Portable Combustion Analyzer (Siegert Version) Operation and Maintenance Manual Instruction 0024-9473 Rev.
PCA3 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.
PCA3 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 ...........................................................................................................
PCA3 Manual 4.8. Oil Derivative .............................................................................................. 30 4.9. Boiler Temperature .................................................................................... 30 4.10. Date Setup................................................................................................ 31 4.11. Time Setup ............................................................................................... 32 4.12. O2 Reference Setup ............
PCA3 Manual 5.14. 5.15. 5.16. 5.17. 5.13.2. Recalling Combustion Test Data .................................................. 58 5.13.3. Recalling Logged Test Data .......................................................... 59 5.13.4. Clearing Memory ......................................................................... 60 5.13.5. Print Average ............................................................................... 60 Downloading Stored Data to a Computer .......................................
PCA3 Manual 7.1. Overview .................................................................................................... 82 ® 7.2. PCA 3 Disassembly ..................................................................................... 82 7.2.1. Tools Required ............................................................................... 82 7.2.2. Procedure ...................................................................................... 82 7.3. Emptying the Water Trap Chamber ..................
PCA3 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.
PCA3 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.
PCA3 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 User batteries, boot, Fyrite® Software, USB cable, and carrying case. Refer to Figure 1-2.
PCA3 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.
PCA3 Manual • • • • • • • • • • • • • • • • • 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. B-Smart® sensor technology allows pre-calibrated sensors to be installed in the field. Sensors are provided with data that can be entered through the PCA®3 software, or instrument calibration menus, for easy calibration.
PCA3 Manual 8472 8473 275 285 7335 7336 8466 8471 265 7334 8465 8470 255 7333 8464 8469 245 7332 8463 8468 235 7331 8462 8467 225 7330 Sales Combo Kit (0024-xxxx) 8461 Sales Combo (0024-xxxx) 8460 1.7.
PCA3 Manual 1.8. Specifications Measurement (Based on Installed Sensors) Oxygen Display Range 0.1 to 20.
PCA3 Manual Equations (Some calculations vary by country) ( ) Definitions O2 TSTK TAIR CO CO2 qA Lambda EFF ETA CO2max A2 B = Measured oxygen (in %) = Measured stack temp (in °C) = Measured primary air temp (in °C) = Measured carbon monoxide (in ppm) = Calculated carbon dioxide (in ppm) = Calculated stack loss (in %) = Calculated excess air = Efficiency based on HHV (in %) = Efficiency based on LHV (in %) = Constant (see table below) = Constant (see table below) = Constant (see table below) Fuel Cons
PCA3 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 4,000 ppm.
PCA3 Manual CHAPTER 2. HARDWARE 2.1. Overview Figure 2-1.
PCA3 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. F1 PRINT Transmits the data displayed on the screen to a printer through the IrDA communications port. PAGE- When viewing the Memory or Logging Directory, each press of this button pages down through the directory.
PCA3 Manual Note that a button may perform multiple functions depending on the current screen that is displayed. 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.
PCA3 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.
PCA3 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 on page 20.
PCA3 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.
PCA3 Manual NOTE: The battery charging icon should appear fully green once the new batteries have been installed. 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 23. 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.
PCA3 Manual Figure 3-2.
PCA3 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.
PCA3 Manual NOTE: Use the ◄► buttons to quickly scroll to the bottom and top of the list. NOTE: In addition to the standard fuels programmed into ® the PCA 3, Bacharach can develop custom fuel codes ® based on the customer’s 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. Fuel Selection 4. Press ENT to save the selection and display the CO2 MAX screen. 5.
PCA3 Manual NOTE: The CO2 Max value is returned to its default value when the analyzer is powered down. 4.3. Auto/Manual CO Zero Selections Select how the PCA®3 performs a zero function. 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 CO Zero Setting, and then press ENT to display the CO ZERO SETTING MENU. 4.
PCA3 Manual Auto Zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurements. Manual zero is used to detect CO that may be present during start-up. The auto/manual zeroing option allows the operator to select the start-up mode. It is selectable from the CO Zero Setting of the Setup Menu. NOTE: Both methods take the user through a 60-second count down to establish a new zero.
PCA3 Manual 4. Use the ▲▼ buttons to highlight the desired pressure units. In the example shown, InchesWater has been selected. 5. Press ENT to save the selection and re-display the SETUP MENU. Figure 4-5. Pressure Units Selection 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.
PCA3 Manual 4.7. Smoke Number Three smoke numbers, as measured by the Bacharach True Spot® Smoke Tester, can be manually entered into the analyzer and their average automatically calculated. The average Smoke Number will be displayed on the Run / Hold screen. Enter smoke numbers 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.
PCA3 Manual 4.8. Oil Derivative This screen allows the user to manually enter YES or NO as to whether oil derivatives were present during the smoke test. This setting will be displayed on the Run / Hold screen. 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.
PCA3 Manual Figure 4-9. Configuring for Boiler Temperature 4.10. Date Setup The date is stored in the format: DD/MM/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.
PCA3 Manual 4.11. Time Setup The time is stored in the format: hh:mm:ss. 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 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.
PCA3 Manual 4. Use the ▲▼ buttons to highlight the desired measurement, and then press ENT to display the REF TO O2 screen for that measurement. In the example shown, CO has been selected. 5. First use the ◄► buttons to move the cursor across the screen until it is over the digit to be changed, and then press the▲▼ buttons until the desired value is displayed. 6.
PCA3 Manual Figure 4-13. Print Pressure Selection 4.14. 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.
PCA3 Manual 4.15. 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 54 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 4-15. Logging Selection 4.16.
PCA3 Manual 4.17. 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.
PCA3 Manual Figure 4-17. Editing a Test ID 4.17.2. Selecting 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. Figure 4-18. Selecting a Test ID 2. Use the ▲▼ buttons to choose a pre-entered Test ID or choose NO Test ID (located at bottom of list) to deselect a previously chosen record, then press ENT to make the selection and return to the Test ID menu. 3.
PCA3 Manual 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 4-19. Clearing a Test ID 4.18. User Name 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.
PCA3 Manual 8. Press ESC to go to the Main Menu or the RUN/HOLD key to return to the Run/Hold screen. Figure 4-20. Entering a User Name 4.18.2. 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. 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 (.....
PCA3 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 LANGUAGE SELECTION, and then press ENT to display The Language Selection Menu. 4. Use the ▲▼ buttons to highlight the desired language, then press ENT to activate the selection and re-display the Setup Menu. Figure 4-22. Selecting a Language 4.20.
PCA3 Manual Figure 4-23. Selecting the Calibration Reminder Period 4.21. 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.
PCA3 Manual NOTE: A number sign (#) denotes the current O2 Reference selected. 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.
PCA3 Manual 4. Use the ▲▼ buttons to highlight RESET FORMAT, then press ENT to display the Reset Format screen. 5. Use the ▲▼ buttons to select YES, then press ENT to reset the display and return to the Run/Hold Format screen. Figure 4-25. Resetting Display Formats Back to Factory Defaults 4.22. NOx Calculation NOx is a combination of NO and NO2. The actual NOx value on the PCA3 is the sum of both NO and NO2 readings (NOx=NO+NO2) from the sensors in positions 4 and 3, respectively.
PCA3 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 -29 ºC and the other sensors at approximately -70 ºC.
PCA3 Manual 5.2. Turning On the Analyzer 1. Connect the probe and hose assembly, and make sure that the analyzer is properly set up according to Initial Setup (page 21) and Configuration Procedures (page 24). IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer! 2. Place the probe in an area that contains fresh air. This ensures that the sensors will be properly zeroed during the warm-up cycle. 3.
PCA3 Manual Figure 5-2. Low Battery Indicator 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. Locating Sampling Points Forced Air Furnace Hot Water Tank Figure 5-3.
PCA3 Manual 90% Efficiency Condensing Furnace 80% Efficiency Fan Assist or Power Vented Furnace Atmospheric/Gravity Vented Boiler Figure 5-5. 90% Efficiency Condensing Furnace Figure 5-6. 80% Efficiency Fan Assist or Power Vented Furnace Figure 5-7. 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.
PCA3 Manual Figure 5-8. 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.
PCA3 Manual List of Combustion Test Data Display Name Description of Measurement or Calculation O2 % Oxygen CO Carbon Monoxide (1) Lambda Excess Air CO2 % Carbon Dioxide CO2Max Carbon Dioxide in flue gas assuming perfect combustion CO/CO2 PPM CO divided by PPM CO2 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.
PCA3 Manual 5.6. Selecting a Pressure Label The pressure measurement can be labeled with types including, differential across heat exchanger, draft reading, and differential pressure. See page 51 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.
PCA3 Manual Figure 5-10. Performing a Temperature Measurement 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.
PCA3 Manual Figure 5-11. Performing a Draft/Pressure Measurement 5. Do one of the following to measure draft or differential pressure: • 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.
PCA3 Manual NOTE: When memory is full, the next reading will not be saved until space is made available by clearing the data (see Clearing Memory section on page 60). Figure 5-14. Saving Test Data 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.
PCA3 Manual Figure 5-15. 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.
PCA3 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.
PCA3 Manual Figure 5-16. 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.
PCA3 Manual Figure 5-17. Setting the Logging Interval 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.
PCA3 Manual 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 52), while the second bank is used to store logged combustion test data as described in Data Logging (page 54). Each bank is independent of each other, and cannot share data or be combined.
PCA3 Manual Figure 5-19. 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. Use the ▲▼ buttons to highlight LOGGING DIRECTORY, and then press ENT to display the LOGGING DIRECTORY screen. 4.
PCA3 Manual 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.
PCA3 Manual 3. Use the ▲▼ buttons to highlight PRINT AVERAGE, press the ENT button to display a directory of stored test data. NOTE: Combustion records that can be used for the Average calculation will be time and date coded. Pressure and Temperature records will also be shown but can not be selected for the Average calculations. 4. Use the ▲▼ buttons to highlight any three consecutive combustion records, then press ENT to display the calculated average for all data stored in the records.
PCA3 Manual Minimum Computer Requirements for Fyrite® User Software Category Minimum Requirement Operating System Windows XP or higher Drive CD ROM drive Access Port USB port (USB 1.1, 2.0, or 3.0) Hard Drive Space Software: Data: 205 MB for the Fyrite® User Software Additional 350 KB for each downloaded file 5.15.
PCA3 Manual Field (1) (2) (3) Column Name Data Name or Value 18 TempUnit 19 NO Temperature Units Nitric Oxide Level (see field 32) 20 ppm NO(O2) Nitric Oxide Level referenced to a % of O2 (see field 28) 21 NO2 Nitrogen Dioxide Level (see field 32) 22 ppm NO2(O2) Nitrogen Dioxide Level referenced to a % of O2 (see field 28) 23 NOx Nitrogen Oxides (NO+NO2) (see field 32) 24 ppm NOx(O2) Nitrogen Oxides Level as referenced to a % of O2 (see field 28) 25 SO2 Sulfur Dioxide (see field 3
PCA3 Manual Figure 5-23.
PCA3 Manual The printout shown in Figure 5-23 shows typical combustion test results of an analyzer containing O2, COLOW, NO, and NO2 sensors. Note that since the SO2 sensor is not installed, three stars (* * *) appear in their data fields. NOTE: Three Stars (***) appear in the data field of sensors that are not calibrated or installed, and in the data fields of that sensor’s related calculated values.
PCA3 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.
PCA3 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.
PCA3 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.
PCA3 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.
PCA3 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 300 °C Accuracy: ±0.3 °C (Alternatively) Ice Water, Boiling Water, Thermometer 6.5.2. TS-Zero Procedure 1.
PCA3 Manual Figure 6-4. T-Stack Zero and Span 6.5.3. TS-Span Procedure 1. Set thermocouple simulator to 300 °C (572 °F), 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.
PCA3 Manual 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 66). 3. Use the ▲▼ buttons to highlight T-Air, and then press ENT to display the CALIBRATE TA-ZERO screen.
PCA3 Manual 6.6.3. TA-Span Procedure 1. Set thermocouple simulator to 100 °C (212 °F), 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 90 to 110 °C (194 to 230 °F).
PCA3 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 66). 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 80. 4.
PCA3 Manual 6. Turn OFF regulator of calibration fixture and remove the CO cylinder. 7. Attach a combination 1,000 ppm CO and 1,000 ppm H2 cylinder to the regulator of the calibration fixture, and then use the ▲▼ and ◄► buttons to enter an applied value that exactly equals the CO concentration stamped on the cylinder. 8. Adjust the regulator for a flow meter indication of approximately 2 SCFH, and then press ENT to display the CALIBRATE H2 screen. NOTE: The calibration range is 400 to 1,500 ppm.
PCA3 Manual 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 66). 2. Use the ▲▼ buttons to highlight SO2, and then press ENT to display the CALIBRATE SO2 screen.
PCA3 Manual 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. 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 followed by the CALIBRATION LIST screen being re-displayed. The sensor will now be marked as being BAD in the DIAGNOSTICS screen. 6.
PCA3 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.
PCA3 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 80. 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.
PCA3 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 66). 2.
PCA3 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.
PCA3 Manual CHAPTER 7. MAINTENANCE 7.1. Overview Customer maintenance of the PCA®3 is limited to the following: • • • • • Battery replacement (see page 21) Sensor re-calibration (see page 66) Water trap / filter assembly maintenance (see pages 53 and 87) Sensor replacement (see page 88) Cleaning the probe (see page 91). All other maintenance should be performed by an authorized Bacharach Service Center. Refer to Service Centers on page 99. 7.2.
PCA3 Manual Figure 7-1.
PCA3 Manual Figure 7-2.
PCA3 Manual Figure 7-3. Tubing Connections - Main Figure 7-4.
PCA3 Manual Figure 7-5.
PCA3 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 53). 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.
PCA3 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 94 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.
PCA3 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.
PCA3 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 94) 7.6.2.
PCA3 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.
PCA3 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 18.8% and the stack temperature must be below 2,000 °F (1,093 °C).
PCA3 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.
PCA3 Manual Missing BAD Sensors No B-Smart Sensors Installed Sensor Replacement on page 88. 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 88. There are no B-Smart sensor(s) installed. Refer to Sensor Replacement on page 88. Low Sensors O2, COLOW, COHIGH, NO, NO2, or SO2 sensor output(s) were low, but still usable. Sensor(s) may need to be replaced in the near future.
PCA3 Manual Item Description Part No.
PCA3 Manual Main PCB Assembly (Replacement Part Not Available) Figure 8-3.
PCA3 Manual Figure 8-3. Replacement Parts (Continued) 8.7. Accessories Standard Accessories Description Part No.
PCA3 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.
PCA3 Manual 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. Information on how to perform these repairs is provided on page 82 (Maintenance). All other repairs should be performed by an authorized Bacharach Service Center (refer to Service Centers on page 99).
PCA3 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): PCA3 (Siegert) 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).
PCA3 Manual 0024-9473 Rev 4 101
PCA3 Manual 102 0024-9473 Rev 4
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PCA3 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.
