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- Operation And Maintenance Manual
Bacharach PCA 2 Operation And Maintenance Manual
Summary of PCA 2
Page 1
Product leadership • training • service • reliability portable combustion analyzer instruction 24-9448 operation & maintenance rev. 4 - july 2009.
Page 2: Warranty
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 rep...
Page 3: Contents
Instruction 24-9448 contents contents 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 pca 2 general descrpton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.2 sales combo & model confguratons . . . . . . . . . . . . . . . . . . . . . .1-...
Page 4: Operation
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...
Page 5: Maintenance
Instruction 24-9448 contents 6 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 pca 2 dsassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 water trap / flter mantenance . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 ...
Page 6: Notes:
Instruction 24-9448 v contents notes:.
Page 7: 1 Introduction
Instruction 24-9448 1-1 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...
Page 8
Instruction 24-9448 1-2 introduction 1.2 sales combo & model configurations sales combo 24-8350 24-8351 24-8352 sales combo (kit) 24-8370 24-8371 24-8372 model type 225 235 245 pca2 only part number 24-7301 24-7302 24-7303 measurements oxygen (o 2 ) 3 3 3 stack temperature 3 3 3 prmary / ambent ar t...
Page 9
Instruction 24-9448 1-3 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 2 ) 3 3 3 stack temperature 3 3 3 prmary / ambent ar temperature 3 3 3 carbon monoxde low (co...
Page 10: 1.3 Features & Benefits
Instruction 24-9448 1-4 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...
Page 11: 1.4 Operational Overview
Instruction 24-9448 1-5 introduction •language optons ncludng englsh, french, and spansh •custom dsplay formats •calbraton remnders - pca2 can be set up to remnd the user that calbraton s past due. 1.4 operational overview the pca 2 s powered by ether ts 4 nternal batteres, or by an optonal ac power...
Page 12
Instruction 24-9448 1-6 introduction analyzer and s placed n the burner’s prmary-ar stream. Begn the combuston test by frst nsertng the analyzer’s probe tube nto the stack-gas stream of the applance under test, and then pressng the run/hold button to dsplay the combuston test run screen. The ana- ly...
Page 13
Instruction 24-9448 1-7 introduction t-stack t-air figure 1-1. Pca 2 components lcd – 160 x 160 graphic display f1 / f2 / f3 – soft menu buttons, whose functions are defined by labels appearing above them on lcd arrow buttons: – moves cursor up the display, or increments an alphanumerical value – mo...
Page 14: 1.5.3 Power (Ac Adapter)
Instruction 24-9448 1-8 introduction 1.5.2 t-air (primary air thermocouple) if thermocouple p/n 104-1797 (10 feet long) or utlty wand p/n 104-1799 (12 nch rdged probe wth handle and 5 foot coled cable) s to be used to measure the burner’s prmary ar temperature, then connect ether of these thermocoup...
Page 15: 1.5.7 Opt (Option)
Instruction 24-9448 1-9 introduction compatble irda wreless prnter by algnng ther irda communcaton ports. Refer to secton 4.16. 1.5.7 opt (option) the opton connector s used for optonal external measurement features. 1.6 front panel buttons descrptons of the front panel buttons are gven below. Note ...
Page 16
Instruction 24-9448 1-10 introduction the arrow buttons move the cursor on the lcd n the d- recton of the arrow. In screens that requre the entry of alphanumercal data, use the buttons to move cursor across the screen and then use the buttons to ncre- ment and decrement the data. When vewng a menu, ...
Page 17: 2 Specifications
Instruction 24-9448 2-1 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 temper...
Page 18: Normal Operating Conditions:
Instruction 24-9448 2-2 specifications normal operating conditions: temperature: analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 104 ºf (0 to 40 ºc) probe tp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,472 ºf (800 ºc) max. Humdty: analyzer . . . . ...
Page 19: Power Requirements:
Instruction 24-9448 2-3 specifications 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 co...
Page 20: Notes:
Instruction 24-9448 2-4 specifications notes:.
Page 21: 3 Initial Setup
Instruction 24-9448 3-1 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...
Page 22
Instruction 24-9448 3-2 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 ana...
Page 23
Instruction 24-9448 3-3 initial setup figure 3-2. Connecting the probe and hose assembly to the pca 2 power p t-stack t-air gas differential pressure hose (— ∆p) (optional) probe handle water trap / filter assembly stack gas thermocouple connector (t-stack) ac power adapter jack (power) option conne...
Page 24: 3.4 Operating Parameters
Instruction 24-9448 4 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 . . . . . . . . .°f pressure unts . . . . . . . . . . . .Inches of water column (nwc) pollut...
Page 25
Instruction 24-9448 5 initial setup that the name of the selected fuel should now appear at the top of the screen. Note: in addition to the standard fuels programmed into the pca2, bacharach can develop custom fuel codes based on the customers specific needs. The pca2 can be programmed with 2 additi...
Page 26
Instruction 24-9448 6 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 . 2. Use...
Page 27
Instruction 24-9448 7 initial setup 3.8 pollution units selection the pca 2 s capable of convertng the measured ppm levels of co, no, no 2 , and so 2 to varous polluton unts usng cfr40 part 60 emsson factors. Note that the polluton-unt conversons for no, no 2 and nox are based on the molecular weght...
Page 28: 3.9 Date Setup
Instruction 24-9448 8 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. Dsplay the main menu by pressng the menu (f2)...
Page 29: 3.10 Time Setup
Instruction 24-9448 9 initial 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 re- cord. Set the analyzer’s nternal clock to the current tme as follows: 1. Dsplay the main menu by pressng the menu (f2) button....
Page 30: 3.11 O
Instruction 24-9448 10 initial setup 3.11 o 2 reference setup the measured values of co, nox, and so 2 can be ndvdually referenced to a specfc o 2 percentage of between 0 and 15%. Indvdually set up the o 2 reference value for each of the above gases as follows: 1. Dsplay the main menu by pressng the...
Page 31
Instruction 24-9448 11 initial setup 3.12 print pressure selection select whether to prnt or not prnt the pressure measurement on the combuston test prntout 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...
Page 32
Instruction 24-9448 12 initial setup 3.13 zoom-display selection combuston test data n the run/hold screen can be shown wth enlarged characters to make vew- ng easer. The operator can set zoom levels to standard, 2x, or 3x. The standard zoom settng wll dsplay 8 lnes of combuston test data at one tme...
Page 33
Instruction 24-9448 13 initial setup 3.14 battery charger selection when usng rechargeable nmh batteres, the ac power adapter can be used to charge the batteres whle nsde the analyzer. The analyzer’s rapd- charger crcut, however, must be frst turned on. Important: when using disposable alka- line ba...
Page 34: 3.15 Logging Selection
Instruction 24-9448 14 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 prede- termned length of tme. Refer to secton 4.14 for detaled nformaton on how to select the loggng functon...
Page 35: 3.17 Test Id Information
Instruction 24-9448 15 initial setup 3.17 test id information test records can be dentfed (e.G. Customer's name, burner number, and locaton) by manually enterng up to three lnes of text, wth each lne con- tanng a maxmum of 20 alphanumerc characters. When a test id s se- lected ths nformaton wll be a...
Page 36
Instruction 24-9448 16 initial setup end ths procedure by hghlghtng edt complete and pressng the ent key to return to the edt test id menu. 9. Press esc to go to the test id menu or the run/hold key to return to the run/hold screen. Select a test id: 1. From the test id menu, use the buttons to hghl...
Page 37: 3.18 Username
Instruction 24-9448 17 initial setup 3.18 username the name of the user or owner of the analyzer (e.G. Company name, ad- dress, phone number) can be stored n memory by manually enterng up to three lnes of text, wth each lne contanng up to 20 alphanumerc characters. Ths nformaton wll appear at the to...
Page 38
Instruction 24-9448 18 initial setup to clear a username proceed as follows: 1. Dsplay the main menu by press- ng 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. 3. Use the buttons to hghlght...
Page 39: 3.19 Language
Instruction 24-9448 19 initial setup 3.19 language informaton on the dsplay screen can be shown n englsh, french, or spansh. Select the desred language as follows: 1. Dsplay the main menu by press- ng the menu (f2) button. If necessary, press esc untl menu appears above f2 . 2. Use the buttons to hg...
Page 40: 3.20 Cal Reminder Period
Instruction 24-9448 20 initial setup 3.20 cal reminder period the analyzer can be set to ndcate a calbraton remnder durng the 60 second warm-up perod. Calbraton remnders can be preset to occur 6, 8, 10, 12, or 15 months after the last calbraton. When the preset perod s exceeded the nstrument wll dsp...
Page 41: 3.21 Run/hold Screen Format
Instruction 24-9448 21 initial setup 3.21 run/hold screen format pca2 testdata s located n the run/hold screen. By pressng the run/ hold key, you should hear the pump runnng and see the word run at the upper-left hand corner of the dsplay. The nstrument s contnuously measurng and calculatng the data...
Page 42
Instruction 24-9448 22 initial setup change the order n whch data s dsplayed as follows: 1. Dsplay the main menu by press- ng 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. 3. Use the button...
Page 43
Instruction 24-9448 23 initial setup reset dsplay format back to factory default settngs as follows: 1. Dsplay the main menu by press- ng 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. 3. Us...
Page 44: 4 Operation
Instruction 24-9448 4-1 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...
Page 45
Instruction 24-9448 4-2 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. Place the probe n an area that...
Page 46: 4.3 Selecting A Fuel
Instruction 24-9448 4-3 operation 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 nec- essary, change the fuel as follows: 1. Dsplay the main menu by pressng the menu (f2) button. 2. Use th...
Page 47: 4.4 Sampling Point
Instruction 24-9448 4-4 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 o...
Page 48: - - -
Instruction 24-9448 4-5 operation 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). • inset probe nto stack (secton 4...
Page 49
Instruction 24-9448 4-6 operation table 4-1 . List of combustion test data display name description of measurement or calculation o 2 % oxygen co carbon monoxde (1) eff combuston effcency co 2 % carbon doxde t-stk stack temperature t-air prmary / ambent ar temperature as measured ether n- ternally o...
Page 50: 4.6 Pressure Label Selection
Instruction 24-9448 4-7 operation 4.6 pressure label selection the pressure measurement can be labeed wth types ncludng gas pres- sure, dfferental across heat exchanger, draft readng, and dfferental pressure. See secton 4.6 of the pca2 instructon manual 24-9448 for pressure and draft measurement pro...
Page 51
Instruction 24-9448 4-8 operation 4.7 temperature measurement label the dfference n temperature between two areas can be measured by us- ng the analyzer's two temperature channels and the temperature screen. By usng the t-ar channel as a reference, the temperature appled to the t-stack channel wll b...
Page 52
Instruction 24-9448 4-9 operation 4.8 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 dspla...
Page 53: 4.9 Saving Test Data
Instruction 24-9448 4-10 operation a. Press the zero (f2) button. 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 hos...
Page 54: 4.11 Emptying The Water Trap
Instruction 24-9448 4-11 operation 4.10 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 f...
Page 55: 4.13 Low Battery Alarm
Instruction 24-9448 4-12 operation 4.12 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 ...
Page 56: 4.14 Data Logging
Instruction 24-9448 4-13 operation 4.14 data logging when the loggng functon s actvated, up to 500 combuston test records wll be automatcally stored n memory at a preset nterval (1, 5, 10, 15, 30 seconds, 1, 2, 5, 10 mnutes) over a predetermned duraton (5, 10, 15, 30 mnutes, 1, 2, 5, 10, 24, 48 hour...
Page 57
Instruction 24-9448 4-14 operation 4.14.1 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 th...
Page 58
Instruction 24-9448 4-15 operation 4.14.2 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...
Page 59
Instruction 24-9448 4-16 operation 4.14.3 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...
Page 60: 4.15 Memory
Instruction 24-9448 4-17 operation 4.14.4 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 ...
Page 61
Instruction 24-9448 4-18 operation 4.15.1 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 ds...
Page 62
Instruction 24-9448 4-19 operation logging directory 1 05/23/06 10:00:00 2 05/23/06 10:30:00 3 05/23/06 11:00:00 4 05/23/06 11:30:00 5 05/23/06 12:00:00 6 05/23/06 12:30:00 7 05/23/06 01:00:00 (more) f1 f2 f3 page- menu page+ log: 6 natural gas o 2 4.0 % co 12 ppm eff 82.6 % co 2 9.5 % t-stk 374 °f ...
Page 63: 4.15.3 Clearing Memory
Instruction 24-9448 4-20 operation 4.15.3 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 ma...
Page 64
Instruction 24-9448 4-21 operation 4.16 downloading stored data to a computer the combuston test data that was stored n ether the analyzer’s memory drectory (secton 4.9), or loggng drectory (secton 4.14), can be down- loaded to a computer usng the pca 2 data recovery program and usb cable that are s...
Page 65
Instruction 24-9448 4-22 operation 4.16.1 pca 2 data recovery program installation the pca 2 data recovery program s suppled wth the analyzer on a cd (p/n 24-1448). Install ths program as follows: 1. Insert the pca 2 cd nto the computer’s cd-rom drve. 2. Locate the cd-rom drve n wndows explorer and ...
Page 66
Instruction 24-9448 4-23 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. Ths completes the nstallaton...
Page 67
Instruction 24-9448 4-24 operation 4.16.2 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. Insert the pca 2 cd nto the computer's cd-rom drve. 2. W...
Page 68
Instruction 24-9448 4-25 operation select (advanced). Name of new usb hardware 4. Select “install the software automatcally (recommended)” and clck next . 5. At the hardware installaton wndow, clck continue anyway . 6. After the found new hardware wzard has fnshed nstallng the software, clck finish ...
Page 69: 4.16.3 Recovering Data
Instruction 24-9448 4-26 operation 4.16.3 recovering data before data can be recovered from the analyzer, nstall the pca 2 data recovery program, usb cable, and usb devce drver as descrbed n sec- tons 4.14.1 and 4.14.2. Recover ether the loggng or combuston data as follows: 1. Start the program by e...
Page 70
Instruction 24-9448 4-27 operation 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 f...
Page 71
Instruction 24-9448 4-28 operation note: the filename is automatically given a csv (comma separated value) extension, allowing the file to be directly opened by most spreadsheet programs for analysis. 3. After selectng a folder and enterng the flename, clck open and then clck start to begn the downl...
Page 72
Instruction 24-9448 4-29 operation 4.17 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-cl...
Page 73
Instruction 24-9448 4-30 operation table 4-2 . Downloaded data fields field column name data name or value 1 date date of test n mm/dd/yy 2 tme tme of test n 12 hour format (am/pm) 3-5 test id informaton input by user 6 fuel fuel name 7 %o2 oxygen level 8 co carbon monoxde level (see feld 26) 9 ppm ...
Page 74: 4.18 Printing Test Data
Instruction 24-9448 4-31 operation (1) %o 2 reference as selected per section 3.12 (2) pressure units as selected per section 3.8 (3) pollution units as selected per section 3.9 (4) shown only on prntout, not on lcd dsplay. 4.18 printing test data combuston or pressure data that s currently beng dsp...
Page 75
Instruction 24-9448 4-32 operation bacharach, inc. Pca 2 sn: xxxxxx ===================== time 01:00:00 pm date 10/06/06 fuel natural gas o2 4.0 % co 12 ppm eff 82.6 % co2 9.5 % t-stack 374 °f t-air 68.0 °f ea 21 % no 18 ppm no temp 70.5 °f no2 6 ppm nox 24 ppm so2 ∗∗∗ ppm co(3) 13 ppm no(3) 19 ppm ...
Page 76
Instruction 24-9448 4-33 operation.
Page 77: 5 Calibration
Instruction 24-9448 5-1 calibration 5 calibration important: before performing any calibration procedure, ensure that fresh batteries are installed or use the optional ac power adapter. Also ensure that the analyzer is at room temper- ature and will be sampling fresh air when turned on. 5.1 smart se...
Page 78: 5.3 Pressure Sensor
Instruction 24-9448 5-2 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. 2. ...
Page 79
Instruction 24-9448 5-3 calibration section 3.8. In the following procedure inwc is selected, but note that any unit-of-measure can be used for calibration purposes. 1. Assemble the pressure sensor calbraton equpment as shown n fgure 5- 1, but do not connect the analyzer to the calibration equipment...
Page 80: 5.4 T-Stack Calibration
Instruction 24-9448 5-4 calibration the calibration range is from –6 to –2 inwc (–15 to –5 mb). An attempt to calibrate outside this range will cause the message “applied value high” (or low) to appear at the bottom of the screen. 7. Wat untl the measured readng stablzes, and then press ent to cal- ...
Page 81
Instruction 24-9448 5-5 calibration known temperature that will be applied for calibration purposes. 4. Set thermocouple smulator to 32 °f (0 °c), and then use the and buttons to enter an appled value that exactly equals the set- tng of the smulator. Alternatively: submerge probe tp nto an ce- water...
Page 82: 5.5 T-Air Calibration
Instruction 24-9448 5-6 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 ...
Page 83
Instruction 24-9448 5-7 calibration the calibration range is from 32 to 41 °f (0 to 5 °c). An attempt to calibrate outside this range will cause the message “applied value high” (or low) to appear at the bottom of the screen. 5. Wat untl the measured readng stablzes, and then press ent to calbrate t...
Page 84
Instruction 24-9448 5-8 calibration 5.6 co-lo sensor calibration note that the co-lo sensor also measures h 2 for the purpose of com- pensatng the co readng for the presence of h 2 n the gas sample. Ths procedure frst spans the co-lo sensor and, optonally, spans the h 2 part of the sensor to known g...
Page 85
Instruction 24-9448 5-9 calibration 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 2 calibration can be bypassed by pressing the esc bu...
Page 86: 5.7 So
Instruction 24-9448 5-10 calibration 5.7 so 2 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 2 n ntrogen, p/n 24-1158 procedure: 1. If not already done, turn on the analyzer and dsplay ...
Page 87: 5.8 No Sensor Calibration
Instruction 24-9448 5-11 calibration 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 88: 5.9 No
Instruction 24-9448 5-12 calibration 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 t...
Page 89
Instruction 24-9448 5-13 calibration 5. Adjust regulator for a flowmeter ndcaton of approxmately 2 scfh. Wat untl the measured readng stablzes (approxmately 3 mnutes), and then press ent to calbrate the no 2 measured value to that of the appled value. The message “good calbraton” should brefly appea...
Page 90
Instruction 24-9448 5-14 calibration this range will cause the message “bad calibration wrong cal entry” to appear in the following step. 5. Adjust regulator for a flowmeter ndca- ton of approxmately 2 scfh. Wat untl the measured readng stablzes (approx- mately 3 mnutes), and then press ent to calbr...
Page 91: 6 Maintenance
Instruction 24-9448 6-1 maintenance 6 maintenance customer mantenance of the pca 2 s lmted to the followng: battery replacement or chargng usng ac power adapter (secton 3.2) sensor re-calbraton (secton 5) water trap / flter assembly mantenance (secton 6.2) sensor replacement (secton 6.3) probe therm...
Page 92: 6.1 Pca 2 Disassembly
Instruction 24-9448 6-2 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. Remo...
Page 93
Instruction 24-9448 6-3 maintenance figure 6-2. Inside view with rear case removed sensor positions 225 24-7301 235 24-7302 245 24-7303 255 24-7304 265 24-7305 275 24-7306 #1 o 2 o 2 o 2 o 2 o 2 o 2 #2 co lo co lo co lo co lo co lo co lo #3 so 2 no 2 so 2 #4 no co hi no no model p/n position sensor ...
Page 94
Instruction 24-9448 6-4 maintenance figure 6-3. Tubing connections models 235 & 245 p/ns 24-7302 & 24-7303 model 255 p/n 24-7304 models 265 & 275 p/ns 24-7305 & 24-7306 model 225 p/n 24-7301 elbow pressure sensor on printed circuit board –∆p +∆p –∆p (bottom) +∆p (top) pressure purge air gas gas in g...
Page 95
Instruction 24-9448 6-5 maintenance figure 6-4. Wiring solder (2 places) red dot on pump indicates positive (red wire) connection battery to j14 battery to j14 gas pump to j8 purge pump to j9 sensor connector (typical 4 places) factory test connector lcd connector (opposite side of board) ribbon cab...
Page 96
Instruction 24-9448 6-6 maintenance figure 6-5. Disassembling the water trap / filter assembly 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...
Page 97
Instruction 24-9448 6-7 maintenance 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 ju...
Page 98
Instruction 24-9448 6-8 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. Remove the bat...
Page 99
Instruction 24-9448 6-9 maintenance 12. Plug the sensor nto analyzer; and then reattach tubng to gas cup. 13. Install the sensor retaner and battery cover. 14. Allow the sensor that was just nstalled tme to stablze n the crcut before contnung wth ths procedure. Stablzaton tme for all sen- sors (exce...
Page 100
Instruction 24-9448 6-10 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 ...
Page 101
Instruction 24-9448 6-11 maintenance 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 ...
Page 102
Instruction 24-9448 6-12 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...
Page 103: 6.7 Pump Replacement
Instruction 24-9448 6-13 maintenance 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 ...
Page 104: 6.8 Cleaning The Probe
Instruction 24-9448 6-14 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 rest...
Page 105: 7 Troubleshooting
Instruction 24-9448 7-1 troubleshooting 7 troubleshooting 7.1 analyzer repair it s recommended that feld repar of the pca 2 be lmted to: checks of prnted crcut board connectors replacng the probe assembly replacng the flter element n the water trap / flter assembly replacng sensors replacng ether th...
Page 106
Instruction 24-9448 7-2 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...
Page 107
Instruction 24-9448 7-3 troubleshooting pressure sensor s measurng pressure outsde the range of +/ - 3 nches of water column at startup. Ensure that the analyzer s samplng atmospherc pressure and restart. The analyzer was turned on wth the probe samplng flue gas. Move the probe to fresh ar and resta...
Page 108
Instruction 24-9448 7-4 troubleshooting 3. Use the buttons to hghlght the desred dagnostc topc, and then press ent to dsplay the nformaton under that topc. 4. Press esc key to ext back to the dagnostc menu or the menu (f2) key to ext back to the man menu. The status screen provdes a quck reference t...
Page 109: 8 Parts & Service
Instruction 24-9448 8-1 parts & service 8 parts & service 8.1 replacement parts item (fig. 8-1) description part no. 1 man pcb assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1442 2 lcd module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1374 3 rear case...
Page 110
Instruction 24-9448 8-2 parts & service item (fig. 8-1) description part no. 17 screw, #4 x 1/2 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-2144 18 battery clp, sngle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-1434 19 battery clp, double . . . . . . . . . . . . ...
Page 111
Instruction 24-9448 8-3 parts & service 4 10 7 6 2 1 9 16 15 13 3 5 8 17 12 14 18 19 11 17 figure 8-1. Parts (2 of 2).
Page 112: 8.2 Accessories
Instruction 24-9448 8-4 parts & service 8.2 accessories standard accessories part no. Carryng case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-0865 batteres, 'aa' alkalne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-0004 12" probe...
Page 113: Optional Accessories
Instruction 24-9448 8-5 parts & service optional accessories part no. Ac power adapter (input: 100–240 vac, 50/60 hz; output: 9 vdc @ 1 a) . . . . . . . .24-1404 ambent ar thermocouples (t-air), k-type: 10 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 114: 8.3 Service Centers
Instruction 24-9448 8-6 parts & service 8.3 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-...
Page 115: Notes:
Notes:.
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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