1. Manuals
  2. Brands
  3. Bacharach Manuals
  4. Test Equipment
  5. PCA 2 24-9448
  6. Operating & maintenance instructions

Bacharach PCA 2 24-9448 Operating & Maintenance Instructions

Portable combustion analyzer
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Portable Combustion Analyzer
Instruction 24-9448
Operation & Maintenance
Rev. 1 - October 2006
Product Leadership • Training • Service • Reliability

Advertisement

Table of Contents
loading

Related Manuals for Bacharach PCA 2 24-9448

Summary of Contents for Bacharach PCA 2 24-9448

  • Page 1 Portable Combustion Analyzer Instruction 24-9448 Operation & Maintenance Rev. 1 - October 2006 Product Leadership • Training • Service • Reliability...
  • Page 2 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.

  • Page 3: Table Of Contents

    Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 PCA 2 General Descrpton .
  • Page 4 Contents 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Operatng Tps .
  • Page 5 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 PCA 2 Dsassembly .

  • Page 6: Instruction

    Contents Notes: Instruction 24-9448...

  • Page 7: Introduction

    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.
  • Page 8 Introduction 1.2 Sales Combo & Model Configurations Sales Combo Sales Combo (Kit) Model Type PCA2 Only Part Number Oxygen (O Stack Temperature Prmary / Ambent Ar Temperature Carbon Monoxde Low (CO Pressure / Draft Carbon Monoxde Hgh (CO Ntrc Oxde (NO) Ntrogen Doxde (NO Sulfur Doxde (SO Combustion Efficiency...
  • Page 9 Sales Combo Sales Combo (Kit) Model Type PCA2 Only Part Number Oxygen (O Stack Temperature Prmary / Ambent Ar Temperature Carbon Monoxde Low (CO Pressure / Draft Carbon Monoxde Hgh (CO Ntrc Oxde (NO) Ntrogen Doxde (NO Sulfur Doxde (SO Combustion Efficiency Excess Ar Carbon Doxde (CO...

  • Page 10: Features & BenefTs

    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. •...

  • Page 11: Operational Overview

    Introduction 1.4 Operational Overview The PCA 2 s powered by ether ts 4 nternal batteres, or by an optonal AC power adapter that operates from any convenent source of 100– 240 VAC, 50/60 Hz power. The type of batteres used can be ether dspos- able alkalne or rechargeable NMH.

  • Page 12: Connector DescrPtOns

    Introduction emsson levels n the stack gas and then dsplay measured and calculated values on ts LCD. Values are lsted n Secton 2 Specfcatons. Durng a test, the CO automatcally flushed wth fresh ar when the detected CO level exceeds 4,000 ppm.
  • Page 13 IrDA – Wireless printer communications port ENT: • Selects a highlighted menu item, or confirms the entry of data • Switches among the Combustion & Emission Test Screens when in the RUN or HOLD mode RUN / HOLD: • Starts and stops a combustion efficiency test •...

  • Page 14: Power (Ac Adapter)

    Introduction 1.5.3 POWER (AC Adapter) The AC power adapter P/N 24-1404 can be used as an external power sup- ply, whch wll run the analyzer on a contnuous bass. When usng rechargeable NMH batteres, the AC power adapter can also be used to charge the batteres whle nsde the analyzer.

  • Page 15: Front Panel Buttons

    1.6 Front Panel Buttons Descrptons of the front panel buttons are gven below. Note that a control may perform multple functons as determned by what screen s beng dsplayed at the tme. The functons of these buttons are defned by labels ap- pearng above them on the LCD.
  • Page 16 Introduction Selects a hghlghted menu. In addton, f changes were made to one of the analyzer’s operatng parameters (e.g., date, tme, O frms those changes and saves them n memory. Starts and stops a combuston test when the Combus- ton Test screen s dsplayed. Pressng ths button n any other screen returns the analyzer to the Combuston Test HOLD screen.

  • Page 17: Specifications

    2 Specifications The PCA 2 Directly Measures and Displays: The gases dsplayed depend on the analyzer’s model number. Refer to Secton 1.2. Oxygen ..........0 to 20.9% Stack Temperature .
  • Page 18 Specifications Normal Operating Conditions: Temperature: Analyzer ....... 32 to 104 ºF (0 to 40 ºC) Probe Tp .

  • Page 19: Power Requirements

    Power Requirements: Four dsposable ‘AA’ alkalne batteres provde at least 15 hours of contnu- ous operaton. NMH rechargeable batteres can also be used, wth the operatng tme dependent on battery type and condton. An optonal AC power adapter, whch runs from any convenent source of 100–240 VAC, 50/60 Hz power, can be used to power the analyzer on a con- tnuous bass.
  • Page 20 Specifications Notes: Instruction 24-9448...

  • Page 21: Initial Setup

    3 Initial Setup 3.1 Scope Before usng the PCA 2, you MUST: • Install batteres, or plug n the optonal AC power adapter (Secton 3.2) • Connect the probe and hose assembly (Secton 3.3) • Check, and f necessary, make changes to the analyzer’s confguraton (Secton 3.4) 3.2 Power 3.2.1 Installing or Replacing Batteries...

  • Page 22: Using The Ac Power Adapter

    Initial Setup 3.2.2 Using the AC Power Adapter The AC power adapter s capable of powerng the analyzer on a contnuous bass. The adapter plugs nto an approprate 100–240 VAC, 50/60 Hz wall outlet, and produces an output of +9 VDC. The adapter’s output connector plugs nto the analyzer’s POWER jack located on the bottom of the unt (Fgure 3-2).
  • Page 23 Option Connector (Optional External Measurement) AC Power Adapter Jack (POWER) Stack Gas Thermocouple Connector (T-STACK) Probe Tube Probe Stop Figure 3-2. Connecting the Probe and Hose Assembly to the PCA 2 Instruction 24-9448 T-STACK T-AIR POWER Draft Gas Sample Hose Hose (+ ∆P) (GAS)

  • Page 24: OperatNg Parameters

    Initial Setup 3.4 Operating Parameters The PCA 2 s set up at the factory for the followng operatng parameters: Fuel .....Natural Gas Temperature Unts .

  • Page 25: Temperature UnTs SelectOn

    3.6 Temperature Units Selection Select to dsplay temperature n ether °F or °C as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button. If necessary, press ESC untl MENU appears above F2. 2. Use the buttons to hghlght SETUP, and then press ENT to dsplay the SETUP MENU.

  • Page 26: Pressure UnTs SelectOn

    Initial Setup 3.7 Pressure Units Selection Select to dsplay pressure n Inches of Water Column (nwc), mllbar (mb), Pascals (Pa), or hectoPascals (hPa) as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button. If necessary, press ESC untl MENU appears above F2.

  • Page 27: PollutOn UnTs SelectOn

    3.8 Pollution Units Selection The PCA 2 s capable of convertng the measured ppm levels of CO, NO, NO polluton unts usng CFR40 Part 60 emsson factors. Note that the polluton-unt conversons for NO, NO and NOx are based on the molecular weght of NO Select to dsplay polluton unts n parts per ml- lon (ppm), pounds of pollutant per mllon BTU...

  • Page 28: Date Setup

    Initial Setup 3.9 Date Setup The date s stored n the format: MM/DD/YY. Its value s part of the date and tme stamp that s saved along wth each combuston test record. Set the analyzer’s nternal clock to the current date as follows: 1.

  • Page 29: Time Setup

    3.10 Time Setup The tme s stored n the format: hh:mm:ss AM/PM. Its value s part of the date and tme stamp that s saved along wth each combuston test record. Set the analyzer’s nternal clock to the current tme as follows: 1.

  • Page 30: Reference Setup

    Initial Setup 3.11 O Reference Setup The measured values of CO, NOx, and SO ndvdually referenced to a specfc O of between 0 and 15%. Indvdually set up the O of the above gases as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button.
  • Page 31 3.12 Print Pressure Selection Select whether to prnt or not prnt the pressure measurement on the combuston test prntout as follows (see Fgure 4-3 on Page 4-31): 1. Dsplay the MAIN MENU by pressng the MENU (F2) button. If necessary, press ESC untl MENU appears above F2.

  • Page 32: Zoom-DSplay SelectOn

    Initial Setup 3.13 Zoom-Display Selection Zoom-dsplay provdes an addtonal combuston test screen that shows the test values of O and effcency n extra large characters, thus al- lowng the operator to vew the dsplay of these values from a longer dstance. Pressng the ENT button whle performng a com- buston effcency test wll now show the zoom- dsplay.

  • Page 33: Battery Charger SelectOn

    3.14 Battery Charger Selection When usng rechargeable NMH batteres, the AC power adapter can be used to charge the bat- teres whle nsde the analyzer. The analyzer’s rapd-charger crcut, however, must be frst turned ON. IMPORTANT: When using disposable alkaline batteries, the analyzer’s battery charger circuit should be OFF to prevent the batteries from overheating.

  • Page 34: Button Sound

    Initial Setup 3.15 Logging Selection When the loggng functon s actvated, up to 500 combuston test records wll be automatcally stored n memory at a preset nterval over a pre- determned length of tme. Refer to Secton 4.12 for detaled nformaton on how to select the loggng functon;...

  • Page 35: Operation

    4 Operation 4.1 Operating Tips • When an analyzer s brought n from a cold vehcle, let t warm up slowly to mnmze condensaton. Temperatures below freezng wll not dam- age the analyzer; however, brngng a cold analyzer nto a warm, humd envronment may cause condensate to form nsde the case.

  • Page 36: TurnNg On The Analyzer And Warm Up

    Operation 4.2 Turning ON the Analyzer and Warm Up 1. Connect the probe and hose assembly, and make sure that the analyzer s properly set up per Secton 3 Initial Setup. IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer! 2.
  • Page 37 4.3 Selecting a Fuel The top lne of the Combuston Test HOLD screen shows the fuel currently selected. In the example shown, the current fuel s NATURAL GAS. If necessary, change the fuel as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button.

  • Page 38: Sampling Point

    Operation 4.4 Sampling Point FORCED AIR FURNACE – For atmospherc burner or gravty vented, forced ar heatng equpment wth a clamshell or sectonal heat exchanger de- sgn, test each of the exhaust ports at the top of the heat exchanger. The probe should be nserted back nto each of the exhaust ports to obtan a flue-gas sample, before any dluton ar s mxed n.

  • Page 39: Performing A Combustion Test

    4.5 Performing a Combustion Test Ensure that the followng has been completed, and then proceed wth the combuston test as descrbed below: • Turn ON analyzer and allow t to warm up (Secton 4.2). • Select fuel beng burned (Secton 4.3). •...
  • Page 40 Operation 4. You can now begn burner-servce procedures. The analyzer readngs wll change quckly to show changes n burner performance. CAUTION: Position the Water Trap with its gas-flow arrow pointing upward. Do not let water condensate go above the tip of the riser tube.

  • Page 41: MakNg A Draft / Pressure Measurement

    4.6 Making a Draft / Pressure Measurement The dfference n pressure (∆P) between two areas can be measured by usng the analyzer’s two pressure ports and the PRESSURE screen. By usng the –∆P port as the reference, the pressure appled to the +∆P port wll be dsplayed on the PRESSURE screen as the dfferental pressure between the two ports.

  • Page 42: Saving Test Data

    Operation b. Dsconnect any hoses connected to the +∆P and –∆P ports, and then press ENT to zero the pressure sensor. c. Reconnect any hoses. When measurng draft, simply leave the –∆P port open to the atmosphere and connect the probe’s draft hose to the +∆P port (see Fgure 3-2 on Page 3-3).

  • Page 43: Ending A Combustion Test

    4.8 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 untl all combuston gases have been flushed from the analyzer as ndcated by the O 4.9 Emptying the Water Trap The Water Trap / Flter Assembly removes...

  • Page 44: Low Battery Alarm

    Operation 4.10 Turning OFF the Analyzer & Purging Turn OFF the analyzer by pressng the I/O but- ton for at least 2 seconds, or untl two beeps are heard. The unt wll count down 5 seconds before shuttng down, gvng the operator an opportu- nty to keep the analyzer turned ON by pressng the RUN/HOLD button.

  • Page 45: Data Logging

    (refer to Secton 4.14). Downloaded data s stored on the computer’s hard drve as a comma-separated-value ASCII text fle wth a CSV extenson, whch can be opened by most spreadsheet programs for analyss. TIP: The latest PCA 2 data recovery software can be download- ed from http://www.bacharach-inc.com/downloads. Instruction 24-9448 Operation 4-11...
  • Page 46 Operation 4.12.1 Turning ON Data Logging IMPORTANT: Before turning ON data logging and starting the data logging process, the analyzer should already be set up to perform a combustion test per Section 4.5. Turn ON data loggng as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button.
  • Page 47 4.12.2 Setting the Logging Interval and Duration The loggng nterval s the length of tme between measurements, whle the loggng duraton s the tme allocated to the loggng process. Set the loggng nterval and duraton as follows: TIP: If the duration is set for more than 10 hours, we recom- mend using the optional AC power adapter to power the analyzer.

  • Page 48: StartNg The Data LoggNg Process

    Operation 4.12.3 Starting the Data Logging Process After turnng ON data loggng and settng the nterval and duraton, the analyzer wll pause at the LOGGING SUMMARY screen, where the currently selected nterval and duraton tme perods are dsplayed. Press ENT to start the combuston test and log- gng process.

  • Page 49: EndNg The Data LoggNg Process

    4.12.4 Ending the Data Logging Process Data loggng wll stop and the pump wll turn OFF after the prescrbed duraton, or after all 500 memory locatons are flled. To ext the Combuston Test LOG screen, press the RUN/HOLD button twice to dsplay the Com- buston Test HOLD screen.

  • Page 50: RecallNg CombustOn Test Data

    Operation 4.13.1 Recalling Combustion Test Data Recall ndvdual combuston test data records as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button. If necessary, press ESC untl MENU appears above F2. 2. Use the buttons to hghlght MEMORY, and then press ENT to dsplay the MEMORY MENU.
  • Page 51 4.13.2 Recalling Logged Test Data Recall ndvdual logged combuston test data records as follows: 1. Dsplay the MAIN MENU by pressng the MENU (F2) button. If necessary, press ESC untl MENU appears above F2. 2. Use the buttons to hghlght MEMORY, and then press ENT to dsplay the MEMORY MENU.

  • Page 52: ClearNg Memory

    Operation 4.13.3 Clearing Memory When all memory (“snap shot”) locatons used to store ndvdual combuston test records have been flled, the next combuston test record saved wll overwrte the oldest. When all loggng memory locatons n the loggng drectory are full, they must be manually cleared n order to store new data.

  • Page 53: DownloadNg Stored Data To A Computer

    4.14 Downloading Stored Data to a Computer The combuston test data that was stored n ether the analyzer’s Memory Drectory (Secton 4.7), or Loggng Drectory (Secton 4.12), can be down- loaded to a computer usng the PCA 2 Data Recovery Program and USB cable that are suppled wth the analyzer.

  • Page 54: Pca 2 Data Recovery Program InstallatOn

    Operation 4.14.1 PCA 2 Data Recovery Program Installation The PCA 2 Data Recovery Program s suppled wth the analyzer on a CD (P/N 24-1425). Install ths program as follows: 1. Insert the PCA 2 CD nto the computer’s CD-ROM drve. 2.
  • Page 55 Operation 5. Clck Install to confrm the destnaton folder and user nformaton. 6. Clck Finish after all fles have been coped nto the destnaton folder. 7. At ths tme the PCA2 Data Recovery Program con should appear under "Start All Programs menu. 8.
  • Page 56 Operation 4.14.2 Computer to PCA 2 Connection & USB Device Driver Installation Connect the USB cable (P/N 104-4032) that was suppled wth the PCA 2, and, f necessary, nstall the analyzer’s USB devce drver as follows: 1. Wth both the PCA 2 and computer turned ON, nsert the appropr- ate ends of the USB cable nto the USB connectors on the PCA 2 and computer as shown n Fgure 4-2.
  • Page 57 3. Select “Install from a lst or specfc locaton (Advanced)” and clck Next>. 4. Select to search for the best drver and then browse to folder C:\Program Fles\PCA2Data. Clck Next>. Select to search for driver in folder C:\Program Files\ PCA2Data 5.

  • Page 58: RecoverNg Data

    1. Start the program by ether double-clckng the PCA2 con on the Wndows desktop, or clckng the PCA2 shortcut n start menu. The “Bacharach PCA 2 Data Recovery Program” wndow should appear. Observe that the wndow s dvded nto two sectons. The left-hand secton s used to recover loggng data, whle combuston data s recov- ered from the rght-hand secton.
  • Page 59 Use this section of window to Recover Logging Data Status line showing PCA 2 is successfully connected to the computer Select a pre-existing folder or create a new folder to store the downloaded file Enter filename File type preset to *.cvs Location of downloaded file Click Start...
  • Page 60 Step 2, but ths tme usng the rght-hand secton of the “Bacharach PCA 2 Data Recovery Program” wndow. NOTE: Once either the logging data or combustion data has been recovered, that portion of the recovery program’s window...

  • Page 61: UnpluggNg The Usb Cable

    USB drver” and then clck Stop. 3. Clck OK to confrm that the devce s to be stopped. 4. Wat untl “Bacharach PCA2 USB drver” s removed from the screen, and then clck Close. 5. The USB cable can now be safely unplugged.

  • Page 62: ImportNg Saved Data Into A Spreadsheet

    Operation 4.15 Importing Saved Data Into a Spreadsheet Data that was recovered and saved as an ASCII text fle wth a “CSV” extenson, as descrbed n Secton 4.14, can easly be opened for vewng n most spreadsheet programs by smply double-clckng the flename. For example: double-clckng the flename Customer XYZ.csv should automat- cally open the spreadsheet program and dsplay the contents of the fle.
  • Page 63 TABLE 4-2 . DOWNLOADED DATA FIELDS Field Column Name Tme Date Fuel ppm CO(O2) %Effcency %CO2 TStk TAr TempUnt ppm NO(O2) ppm NO2(O2) ppm NOx(O2) ppm SO2(O2) CO_O2Ref NOx_O2Ref SO2_O2Ref Pressure Pressure Unts Polluton Unts PS Voltage NO Temp (1) %O reference as selected per Section 3.11 (2) Pressure units as selected per Section 3.7 (3) Pollution units as selected per Section 3.8...

  • Page 64: Printing Test Data

    Operation 4.16 Printing Test Data Combuston or pressure data that s currently beng dsplayed can be sent to a prnter usng IrDA protocol as descrbed below. Data that s stored n memory can also be prnted by frst dsplayng the stored test data as descrbed n Sectons 4.13.1 &...
  • Page 65 (i.e., oxygen level above 16%). Three (XXX) indicate sensor over- range. Operation BACHARACH, INC. PCA 2 SN: xxxxxx FUEL 4.0 % 12 ppm 82.6 % 9.5 % 374 °F...
  • Page 66 Operation Notes: 4-32 Instruction 24-9448...

  • Page 67: Calibration

    ON. 5.1 Smart Sensors The PCA 2 uses Bacharach’s new “Smart Sensor” technology, meanng that the calbraton data for each sensor s stored n nonvolatle memory on the sensor’s prnted crcut board.

  • Page 68: Pressure Sensor CalBratOn

    Calibration Any errors detected durng warm-up wll be lsted on the dsplay mmedately fol- lowng warm-up. For example, the screen to the rght shows that the battery s low. Correct any errors before proceedng. Refer to Secton 7.3 for a lstng of error messages and ther meanng.
  • Page 69 play the CALIBRATE PRESSURE screen. “Measured” is the pressure value currently being detected by the pressure sensor, while “Applied” is a known value of pressure that will be applied for calibration purposes. 4. With both the –∆P and +∆P ports open to the atmosphere, observe that the current Measured pressure readng should be 0 ±0.01 nwc.

  • Page 70: T-Stack CalBratOn

    Calibration 5.4 T-Stack Calibration Ths procedure frst zeros and then spans the stack-temperature channel to known temperature values. The use of an electronc thermocouple smulator s the preferred method of producng the desred calbraton temperatures. Alternatvely, contaners of ce water and bolng water can be used. Material Required: •...
  • Page 71 5. Wat untl the Measured readng stablzes, and then press Measured value to that of the Appled value; after whch the message “Good Calbraton” should brefly appear followed by the CALIBRATE TS-SPAN screen. TS-Span Procedure: 6. Set thermocouple smulator to 572 °F (300 °C), and then use the tons to enter an Appled value that exactly equals the settng of the smulator.
  • Page 72 Calibration 5.5 T-Air Calibration Ths procedure frst zeros and then spans the ambent-temperature chan- nel to known temperature values. The use of an electronc thermocouple smulator s the preferred method of producng the desred calbraton temperatures. Alternatvely, contaners of ce water and bolng water can be used. Material Required: •...
  • Page 73 The calibration range is from 32 to 41 °F (0 to 5 °C). An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. 5. Wat untl the Measured readng stablzes, and then press calbrate the TA-Zero Measured value to that of the Appled value;...

  • Page 74: Co-Lo Sensor CalBratOn

    Calibration 5.6 CO-LO Sensor Calibration Note that the CO-LO sensor also measures H pensatng the CO readng for the presence of H procedure frst spans the CO-LO sensor and, optonally, spans the H of the sensor to known gas levels. Material Required: •...
  • Page 75 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. The sen- sor will now be marked as being BAD in the DIAGNOSTICS screen. NOTE: H calibration can be bypassed by pressing the ESC button, after which the CALIBRATION LIST screen is re-dis- played.

  • Page 76: Sensor CalBratOn

    Calibration 5.7 SO Sensor Calibration Ths procedure spans the optonal sulfur doxde sensor to a known gas level. Material Required: • Calbraton Kt, P/N 24-7059 • Gas Cylnder: 100 ppm SO Procedure: 1. If not already done, turn ON the analyzer and dsplay the CALIBRATION LIST screen per Secton 5.2.

  • Page 77: No Sensor CalBratOn

    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.

  • Page 78: Sensor CalBratOn

    Calibration brefly appear followed by the CALIBRATION LIST screen beng re-dsplayed. 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”...

  • Page 79: Co-Hi Sensor CalBratOn

    cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step. 5. Adjust regulator for a flowmeter ndcaton of approxmately 2 SCFH. Wat untl the Measured readng stablzes (approxmately 3 mnutes), and then press Appled value. The message “Good Calbraton” should brefly appear followed by the CALIBRATION LIST screen beng re-dsplayed.
  • Page 80 Calibration 4. Use the Appled value that exactly equals the concen- traton stamped on the CO cylnder. The calibration range is from 250 to 11,000 ppm. An attempt to calibrate out- side this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

  • Page 81: Maintenance

    Sensor replacement (Secton 6.3) • Probe thermocouple replacement (Secton 6.6) • Pump (gas or purge) replacement (Secton 6.7) • Cleanng the probe (Secton 6.8) All other mantenance should be performed by an authorzed Bacharach Servce Center. Refer to Secton 8.3. Instruction 24-9448 Maintenance...

  • Page 82: Pca 2 DSassembly

    Maintenance 6.1 PCA 2 Disassembly The followng procedure descrbes how to dsassemble the analyzer, whle Fgures 6-1 thru 6-4 llustrate how the analyzer s put together. Tools Requred: • Medum Phllps Screwdrver Procedure: 1. Unplug all thermocouples from bottom of analyzer. 2.
  • Page 83 Model Position Sensors Type and position determined by model number Gas Pump Motor Connector Battery Connector on printed circuit board Gas Pump Purge Air In Figure 6-2. Inside View with Rear Case Removed Instruction 24-9448 Sensor Positions 24-7301 24-7302 24-7303 24-7304 +∆P –∆P Pressure...
  • Page 84 Maintenance PRESSURE SENSOR on printed circuit board +∆P (Top) –∆P (Bottom) To Sensors GAS PUMP Model 225 P/N 24-7301 Model 255 P/N 24-7304 P/Ns 24-7302 & 24-7303 P/Ns 24-7305 & 24-7306 Figure 6-3. Tubing Connections PURGE PUMP –∆P PRESSURE +∆P PURGE AIR Gas OUT Gas IN...
  • Page 85 Purge Pump to J9 Wire Routing Solder (2 Places) Battery to J14 Red dot on pump indicates positive (red wire) connection Solder Connections Instruction 24-9448 LCD Connector (opposite side of board) Factory Test Connector Pump to J8 Battery to J14 Lock Tabs (both ends) Ribbon Cable Conection...

  • Page 86: Water Trap / FLter MaNtenance

    Maintenance 6.2 Water Trap / Filter Maintenance 6.2.1 Emptying the Water Trap Chamber The water trap chamber should be empted after every test, or when the water condensate approaches the tp of the rser tube (refer to Secton 4.9). 1. Remove water trap chamber per Fgure 6-5. 2.

  • Page 87: Smart Sensor Replacement

    6.3 Smart Sensor Replacement Bacharach’s Smart sensor technology allows new sensors to be nstalled wthout needng to be calbrated nsde the analyzer. NOTE: Sensors may be purchased with and without the Smart sensor technology PCB. See Section 6.4 on how to change just the sensor itself. Calibration must be performed if the sensor is purchased without the Smart technology PCB.

  • Page 88: Sensor Only Replacement

    Maintenance 6.4 Sensor Only Replacement All sensors are replaced n a smlar manner. Do the followng to replace ether the O2, CO-LO, CO-HI, NO, NO2, or SO2 sensor. Refer to Section 8.1 Replacement Parts for list of sensors and part numbers. Turn OFF the analyzer.
  • Page 89 12. Plug the sensor nto analyzer; and then reattach tubng to gas cup. 13. Install the sensor retaner and battery cover. 12. Allow the sensor that was just nstalled tme to stablze n the crcut before contnung wth ths procedure. Stablzaton tme for all sen- sors (except for the NO sensor) s about 1 hour.

  • Page 90: NTrC OxDe Sensor Battery Replacement

    Maintenance 6.5 Nitric Oxide Sensor Battery Replacement A sngle lthum battery, located on the NO Smart Sensor assembly, apples a bas voltage to the NO sensor to prevent the sensor from destablzng when the analyzer s turned off. The NO bas battery s expected to last at least the lfe of the NO sensor.

  • Page 91: Thermocouple Replacement

    6.6 Thermocouple Replacement Usng the approprate thermocouple replacement kt lsted below, replace the probe’s thermocouple as follows: Thermocouple Replacement Kits: Part Number Replaces Thermocouple in a Probe with a Tube Length of . . . 24-8413 6 nches 24-8414 12 nches 24-8415 24 nches 24-8416...
  • Page 92 Maintenance 3. Pull old thermocouple from probe body and dscard. 4. The new thermocouple has been coled for shppng purposes. Straghten the thermocouple usng your thumb and ndex fnger. 5. If not already done, nstall suppled O-Rngs onto thermocouple. 6. Insert thermocouple nto probe body untl t “bottoms out.” 7.

  • Page 93: Pump Replacement

    6.7 Pump Replacement Parts & Tools Required: • Replacement Pump: Gas Pump P/N 24-1393 Purge Pump P/N 3015-1716 • Solderng Iron and Solder • Medum Phllps Screwdrver • Small Flat Blade Screwdrver Procedure: 1. Gan access to both the gas and purge pumps by removng the rear case.

  • Page 94: Cleaning The Probe

    Maintenance 6.8 Cleaning the Probe The probe tube and gas-sample hose wll become drty under normal use. Note that the water trap’s flter element should prevent soot from reachng the analyzer’s nternal components. If the probe s not kept clean, t could become clogged and restrct the flow of gas nto the analyzer, resultng n ncorrect combuston test readngs and calculatons.
  • Page 95 Maintenance Notes: Instruction 24-9448 6-15...

  • Page 96: ReplacNg The FLter Element

    Replacng ether the gas or purge pump Informaton on how to perform these repars s provded n Secton 6. All other repars should be performed by an authorzed Bacharach Servce Center (refer to Secton 8.3). Any repars performed by an unauthor- ized servce organzaton wll vod the analyzer’s warranty and release...

  • Page 97: Error Messages DSplayed After Warm-Up

    Troubleshooting 7.3 Error Messages Displayed After Warm-Up If there were problems detected durng warm-up, error messages that descrbe the nature of the problems are dsplayed mmedately followng the analyzer’s 60 second warm-up perod. If problems were detected, the analyzer wll not automatcally swtch to the Combuston Test HOLD screen after warm-up.
  • Page 98 7.4 Diagnostics and Status Screens The DIAGNOSTICS screen lsts the current status of all the SMART gas sensors nstalled and the O The STATUS screen provdes a quck reference of key tems when troubleshootng. Instruction 24-9448 sensor status and mV output. Troubleshooting DIAGNOSTICS O2 Value: 41mv Good...
  • Page 99 Troubleshooting Notes: Instruction 24-9448...

  • Page 100: Parts & Service

    8 Parts & Service 8.1 Replacement Parts Item (Fig. 8-1) Man PCB Assembly ......24-1371 LCD Module .
  • Page 101 Parts & Service Item (Fig. 8-1) Sensors (NOT-calbrated): ......... .24-0788 sensor PCB only * .
  • Page 102 Instruction 24-9448 (O2 is not a Smart sensor) IN (Bottom) OUT (Top) (typical 2 places) Figure 8-1. Parts (1 of 2) Parts & Service (typical 3 places) (typical 2 places) (typical 4 places)
  • Page 103 Parts & Service Figure 8-1. Parts (2 of 2) Instruction 24-9448...

  • Page 104: AccessorEs

    8.2 Accessories Standard Accessories Carryng Case ......... . 24-0865 Batteres, 'AA' Alkalne (4 requred) .
  • Page 105 Parts & Service Optional Accessories AC Power Adapter (Input: 100–240 VAC, 50/60 Hz; Output: 9 VDC @ 1 A) ..24-1404 PCA 2 Protectve Boot wth magnet ......24-1409 Ambent Ar Thermocouples (T-AIR), K-Type: 10 ft.

  • Page 106: Service Centers

    United States Bacharach Inc. 621 Hunt Valley Crcle New Kensngton, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Emal: help@bacharach-nc.com Canada Bacharach of Canada, Inc. 250 Shelds Court Unt #3 Markham, Ontaro L3R 9W7 Canada Phone: 905-470-8985 Fax: 905-470-8963 Emal: bachcan@drect.com México Bacharach de Méxco...
  • Page 107 Notes:...
  • Page 108 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 Website: www.bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A. ISO 9001:2000...

This manual is also suitable for:

Pca 2

Table of Contents