Bacharach 24-9448 manual

Product Leadership • T raining • Service • Reliability Portable Combustion Analyzer Instruction 24-9448 Operation & Maintenance Rev . 1 - October 2006[...]

W ARRANTY 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 optio[...]

Instruction 24-9448 i Contents Contents 1 I n t r o d u c t i o n .................................. 1 - 1 1. 1 PCA 2 Gene ra l Descr ip tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 1.2 Sales Com bo & Mode l C onf ig urati ons . . . . . . . . . . . . . . . . . . . . . . 1 - 2 1 . 3 F e a t u r e s & B e n e f i t[...]

Instruction 24-9448 ii Contents 4 Operation .................................... 4 - 1 4 . 1 O p e r a t i n g T i p s ......................................... 4 - 1 4. 2 T ur ni ng ON th e A na lyze r a nd W a rm Up . . . . . . . . . . . . . . . . . . .4-2 4 . 3 S e l e c t i n g a F u e l ....................................... 4 - 3 4 . 4 S a m[...]

Instruction 24-9448 iii Contents 6 Maintenance .................................. 6 - 1 6 . 1 P C A 2 D i s a s s e m b l y .................................... 6 - 2 6.2 W ater Trap / Filter Mai nte na nce . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6 6.2 .1 Em ptying the W ater Trap Chambe r . . . . . . . . . . . . . . . . . 6 -6 6.2 . 2[...]

Instruction 24-9448 iv Contents Notes:[...]

Instruction 24-9448 1-1 Introduction 1 Introduction 1 . 1 PC A 2 General Description The PCA 2 is a comm ercia l-grad e ha nd -h el d c om busti on and e m issio ns ana lyze r designed f or on -dem a nd sam pling of ligh t i nd ustria l, i nstitu - tio na l, comme rc ial a nd res ide ntial fu rnaces, ap pliances, and boil ers. T he basi c i nstrume[...]

Instruction 24-9448 1-2 Introduction 1 . 2 Sales Combo & Model Configurations Sales Combo 24-8350 24-8351 24-8352 Sales Combo (Kit) 24-8370 24-8371 24-8372 Model T ype 225 235 245 PCA2 Only Part Number 24-7301 24-7302 24-7303 Measurements Oxygen (O 2 ) 333 Stack Temperature 333 Primary / Ambient Air Temperature 333 Carbon Monoxide Low (CO Low )[...]

Instruction 24-9448 1-3 Introduction Sales Combo 24-8353 24-8354 24-8355 Sales Combo (Kit) 24-8373 24-8374 24-8375 Model T ype 255 265 275 PCA2 Only Part Number 24-7304 24-7305 24-7306 Measurements Oxygen (O 2 ) 3 3 3 Stack Temperature 3 3 3 Primary / Ambient Air Temperature 3 3 3 Carbon Monoxide Low (CO Low ) 3 3 3 Pressure / Draft 3 3 3 Carbon Mo[...]

Instruction 24-9448 1-4 Introduction 1 . 3 F eatures & Benefit s • Pow ered b y 4 ‘ A A ’ alka li ne b atteries, o r Ni M H re chargeab le b atteries. A n op tional AC po we r ada pter p r ovid es contin uo us opera tio n. • I nte r na l charg ing ci rcu it allow s recha rgeab le b atteries to be charged insid e the analyzer with th e u[...]

Instruction 24-9448 1-5 Introduction 1 . 4 Op erational Ov er view The PCA 2 is pow ered by e ith er its 4 in t ernal batte r ies, or b y an opti onal A C pow er ada pter tha t ope rates from any co nv enie nt source of 1 00 – 24 0 V AC, 50/6 0 Hz pow er . The ty pe of b atteries used can be ei the r d ispos- ab le alka li ne o r re chargeab le N[...]

Instruction 24-9448 1-6 Introduction e m iss ion lev els in the stack gas an d th en disp la y m easured an d calcula ted val ues on i ts LCD. V al ues a re listed i n Sectio n 2 S peci f ica tio ns. Dur i ng a test, the CO Low sensor is p rotected f rom high CO le vels b y being a utom atically f l ushed with fresh air wh en th e detected C O le v[...]

Instruction 24-9448 1-7 Introduction T-STACK T-AI R F igure 1 - 1. PCA 2 Co mponents LCD – 160 x 160 graphic display F1 / F2 / F3 – Soft Menu Buttons, whose functions are dened by labels appearing above them on LCD Arrow Buttons: – Moves cursor up the display , or increments an alphanumerical value – Moves cursor down the display , or de[...]

Instruction 24-9448 1-8 Introduction 1 .5 .3 POWE R (A C Adapter) The A C powe r ada pter P / N 24 - 1 404 ca n be used as an externa l pow er su p- p ly , which wi ll r un the analyzer o n a contin uo us basis. W he n using re chargeab le NiM H batte r ies, th e AC po wer a dap ter can a lso be used to charge the b atteries w hi le insi de th e a [...]

Instruction 24-9448 1-9 Introduction 1 .6 F r ont Panel B ut tons Descr ip tions o f the fron t panel b uttons are g iv en bel ow . Note tha t a contro l ma y perform m ulti pl e fu nctio ns as determined b y wha t screen is being displa ye d at th e ti me . T he functio ns of these b utto ns a re defi ne d by labe ls ap- pear ing above t hem o n t[...]

Instruction 24-9448 1-10 Introduction Sel e cts a h ighlighted m en u. I n a dditio n , if cha nges w ere ma de to one o f the analyzer’ s ope rating param eters ( e.g. , date, tim e, O 2 refe rence, etc. ), p ressing this bu tt on con - f irms those changes an d sav es the m i n me mory . Star ts and stops a co mbus tion test w he n the Com bus-[...]

Instruction 24-9448 2-1 Specications 2 Specif ications The PCA 2 Directly Measures and Displays: The gases disp lay ed depe nd o n the analyzer’ s mod el n umber . Refe r t o Se ction 1 .2 . O x y g e n .............................................. 0 t o 2 0 . 9 % Stack T em pera ture . . . . . . . . . . . . . . . . . . . . – 4 t o 2 , 192 [...]

Instruction 24-9448 2-2 Specications Normal Operating Conditions: Te mpe rature: A nalyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 1 0 4 º F (0 to 40 º C ) Pr obe Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,4 72 ºF (80 0 º C ) Ma x. H um idi ty : A nalyzer . . . . . . . . . . . . . .1 5 [...]

Instruction 24-9448 2-3 Specications Power Requirements: F our d isposab le ‘ A A ’ al kal ine ba tteries pro v id e at l east 15 h ours of con tinu - ous o pera tion. NiM H recha rgeab le b atteries can also be used, w ith th e ope rating time d epen de nt o n ba t tery ty pe and con d iti on. An o p tio nal A C po we r ad ap te r , w hic h[...]

Instruction 24-9448 2-4 Specications Notes:[...]

Instruction 24-9448 3-1 Initial Setup 3 Initial Setup 3. 1 Scope Befo re using the PCA 2 , yo u M UST : • I nstal l ba tter ies, o r pl ug in the op tional A C pow er ada pter ( S ection 3.2) • C onn e ct the p robe and hos e assemb ly (Sectio n 3 .3) • Check, and if necessar y , make c ha nges to the analyzer’ s config u ra tion (Section 3[...]

Instruction 24-9448 3-2 Initial Setup 3. 2 .2 U sing th e A C Power A dapter The A C powe r ada pter is ca pab le of po wering the analyzer o n a con ti n uous basis. The a dap ter pl ugs into an ap pro priate 1 0 0 – 24 0 V AC, 50/6 0 Hz wall ou tle t , and p roduces an ou tp ut of +9 V DC. T he a dapte r ’ s ou tpu t connector p lugs in t o t[...]

Instruction 24-9448 3-3 Initial Setup F igure 3- 2 . Connecti n g the Probe and Hose Asse mbl y to the PCA 2 POWER P T-STA CK T-AIR GAS Differential Pressure Hose (— ∆P) (Optional) Probe Handle Water Trap / Filter Assembly Stack Gas Thermocouple Connector (T-STACK) AC Power Adapter Jack (POWER) Option Connector (Optional External Measurement) D[...]

Instruction 24-9448 3-4 Initial Setup 3.4 Operating Parameters The PCA 2 is set u p at th e factory for th e fo l lo w i ng ope rating param eters: F u e l ..................... N a t u r a l G a s Te mpe rature U n its . . . . . . . . . °F Pressur e U n its . . . . . . . . . . . . Inches o f W a t er Co lumn (inw c) Po llu tion U n its . . . . . [...]

Instruction 24-9448 3-5 Initial Setup 3. 6 T emp erature U nit s Select ion Sel e ct to d ispla y tem pera ture i n ei ther ° F or °C as fo llow s: 1. D isp lay th e M A I N M EN U by p ressing the MEN U (F2) b utton. If necessary , pres s ESC until ME N U ap pea rs abov e F2 . 2. Use th e bu ttons to h ighlight S E T U P , and th en pre ss E NT [...]

Instruction 24-9448 3-6 Initial Setup 3. 7 P ressure U nits Selec tion Sel e ct to d ispla y p ressure i n Inches o f W a t er Col umn (i nw c ), mil libar (mb ) , Pascals ( P a), o r hectoP asca ls ( hPa ) as follo ws: 1. Disp lay th e M A I N M EN U by p ressing the MEN U (F2) b utton. If necessary , pres s ESC until ME N U ap pea rs abov e F2 . [...]

Instruction 24-9448 3-7 Initial Setup 3.8 P ollution U nit s Select ion The PCA 2 is capa bl e of con verting the m easured pp m l evels o f CO, NO , NO 2 , and SO 2 to var ious poll utio n un its using CF R4 0 Par t 6 0 emissi on factors. No te that th e pollu tion -unit con ve rsions fo r NO, NO 2 a nd NOx are based o n the mo lecular w eight o f[...]

Instruction 24-9448 3-8 Initial Setup 3.9 Date Setup The date is stored in th e forma t: M M / DD/ Y Y . Its valu e is par t of th e date and time s ta mp tha t is sa ved alon g w ith eac h comb ustio n t est record. Set th e a na lyze r ’ s internal clock to the current date as f ollo ws: 1. Disp lay th e M A I N M EN U by p ressing the MEN U (F[...]

Instruction 24-9448 3-9 Initial Setup 3. 1 0 Time Setu p The time is stored in th e forma t: hh:mm:ss A M / PM. Its valu e is par t of th e d a t e and time stamp t hat is sa ved alo ng w ith ea ch comb ustio n test record. Set the analyze r ’ s internal clock to the current time as f ollow s: 1. D isp lay th e M A I N M EN U by p ressing the MEN[...]

Instruction 24-9448 3-10 Initial Setup 3. 1 1 O 2 R eference Setup The meas u red valu es of CO, N O x, a nd SO 2 can be individ ua lly ref eren ced t o a specif ic O 2 percen tage of be tween 0 an d 15 % . Individ ua lly set u p the O 2 re fere nce valu e fo r each of th e abov e gases as fo l lo ws: 1. D isp lay th e M A I N M EN U by p ressing t[...]

Instruction 24-9448 3-1 1 Initial Setup 3. 1 2 Print P ressure Se l ection Sel e ct wh eth er to pri nt o r not p r int th e pressure meas u rem en t on th e c om busti on test printou t as fo llow s (see Fig ure 4 -3 on Pag e 4 -31 ): 1. D isp lay th e M A I N M EN U by p ressing the MEN U (F2) b utton. If necessary , pres s ESC until ME N U ap pe[...]

Instruction 24-9448 3-12 Initial Setup 3. 1 3 Zoom - Displa y Selection Zo om -d isp lay p rov id es an ad d itio na l com bustio n test screen tha t sho ws th e t est val ues of O 2 , CO , and efficien cy i n extra large characters, th us a l- lo w ing the o pera t or to v ie w the disp lay o f these valu es from a lo nger distance. Pr essing th e[...]

Instruction 24-9448 3-13 Initial Setup 3. 1 4 Bat ter y Charger Selection W he n using re chargeab le NiM H batte r ies, th e A C pow er ada pter can be used to charge the b at- teries w h ile insid e the analyzer . T he ana lyze r ’ s ra pid - charger circu it, h owe ver , m ust be fi rst tur ned O N. IM PORT ANT : W h en using disposa ble alkal[...]

Instruction 24-9448 3-14 Initial Setup 3. 1 5 Logging Selection W he n the log g i ng function is acti va t ed, up to 50 0 com bustio n test records wi ll be au toma tical ly stored in me mo r y at a p reset interval ov er a pre- de t ermined l ength of time. Refe r t o Se ction 4. 12 fo r detailed in fo rmati on on ho w to select th e loggi ng fun[...]

Instruction 24-9448 4-1 Operation 4 Operation 4. 1 O perating Tips • W h en an a nalyzer is b rough t in f rom a col d ve h icl e, let i t warm u p slow ly to mi ni mize cond ensa tion. T em pera tu res bel ow freezi ng wi ll not dam- age th e ana lyzer; h ow eve r , bri ng ing a col d a nalyzer in t o a warm, h um id en v ironme nt ma y ca use c[...]

Instruction 24-9448 4-2 Operation 4. 2 T urning ON the Analyzer and W ar m Up 1. C onnect th e probe and h ose assem bl y , and mak e su re tha t the ana lyze r is pro per ly set u p per Section 3 I nitial Setup . IM PORT ANT : DO NOT insert pro be into stack bef ore tu rning ON t he an al yzer ! 2. Place the p robe in a n area that con tai ns fres[...]

Instruction 24-9448 4-3 Operation 4.3 Select ing a F uel The top line of th e Comb ustio n Test H OL D screen sh ows th e fuel currentl y sel ect ed. In the exam pl e sh own, the cur ren t f ue l is NAT U R A L GA S. I f necessary , change th e f ue l as fo l low s: 1. D isp lay th e M A I N M EN U by p ressing the MEN U (F2) b utton. 2. Use th e b[...]

Instruction 24-9448 4-4 Operation 4.4 Sampling P oint FOR CED AIR FURNACE – F or a tm osp he r ic b urne r or g ra v ity ve nted, f orced a ir h eating equip m en t with a clams he l l o r sectio nal hea t e xchang er d e- sign, tes t each of th e exha us t ports a t th e top o f th e h eat exch a nge r . The p rob e sho uld be inserted b ack int[...]

Instruction 24-9448 4-5 Operation 4.5 Per forming a Combustion T est Ensure that th e fo l lo w ing has been com pl eted, and th en proceed with th e com bustio n test as described bel ow: • T u rn ON ana lyze r a nd allo w it to warm up (Section 4 .2). • S el ec t fue l being burned (Section 4.3) . • I nset p robe into stack (Section 4.4 ). [...]

Instruction 24-9448 4-6 Operation 4. Y ou can no w begi n burner-se r v ice proced u res. The ana lyze r readi ngs wi ll cha nge quickl y t o sho w changes in burner pe r fo rma nce. CA UTI ON: Position t h e W ater T rap wit h its gas-f low arrow poin ting up ward. Do n ot let water condensate go abo ve the tip of t h e ri ser tub e. T h e sensors[...]

Instruction 24-9448 4-7 Operation 4.6 Making a Dra f t / P ressure Measuremen t The di f fe rence in pres su re ( ∆ P) be tween tw o a reas can be measured b y using th e a na lyze r ’ s two p ressure ports a nd th e PRE S SU RE screen. By using th e – ∆ P port as the re fere nce, the p ressure ap plied to th e + ∆ P port wi ll be d isp l[...]

Instruction 24-9448 4-8 Operation b. Disconnect any h oses connected to the + ∆P a nd –∆P po r ts, a nd th en p ress E NT to zero the p ressure sensor . c. Re connect any h oses. W he n measur ing dra ft , simp ly l eav e the –∆P po rt op e n to th e a t mo s ph e re an d co nn ec t th e p rob e’ s draf t h o se to th e + ∆ P po rt ( [...]

Instruction 24-9448 4-9 Operation 4.8 Ending a C ombustion T est WARNING! Burn Hazard. Do n ot touch t h e pro be after re moving it fro m the sta ck. Allow t h e pro be to co ol be fore handli ng ( about 5 mi nutes ) . 1. R emo ve p r obe from sta ck. 2. A llow th e pum p to r un until a ll c om busti on gases ha ve bee n f lush ed from the analyz[...]

Instruction 24-9448 4-10 Operation 4. 1 0 T ur ning OF F the Analyzer & Purg ing T ur n OFF the analyze r by pres si ng th e I /O bu t- ton fo r at l east 2 secon ds , or un ti l two bee ps a re heard. The unit wi ll c oun t down 5 secon ds befo re sh utting do wn , g iving the o pera t or an op portu- nity to kee p the ana lyze r tu rned ON b [...]

Instruction 24-9448 4-1 1 Operation 4. 1 2 Data Logg ing W he n the log g i ng function is acti va t ed, up to 50 0 comb ustio n t est records wi ll be au toma tical ly sto red i n me mory a t a preset in ter val (1 , 5 , 1 0, 15, 30 sec on ds, 1, 2 , 5, 10 min utes ) ove r a pred etermined d u rati on (5, 1 0, 15, 30 m inu tes, 1, 2 , 5, 1 0, 2 4,[...]

Instruction 24-9448 4-12 Operation 4 . 1 2 . 1 T urning ON Data L ogging IM PORT ANT : B ef ore turn ing ON data logging and starting t h e data logg ing pr oce ss, the anal yzer shou ld alread y be set up to perf orm a com bustion test per Section 4.5. T ur n ON da ta logging as follo ws: 1. D isp lay th e M A I N M EN U by p ressing the MEN U (F2[...]

Instruction 24-9448 4-13 Operation 4 . 1 2 .2 Setting the Lo gging Inter val a nd Duratio n The log g i ng interval is the l ength of time betw een m easurem ents, w hi le the l oggi ng dura tion is th e time al loca t ed to the l ogg ing process. Set the log g i ng interval and dura tion as f ollo ws: TIP: If t h e du ration is set for mo re than [...]

Instruction 24-9448 4-14 Operation 4 . 1 2 .3 Star ting the Data Loggi ng Process A f ter tur ni ng ON da ta logging a nd s etti ng th e interval and d u rati on, the analyzer wil l pa use a t the LO G GING SU M M A RY screen, w here t he cur ren tly se lected i nte r val a nd d u ra tion time periods are d isp lay ed. Press E NT to sta rt the com [...]

Instruction 24-9448 4-15 Operation 4 . 1 2 .4 Ending the Data Log ging Process Da ta loggi ng wi ll stop and th e pum p w il l tu rn OFF a ft er th e prescribed dura tion, or after al l 50 0 mem ory locati ons are f i l le d . To e x it th e Comb ustion T est LO G screen, press the R U N/H OLD bu tt on tw ice t o d isp lay th e Com- bus tion T est [...]

Instruction 24-9448 4-16 Operation 4 . 1 3 . 1 Recalling Com bustio n T est Data Re cal l individu a l comb ustio n t est da ta re cords as f ollow s: 1. D isp lay th e M A I N M EN U by p ressing the MEN U (F2) b utton. If necessary , pres s ESC until ME N U ap pea rs abov e F2 . 2. Use th e bu ttons to h ighlight ME MO RY , and th en pre ss E NT [...]

Instruction 24-9448 4-17 Operation 4 . 1 3 .2 Recalling L ogged T est Data Re cal l individu a l logg ed c om busti on test data recor d s as fo llow s: 1. D isp lay th e M A I N M EN U by p ressing the MEN U (F2) b utton. If necessary , pres s ESC until ME N U ap pea rs abov e F2 . 2. Use th e bu ttons to h ighlight ME MO RY , and th en pre ss E N[...]

Instruction 24-9448 4-18 Operation 4 . 1 3 . 3 Clearing Memor y W he n a ll mem ory ( “sna p sho t ” ) loca tions used to store individ ua l comb ustio n test rec ords ha ve been fil led, the next com bustio n test record sa ved wi ll ove r w rite the o ld est. W he n a ll loggi ng me mo r y locatio ns in the lo gg i ng di rect ory a re fu ll, [...]

Instruction 24-9448 4-19 Operation 4. 1 4 Do wn load ing S tore d Data to a Compu ter The com bustio n test data tha t was stored in ei the r the analyzer’ s Me mory Di rect ory (Sec tio n 4 . 7), or Logg ing Di rec tory (Se ction 4. 12), can be d own- loa ded to a com p uter using th e PCA 2 Data Recove r y P rog ram a nd U SB cab le tha t a re [...]

Instruction 24-9448 4-20 Operation 4 . 1 4 . 1 PCA 2 Da t a Reco ver y Program Ins t alla tion The PCA 2 Da t a Re cov er y P rogra m is su pp l ied wi th the ana lyze r on a CD ( P/ N 24 - 1 425). Instal l this progra m as fo llow s: 1. I nsert the PCA 2 CD into the co mp uter’ s CD-ROM d rive. 2. L ocate th e CD -ROM dr ive in Wind ows Exp lore[...]

Instruction 24-9448 4-21 Operation 5. Cl ick Install to conf i rm the de sti nati on fo ld er and use r i nforma tion. 6. Cl ick Finish aft er all f i les ha ve bee n copi ed into the d estinatio n fo lde r . 7 . At this ti me th e PCA 2 Da ta R ecove r y P rog ram icon sh ould a ppear und er "Sta r t A l l P rog rams m en u. 8. T h is com pl [...]

Instruction 24-9448 4-22 Operation 4 . 1 4 .2 Computer to PC A 2 Connecti on & USB D ev ice D river Installa tion Connect the U SB cabl e ( P/ N 1 0 4 - 4032) that w as su pp l ied with th e PCA 2 , and, if necessar y , instal l the analyzer’ s USB d evice d rive r as follo ws: 1. With both th e PCA 2 a nd co mp ute r tu r ned O N, insert the[...]

Instruction 24-9448 4-23 Operation 3. Se l ect “Ins tall fro m a lis t o r s p ecifi c l oc a ti on ( Ad va nc ed) ” a n d c li ck Ne xt> . 4. S el e ct to sea rch fo r the best driver an d the n brow se t o fo ld er C: P rog ram F i les PCA 2 Da ta . Click Next> . 5. At the Hardw a re Insta llatio n w indo w , click Continue Any way [...]

Instruction 24-9448 4-24 Operation 6. A ft er th e Fo und Ne w Ha rdw a re Wizard has f i nished instal li ng th e software, click Finish to clos e the Wizard . 4 . 1 4 .3 Recov e ring Data Befo re data can be recovered from t he ana lyze r , i nstal l the PCA 2 Da ta Re cov er y P rogra m, USB cab le, an d USB device dr iv er as described in Se c-[...]

Instruction 24-9448 4-25 Operation Status line showing PCA 2 is successfully connected to the computer Use this section of window to Recover Logging Data Use this section of window to Recover Combustion Data Start the download process by clicking the desired Open Log / Data File button Select a pre-existing folder or create a new folder to store th[...]

Instruction 24-9448 4-26 Operation NOTE: The f ilename is automaticall y given a CSV ( Com ma Separated V al ue ) e xtensi on, al l owi ng the f ile to be di rectl y opened by mos t spreadsheet pr og rams f or anal ysis. 3. A ft er se lecti ng a fo ld er and e ntering the fi le name, click Open and th en click Star t t o begi n the d own loa d proc[...]

Instruction 24-9448 4-27 Operation 4 . 1 4 . 4 Unpluggin g the US B Cable CA UTI ON: To avo id possib l e electro nic damage to the ana- l yzer , it is not advisable to u npl ug the USB cab le wit h out first tu rning OFF the PCA 2 U SB connection usi ng the “S af el y R emove H ardwa re ” i con in t he Wind ows XP system tra y . Do the f ollo [...]

Instruction 24-9448 4-28 Operation 4. 1 5 Im portin g S a v ed D ata In to a Spr ea dsh eet Da ta that w as rec ov ered and sa ved as an A SCI I text f i le with a “CS V ” extensi on, as described in S ection 4. 1 4, ca n easily be o pene d for vie w i ng in most sp reads heet p rog rams by sim pl y dou bl e- clicki ng the filenam e. Fo r exam [...]

Instruction 24-9448 4-29 Operation TABL E 4 -2 . D OW N L OADED DA TA FI ELD S Fie ld Colum n Name Data N a me or V a lue 1 T ime T ime o f Test in 12 ho u r fo rmat (A M / PM ) 2 Da t e Da te of Test in mm / dd /y y 3 F ue l Fuel N ame 4 %O2 Oxygen Leve l 5 CO Carbon M ono x id e L eve l (see fiel d 26) 6 pp m CO(O2) Carbon M ono x id e L eve l re[...]

Instruction 24-9448 4-30 Operation 4. 1 6 P r inting T est Data Comb ustio n or pre ssur e data tha t is cur ren tly be i ng displa yed can be se nt to a printer using IrD A pro t ocol as described be low . Da ta that is stored in m emo r y can a lso be printed b y f i rst di sp laying the stored test da ta as described in S ections 4. 13. 1 & [...]

Instruction 24-9448 4-31 Operation F igure 4-3 . Pr inter Al ig nmen t & S am ple P rintou t BACHARACH, INC. PCA 2 SN: xxxxxx ===================== TIME 01:00:00 PM DA TE 10/06/06 FUEL NA TURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 % T -ST ACK 374 °F T -AIR 68.0 °F EA 21 % NO 18 ppm NO T emp 70.5 °F NO2 6 ppm NOX 24 ppm SO2 ∗∗∗ ppm[...]

Instruction 24-9448 4-32 Operation Notes:[...]

Instruction 24-9448 5-1 Calibration 5 Cal ibration IM PORT ANT : B ef ore perf ormi ng an y calib ration proced ure, ensur e that fresh batteries are i n stalled or use t h e opt i onal A C power adapter . A lso ensure t hat the analy z er is at room tem per- atur e and will b e samp ling fresh ai r when tu rn ed ON . 5. 1 Smar t Sensors The PCA 2 [...]

Instruction 24-9448 5-2 Calibration A n y err ors d etect ed duri ng warm- up wil l be listed on th e d isp lay imm ed iate ly fo l- lo w ing warm- up . For e xa m pl e, the screen to the right s how s that th e ba tter y is lo w . Correc t any e r rors bef ore proceeding. Refe r to Se ction 7 .3 for a listing of e r ror mess ages and th eir meani [...]

Instruction 24-9448 5-3 Calibration p lay th e CA L I BR ATE PR E SS U R E screen. “Mea su red” is the p ressur e value curre ntl y bei n g detected by the pr essure se n sor , w hile “ App lied ” i s a known v alue of pr essure t h at wil l be app lied for cal ibr ation purposes. 4. Wi th both the –∆ P a nd + ∆ P ports open to the a [...]

Instruction 24-9448 5-4 Calibration 5.4 T - Stack Calibration Th is procedure fi rst zeros and th en spans th e stack - t em pera ture cha nne l to k no w n tem pera tu re valu es. The use of an el ect ronic th ermocou pl e sim u la t or is th e pref erred meth od of prod ucing the d esired ca libra tion te mper atures. A lternati vel y , co ntaine[...]

Instruction 24-9448 5-5 Calibration 5. W ai t u ntil th e Measured reading stabilizes, and th en pre ss E NT to ca libra te the TS -Zero Measured v a lu e t o tha t of the Ap plied v alue ; af ter whic h the m essage “G ood Ca libra tion ” sh ould b r ief ly a ppear fo l lo wed b y the CA L I BR ATE TS - SP A N s creen. TS - S pan Proc edu re: [...]

Instruction 24-9448 5-6 Calibration 5. 5 T - Ai r C al ib rat ion Th is procedure fi rst zeros and th en spans th e ambi ent- temp erature chan- ne l to k nown tem pera ture valu es. The use of an el ect ronic th ermocou pl e sim u la t or is th e pref erred meth od of prod ucing the d esired ca libra tion te mper atures. A lternati vel y , co ntai[...]

Instruction 24-9448 5-7 Calibration Th e calib ration ra n ge is from 3 2 t o 4 1 °F ( 0 to 5 ° C) . A n attem pt to cali brate outside th i s rang e will cause the message “B ad C ali bration Wro ng CA L Entry” to ap pear in t h e fo llowi ng step. 5. W ai t u ntil th e Measured reading stabilizes, a nd th en p ress E NT to cal ibr ate the T[...]

Instruction 24-9448 5-8 Calibration 5.6 C O - L O Sensor C alibration Note tha t the CO-LO sensor also meas u res H 2 fo r the p u rpose of com - pensa ting the CO rea d ing for th e prese nce of H 2 in the gas sam pl e. T his proced u re f ir st sp a ns the CO-LO sensor an d , op tionally , s pans the H 2 par t of th e sensor to kno w n gas le vel[...]

Instruction 24-9448 5-9 Calibration If t h e sensor ’s ou tput is too low to be usable, t h en the message “B ad Calib ration Sensor End of Li fe, En try Not Saved ” will a ppear . Th e sen- sor wi ll now be mar k ed as being BA D in the DIAG NOSTI CS screen. NOTE: H 2 calib ration can be bypassed by p ressing t h e ESC bu tton, after which t[...]

Instruction 24-9448 5-10 Calibration 5. 7 S O 2 Sensor C alibration Th is procedure sp a ns the o ptio na l sul fu r dioxid e sensor to a kno w n gas l eve l. Mat er ial Re quir ed: Calibra tion Kit, P/ N 24 - 7059 Gas Cylind er: 1 0 0 pp m S O 2 in Nitrog en, P/ N 24 - 1 158 Proce dure: 1. I f not alread y don e, tu rn ON th e a nalyzer and disp l[...]

Instruction 24-9448 5-1 1 Calibration If t h e sensor ’s ou tput is too low to be usable, t h en the message “B ad Calib ration Sensor End of Li fe, En try Not Saved ” will a ppear fo llowed by the CALI BR ATION LIS T screen bei ng re-displa yed. T he sensor wil l now be mar k ed as being BA D in the D I A GNOS TICS screen. 6. Tu r n O F F re[...]

Instruction 24-9448 5-12 Calibration brie f ly a ppear fo l lo wed b y the CA L I BR ATIO N L I ST screen being re-d isp lay ed. If t h e sensor ’s ou tput is low , but s till usab l e, then t h e message “G ood Calib ration W A RNI NG Low Sensor” w ill ap pear . T he sensor wil l n ow be mar k ed as being Low in t h e DIAG NOSTICS scr een. I[...]

Instruction 24-9448 5-13 Calibration caus e t he mes sage “ Bad Cal ib ra tion Wro ng CA L E ntry ” to ap pea r i n t he f ol low ing step . 5. Adj ust regu lato r for a f lowm eter indica tion o f ap proximate ly 2 SCF H. W ait un ti l the M easured reading stabiliz es ( ap pro x imatel y 3 minu tes) , and th en pre ss E NT to ca libra te the [...]

Instruction 24-9448 5-14 Calibration 4. U se the and bu ttons to ente r a n App lied v a lu e that e xactly eq ua ls the co ncen - tra tion stam ped on th e C O cylind er . The ca li br atio n ra nge is fro m 2 50 to 1 1 ,000 pp m. An at tem pt to c ali br ate o ut - side th is r ang e wi ll cause the mess a ge “B ad Cal ib ra tion Wr ong CA L E [...]

Instruction 24-9448 6-1 Maintenance 6 Maintenan c e Custom er maintenance of th e PCA 2 is l imited to the f ollowing: Battery rep lace men t or chargi ng using A C pow er ada pter (Section 3.2) Sensor re-ca libra tion ( S ection 5) W a ter trap / filter asse mb ly maintenance (Section 6.2) Sensor re pla ceme nt (Section 6.3) Pr obe th ermocou pl e[...]

Instruction 24-9448 6-2 Maintenance 6. 1 PC A 2 Disassembly The fo l lo w ing procedure describes h ow to d isassem bl e the analyzer , w hi le F igu res 6 - 1 thr u 6 - 4 il lustra te ho w the analyzer is p ut toge ther . Too ls R equi red: Medium Phill ips Screw d rive r Pr ocedure: 1. Un pl ug al l the rmocou pl es f rom bottom of analyzer . 2. [...]

Instruction 24-9448 6-3 Maintenance F igure 6-2. Inside View with Rear Case R emo ved Sensor Positions 225 24-7301 235 24-7302 245 24-7303 255 24-7304 265 24-7305 275 24-7306 #1 O 2 O 2 O 2 O 2 O 2 O 2 #2 CO LO CO LO CO LO CO LO CO LO CO LO #3 SO 2 NO 2 SO 2 #4 NO CO HI NO NO Model P/N Position Sensor Retainer Purge Pump Gas Pump GAS Purge Air In P[...]

Instruction 24-9448 6-4 Maintenance F igure 6-3 . T ubi ng Connections Models 235 & 245 P/Ns 24-7302 & 24-7303 Model 255 P/N 24-7304 Models 265 & 275 P/Ns 24-7305 & 24-7306 Model 225 P/N 24-7301 PRESSURE SENSOR on printed circuit board –∆P +∆P –∆P (Bottom) +∆P (T op) PRESSURE PURGE AIR GAS Gas IN GAS PUMP PURGE PUMP Gas [...]

Instruction 24-9448 6-5 Maintenance F igure 6-4 . Wiring Solder (2 Places) Red dot on pump indicates positive (red wire) connection Battery to J14 Battery to J14 Gas Pump to J8 Purge Pump to J9 Sensor Connector (typical 4 places) Factory T est Connector LCD Connector (opposite side of board) Ribbon Cable Conection between LCD Assembly and Printed C[...]

Instruction 24-9448 6-6 Maintenance F igure 6-5 . Di sassemb ling t he Water Trap / Filter Assem bl y FIL TER ELEMENT “A” “B” Pry apart filter chamber using a small flat-blade screwdriver inserted into notch When re assem- bling f ilter chambe r , make su re surfaces “A” and “B” contact each ot her W A TER TRAP CHAMBER FIL TER CHAMB[...]

Instruction 24-9448 6-7 Maintenance 6.3 Smar t Sensor R eplacement Bacha rach ’ s Sma r t sensor tech nol og y al low s ne w sensors t o be i nsta l led witho ut n eedi ng to be ca libra ted in si de th e a nalyzer . N OTE : Se nso rs ma y be p ur c hase d wi th a nd wi t hou t th e Sm art se nso r te ch no log y PC B. See Sec tio n 6.4 on ho w t[...]

Instruction 24-9448 6-8 Maintenance 6.4 Sensor Only R eplacement A l l senso rs a re rep laced in a simi la r manner . Do th e fo l lo w i ng to rep lace ei the r the O2, CO -L O, CO-HI , NO, N O2 , or SO2 senso r . Refer to Sectio n 8. 1 Replacem ent Part s for list of sensors and par t numbers. T ur n OFF the analyze r . Remo ve the b attery cov [...]

Instruction 24-9448 6-9 Maintenance 12. Plu g the senso r i n t o ana lyzer; an d then rea ttach tub ing t o gas cu p. 13. Insta ll the senso r retai ne r a nd b attery cove r . 12. A l lo w the se ns or tha t was j ust insta lled time to stab i lize i n the circu it bef ore con ti n u ing with this procedure. Stab il izatio n time fo r a ll sen - [...]

Instruction 24-9448 6-10 Maintenance 6.5 Nitric Oxide Sensor Batter y Replacement A single li th ium b attery , l oc a t ed on th e NO Smart S enso r assemb ly , ap plie s a bias v olta ge t o the N O sensor to p reven t the s ensor from d estabili zing w hen th e ana lyzer is turned o f f. T he NO b ias ba tt ery is expected t o last a t leas t th[...]

Instruction 24-9448 6-1 1 Maintenance 6.6 T her mocouple Replacement U si ng th e ap prop r iate th ermocou pl e rep lacem en t kit listed belo w , re place the p robe’ s th ermocou p le as fo llow s: Ther mo cou ple Re pla ce men t Kit s: Part Number Replaces Thermocouple in a Probe with a T ube Length of . . . 24-8413 6 inches 24-8414 12 inches[...]

Instruction 24-9448 6-12 Maintenance 3. Pu ll ol d therm o cou pl e fr om p robe body an d d isca rd. 4. The ne w the rmocou pl e has been coiled f or ship ping p u rposes. Straigh t en th e therm ocoup le us i ng yo u r th umb and ind ex f inger . 5. If not already d on e, i nstal l su pp l ied O-Rings on t o the rmocou pl e. 6. Insert therm oc ou[...]

Instruction 24-9448 6-13 Maintenance 6. 7 P ump Replacement Par t s & T ools Req uire d: Repla cem en t P ump : Gas Pu m p P/ N 2 4 - 1 393 Pu rge Pu m p P/ N 3 01 5 - 1 71 6 Sol dering I ron and Sol der Medium Phill ips Screw d rive r Small F lat Bla de Screw d rive r Proce dure: 1. Ga in access to both the g as a nd p urge pum ps by re moving[...]

Instruction 24-9448 6-14 Maintenance 6.8 Clean ing the Pr ob e The prob e tube and gas-sam pl e hose wi ll bec om e di r ty unde r normal use. Note tha t the w ater tra p’ s fi lte r ele me nt sh ould p reve nt soot from rea chi ng the analyze r ’ s internal com p on en ts. I f the p robe is not k ep t clean, it co u ld becom e clogg ed a nd re[...]

Instruction 24-9448 6-15 Maintenance Notes:[...]

Instruction 24-9448 7-1 T roubleshooting 7 T roubles hooting 7 . 1 Analyzer Repair It is reco mmen ded tha t f ie ld rep a ir of the PCA 2 be limited to: Checks of p ri nted circu it bo a rd connectors Rep laci ng the p robe asse mbl y Repla ci ng the filter e lem en t in the wa ter tra p / f i lter asse mb ly Repla ci ng senso rs Repla ci ng ei th[...]

Instruction 24-9448 7-2 T roubleshooting 7 .3 Erro r Mess ages Di spla y ed A f ter W arm- U p If the re w ere p rob l ems detected duri ng w arm- up , erro r me ssage s tha t de scr ibe the n ature o f th e pro bl em s are disp la yed i mm ediate ly f oll owing th e analyze r’ s 60 secon d w a rm -u p perio d. If pro bl em s w ere d etected, th [...]

Instruction 24-9448 7-3 T roubleshooting 7 . 4 D iagn ostics and S tatus Scree ns The D I AG NOST ICS scr een lists the cur ren t sta tus of all th e SM A RT g as se nsors ins ta lle d and th e O 2 senso r sta tus an d m V o utp u t. The STATUS screen p r ovid es a quick ref erence o f key i tems w he n troub le shooting. D IAG NO ST ICS O2 Va l u [...]

Instruction 24-9448 7-4 T roubleshooting Notes:[...]

Instruction 24-9448 8-1 Parts & Service 8 P ar t s & Ser vice 8. 1 Replacement P ar ts Item (Fig. 8-1) Description Part No. 1 Main PCB Assembly ............................ 2 4 - 1 3 7 1 2 L C D M o d u l e ................................... 2 4 - 1 3 7 4 3 R e a r C a s e ..................................... 2 4 - 1 3 8 1 4 T o p C a s e[...]

Instruction 24-9448 8-2 Parts & Service Item (Fig. 8-1) Description Part No. 18 Sensors (NOT-calibrated): 18A O 2 .......................................... 2 4 - 0 7 8 8 O 2 sensor PCB only * . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1364 18B CO-H 2 ....................................... 2 4 - 0 7 8 9 18C CO HI .................[...]

Instruction 24-9448 8-3 Parts & Service F igure 8- 1 . Parts ( 1 of 2 ) 22 22 25 25 9 22 –∆P +∆P –∆P (Bottom) Pressure Sensor +∆P (T op) PRESSURE PURGE AIR GAS IN (Bottom) OUT (T op) OUT IN 23 25 26 24 16 (typical 4 places) 15 (typical 2 places) 14B (typical 2 places) 14A 14C (typical 3 places) 23 14 1 1 12 17A 18A 17C 18C 17C 18D 1[...]

Instruction 24-9448 8-4 Parts & Service 4 10 7 6 2 1 9 18 17 13 3 5 8 19 12 14 20 21 1 1 19 F igure 8- 1 . Parts ( 2 of 2 )[...]

Instruction 24-9448 8-5 Parts & Service 8.2 Accessories Stand ard Acces sorie s P a r t No. C a r r y i n g C a s e .......................................... 2 4 - 0 8 6 5 Batterie s , ' A A ' Al ka li ne ( 4 req u i red) . . . . . . . . . . . . . . . . . . . . . . . . 20 4 - 0 0 04 12" P r obe, H ose, a nd W ate r T rap / Fi lt[...]

Instruction 24-9448 8-6 Parts & Service Opt ional Acce ssori es P a r t No. A C Pow er Ada pter ( I np ut : 100 –2 4 0 V AC, 50/6 0 Hz; Outp ut: 9 VD C @ 1 A) . . . . . . . . 24 - 1 40 4 PCA 2 P rotective Boot with magne t . . . . . . . . . . . . . . . . . . . . . . . . . .2 4 - 1 4 0 9 A mb ien t A i r T he rmocou pl es ( T -A I R) , K- T yp[...]

Instruction 24-9448 8-7 Parts & Service 8.3 Ser vice Cen t ers United St ate s Bacharach Inc. 621 H unt V al le y Ci rcle Ne w Kensing ton, P A 1 5 06 8 Pho ne: 7 24 -3 34 - 50 5 1 F a x: 724 -33 4 -5723 Email : he lp@bacharach -inc.co m Canada Bacharach o f Ca nada, Inc. 250 Sh ie lds Court Unit #3 Ma rkham, Ontario L 3R 9W7 Canada Pho ne: 905[...]

Notes:[...]

Headquarters: 621 Hunt V alley Circle, New Kensington, P A 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • T oll Free: 800-736-4666 Website: www .bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A. ISO 9001:2000[...]