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Bacharach 450 Operating & Maintenance Instructions
Summary of 450
Page 1
Environmental combustion analyzer model 450 instruction 0024-9400 operation & maintenance rev. 6 – june 2013 product leadership • training • service • reliability.
Page 2
Ii instruction 0024-9400 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 warran...
Page 3: Table Of Contents
Eca 450 contents instruction 0024-9400 iii table of contents 1 introduction .................................................................................................................... 1 1.1 general description ....................................................................................
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Contents eca 450 iv instruction 0024-9400 2.17.10.2 resetting display format back to factory default ............................................. 44 2.17.11 primary air ............................................................................................................................... 45...
Page 5: 1 Introduction
Eca 450 introduction instruction 0024-9400 1 1 introduction 1.1 general description the bacharach environmental combustion analyzer model 450 (hereafter referred to as the eca 450) is an industrial grade environmental and combustion efficiency analyzer that is designed for the testing of fuel-burnin...
Page 6: 1.3 Technical Data
Introduction eca 450 2 instruction 0024-9400 • performs data logging. A series of combustion tests can be automatically started at user-defined intervals, and the data saved for reviewing at the conclusion of the logging period. The data can be stored in either the analyzer’s internal memory, sent t...
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Eca 450 introduction instruction 0024-9400 3 optionally . . . • nox content in the range of 0 to 4,000 ppm nox. • nox content referenced to a user defined percentage of oxygen in the range of 0 to 17,000 ppm nox. • nitric oxide content referenced to a user defined percentage of oxygen in the range o...
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Introduction eca 450 4 instruction 0024-9400 front panel controls and indicators: sixteen embossed push-button switches with tactile feedback (refer to section 1.6). One power led. Display: 2¼" × 8", 20 character by 4 line alphanumeric vacuum-fluorescent display panel. Power requirements : internal ...
Page 9: 1.4 Operation Overview
Eca 450 introduction instruction 0024-9400 5 1.4 operation overview the eca 450 is microprocessor controlled, allowing it to be easily operated and configured to suit each operator’s individual needs. Using a system of menu selections, the operator is guided through the proper operation and set- up ...
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Introduction eca 450 6 instruction 0024-9400 1.5 front panel connections and controls figure 1-1. Eca 450 components rs 232 power opt t-stack t-air pressure gas p ref eca 450 set up calibrate memory fuel menu print power i/o run save enter v esc pressure print – prints contents of either the combust...
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Eca 450 introduction instruction 0024-9400 7 1.5.2 t-air (primary air thermocouple) if thermocouple 0104-1797 (10 feet long) or utility wand 0104-1799 (12 inch ridged probe with handle and 5 foot coiled cable) is to be used to measure the burner’s primary air temperature, then connect either thermoc...
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Introduction eca 450 8 instruction 0024-9400 1.6 front panel keypad controls descriptions of the front panel keypad controls are given below. Note that a control may perform multiple functions as determined by what screen is being displayed at the time. I/o turns the analyzer on and off. Note that w...
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Eca 450 introduction instruction 0024-9400 9 calibrate shortcut key to the calibration list menu screen, where operators can choose the sensor to be calibrated. Note that a 4-place alphanumerical password must first be entered to begin calibration. Enter selects a menu item that has been chosen by t...
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Introduction eca 450 10 instruction 0024-9400 notes:.
Page 15: 2 Operation
Eca 450 operation instruction 0024-9400 11 2 operation 2.1 turning on the analyzer important! Prior to initially operating the analyzer, be sure to first charge the battery per section 4.1. Before turning on the analyzer, connect the probe’s gas hose, pressure hose, and thermocouple to the analyzer’...
Page 16: 2.3 Fuel Selection
Operation eca 450 12 instruction 0024-9400 2.3 fuel selection the fuel currently being used for combustion analysis is displayed in the top line of the combustion test run/hold screen. «hold««««««««««ngas« in the above example, the current fuel is ngas (natural gas). Fuel codes: ngas = natural gas o...
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Eca 450 operation instruction 0024-9400 13 2.4 performing a combustion test important! When measuring nitrogen dioxide (no 2 ) and sulfur dioxide (so 2 ), it is recommended that a sampler conditioner (bacharach p/n 0024-7224) be used to assure accurate readings. 1. If not already done, turn on analy...
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Operation eca 450 14 instruction 0024-9400 7. Tip: use keys to quickly advance to the top and bottom of screen. Also note that if “– – – –”, “x x x x”, or “* * * *” appear in a data field, then data cannot be displayed for that measurement. Refer to section 5.3 error symbols for an explanation of th...
Page 19
Eca 450 operation instruction 0024-9400 15 2.5 ending a combustion test 1. After performing a combustion test per section 2.4, press run key to end the test. You should hear the pump stop running. Warning: burn hazard! Take all necessary precautions when handling a hot probe and probe stop. Caution:...
Page 20: 2.7 Saving Test Data
Operation eca 450 16 instruction 0024-9400 2.7 saving test data by pressing the save key, data that is currently being displayed in either the combustion test or pressure screen is stored in one of the analyzer’s over 1000 internal memory locations. Observe that the following message appears when th...
Page 21
Eca 450 operation instruction 0024-9400 17 2.9 recalling test data stored in memory to recall the contents of a particular memory location containing either combustion test data or a pressure measurement, do the following: 1. Press memory key to display the memory menu screen. 2. Use ∧∨ keys to plac...
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Operation eca 450 18 instruction 0024-9400 4. Press enter key to display the contents of chosen memory location. Observe that “mem:nnnn ” (where nnnn denotes the memory location number) appears in the top line, signifying that the data being displayed was recalled from memory. Also note that if any ...
Page 23: 2.10 Printing Data
Eca 450 operation instruction 0024-9400 19 2.10 printing data by pressing the print key, the data which is currently being displayed in either the combustion test or pressure screen is printed on the analyzer’s internal printer. Note that the contents of no other screen can be printed. Data which ha...
Page 24
Operation eca 450 20 instruction 0024-9400 2.11 downloading data to a personal computer test data that was stored in memory can be downloaded to a personal computer in ascii text, comma-delimited format, which can then be imported into most spreadsheet programs for analysis. The following describes ...
Page 25
Eca 450 operation instruction 0024-9400 21 3. After hyperterminal is running: click transfer , click capture text , then click start to accept the default drive\directory\filename to which all received data will be stored as an ascii text file. Note: by default, the captured text file will be stored...
Page 26: 2.12 Data Logging
Operation eca 450 22 instruction 0024-9400 7. Observe that hyperterminal displays the data as it’s being received. After all data has been transmitted, the analyzer re-displays the memory menu screen. Tip: the download process can be stopped by pressing the esc key. 8. To stop capturing data and sav...
Page 27
Eca 450 operation instruction 0024-9400 23 4. Use ∧∨ keys to place cursor next to one of the following three methods of storing test data: logging ª internal pc both • internal: stores test data in the analyzer’s internal memory (over 1000 data sets can be saved). • pc: sends test data out the analy...
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Operation eca 450 24 instruction 0024-9400 8. With the analyzer set up per section 2.4 performing a combustion test , press enter key to begin testing and logging. «log«««(0025)««ngas« this display shows that the analyzer is logging and currently saving data to internal memory location 25. Observe t...
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Eca 450 operation instruction 0024-9400 25 2.13 importing saved data into a spreadsheet a text file that was created as described in either section 2.11 downloading data to a personal computer, or section 2.12 data logging can be imported into spreadsheet programs that are capable of importing comma...
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Operation eca 450 26 instruction 0024-9400 table 2. Typical spreadsheet for the eca 450* testid1 testid2 testid3 fuel temp unit press unit customer name address burner number natural gas °f inwc customer name address burner number inwc poll unit date time o2 co eff co2 tstack tair source ppm 01/14/0...
Page 31
Eca 450 operation instruction 0024-9400 27 2.14 primary air temperature measurement to properly calculate net stack temperature, the analyzer must know the burner’s primary air temperature. The following sections describe four methods of measuring and supplying this temperature value to the analyzer...
Page 32
Operation eca 450 28 instruction 0024-9400 2. Use ∧∨ keys to place cursor next to “primary air”; then press enter to display the primary air screen. Note: the message “primary air is measured by tc” will appear if a thermocouple is plugged into the t-air socket. This thermocouple must be removed to ...
Page 33
Eca 450 operation instruction 0024-9400 29 5. Wait until temperature display stabilizes; then press enter to save the displayed temperature value in the analyzer’s temperature memory buffer and return to the setup list screen. Note: the temperature memory buffer is cleared when the analyzer is turne...
Page 34
Operation eca 450 30 instruction 0024-9400 4. Use ∧∨ keys to place cursor next to “enter”; then press enter to display the primary air temperature screen. Primary air measure ª enter 5. Press enter to move the cursor into the temperature data field; then use the ∧ , ∨ , , and > keys as necessary to ...
Page 35
Eca 450 operation instruction 0024-9400 31 2.15 differential pressure measurement to measure the differential pressure between two confined areas, do the following: 1. Press pressure key to display the pressure screen. ««««««pressure«««««« n.Nn xxxx where: n.Nn = current pressure reading xxxx = pres...
Page 36: 2.16 Statistics Mode
Operation eca 450 32 instruction 0024-9400 2.16 statistics mode the statistics mode configures the eca 450 to perform a statistical analysis of measured emissions data taken over a preset interval and duration. At the end of the prescribed duration, the average and standard deviation are calculated ...
Page 37
Eca 450 operation instruction 0024-9400 33 5. The statistics duration is the length of time allocated to collecting data. Use ∧∨ keys to select desired duration; then press enter to make the selection and display the statistics summary screen. Note: the minimum and maximum duration values are depend...
Page 38
Operation eca 450 34 instruction 0024-9400 8. At the conclusion of the data collection process, the eca 450 calculates the average and standard deviation values of the emissions data just recorded. A final statistics screen then appears that shows the average and one standard deviation of each gas m...
Page 39
Eca 450 operation instruction 0024-9400 35 2.17 setting up the analyzer the analyzer has been set up at the factory for the following defaults: temperature units .................... °f pressure units ........................... Inches of water column (inwc) pollution units ............................
Page 40
Operation eca 450 36 instruction 0024-9400 2.17.1 temperature units select to display the temperature in either degrees centigrade (c) or fahrenheit (f) as follows: 1. Press setup key to display the setup list screen. 2. Use ∧∨ keys to place cursor next to “temperature units”; then press enter to di...
Page 41
Eca 450 operation instruction 0024-9400 37 5. Use ∧∨ keys to place cursor next to “pollution units”; then press enter to display the pollution units screen. Pollution units ª ppm #/mbtu mg/m3 g/gj 6. Use ∧∨ keys to place cursor next to either “ppm”, “#/mbtu”, “mg/m 3 ”, or “g/gj”; then press enter t...
Page 42
Operation eca 450 38 instruction 0024-9400 4. Press > key to place cursor on the month, day, or year digit to be changed; then, use ∧∨ keys to set that digit to desired number. Repeat this step until all digits are set correctly. 5. Press enter to save selections and start clock. Then press esc to r...
Page 43
Eca 450 operation instruction 0024-9400 39 3. Use ∧∨ keys to place cursor next to the desired gas whose oxygen reference is to be set; then press enter to display the o 2 reference screen for that gas. Co ref to o2 n % where: n = oxygen reference 4. Use ∧∨ keys to choose desired oxygen reference val...
Page 44
Operation eca 450 40 instruction 0024-9400 3. Use ∧∨ keys to place cursor next to “edit test id”; then press enter to display the edit test id menu, which shows the first line of each test id record. Edit test id ª 0 customer1 1 ..... 2 ..... 31 ..... Note: five periods (. . . . .) are used to ident...
Page 45
Eca 450 operation instruction 0024-9400 41 3. Use ∧∨ keys to place cursor next to “select test id”; then press enter to display the select test id menu, which shows the first line of each test id record. Select test id ª 0 customer1 1 ..... 2 ..... 31 ..... No test id note: five periods (. . . . .) ...
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Operation eca 450 42 instruction 0024-9400 5. The computer’s communication program and the connection to the eca 450 can now be closed. 6. Press esc to end this procedure and return to setup list screen. 2.17.8.4 clearing test id information clear all or individual pre-entered test id information fr...
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Eca 450 operation instruction 0024-9400 43 2.17.9 display timeout to conserve battery life, the vacuum fluorescent display panel can be configured to turn itself off after 5 to 60 minutes of keyboard inactivity. Select the display’s time-delay off period as follows: 1. Press setup key to display the...
Page 48
Operation eca 450 44 instruction 0024-9400 2.17.10.1 changing display format change the order in which the data is displayed in the combustion test hold/run screen as follows: note: changing the order of the combustion test data as displayed on the analyzer’s front panel does not change the order in...
Page 49
Eca 450 operation instruction 0024-9400 45 4. Use ∧∨ keys to choose “yes”; then press enter to reset the display and return to the display format screen. Reset display format no ª yes 5. When finished, press esc to return to the setup list screen. 2.17.11 primary air refer to section 2.14 primary ai...
Page 50
Operation eca 450 46 instruction 0024-9400 4. Use ∧∨ keys to choose which user name line to edit; then press enter to begin editing that line. 5. Use ∧∨ keys to display the first desired character. Then use the > key to move cursor to the next character’s position. Repeat this step until the line is...
Page 51
Eca 450 operation instruction 0024-9400 47 2.17.16 high resolution nox enable when high resolution nox enable is turned on the eca 450 will display the values of no, no 2 and nox at a resolution of 0.1 ppm when the values of these gases are ≥ 100 ppm, the resolution for that gas switches to 1 ppm. W...
Page 52
Operation eca 450 48 instruction 0024-9400 5. When high resolution nox enable is turned on, and when viewing the combustion test run screen, observe in the example screens below that if the value of no, no 2 , or nox is 0.1 ppm, but when a gas value is ≥ 100 ppm the resolution becomes 1 ppm. «run«««...
Page 53: 3 Calibration
Eca 450 calibration instruction 0024-9400 49 3 calibration bacharach recommends that the eca 450 be calibrated by your nearest bacharach service center (refer to section 6.3). The analyzer, however, can be calibrated in the field if your facility has the necessary equipment and qualified personnel t...
Page 54: 3.2 Calibration Fixtures
Calibration eca 450 50 instruction 0024-9400 3.2 calibration fixtures a gas and pressure fixture will be required to perform the various calibration procedures described in the sections that follow. Parts required: • calibration kit (refer to section 6.2) • calibration gas (refer to section 6.2) • b...
Page 55
Eca 450 calibration instruction 0024-9400 51 3.3 starting and ending a calibration procedure start any calibration procedure by first pressing the calibrate shortcut key. Before calibration can begin, however, a 4-place alphanumerical password must be entered. Enter the password by first pressing th...
Page 56
Calibration eca 450 52 instruction 0024-9400 2. With the calibrate pressure screen displayed, and with the hose from the calibration fixture connected to the analyzer’s pressure port, adjust the bellows for a micro manometer reading of − 4 in. H 2 o column ( − 10 mb). 3. Wait until the measured read...
Page 57
Eca 450 calibration instruction 0024-9400 53 4. Wait until measured reading on screen stabilizes. Then use the ∧∨ and keys to enter an applied value of 32 °f (0 °c). Typical calibrate ts-zero screen during calibration: «calibrate ts-zero«« measured 31°f applied 032°f 5. Press enter to calibrate the ...
Page 58: 3.7 Calibrate Hc Sensor
Calibration eca 450 54 instruction 0024-9400 2. Plug simulator’s k-type connector into analyzer’s t-air jack (see figure 1-1). 3. Enter calibration list screen; then choose t-air per section 3.3 to display the calibrate ta-zero screen. 4. Wait until measured reading on screen stabilizes. Then use th...
Page 59
Eca 450 calibration instruction 0024-9400 55 procedure: 1. Enter calibration list screen; then choose hc per section 3.3 to display the calibrate hc screen. A t the conclusion of this step the pump should be running. 2. Using the gas fixture shown in figure 3-1, attach a ch 4 calibration gas cylinde...
Page 60
Calibration eca 450 56 instruction 0024-9400 3. Adjust regulator of calibration fixture for a flow meter indication of approximately 2 scfh. 4. Wait until measured reading on screen stabilizes (approximately 3 minutes). Then use the ∧∨ and keys to enter an applied value that equals the concentration...
Page 61: 3.9 Calibrate So
Eca 450 calibration instruction 0024-9400 57 11. Press enter to calibrate the analyzer’s measured value to that of the applied value; after which the message “good calibration” should appear along with the calibration list screen being redisplayed. If the message “sensor output low” or “sensor not c...
Page 62: 3.10 Calibrate No Sensor
Calibration eca 450 58 instruction 0024-9400 3.10 calibrate no sensor the following procedure spans the optional nitric oxide sensor to a known gas level. Material required: • calibration gas fixture (section 3.2) • gas cylinder: 250 ppm no in nitrogen (refer to section 6.2) procedure: 1. Enter cali...
Page 63: 3.11 Calibrate No
Eca 450 calibration instruction 0024-9400 59 3.11 calibrate no 2 sensor this screen is used to span the optional nitrogen dioxide sensor to a known gas level. Material required: • calibration gas fixture (section 3.2) • gas cylinder: 100 ppm no 2 (refer to section 6.2) procedure: 1. Enter calibratio...
Page 64
Calibration eca 450 60 instruction 0024-9400 3.12 calibrate co-hi sensor this procedure spans the optional carbon monoxide high sensor (4,000 – 80,000 ppm co) to a known gas level. Material required: • calibration gas fixture (section 3.2) • gas cylinder: 4,000 ppm co in air (refer to section 6.2) p...
Page 65: 4 Maintenance
Eca 450 maintenance instruction 0024-9400 61 4 maintenance field maintenance of the eca 450 is limited to the following: • battery charging • water trap filter replacement • printer paper replacement • sensor replacement • cleaning the probe • resetting the microprocessor • replacing the internal pa...
Page 66
Maintenance eca 450 62 instruction 0024-9400 4.2 water-trap / filter assembly the water-trap / filter assembly removes water condensate from the gas sample, and also prevents soot from contaminating the internal components of the analyzer. Figure 4-1. Water trap / filter assembly outlet end inlet en...
Page 67
Eca 450 maintenance instruction 0024-9400 63 4.3 printer paper replacement parts required: • replacement paper roll (refer to section 6.1) procedure: 1. Open printer by pressing the printer’s front-panel latch. See figure 4-2. 2. The paper-roll carrier is mounted on the rear of the printer’s front p...
Page 68: 4.4 Sensor Replacement
Maintenance eca 450 64 instruction 0024-9400 4.4 sensor replacement the following sections described in detail how to replace the various sensors located in the analyzer’s sensor compartment. Refer to figure 4-3 for the location and positioning of those sensors. Note: when a sensor-error message app...
Page 69
Eca 450 maintenance instruction 0024-9400 65 4.4.1 o 2 , co, no, no 2 , & so 2 sensor replacement all sensors, with the exception of the hc sensor, are replaced in a similar manner. Do the following to replace either the o 2 , co-lo, co-hi, no, no 2 , or so 2 sensor. Material required: • medium phil...
Page 70
Maintenance eca 450 66 instruction 0024-9400 4.4.2 nitric oxide sensor battery replacement a single lithium battery, located on top of the nitric oxide printed circuit board, applies a bias voltage to the no sensor to prevent the sensor from destabilizing when the analyzer is turned off. This batter...
Page 71
Eca 450 maintenance instruction 0024-9400 67 4.4.3 hc sensor replacement unlike the other sensors that are held in place by their associated bayonet holders, the hc sensor is plugged into its printed circuit board which, in turn, is secured inside the sensor compartment with four screws. Remove this...
Page 72
Maintenance eca 450 68 instruction 0024-9400 4.5 replacing internal particulate filter an internal particulate filter is located at the inlet of the pump to protect the pump in the event dirt is drawn into the analyzer’s gas inlet. Under normal operating conditions, the probe’s water trap / filter a...
Page 73
Eca 450 maintenance instruction 0024-9400 69 4.6 cleaning the probe and sampling hoses if the combustion analyzer is used on either coal or oil fired burners, particulates can accumulate within the probe and sampling hoses. These particulates may, in time, build up and restrict the flow of gas into ...
Page 74
Maintenance eca 450 70 instruction 0024-9400 3. Clean probe assembly by generously spraying carburetor cleaner through each of the barbed fittings of the probe handle, while allowing the cleaner to flow out of the probe tip. 4. After spraying with carburetor cleaner, remove all the residual cleaner ...
Page 75
Eca 450 maintenance instruction 0024-9400 71 notes:.
Page 76: 5 Troubleshooting
Parts & service eca 450 72 instruction 0024-9400 5 troubleshooting 5.1 analyzer repair it is recommended that field repair of the eca 450 be limited to: • simple checks of printed circuit board connectors • replacing the probe assembly • replacing the filter element in the water trap / filter assemb...
Page 77: 5.3 Error Symbols
Eca 450 parts & service instruction 0024-9400 73 co-hi sensor error – co-hi sensor was exposed to flue gas during warm-up. Co-lo sensor error – co sensor was exposed to flue gas during warm-up. Pressure sens. Error – pressure sensor is measuring a pressure that is outside the of range of ±3 inches o...
Page 78
Parts & service eca 450 74 instruction 0024-9400 5.4 troubleshooting guide the following table lists the causes and remedies for most of the problems that may arise with the analyzer. If the information in table 5-1 does not solve the problem, or for help with any problem that is not listed, then pl...
Page 79
Eca 450 parts & service instruction 0024-9400 75 symptom probable cause & remedy “low battery” message appears at bottom of display, accompanied by a beeping alert tone. Battery close to being discharged. Analyzer will run for only several minutes after this message first appears before turning itse...
Page 80
Parts & service eca 450 76 instruction 0024-9400 symptom probable cause & remedy “noxide sensor error” message appears at bottom of display. A. Analyzer was turned on with probe sampling flue gas. Remove probe from stack and restart. B. No sensor not zeroed at start up. Turn analyzer off and then on...
Page 81
Eca 450 parts & service instruction 0024-9400 77 symptom probable cause & remedy “sensor output low” message appears during calibration. Sensor is nearing the end of its useful life. Calibration is still good, but the sensor should be replaced soon. “sensor not calibrated” message appears during cal...
Page 82
Parts & service eca 450 78 instruction 0024-9400 symptom probable cause & remedy erratic combustion test screen data. A. Faulty sensor(s): - check that all sensors are properly installed and their wiring harnesses are correctly connected to the analyzer. Refer to section 4.4. - check sensor calibrat...
Page 83: 6 Parts & Service
Eca 450 parts & service instruction 0024-9400 79 6 parts & service 6.1 replacement parts complete eca 450 basic configuration (o 2 , co, stack temp., ambient temp, and pressure measurement), with sampling probe (12 in. Tube) and hose assembly .......................................... 0024-7221 ac a...
Page 84: 6.2 Accessories
Parts & service eca 450 80 instruction 0024-9400 6.2 accessories calibration kit (gas not supplied) ................................................. 0024-7059 flue gas sample conditioning unit: compact system . Includes peltier chiller/probe assembly, built-in filter, condensate pump, and 15 ft hos...
Page 85: 6.3 Service Centers
Eca 450 parts & service instruction 0024-9400 81 6.3 service centers service and replacement parts can be obtained by contacting a bacharach service center at the following locations: united states bacharach, inc. 621 hunt valley circle new kensington, pa 15068 phone: 724-334-5051 fax: 724-334-5723 ...
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Headquarters: 621 hunt valley circle, new kensington, pa 15068 ph: 724-334-5000 • fax: 724-334-5001 • toll free: 1-800-736-4666 website: www.Mybacharach.Com • e-mail: help@mybacharach.Com.