Bacharach PCA 400 User Manual
  1. Manuals
  2. Brands
  3. Bacharach Manuals
  4. Measuring Instruments
  5. PCA 400
  6. User manual

Bacharach PCA 400 User Manual

Combustion analyzer
Hide thumbs Also See for PCA 400:
Table of Contents

Advertisement

Quick Links

Combustion Analyzer
for Commercial & Light Industrial Use
Combustion & Emissions
P/N: 0024-9551 | July 2018 Revision 1
®
User
Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PCA 400 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Bacharach PCA 400

Summary of Contents for Bacharach PCA 400

  • Page 1 ® Combustion Analyzer for Commercial & Light Industrial Use Combustion & Emissions User Manual P/N: 0024-9551 | July 2018 Revision 1...
  • 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

    400 User Manual ® Table of Contents Introduction ............. 6 About this Manual ......................6 Conventions ........................6 1.2.1 Short Form Instructions..........................6 1.2.2 Iconography ..............................7 General Safety Statements ..................... 7 Product Overview ......................8 Product Description ......... 9 Combustion & Emissions Analyzer ................10 2.1.1 Overview ..............................10 2.1.2...
  • Page 4 400 User Manual ® Settings & Features ........32 Language Selection ......................32 Date & Time ........................32 Username ........................33 Button Sound ......................... 34 Inactivity Timeout ......................34 Post-Purge Period ......................34 Carbon Monoxide (CO) Zero ..................34 Sensor Setup ........................35 Bluetooth Setup ......................
  • Page 5 Service Center Locations ....................72  Service Center Locations Location Contact Information Shipping Address Phone: +1 724 334 5000 Bacharach, Inc. Toll Free: +1 800 736 4666 621 Hunt Valley Circle United States Fax: +1 724 334 5001 New Kensington, PA 15068, USA Email: help@mybacharach.com...

  • Page 6: Introduction

    Iconography ..............................7 General Safety Statements ....................7 Product Overview ......................8 1.1 About this Manual Thank you for investing in a Bacharach PCA 400 Combustion Analyzer. To ensure operator ® safety and the proper use of the PCA 400, please read the contents of this manual for ®...

  • Page 7: Iconography

    400 User Manual ® 1.2.2 Iconography Alert Icon Description Imminently hazardous situation which, if not avoided, will result DANGER in death or serious injury. Potentially hazardous situation which, if not avoided, could WARNING result in death or serious injury. Potential electrical shock hazard which, if not avoided, could WARNING result in death or serious injury.

  • Page 8: Product Overview

    ® 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. CAUTION: When the instrument is used in an inefficient furnace or boiler application where there is a high soot concentration, the probe’s sample filter may become...

  • Page 9: Product Description

    400 User Manual ® 2. Product Description Combustion & Emissions Analyzer ................10 2.1.1 Overview ..............................10 2.1.2 Keypad .................................11 2.1.3 Display .................................11 2.1.4 Instrument Connections ..........................13 2.1.5 Interfaces ..............................14 2.1.6 Components ...............................15 Sample Line & Probe Assembly ..................16 2.3 Power Configurations ..................... 17 Fig.

  • Page 10: Combustion & Emissions Analyzer

    400 User Manual ® 2.1 Combustion & Emissions Analyzer The PCA 400 is designed for use in commercial and light industrial applications. ® The analyzer is capable of measuring O , CO, NO, NO or SO , stack / ambient temperatures, and pressure.

  • Page 11: Keypad

    400 User Manual ® 2.1.2 Keypad Fig. 2-3: Navigation Keypad Back Key - Displays the previously viewed screen. In addition, if changes have been made to one of the analyzer’s operating parameters (e.g., date, time, O reference, etc.), pressing this button aborts any changes, restores the old values and displays the previously viewed screen.
  • Page 12 400 User Manual ® Status Icons Icon Name Description Pump OFF Sample pump is idle Pump ON Sample pump is operating 100% Charge 75% Charge Battery / Power Status 50% Charge 25% Charge Bluetooth Active Bluetooth is enabled and compatible devices may be connected ®...

  • Page 13: Instrument Connections

    400 User Manual ® Function Icons Icon Name Description Measure Touch to select test to perform (combustion, pressure, temperature) Turn On Pump Touch to turn on pump; used with to toggle RUN / HOLD mode Stop Pump Touch to stop pump; used with to toggle RUN / HOLD mode Print Touch to print data to IrDA + Bluetooth printer...

  • Page 14: Interfaces

    400 User Manual ® 2.1.5 Interfaces Computer Interface Data that has been stored in the analyzer’s onboard memory can be uploaded to a personal computer by connecting the included Micro-B USB Cable between the USB ports of the computer and the analyzer. Fig.

  • Page 15: Components

    Communication Range ® Lorem ipsum (9.1 m) 2.1.6 Components 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. 0024-9551 Revision 1...

  • Page 16: Sample Line & Probe Assembly

    400 User Manual ® Fig. 2-8: Sensor & Battery Positions Sensor Position 1 - O Sensor Position 4 - NO Sensor Position 2 - CO or CO Battery Compartment HIGH Sensor Position 3 - NO or SO 2.2 Sample Line & Probe Assembly The PCA 400’s sample line and probe are modular, allowing users to quickly swap ®...

  • Page 17: Power Configurations

    400 User Manual ® IMPORTANT: Replacement parts and accessories are sold separately. See Part Numbers (Section 7.1) for more information. 2.3 Power Configurations The PCA 400 comes standard with a rechargeable lithium-ion battery pack which is ® capable of powering the analyzer for up to 12-hours. Users may also run the analyzer on 4 ×...

  • Page 18: Operation

    400 User Manual ® 3. Operation Setup ..........................18 3.1.1 Operation Tips ............................18 3.1.2 Inspection / Prerequisites ..........................20 3.1.3 Connecting Probe Assembly ........................21 3.2 Performing Combustion Test ..................22 3.2.1 Combustion User Preferences ........................22 3.2.2 Combustion Analysis ..........................23 3.2.3 Additional Settings .............................25 3.3 Performing Pressure Test ....................
  • Page 19 400 User Manual ® Start Analyzer in Fresh Air Ensure that the analyzer is sampling fresh air during initial 60-second warm-up period. Pulling a stack gas sample through the analyzer during its warm-up period will not damage the analyzer, but it will result in incorrect sensor readings, and may result in sensor error messages appearing after the warm-up cycle completes.

  • Page 20: Inspection / Prerequisites

    400 User Manual ® Purge Analyzer After Each Use The analyzer should be purged after performing a combustion test. After removing probe from the stack, let the pump run for at least 10-minutes to remove any stack gases and dry any condensate from inside the sensor chamber and probe assembly.

  • Page 21: Connecting Probe Assembly

    400 User Manual ® 3.1.3 Connecting Probe Assembly Connect Analyzer to Sample Line Firmly insert the gray quick-connector into the base of the analyzer. Users will hear a click once a secure connection has been made. Fig. 3-3: Insert Gray Quick-Connector into Analyzer Connect Probe to Sample Line Firmly insert the blue quick-connector into the base of the probe handle.

  • Page 22: Performing Combustion Test

    400 User Manual ® Turn On Analyzer Press the POWER button to begin a 60-second warm-up period. Users will hear the pump begin operation and splash screen should appear on the analyzer’s display. Fig. 3-5: Press Power Button 60-SECOND WARM-UP CAUTION: Ensure that the analyzer is sampling fresh air during the warm-up.

  • Page 23: Combustion Analysis

    400 User Manual ® 3.2.2 Combustion Analysis 1. Select Folder / Memory Location (User Discretion) The PCA 400 gives users the ability to organize their records in a folder structure for later ® viewing and downloads. f To change Folder / Memory Location: Main Menu  Memory ( )  use navigation keys to highlight the desired folder ...
  • Page 24 400 User Manual ® 5. Run Sample Pump After starting the pump, allow readings to stabilize for a minimum of 3-minutes or as long as required by manufacturer specifications / compliance testing procedures. f To start the pump: press Run / Hold ( ) f To stop the pump: press Run / Hold ( ) Fig.

  • Page 25: Additional Settings

    400 User Manual ® CAUTION: The probe MAY BE HOT after analysis and can cause bodily harm and / or damage to the analyzer. Allow the probe sufficient time (about 5-minutes) to cool before handling or storing in the supplied carrying case. CAUTION: Never disconnect the probe from the instrument until purging is complete.
  • Page 26 400 User Manual ® Run / Hold Format (List View) The analyzer allows users to customize the order in which analysis results are displayed. f To update Run / Hold Format: Options ( )  Run / Hold Format  set prioritization via dropdown menu ...
  • Page 27 400 User Manual ® Line Graph Settings (Trending View) The analyzer allows users to customize the order in which analysis results are displayed. f To update Line Graph Settings: Options ( )  Line Graph Settings  set parameters & time via dropdown menu ...

  • Page 28: Performing Pressure Test

    400 User Manual ® 3.3 Performing Pressure Test 3.3.1 Pressure User Preferences Pressure Units Select to display pressure in Inches of Water Column (inwc), Millibar (mB), Pascal (Pa), Hecto- Pascal (hPa) or Millimeters of Water Column (mmwc). f To change Pressure Units: Main Menu  Settings ( )  Pressure Units  select InchesWater, milliBar, Pascals, HectoPascals or mmH 3.3.2 Pressure Analysis 1.
  • Page 29 400 User Manual ® 4. Insert Probe Tube into Measurement Area After identifying the flue / exhaust stack, select a safe and convenient location from which to take measurements. f To measure draft: insert the probe tube into the flue / exhaust stack / measurement area and observe the reading on the Pressure screen.

  • Page 30: Temperature Test

    400 User Manual ® 3.4 Performing Temperature Test 3.4.1 Temperature User Preferences Temperature Units Select to display temperature in Fahrenheit (ºF) or Celsius (ºC). f To change Temperature Units: Main Menu  Settings ( )  Temperature Units  select Fahrenheit or Celsius 3.4.2 Temperature Analysis 1.
  • Page 31 400 User Manual ® 3. Select Measurement Type f To select Measurement Type: Main Menu  Measure ( )  select Temperature 4. Zero Readings If the analyzer is not displaying zero with both thermocouples exposed to the same conditions, the temperature channels need to be zeroed 5.

  • Page 32: Settings & Features

    400 User Manual ® 4. Settings & Features Language Selection ......................32 Date & Time ........................32 Username ........................33 Button Sound ........................34 Inactivity Timeout ......................34 Post-Purge Period ......................34 Carbon Monoxide (CO) Zero ..................34 Sensor Setup........................35 Bluetooth Setup ......................

  • Page 33: Username

    400 User Manual ® Fig. 4-1: Date and Time Menu Date - change date (must delete / clear current date before you can add new date). Date Format - change between month / day / year and day / month / year calendar formats. Time - change time (must delete / clear current time before you can add new time).

  • Page 34: Button Sound

    400 User Manual ® 4.4 Button Sound The analyzer includes a sound transducer which beeps to signal when a button has been pressed. The audible notification can be turned OFF and ON by changing the user preferences. Enabling / Disabling Button Sound f To enable / disable Button Sound: Main Menu ...

  • Page 35: Sensor Setup

    400 User Manual ® Auto-Zero When the CO channel is set to Auto-Zero, the CO sensor is zeroed to the ambient CO level during start up. Changing CO Zero Method Auto-Zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurements.

  • Page 36: Bluetooth ® Setup

    400 User Manual ® Fig. 4-3: Sensor Setup Position 1 - the analyzer is required have an O sensor in this position. Position 2 - the analyzer can optionally have either Position 1 or a CO sensor in this position. HIGH Position 3 - the analyzer can optionally have None, Position 2...

  • Page 37: Printer Setup

    400 User Manual ® 4.10 Printer Setup The PCA 400 is capable of wirelessly transmitting data to compatible IrDA (Infrared Data ® Associated) or IrDA + Bluetooth Printers. Users can quickly change between the two ® communication protocols by selecting the appropriate printer type from the analyzer’s settings.

  • Page 38: Onboard Data Logging

    400 User Manual ® 4.11 Onboard Data Logging When the logging function is activated, up to 500 combustion test records can be automatically stored in memory at a preset interval over a predetermined duration. IMPORTANT: If the combination of the logging duration / interval frequency exceeds the available memory, the analyzer will stop logging results once its memory is full.

  • Page 39: Memory File Management

    400 User Manual ® Fig. 4-5: Data Logging Settings Duration - total duration of the combustion test (5-minutes, 10-minutes, 15-minutes, 30-minutes, 1-hour, Metro Hospital 2-hours and 5-hours). Interval - time elapsed in between logged results Duration 5 Minutes (5-seconds, 10-seconds, 15-seconds, 1-minute, 5-minutes and 10 minutes).

  • Page 40: Fresh Air Purge Without Removing Probe

    Fig. 4-6: Recalling Memory Folder / Memory Location - targeted Folder / Memory Location where data will be saved. Acme Powerplant Directory PCA 400 Saved Test Results Default Acme Powerplant Navigation Arrows - scrolls to the 10 previous or next Boiler 1 10 files / records.

  • Page 41: Sensor Protection / Dilution Mode

    400 User Manual ® 4.14 Sensor Protection / Dilution Mode Sensor Protection / Dilution Mode allows the instrument to dillute the gas sample in order to protect its sensors from over-ranging during combustion analysis. Enabling Sensor Protection Sensor Protection allows the PCA 400 to engage a second pump, diluting the sample (and ®...

  • Page 42: Care & Maintenance

    400 User Manual ® 5. Care & Maintenance Emptying the Water Trap ....................42 Replacing the Filter Element ..................43 Cleaning the Probe Assembly..................44 Sensor Replacement ....................... 45 B-Smart Sensor Calibration ..................48 ® 5.5.1 B-Smart Sensors ............................48 ® 5.5.2 Starting a Calibration ..........................49 5.5.3...

  • Page 43: Replacing The Filter Element

    400 User Manual ® 2. Pour Condensate & Reassemble Water Trap Remove liquid condensate from the reservoir and reassemble the Water Trap by firmly pressing the bayonet connections into place and twisting in a clockwise fashion. IMPORTANT: When disassembling the Water Trap, care should be taken to ensure that the o-ring does not dislodge from the Water Trap Chamber.

  • Page 44: Cleaning The Probe Assembly

    400 User Manual ® 2. Open Filter Chamber Using a small flat-blade screwdriver, pry apart the Filter Chamber. Remove and discard the old Water Trap Filter. 3. Install New Filter Install new filter and reassemble the Filter Chamber, making sure that surfaces “A” and “B” contact each other.

  • Page 45: Sensor Replacement

    400 User Manual ® CAUTION: Carburetor cleaner will cause damage to plastic components. Take precautions to avoid spraying cleaner onto the probe handle or analyzer. 2. Clean Sample Line with Carburetor Cleaner Insert the plastic spray tube of the carburetor cleaner into the sample line, and liberally spray the cleaner through the hose and out of the probe tube.
  • Page 46 400 User Manual ® Materials / Equipment Required Before beginning the process of replacing sensors, obtain the following items: Phillips-head Screwdriver  Replacement Sensor  1. Turn OFF the Analyzer Press and hold the Power Key and allow the analyzer to complete its shutdown procedure. 2.
  • Page 47 400 User Manual ® 4. Remove Sensor Cap Assembly While holding the base of the sensor, firmly twist the gas cup in a counterclockwise fashion and pull straight up to remove. 5. Remove Shorting Springs from Replacement Sensor Remove the replacement sensor from its plastic canister / packaging. Note that the CO , SO and NO sensors have a shorting spring installed between two of their pins.

  • Page 48: B-Smart ® Sensor Calibration

    The analyzer’s diagnostics screen shows which sensors have been installed and their current end-of-life condition (Good or Low). Sensors should be calibrated by an authorized Bacharach Service Center (Section 7.2) every 6-months to 1-year to ensure that the analyzer continues to meet its published accuracy specifications.

  • Page 49: Starting A Calibration

    400 User Manual ® 5.5.2 Starting a Calibration Start any calibration procedure by taking the following steps: 1. Turn ON the Analyzer Turn the analyzer ON, allowing it to cycle through its 60-second warm-up period in fresh air. During the warm-up, the analyzer’s operation is checked and sensors are set to the following ambient conditions: •...
  • Page 50 6. Remove Cap Assembly (Gas Cup) While holding the base of the sensor, firmly twist the cap assembly in a counterclockwise fashion to remove. (Set the old sensor aside if it is to be returned to Bacharach for recalibration.) 0024-9551 Revision 1...
  • Page 51 1. Place the old sensor in the bubble wrap and plastic container supplied with the replacement B-Smart sensor. ® 2. Seal the plastic container in the pre-paid shipping envelope and return it to Bacharach, Inc. at the following address: ATTN: B-SMART SENSOR PROGRAM BACHARACH, INC.

  • Page 52: Manual Sensor Calibration

    400 User Manual ® 10. Reinstall the Analyzer’s Rear Cover Using a Phillips-head screwdriver, return Battery & Component Doors to the rear of the analyzer. 11. Allow Replacement Sensor to Stabilize Allow the sensor which was just installed to stabilize in the circuit before continuing with this procedure.

  • Page 53: Sensor Calibration

    400 User Manual ® 5.6.2 CO Sensor Calibration IMPORTANT: The CO sensor also measures H for the purpose of compensating the CO reading for the presence of H in the gas sample. This procedure first spans the CO sensor and, optionally, spans the H part of the sensor to know gas levels.
  • Page 54 400 User Manual ® 1. Access the CO Calibration Menu f To access the CO Calibration Menu: Calibration Menu  CO  CO + H IMPORTANT: “Measured” is the current CO reading, while “Applied” refers to the known CO level which will be applied to the sensor for calibration purposes. CAUTION: Unless instructed by the manufacturer or an authorized service provider, DO NOT reset sensor gain ( ) during the calibration process.
  • Page 55 400 User Manual ® 4. Enter Applied Value Using the touch interface or keypad buttons, enter an applied value which exactly equals the concentration stamped on the CO cylinder. IMPORTANT: The calibration range is from 9 to 1,500 ppm. An attempt to calibrate outside of this range will cause the message “Applied Value High”...

  • Page 56: So Sensor Calibration

    400 User Manual ® 10. Allow Reading to Stabilize Wait until the measured reading stabilizes (approximately 3 minutes), and press Save ( ) to calibrate the H measured value to that of the applied value. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen.

  • Page 57: No Sensor Calibration

    400 User Manual ® IMPORTANT: The calibration range is from 9 to 1,800 ppm. An attempt to calibrate outside of this range will cause the message “Applied Value High” or “Applied Value Low” appear at the bottom of the screen. 5.

  • Page 58: No Sensor Calibration

    400 User Manual ® 3. Adjust Flow Rate Adjust the regulator to ensure that the flow rate is sufficient enough to calibrate the sensor. (For more information about adjusting the flow rate, see Figure 5-8.) 4. Enter Applied Value Using the touch interface or keypad buttons, enter an applied value which exactly equals the concentration stamped on the NO cylinder.
  • Page 59 400 User Manual ® IMPORTANT: “Measured” is the current NO reading, while “Applied” refers to the known NO level which will be applied to the sensor for calibration purposes. CAUTION: Unless instructed by the manufacturer or an authorized service provider, DO NOT reset sensor gain ( ) during the calibration process.

  • Page 60: Co High Sensor Calibration

    400 User Manual ® 5.6.6 CO Sensor Calibration HIGH Materials / Equipment Required Before manually calibrating the CO sensor, obtain the following items: HIGH Calibration Kit (P/N: 0024-7059)  Gas Cylinder (500 ppm CO in Air, P/N: 0024-0492)  1. Access the CO Calibration Menu f To access the CO Calibration Menu: Calibration Menu ...

  • Page 61: Troubleshooting

    400 User Manual ® 6. Remove Calibration Cylinder Turn OFF regulator and remove the 500 ppm CO cylinder. 5.7 Troubleshooting 5.7.1 Error Codes Message Message Type Description probe thermocouple connected the analyzer’s T-Stack connector. Plug the probe T-STK Disconnected Warning thermocouple plug into the T-Stack connector at the bottom of the instrument.

  • Page 62: Error Symbols

    400 User Manual ® 5.7.2 Error Symbols 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 16% and the stack temperature must be below 2,000 °F (1,093 °C).
  • Page 63 400 User Manual ® Folder Allocation Displays the number of available folders out of the analyzer’s limit of 30. f To display Folder Allocation: Main Menu  Status ( )  Folder Allocation Date and Time Displays the date and time. Users can change the date and time by accessing the Settings Menu (Section 4.2).

  • Page 64: Additional Information

    400 User Manual ® 6. Additional Information 6.1 Technical Specifications ....................64 6.1.1 Instrument Details .............................64 6.1.2 Approvals ..............................65 6.1.3 Measurement Range & Accuracy ......................65 6.1.4 Calculated Readings ..........................66 Reporting Software ....................67 ® 6.2.1 Downloaded Stored Data to a Computer ....................67 6.2.2 Importing Saved Data ..........................67 400 App ........................

  • Page 65: Approvals

    400 User Manual ® 6.1.2 Approvals Approval Description tested accordance with European Directive 2014/30/EU. EN 50270:2015 Electromagnetic compatibility: electrical apparatus for the detection and measurement of combustible gases, toxic gases and oxygen. FCC: FCC Part 15.225 and RSS 210 – Intentional Radiator 6.1.3 Measurement Range &...

  • Page 66: Calculated Readings

    400 User Manual ® Measurement Range Resolution Accuracy Response Time -20° to 537 C 0.1° C Ambient ±1° C (0° to 100° C) T90 < 70 seconds Temperature (-4° to 999° F) (0.1° F) ±2° C (0° to 124° C) -20°...

  • Page 67: Pca ® Reporting Software

    For more information about the installation of the PRS, refer to the operation manual (P/N: 0024-9552) which can be downloaded from Bacharach’s website, www.mybacharach.com. Minimum Computer Requirements for PCA Reporting Software ®...
  • Page 68 400 User Manual ® The table below contains listings and descriptions of the 32 data fields that are downloaded with each data record. Note that for sensors that are not installed, all related data fields for those sensors will be marked as “***”. For example, if the analyzer does not contain an SO sensor, then “***”...
  • Page 69 400 User Manual ® 6.3 PCA 400 App ® To download the PCA 400 App, visit www.mybacharach.com/apps. The companion ® smartphone application allows users to perform a variety of functions without needing to be in front of their analyzer: • Control the PCA 400 (start and stop the analyzer via Bluetooth ®...

  • Page 70: Parts & Accessories

    400 User Manual ® 7. Parts & Accessories Part Numbers ........................70 Service Center Locations ....................72 7.1 Part Numbers Product Description / Part Number Accessories The Active Sample Conditioner extracts water vapor from samples, allowing the Description: 400 to accurately read levels of ®...
  • Page 71 400 User Manual ® Product Description / Part Number Sample Line & Probe Assembly (continued) Buna-N tubing is recommended for Description: applications which do not require Buna-N Sample Line Assembly with Water Trap, 7.5' accurate NO or SO measurement. P/N: 0024-3234 Buna-N Sample Line Assembly with Water Trap, 15' P/N:...

  • Page 72: Service Center Locations

    Returned Merchandise Authorization Number (RMA #). All returned goods must be accompanied with an RMA #. Pack the equipment securely (in its original packing, if possible), as Bacharach cannot be held responsible for any damage incurred during shipping to our facility.
  • Page 73 Bacharach, Inc. 621 Hunt Valley Circle, New Kensington, PA 15068 USA Pittsburgh, PA USA | Dublin, IRE | Gloucester, UK | Stanardsville, VA USA | Toronto, CAN www.mybacharach.com | help@mybacharach.com...

This manual is also suitable for:

0024-9551

Table of Contents

Save PDF