0024-0784 0501-3824 0501-3822 8 9 10 11 12 13 14 15 16 17 18 19 Oxygen Sensor Carbon Monoxide Sensor Nitric Oxide Sensor Carbon Monoxide Sensor Filter Nitric Oxide Sensor Filter Pump Assembly Fuse, 1.
Parts & Service PCA 8.2 Accessories Description Part No. STANDARD ACCESSORIES: Battery, “AA” Alkaline Complete Probe and Hose Assembly (Gas & Draft) Instruction Manual Plastic Carrying Case 0204-0004 0024-3004 0024-9219 0024-1078 OPTIONAL ACCESSORIES: Ambient Thermocouple, 10 ft. K-type Ambient Thermocouple, 1 in.
PCA Parts & Service Figure 8-1.
Parts & Service PCA FUSE 14 15 9 10 11 12 8 – + 13 RED BLACK 16 17 18 19 Figure 8-1.
PCA Parts & Service / ! ( * Figure 8-1.
Parts & Service PCA 8.3 Service Centers United States Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Email: help@bacharach-inc.com Canada Bacharach of Canada, Inc. 20 Amber St. Unit #7 Markham, Ontario L3R SP4 Canada Phone: 905-470-8985 Fax: 905-470-8963 Email: bachcan@idirect.
Appendix A PCA APPENDIX A Display Screen Translations English French Spanish BACHARACH, INC. PCA nn ECHAUFFEMENT nn BACHARACH, INC. PCA nn CALENTAMIENTO nn Warm Up Screen BACHARACH, INC. PCA nn Warmup nn Sensor Status Screen (Errors) NO ERRORS DETECTED LOW BATTERY O2-SENSOR ERROR CO-SENSOR ERROR DRAFT-SENSOR ERROR T-STACK SENSOR ERROR T-AIR SENSOR ERROR NX-SENSOR ERROR PAS D D'ERREUR RELEVEE BATTERIE FAIBLE ERREUR CELLULE O2 ERREUR CELLULE CO ERREUR CELLULE PRESS ERR. CELLULE T. CHEMI. ERR.
Appendix A English PCA French Spanish GARDE LOCATION MEMOIRE nn SALVANDO EN MEMORIA LOCALIZACION nn Saving Memory Screen SAVING MEMORY LOCATION nn Memory Directory Screen MEMORY DIRECTORY MEMORY EMPTY CLEAR MEMORY LISTE MEMOIRE MEMOIRE VIDE EFFACER MEMOIRE DIRECTORIO MEM MEMORIA VACIA BORRAR MEMORIA PRESSION MEM PRESSION MEMORIA DRAFT DRAFT EFFACER MEMOIRE BORRAR MEMORIA MEMOROIRE A PC TRANSM.
PCA English Appendix A French Spanish PROGRAMME HEURE DATE SETUP HORA FECHA PROGRAMME PRINTER IR - HP IR - IRDA RS232 SETUP PRINTER IR - HP IR - IRDA RS232 Time/Date Setup Screen SETUP TIME DATE Printer Setup Screen SETUP PRINTER IR - HP IR - IRDA RS232 Maintenance Password Screen MAINTENANCE PASSWORD MAINTENANCE MOT DE PASSE MANTENIMIENTO PASSWORD MAINTENANCE CALIBRAGE USER NAME MANTENIMIENTO CALIBRACION NOMBRE DEL USUARIO CALBRAGE TS-ZERO TS-PTEE TA-ZERO TA-PTEE NX CO PRESSION CALIBRAR TS
Appendix A English PCA French Spanish Calibrate TA-Span Screen CALIBRATE TA-SPAN MEASURED APPLIED BAD CALIBRATION ENTRY CALIBRER TA PORTEE MESUREE APPLIQUEE ERREUR D'ETALONNAGE CALIBRAR TA-SPAN MEDIDO APLICADO CALIBRACION-INCORRECTA CALIBRER NX MESUREE APPLIQUEE ERREUR D'ETALONNAGE CALIBRAR NX MEDIDO APLICADO CALIBRACION-INCORRECTA CALIBRER CO MESUREE APPLIQUEE ERREUR D'ETALONNAGE CALIBRAR CO MEDIDO APLICADO CALIBRACION-INCORRECTA GAZ TEST CO/H2 VALEUR CO ENTRER VALEUR CO ERREUR D'ETALONNAGE GA
PCA Appendix B APPENDIX B – Printout Translations English French Spanish Combustion Test Data [Line 1: user name] [Line 2: user name] [Line 3: user name] BACHARACH, INC. PCA 65 SN: xxxxxx ==================== ID1: [optional data] ID2: [optional data] ID3: [optional data] TIME DATE 04:27:35 pm 02/24/1999 FUEL NATGAS STACK-TEMP AMB.-TMP O2 CO2 CO CO( 0% O2) NX NX( 0% O2) EFFICIENCY AIR DRAFT [Line 1: user name] [Line 2: user name] [Line 3: user name] BACHARACH, INC.
Appendix B PCA NOTES: B-2 Instruction 0024-9219
World Headquarters 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 Website: www.mybacharach.com • E-mail: help@mybacharach.com Printed in U.S.A.
