Bacharach PCA®2 Combustion Analyzer Manual PDF

116 Pages·2009·7.94 MB·English

Portable Combustion Analyzer
Instruction 24-9448
Operation & Maintenance
Rev. 4 - July 2009
Product Leadership • Training • Service • Reliability
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.’s
reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given
by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc.
The Oxygen (O) sensor has a limited warranty of one (1) year. Routine service and calibration are excluded
2
from this warranty.
Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s
remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach,
to the replacement of this Product or parts thereof that are defective in title.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY
AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IM-
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARIS-
ING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall be limited
to those provided herein to the exclusion of any and all other remedies including, without limitation incidental or
consequential damages. No agreement varying or extending the foregoing warranties, remedies or this limita-
tion will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.
Register Your Warranty by Visiting
www.bacharach-inc.com
Notice:
Product improvements and enhancements are continuous, therefore the specifications and information
contained in this document may change without notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this material.
No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Bacharach, Inc.
Copyright © 2006, Bacharach, Inc., all rights reserved.
BACHARACH is a registered trademark of Bacharach, Inc. All other trademarks,
trade names, service marks and logos referenced herein belong to their respective companies.
A Instruction 24-9448
Contents
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 PCA 2 General Descrpton ...............................1-1
1.2 Sales Combo & Model Confguratons ......................1-2
1.3 Features & Benefts ....................................1-4
1.4 Operatonal Overvew ...................................1-5
1.5 Connector Descrptons ..................................1-6
1.5.1 Probe Connectons (Gas, Pressure, T-Stack) ............1-6
1.5.2 T-AIR (Prmary Ar Thermocouple) ...................1-6
1.5.3 POWER (AC Adapter) .............................1-8
1.5.4 ∆P (Differential Pressure) ..........................1-8
1.5.5 USB (Computer Interface) ..........................1-8
1.5.6 IrDA (Prnter Interface) ............................1-8
1.5.7 OPT (Opton) .....................................1-9
1.6 Front Panel Buttons ....................................1-9
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Scope ................................................3-1
3.2 Power ................................................3-1
3.2.1 Installng or Replacng Batteres .....................3-1
3.2.2 Usng the AC Power Adapter ........................3-2
3.3 Connectng the Probe and Hose Assembly ...................3-2
3.4 Operatng Parameters .................................. 3-4
3.5 Fuel Selecton ........................................ 3-4
3.6 Temperature Unts Selecton ............................ 3-5
3.7 Pressure Unts Selecton ................................ 3-6
3.8 Polluton Unts Selecton .................................3-7
3.9 Date Setup ........................................... 3-8
3.10 Tme Setup .......................................... 3-9
3.11 O2 Reference Setup ...................................3-10
3.12 Prnt Pressure Selecton ...............................3-11
3.13 Zoom-Dsplay Selecton ................................3-12
3.14 Battery Charger Selecton ..............................3-13
3.15 Loggng Selecton ....................................3-14
3.16 Button Sound ........................................3-14
3.17 Test ID Informaton. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3.18 Username. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3.19 Language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.20 Cal Remnder Perod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3.21 Run/Hold Screen Format ..............................3-21
Instruction 24-9448 
Contents
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operatng Tps .........................................4-1
4.2 Turnng ON the Analyzer and Warm Up ...................4-2
4.3 Selectng a Fuel ....................................... 4-3
4.4 Samplng Pont ....................................... 4-4
4.5 Performng a Combuston Test ........................... 4-5
4.6 Pressure Label Selecton .................................4-7
4.7 Temperature Measurement Label ........................ 4-8
4.8 Makng a Draft / Pressure Measurement .................. 4-9
4.9 Savng Test Data ......................................4-10
4.10 Endng a Combuston Test .............................4-11
4.11 Emptyng the Water Trap ..............................4-11
4.12 Turnng OFF the Analyzer & Purgng ...................4-12
4.13 Low Battery Alarm ...................................4-12
4.14 Data Loggng ........................................4-13
4.14.1 Turnng ON Data Loggng ........................4-14
4.14.2 Settng the Loggng Interval and Duraton ...........4-15
4.14.3 Startng the Data Loggng Process .................4-16
4.14.4 Endng the Data Loggng Process ..................4-17
4.15 Memory ............................................4-17
4.15.1 Recallng Combuston Test Data ...................4-18
4.15.2 Recallng Logged Test Data .......................4-19
4.15.3 Clearng Memory .............................. 4-20
4.16 Downloadng Stored Data to a Computer ..................4-21
4.16.1 PCA 2 Data Recovery Program Installaton ......... 4-22
4.16.2 Computer to PCA 2 Connecton & USB Devce
Drver Installaton ............................. 4-24
4.16.3 Recoverng Data ............................... 4-26
4.17 Importng Saved Data Into a Spreadsheet ..................4-29
4.18 Prntng Test Data ....................................4-31
5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Smart Sensors .........................................5-1
5.2 Startng a Calbraton ...................................5-1
5.3 Pressure Sensor Calbraton ............................. 5-2
5.4 T-Stack Calbraton .................................... 5-4
5.5 T-Ar Calbraton ...................................... 5-6
5.6 CO-LO Sensor Calbraton .............................. 5-8
5.7 SO Sensor Calbraton .................................5-10
2
5.8 NO Sensor Calbraton .................................5-11
5.9 NO Sensor Calbraton .................................5-12
2
5.10 CO-HI Sensor Calbraton ..............................5-13
 Instruction 24-9448
Contents
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 PCA 2 Dsassembly .................................... 6-2
6.2 Water Trap / Flter Mantenance ......................... 6-6
6.2.1 Emptyng the Water Trap Chamber ................. 6-6
6.2.2 Replacng the Flter Element ....................... 6-6
6.3 Smart Sensor Replacement ...............................6-7
6.4 Sensor Only Replacement ............................... 6-8
6.5 Ntrc Oxde Sensor Battery Replacement ..................6-10
6.6 Thermocouple Replacement .............................6-11
6.7 Pump Replacement ....................................6-13
6.8 Cleanng the Probe ....................................6-14
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Analyzer Repar ........................................7-1
7.2 Error Symbols .........................................7-1
7.3 Error Messages Dsplayed After Warm-Up ..................7-2
7.4 Dagnostcs and Status Screens ...........................7-3
8 Parts & Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Replacement Parts ......................................8-1
8.2 Accessores ........................................... 8-4
8.3 Servce Centers ....................................... 8-6
Instruction 24-9448 
Contents
Notes:
v Instruction 24-9448
Introduction
1 Introduction
1.1 PCA 2 General Description
The PCA 2 s a commercal-grade hand-held combuston and emssons
analyzer desgned for on-demand samplng of lght ndustral, nsttu-
tonal, commercal and resdental furnaces, applances, and bolers. The
basc nstrument s suppled wth a probe and hose assembly, nstructon
manual, factory calbrated smart sensors, 4 'AA' alkalne batteres, Data
Download Software wth USB cable and carryng case.
Because of the PCA 2’s ablty to measure up to four gases smultaneously,
t s the perfect tool for servce techncans, nspectors and boler contrac-
tors who need to determne combuston effcency, excess ar, stack gas O
2
and CO levels, stack temperature, draft, and dfferental pressure. The
analyzer can also drectly measure and dsplay NO, NO and SO wth the
2 2
nstallaton of the approprate sensors. Combuston effcency calculatons
can be conducted for the followng fuels: natural gas, ol #2, ol #4, ol #6,
propane, coal, wood, kerosene, bagasse, and dgester gas. A large backlt
graphcal dsplay shows up to eght combuston test values smultaneously,
and ncludes a zoom capablty that provdes an extra large dsplay.
Smart sensor technology allows a new sensor to be nstalled n the feld
wthout havng to calbrate the analyzer before use. New and nnovatve
probe and analyzer desgns allow the PCA 2 to be easly servced, thus
lowerng the cost of ownershp.
Advanced data storage and communcaton features allow the operator
to store up to 500 ndvdual combuston test records, whch can later be
recalled for vewng, prntng, or downloadng to a personal computer. In
ts data loggng mode, the analyzer can store an addtonal 500 data logged
records.
An optonal AC power adapter allows the analyzer to run contnuously for
data loggng purposes.
The optonal sample condtonng probe s recommended when measurng
NO and SO to ensure the hghest degree of measurement accuracy.
2 2
Instruction 24-9448 1-1
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 Type 225 235 245
PCA2 Only Part Number 24-7301 24-7302 24-7303
Measurements
Oxygen (O ) 3 3 3
2
Stack Temperature 3 3 3
Prmary / Ambent Ar Temperature 3 3 3
Carbon Monoxde Low (CO ) 3 3 3
Low
Pressure / Draft 3 3 3
Carbon Monoxde Hgh (CO ) 3
Hgh
Ntrc Oxde (NO) 3
Ntrogen Doxde (NO )
2
Sulfur Doxde (SO )
2
Calculations
Combustion Efficiency 3 3 3
Excess Ar 3 3 3
Carbon Doxde (CO ) 3 3 3
2
NOx (NOx = NO + NO )
2
NOx referenced to %O
2
CO referenced to %O 3 3 3
2
NO referenced to %O 3
2
NO referenced to %O
2 2
SO referenced to %O
2 2
Refer to Secton 8.2 for a lstng of standard and optonal accessores.

1-2 Instruction 24-9448
Introduction
Sales Combo 24-8353 24-8354 24-8355
Sales Combo (Kit) 24-8373 24-8374 24-8375
Model Type 255 265 275
PCA2 Only Part Number 24-7304 24-7305 24-7306
Measurements
Oxygen (O ) 3 3 3
2
Stack Temperature 3 3 3
Prmary / Ambent Ar Temperature 3 3 3
Carbon Monoxde Low (CO ) 3 3 3
Low
Pressure / Draft 3 3 3
Carbon Monoxde Hgh (CO )
Hgh
Ntrc Oxde (NO) 3 3
Ntrogen Doxde (NO ) 3
2
Sulfur Doxde (SO ) 3 3
2
Calculations
Combustion Efficiency 3 3 3
Excess Ar 3 3 3
Carbon Doxde (CO ) 3 3 3
2
NOx (NOx = NO + NO ) 3
2
NOx referenced to %O 3
2
CO referenced to %O 3 3 3
2
NO referenced to %O 3 3
2
NO referenced to %O 3
2 2
SO referenced to %O 3 3
2 2
Instruction 24-9448 1-3
Introduction
1.3 Features & Benefits
• Powered by 4 ‘AA’ alkalne batteres, or NMH rechargeable batteres.
An optonal AC power adapter provdes contnuous operaton.
• Internal chargng crcut allows rechargeable batteres to be charged
nsde the analyzer wth the use of the optonal AC power adapter.
• O and CO measurement standard. Optonal measurement of up to
2 Low
two addtonal gases: CO , NO, NO , or SO .
Hgh 2 2
• Wth the approprate sensors nstalled, the analyzer optonally ds-
plays polluton conversons for CO, NO, NO , and SO . Polluton con-
2 2
versons nclude ppm, #/MBTU, mg/m3, and g/GJ.
• Smart sensor technology allows pre-calbrated sensors to be nstalled
n the feld.
• Automatc zero of all sensng channels on ambent ar when the ana-
lyzer s frst turned ON.
• Automatc flushng of the CO sensor wth fresh ar f the CO level
Low
exceeds 4,000 ppm, thus protectng the CO sensor from hgh CO
Low
levels. To measure CO levels above 4,000 ppm, the analyzer automat-
cally swtches to ts CO sensor, f nstalled.
Hgh
• Automatc purgng of the gas-sample system f the detected gas levels
are abnormally hgh when the analyzer s turned OFF.
• Dsplays temperatures n ether °F or °C.
• Dsplays pressure n ether nwc, mb, Pa, or hPa.
• Backlt graphc LCD wth zoom capabltes.
• Low battery alarm.
• Stores 500 ndvdual combuston records, whch can later be recalled
for vewng, prntng, or downloadng to a personal computer. Stores an
addtonal 500 data logged records.
• Wreless IrDA lnk used for prntng current and stored combuston
records, pressure records, sensor calbraton data, and dagnostc data.
• USB connectvty for downloadng stored data to a personal computer.
• Feld replaceable sensors and thermocouple.
• Two year warranty on analyzer and all gas sensors except the O sen-
2
sor whch has a one (1) year warranty.
1-4 Instruction 24-9448