Portable Combustion Analyzer Instruction 0024-9472 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.
Contents 1.0 Introduction ..................................................................................... 6 1.1 About This Manual ................................................................ 6 1.1.1 General Warnings and Cautions ........................... 6 1.2 PCA®3 General Description ................................................... 7 1.3 Sales Combo & Model Configurations .................................. 8 1.4 Features & Benefits ...........................................................
Operation ......................................................................................... 42 4.1 Operating Tips ..................................................................... 42 4.2 Turning ON the Analyzer and Warm Up ........................... 43 4.3 Sampling Point ..................................................................... 44 4.4 Performing a Combustion Test ........................................... 45 4.5 Pressure Label Selection ...........................................
6 Maintenance ...................................................................................... 85 6.1 PCA®3 Disassembly ............................................................. 86 6.2 Water Trap / Filter Maintenance ........................................ 90 6.2.1 Emptying the Water Trap Chamber ................... 90 6.2.2 Replacing the Filter Element .............................. 90 6.3 Sensor Replacement ............................................................. 91 6.
PCA®3 1.0 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, which provides important information on the operation and maintenance of the analyzer. Warning Statements The use of the word WARNING (and the symbol at left) in this manual denotes a potential hazard associated with the use of this equipment.
PCA®3 1.2 PCA®3 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.
PCA®3 1.
PCA®3 Sales Combo 0024-8443 0024-8444 0024-8445 0024-8446 Sales Combo (Kit) 0024-8450 0024-8451 0024-8452 0024-8453 Model Type PCA 3 Only Part Number ® 255 265 275 285 0024-7323 0024-7324 0024-7325 0024-7326 Measurements Oxygen (O2) • • • • Stack Temperature • • • • Primary/Ambient Air Temperature • • • • Carbon Monoxide Low (COLow) • • • • Pressure/Draft • • • • Carbon Monoxide High (COHigh) • Nitric Oxide (NO) • Nitrogen Dioxide (NO2) • Sulfur Dioxide (SO2) • •
PCA®3 1.4 Features & Benefits 10 • 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.
PCA®3 1.5 Operational Overview The PCA®3 is powered by either its four internal batteries or by an optional AC power adapter that operates from any convenient source of 100–240 VAC, 50/60 Hz power. The type of batteries used can be either disposable alkaline or rechargeable NiMH. The PCA®3 is controlled by 11 front panel push buttons, while a color graphic LCD (with automatic dimming feature) is used to display all combustion and emission test data and analyzer parameters.
PCA®3 During a test, the COLow sensor is protected from high CO levels by being automatically flushed with fresh air when the detected CO level exceeds 4,000 ppm. The analyzer will automatically start using its optional COHigh sensor, if installed, at CO levels starting at 4,001 ppm, thus providing continuous CO readings up to 20,000 ppm. 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.
PCA®3 IrDA – Wireless printer communications port Color LCD F1 / F2 / F3 – Soft Menu Buttons, whose functions are defined by labels appearing above them on LCD ENT - Selects a highlighted menu item, or confirms the entry of data USB – Computer communications connector RUN / HOLD: • Starts and stops a combustion efficiency test Arrow Buttons: • Pressing this button during the 5 second turn-off period will keep the analyzer turned ON – Moves cursor up the display, or increments an alphanumerical value
PCA®3 1.6.2 T-AIR (Primary Air Thermocouple) If thermocouple P/N 0104-1797 (10 feet long) or Utility Wand P/N 0104-1799 (12-inch ridged probe with handle and 5 foot coiled cable) is to be used to measure the burner’s primary air temperature, then connect either of these thermocouples to the analyzer’s T-AIR connector. 1.6.3 POWER (AC Adapter) The AC power adapter P/N 0024-1254 can be used as an external power supply, which will run the analyzer on a continuous basis. 1.6.
PCA®3 1.7 Front Panel Buttons Descriptions of the front panel buttons are given below. Note that a control may perform multiple functions as determined by what screen is being displayed at the time. The functions of these 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. PRINT (F1): Transmits the data displayed on the screen to a printer through the IrDA communications port.
PCA®3 Selects a highlighted item. In addition, if changes were made to one of the analyzer’s operating parameters (e.g., date, time, O2 reference, etc.), pressing this button confirms those changes and saves them in memory. Starts and stops a combustion test when the Combustion Test screen is displayed. Pressing this button in any other screen returns the analyzer to the Combustion Test HOLD screen.
PCA®3 2.0 Specifications The PCA®3 Directly Measures and Displays: The gases displayed depend on the sensors installed in the analyzer. Refer to Section 1.3. Oxygen ......................................................................................... 0.1 to 20.9% Stack Temperature ........................................-4 to 2,192 °F (-20 to 1,200 °C) Primary/Ambient Air Temperature ....................-4 to 999 °F (-20 to 537 °C) Carbon Monoxide (CO) (H2 compensated) .............................
PCA®3 Normal Operating Conditions: Temperature: Analyzer 32 to 104 °F (0 to 40 °C) Probe Tip 1,472 °F (800 °C) 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: 18 O2 ±0.3% O2 on practical concentrations of stack gas (mix of O2, CO2, and N2) CO ±5% of reading or ±10 ppm, whichever is greater between 0-2,000 ppm, and ±10% of reading between 2,001-20,000 ppm.
PCA®3 Power Requirements: Four disposable ‘AA’ alkaline batteries provide a minimum of 10 hours of continuous operation. NiMH rechargeable batteries can also be used, with the operating time dependent on battery type and condition. An optional AC power adaper, which runs from any convenient source of 100-240 VAC, 50/60 Hz power, can be used to power the analyzer on a continuous basis. Warm-Up Time: Warm-up time is 60 seconds. Sensors are checked and auto zeroed during warm-up.
PCA®3 3.0 Initial Setup 3.1 Scope Before using the PCA®3, you MUST: • Install batteries, or plug in the optional AC power adapter (Section 3.2) • Connect the probe and hose assembly (Section 3.3) • Check, and if necessary, make changes to the analyzer’s configuration (Section 3.4) 3.2 Power 3.2.1 Installing or Replacing Batteries Either alkaline or NiMH rechargeable batteries can be used to power the analyzer. Install or replace the batteries as described below: 1.
PCA®3 3.2.2 Using the AC Power Adapter The AC power adapter is capable of powering the analyzer on a continuous basis. The adapter plugs into an appropriate 100-240 VAC, 50/60 Hz wall outlet, and produces an output of +6 VDC. The adapter’s output connector plugs into the analyzer’s POWER jack located on the botton of the unit (Figure 3-2). 3.3 Connecting the Probe & Hose Assembly To attach the probe and hose assembly to the analyzer (Figure 3-2): 1.
PCA®3 Option Connector (Optional External Measurement) POWER AC Power Adapter Jack (POWER) T-STACK Primary / Ambient Air Thermocouple (T-AIR) (Optional) T-AIR GAS P Differential Pressure Hose (— ∆P) (Optional) Stack Gas Thermocouple Connector (T-STACK) Draft Hose (+ ∆P) Gas Sample Hose (GAS) Probe Tube Probe Stop Water Trap / Filter Assembly Probe Handle Figure 3-2.
PCA®3 3.4 Operating Parameters The PCA®3 is set up at the factory for the following operating parameters: Fuel .......................................Natural Gas Temperature Units ..............°F Pressure Units .....................Inches of Water Column (inwc) Pollution Units .....................ppm Date.......................................Current MM/DD/YY Time ......................................Current EST HH:MM AM/PM O2 Reference .........................0% Print Pressure ......................
PCA®3 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. Consult factory for price and delivery. 3.
PCA®3 3.7 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. Use the ▲▼ buttons to highlight PRESSURE UNITS, and then press ENT to display the PRESSURE UNITS MENU. 4.
PCA®3 3.8 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. Select to display pollution units in parts per million (ppm), pounds of pollutant per million BTU (#/Mbtu), milligrams of pollutant per cubic meter of gas (mg/m3), or grams of pollutant per gigajoule (g/GJ) as follows: 1.
PCA®3 3.9 Date Setup The date is stored in the format: MM/DD/YY. Its value is part of the date and time stamp that is saved along with each combustion test record. Set the analyzer’s internal clock to the current date 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.
PCA®3 3.10 Time Setup The time is stored in the format: hh:mm:ss AM/PM. Its value is part of the date and time stamp that is save along with each combustion test record. Set the analyzer’s internal clock to the current time 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.
PCA®3 3.11 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.
PCA®3 3.12 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.
PCA®3 3.13 Zoom-Display Selection Combustion test data in the Run/Hold screen can be shown with enlarged characters to make viewing easier. The operator can set zoom levels to Standard, 2X, or 3X. The Standard zoom setting will display seven lines of combustion test data at one time, 2X which will display five lines of combustion test data with enlarged characters, and 3X which will display four lines of combustion test data with enlarged characters.
PCA®3 3.14 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 Section 4.14 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. 3.15 Button Sound The audible sound used to signal when a button is pressed can be turned OFF and ON as follows: 1.
PCA®3 3.16 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.
PCA®3 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. Select a Test ID: 1. From the Test ID menu, use the ▲▼ buttons to highlight SELECT TEST ID, and then press ENT to display the SELECT TEST ID menu, which displays the first line of each Test ID record. 2.
PCA®3 3.17 Username The name of the user or owner of the analyzer (e.g. company name, address, phone number) can be stored in memory by manually entering up to three lines of text, with each line containing up to 20 alphanumeric characters. This information will appear at the top of each printout until new information is entered or cleared. TIP: To save time Username Information can be entered using the Fyrite® User Software. Username Information can be entered as follows: 1.
PCA®3 8. Press ESC to go to the Main Menu or the RUN/HOLD key to return to the Run/Hold screen. To Clear a Username proceed 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 USERNAME, and then press ENT to display all three lines of the EDIT USERNAME screen. Periods(.....) identify empty lines. 4.
PCA®3 3.18 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.
PCA®3 3.19 Cal Reminder Period The analyzer can be set to indicate a calibration reminder during the 60 second warm-up period. Calibration reminders can be preset to occur never, 6, 8, 10, 12, or 15 months after the last calibration. When the preset period is exceeded the instrument will display the reminder, and how long since the sensors were last calibrated. The reminder will be displayed at the end of the 60 second warm-up period.
PCA®3 3.20 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. Press the RUN/HOLD key again, the pump should stop running and the word HOLD should be shown at the upper-left hand corner of the display.
PCA®3 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. Use the ▲▼ buttons to highlight RUN/HOLD FORMAT, and then press ENT to display Run/Hold Format Menu. 4.
PCA®3 Reset Display format back to factory default settings 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 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.
PCA®3 4 Operation 4.1 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.
PCA®3 • When storing the analyzer, it’s a good idea to empty the water trap and leave it open to further dry it out. • Calibrate the analyzer every 6 months - 1 year to ensure its accuracy. 4.2 Turning ON the Analyzer and Warm Up Connect the probe and hose assembly, and make sure that the analyzer is properly set up per Section 3. IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer! 1. Place the probe in an area that contains fresh air.
PCA®3 4.3 Sampling Point O 2, CO, Stack Temp. FORCED AIR FURNACE: For atmospheric burner or gravity vented, forced air heating equipment with a clamshell or sectional heat exchanger design, test each of the exhaust ports at the top of the heat exchanger. The probe should be inserted back into each of the exhaust ports to obtain a flue-gas sample, before any dilution air is mixed in.
PCA®3 4.4 Performing a Combustion Test Ensure that the following has been completed, and then proceed with the combustion test as described below: • Turn ON analyzer and allow it to warm up (Section 4.2). • Select fuel being burned (Section 3.5). • Inset probe into stack (Section 4.3). • If necessary, insert optional primary air thermocouple into combustionair stream of burners that use an outside source of combustion air. 1. Press the RUN/HOLD button to start the test.
PCA®3 4. Pressing the RUN/HOLD button holds all readings, stops the pump and displays the Combustion-Test HOLD screen. Press the ▲▼ buttons to scroll through all test values. Pressing RUN/HOLD again restarts the pump and resumes testing.
PCA®3 4.5 Pressure Label Selection The pressure measurement can be labeled with types including, differential across heat exchanger, draft reading, and differential pressure. See Section 4.7 for pressure and draft measurement procedures. Label data 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 PRESSURE, and then press ENT to display the PRESSURE MENU. 3.
PCA®3 4.6 Temperature Label Selection & 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.
PCA®3 4.7 Making 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 (Section 4.2).
PCA®3 • To measure draft, simply insert the probe into the stack and observe the draft reading on the PRESSURE screen. • To measure differential pressure, connect two sampling hoses to the +∆P and –∆P ports, and place the open end of each hose into the areas being measured. The 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.
PCA®3 4.9 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%. 4.
PCA®3 4.11 Turning OFF the Analyzer & 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. If the PCA®3 was not purged with fresh air as described in Section 4.
PCA®3 The stored logged data can either be viewed on the display using the analyzer’s memory function (refer to Section 4.14), or downloaded to a personal computer using the supplied Fyrite® User Software and USB cable. Downloaded data is stored on the computer’s hard drive as a comma-separated-value ASCII text file with a CSV extension, which can be opened by most spreadsheet programs for analysis. 4.13.
PCA®3 4.13.2 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: TIP: If the duration is set for more than 10 hours, we recommend using the optional AC power adapter to power the analyzer. 1. As soon as logging is turned ON as described in Section 4.14.1, the LOGGING INTERVAL screen appears. 2.
PCA®3 4.13.3 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.
PCA®3 4.14 Memory There are two memory banks, each containing 500 memory locations. The first bank is used to store combustion test data as described in Section 4.8., while the second bank is used to store logged combustion test data as described in Section 4.13. Each bank is independent of each other, and cannot share data or be combined. Individual memory locations in each memory bank can be recalled for viewing on the display or printed (refer to Sections 4.15.1 & 4.15.
PCA®3 4.14.1 Recalling Combustion Test Data Recall individual combustion test data records as follows: 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2. 2. Use the ▲▼ buttons to highlight MEMORY, and then press ENT to display the MEMORY MENU. 3. Use the ▲▼ buttons to highlight MEMORY DIRECTORY, and then press ENT to display the MEMORY DIRECTORY screen. 4. Use the ▲▼ buttons to highlight the desired memory location to be recalled.
PCA®3 4.14.2 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. Use the ▲▼ buttons to highlight LOGGING DIRECTORY, and then press ENT to display the LOGGING DIRECTORY screen. 4. Use the ▲▼ buttons to highlight the desired data logging location to be recalled.
PCA®3 4.14.3 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. Each memory bank can be individually cleared, or all memory locations in both banks can be cleared simultaneously.
PCA®3 4.15 Downloading Stored Data to a Computer The combustion test data that was stored in either the analyzer’s Memory Directory (Section 4.8), or Logging Directory (Section 4.14), can be downloaded to a computer using the Fyrite® User Software and USB cable that are supplied with the analyzer. The following procedures assume that the operator is familiar with creating folders and navigating the file structure of the Windows operating system.
PCA®3 4.15.1 Fyrite® User Software Installation Windows XP: 1. Insert the Fyrite® User Software CD into the computer’s disc drive. 2. After the CD is loaded, the Setup window will be displayed. Click OK. If applicable, wait for the Net 3.5 Framework setup to complete. 3. Click “Next” on the “Welcome” screen to begin the installation. 4. Respond to the prompts on the screens that follow. 5. Click “Finish”... “Next”... “Close”... “OK” After the installation: 1.
PCA®3 4. Click “Next” “Continue anyway”... “Finish” Windows Vista: 1. Insert the Fyrite® User Software CD into the computer’s disc drive. 2. After the CD is loaded, the Security window will be displayed. Click on OK. If applicable, wait for the Net 3.5 Framework setup to complete. 3. Click “Continue”... “Next”... “Install”... “Install...
PCA®3 Click “Finish” “Next”... “Next”... “Next”... Click “Continue” “Close”... “OK” After the installation: 1. Open Fyrite® User Software via the desktop icon. 2. Connect instrument to the PC with USB cable (P/N 0104-4032). 3. Click “Next”.... “Next”... “Continue anyway”...
PCA®3 4.
PCA®3 Table 4-2 — Downloaded Data Fields Field 1 2 3-5 Column Name Data Name or Value Date Date of Test in mm/dd/yy 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) 9 ppm CO(O2) Carbon Monoxide Level referenced to a % of O2 (see field 25) 10 % Efficiency Combustion Efficiency 11 % CO2 Carbon Dioxide Level 12 %EA Excess Air 13 TStk Stack Temperature 14 TAir Primary/Am
PCA®3 4.18 Printing Test Data Combustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described below. Data that is stored in memory can also be printed by first displaying the stored test data as described in Sections 4.14.1 & 4.14.2. In addition to printing combustion and pressure data, the contents of any screen that shows the label “PRINT” above the F1 button can be printed. For example, the information shown in the DIAGNOSTIC screen can be printed.
PCA®3 BACHARACH, INC. PCA 3 SN: xxxxxx ===================== TIME 01:00:00 PM DATE 08/04/10 FUEL NATURAL GAS O2 CO EFF CO2 T-STACK T-AIR EA NO NO2 NOX SO2 CO(3) NO(3) NO2(3) NOX(3) SO2(3) 8 to 16 in. (20.32 to 40.64 cm) 4.0 12 82.6 9.5 374 68.0 21 18 6 24 13 19 6 25 % ppm % % °F °F % ppm ppm ppm ppm ppm ppm ppm ppm ppm PRESSURE –0.
PCA®3 5 Calibration IMPORTANT: Before performing any calibration procedure ensure that fresh 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. 5.1 B-Smart Sensors The PCA®3 uses Bacharach’s B-Smart® Sensor technology for COLow, COHigh, NO, NO2, and SO2.
PCA®3 5.2 Starting a Calibration Start any calibration procedure by doing the following: 1. Place the probe in an area of fresh air, turn ON the analyzer, allowing it to cycle through its 60 second warm-up period. During warm-up, the analyzer’s operation is checked and the sensors are set to the following ambient conditions: • Oxygen sensor spanned to 20.9% • All gas sensors are zeroed • The pressure sensor is zeroed 2.
PCA®3 5.3 B-Smart® Sensor Replacement & Calibration To replace a B-Smart® sensor and calibrate, do the following: 1. Enter the CALIBRATION MENU per Section 5.2. 2. Use the ▲▼ buttons to select B-SMART®. Press ENTER to display the B-Smart code screen 3. Use the ▲▼ buttons to enter the 10 or 14 digit alphanumeric code supplied with the B-Smart® sensor. Use the ◄► buttons to move the cursor across the screen. Press ENTER. NOTE: There are two B-Smart® sensor code lengths.
PCA®3 5.4 Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value. Material Required: • Bellows • Manometer • Range: ±8 in. of water column (±20 mb) • Accuracy: ±0.01 in. of water column (±0.025 mb) Procedure: NOTE: The unit-of-measure for pressure is selected per Section 3.7. In the following procedure inwc is selected, but note that any unit-of-measure can be used for calibration purposes. 1.
PCA®3 6. Use the ▲▼ and ◄► buttons to enter an Applied value that exactly equals the manometer reading. 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. 7.
PCA®3 5.5 T-Stack Calibration This procedure first zeros and then spans the stack-temperature channel to known temperature values. 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. Material Required: • Thermocouple Simulator (K-type) • Range: 0 to 600 °F • Accuracy: ±0.5 °F • (Alternatively) Ice-Water, Boiling Water, Thermometer TS-Zero Procedure: 1.
PCA®3 4. Set thermocouple simulator to 32 °F (0 °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 an ice-water bath with a thermometer, wait several minutes, and then use the ▲▼ and ◄► buttons to enter an Applied value that exactly equals the thermometer reading. The calibration range is from 32 to 41 °F (0 to 5 °C).
PCA®3 5.6 T-Air Calibration This procedure first zeros and then spans the ambient-temperature channel to known temperature values. 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. Material Required: • Thermocouple Simulator (K-type) • Range: 0 to 600 °F • Accuracy: ±0.5 °F • (Alternatively) Ice-Water, Boiling Water, Thermometer TA-Zero Procedure: 1.
PCA®3 4. Set thermocouple simulator to 32 °F (0 °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 an ice-water bath with a thermometer, wait several minutes, and then use the ▲▼ and ◄► buttons to enter an Applied value that exactly equals the thermometer reading. The calibration range is from 32 to 41 °F (0 to 5 °C).
PCA®3 5.7 COLow Sensor Calibration Note that the COLow sensor also measures H2 for the purpose of compensating the CO reading for the presence of H2 in the gas sample. This procedure first spans the COLow sensor and, optionally, spans the H2 part of the sensor to known gas levels. The user has the option to perform a CO only calibration or a CO/H2 calibration using the PCA®3 soft keys.
PCA®3 5. Adjust the regulator for a flowmeter 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. The message “Good Calibration” should briefly appear followed by the TEST GAS CO/H2 screen. If the sensor’s output is low, but still usable, then the message “Good Calibration WARNING Low Sensor” will appear.
PCA®3 If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life” will appear followed by the CALIBRATION LIST screen being re-displayed. The sensor will now be marked as being BAD in the DIAGNOSTICS screen. 10. Turn OFF the regulator and remove the gas cylinder. NOTE: A CO-only calibration can be done by pressing F3 in Step 5 (instead of ENT). 5.8 SO2 Sensor Calibration This procedure spans the optional sulfur dioxide sensor to a known gas level.
PCA®3 5. Adjust regulator for a flowmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximately 3 minutes), 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. If the sensor’s output is low, but still usable, then the message “Good Calibration WARNING Low Sensor” will appear.
PCA®3 The calibration range is from 9 to 900 ppm. An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. 5. Adjust regulator for a flowmeter 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.
PCA®3 5.10 NO2 Sensor Calibration This procedure spans the optional nitrogen dioxide sensor to a known gas level. Material Required: • Calibration Kit, P/N 0024-7059 • Gas Cylinder: 100 ppm NO2 in Nitrogen, P/N 0024-1157 Procedure: 1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2. 2. Use the ▲▼ buttons to highlight NO2, and then press ENT to display the CALIBRATE NO2 screen.
PCA®3 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. 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 followed by the CALIBRATION LIST screen being re-displayed. The sensor will now be marked as being BAD in the DIAGNOSTICS screen. 6. Turn OFF regulator and remove gas cylinder. 5.
PCA®3 5. Adjust regulator for a flowmeter 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. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed. If the sensor’s output is low, but still usable, then the message “Good Calibration WARNING Low Sensor” will appear.
PCA®3 6 Maintenance Customer maintenance of the PCA®3 is limited to the following: • Battery replacement (Section 3.2.1) • Sensor re-calibration (Section 5) • Water trap / filter assembly maintenance (Section 6.2) • Sensor replacement (Section 6.3) • Probe thermocouple replacement (Section 6.5) • Cleaning the probe (Section 6.6) All other maintenance should be performed by an authorized Bacharach Service Center. Refer to Section 8.3.
PCA®3 6.1 PCA®3 Disassembly The following procedure describes how to disassemble the analyzer, while Figures 6-1 thru 6-4 illustrate how the analyzer is put together. Tools Required: • Medium Phillips Screwdriver Procedure: 1. Unplug all thermocouples from bottom of analyzer. 2. Remove battery cover and then remove batteries.
PCA®3 Sensor Positions Model Position 225 235 245 255 265 275 #1 O2 O2 O2 O2 O2 O2 #2 COLow COLow COLow COLow COLow COLow SO2 NO2 SO2 NO COHigh NO NO #3 #4 Sensors Sensor Retainer Type and position determined by model number Purge Pump Motor Connector Gas Pump Motor Connector Battery & Pump Chassis Pressure Sensor on printed circuit board Battery Connector on printed circuit board ¨3 (Top) ±¨3 (Bottom) Gas Pump Purge Pump Purge Air In Hose Connector Plate GAS ¨3 ±¨
PCA®3 PRESSURE SENSOR on printed circuit board 287 ¨3 7RS ±¨3 %RWWRP PURGE PUMP ±¨3 PRESSURE IN 7R 6HQVRUV ¨3 PURGE AIR GAS GAS PUMP *DV 287 Gas IN Models 235 & 245 P/Ns 0024-7321 & 0024-7322 Model 225 P/N 0024-7320 Elbow Model 255 P/N 0024-7323 Elbow Models 265 & 275 P/Ns 0024-7324 & 24-7325 Elbow Elbow Figure 6-3.
PCA®3 Sensor Connector (typical 4 places) LCD Connector (opposite side of board) Purge Pump to J9 Gas Pump to J8 J9 J8 Battery to J14 J14 Wire Routing Connectors Solder (2 Places) Battery to J14 Red dot on pump indicates positive (red wire) connection Solder Connections Figure 6-4.
PCA®3 6.2 Water Trap / Filter Maintenance 6.2.1 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 per Figure 6-5. 2. Pour out liquid condensate, and then reassemble trap. 6.2.2 Replacing the Filter Element Replace the filter element when it becomes visibly dirty or becomes saturated with water.
PCA®3 6.3 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 Section 8.1 Replacement Parts for list of sensors and part numbers. 1. Turn OFF the analyzer. 2. Remove the battery cover. 3. Remove the sensor retainer. 4. Remove the tubing from the gas cup of sensor being replaced. 5. Unplug the sensor along with its printed circuit board from the analyzer’s main board. 6.
PCA®3 9. Attach the gas cup to new sensor, making sure that when the sensor assembly is plugged into the analyzer’s main board, the tubing connections on top of gas cup are aligned as shown in Figure 6-3. 10. Plug the sensor into analyzer; and then reattach tubing to gas cup. 11. Install the sensor retainer and battery cover. 12. Allow the sensor that was just installed time to stabilize in the circuit before continuing with this procedure.
PCA®3 4. Re-install the Smart Sensor assembly. 5. Before powering up and using the analyzer, allow the Nitric Oxide sensor to stabilize as described below. Note that recalibration of the Nitric Oxide sensor is not required after replacing its bias battery. Depending on how long the Nitric Oxide sensor was without bias voltage, the time required for the sensor to completely stabilize varies from less than a minute to several days. Typical stabilization times are shown below.
PCA®3 6.5 Thermocouple Replacement Using the appropriate thermocouple replacement kit listed below, replace the probe’s thermocouple as follows: Thermocouple Replacement Kits: Part Number Replaces Thermocouple in a Probe with a Tube Length of... 0024-8413 6 inches 0024-8414 12 inches 0024-8415 24 inches 0024-8416 36 inches Each Kit contains a thermocouple assembly, two O-rings, and two wire splice connectors.
PCA®3 3. Pull old thermocouple from probe body and discard. 4. The new thermocouple has been coiled for shipping purposes. Straighten the thermocouple using your thumb and index finger. 5. If not already done, install supplied O-Rings onto thermocouple. 6. Insert thermocouple into probe body until it “bottoms out.” 7. Strip 1/4 inch of insulation from each of the probe’s thermocouple connector wires. IMPORTANT: In Step 8, the thermocouple wires must first be twisted together and then crimped. 8.
PCA®3 6.6 Cleaning the Probe The probe tube and gas-sample hose will become dirty under normal use. Note that 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.
PCA®3 7 Troubleshooting 7.1 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 Information on how to perform these repairs is provided in Section 6. All other repairs should be performed by an authorized Bacharach Service Center (refer to Section 8.3).
PCA®3 7.3 Error Messages Displayed After Warm-Up If there were problems detected during warm-up, error messages that describe the nature of the problems are displayed immediately following the analyzer’s 60 second warm-up period. If problems were detected, the analyzer will not automatically switch to the Combustion Test HOLD screen after warm-up. The analyzer, however, can still be used to perform any test that does not depend on the sensor that is in error.
PCA®3 Stack or Air temperature channel is measuring temperature outside the range of -4 to 212 °F at startup. Make sure that the Stack and Air thermocouples are sampling ambient room air within the temperature range at startup. Message will indicate which channel(s) are in error. Pressure sensor is measuring pressure outside the range of +/ - 3 inches of water column at startup. Ensure that the analyzer is sampling atmospheric pressure and restart.
PCA®3 Access the Diagnostic menu 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 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. Press ESC key to exit back to the Diagnostic menu or the Menu (F2) key to exit back to the Main Menu.
PCA®3 8 Parts & Service 8.1 Replacement Parts Item Description Part No.
PCA®3 16K Sensor, NOT-calibrated, NO2 0024-1027 16L Sensor, NOT-calibrated, SO2 0024-0998 17 Screw, #4 x 1/2” LG 0002-2144 18 Battery Clip, Single 0004-1434 19 Battery Clip, Double 0024-1433 20 Cable Assembly 0024-1521 21 Tubing, Vinyl, 1/8 ID x 3/16 OD* 0003-6104 22 Tubing, Silicon, 1/16 ID x 1/8 OD* 00036372 23 Tubing, Silicon, 3/32 ID x 5/32 OD* 0103-6101 24 Tubing, Silicon, 1/8 ID x 3/16 OD* 0103-6102 25 Tubing, 1/8 ID x 1/4 OD* 0003-6105 26 Elbow 0003-6170 -- Bias
4 10 7 8 6 2 1 9 14 16 19 18 11 12 15 13 3 17 17 5 PCA®3 103
PCA®3 8.2 Accessories Standard Accessories 104 Description Part No.
PCA®3 Optional Accessories Description Part No. AC Power Adapter: 0024-1254 (Input: 100-240 VAC, 50/60 Hz; Output: 6 VDC @ 1 A) 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.
PCA®3 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@MyBacharach.com Canada Bacharach of Canada, Inc. 20 Amber Street Unit #7 Markham, Ontario L3R 5P4 Canada Phone: 905-470-8985 Fax: 905-470-8963 Email: bachcan@idirect.
PCA®3 NOTES 107
World Headquarters 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Toll Free: 800-736-4666 • Fax: 724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.
