Bacharach PCA 2 24-9448 User Manual

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Portable Combustion Analyzer

Instruction 24-9448

Operation & Maintenance

Rev. 1 - October 2006

Product Leadership • Training • Service • Reliability

WARRANTY

Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc.’s applicable specifications. Bacharach’s liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s option, of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc.’s reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc. The Oxygen (O2) sensor has a limited warranty of one (1) year. Routine service and calibration are excluded from this warranty.

Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach, to the replacement of this Product or parts thereof that are defective in title.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARIS ING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall be limited to those provided herein to the exclusion of any and all other remedies including, without limitation incidental or consequential damages. No agreement varying or extending the foregoing warranties, remedies or this limita tion will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.

www.bacharach-inc.com

Notice:

Product improvements and enhancements are continuous, therefore the specifications and information contained in this document may change without notice.

Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.

No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Bacharach, Inc.

Copyright © 2006, Bacharach, Inc., all rights reserved. BACHARACH is a registered trademark of Bacharach, Inc. All other trademarks, trade names, service marks and logos referenced herein belong to their respective companies.

Instruction 24-9448

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 PCA 2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Sales Combo & Model Configurations . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Features & Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.4 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.5 Connector Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.5.1 Probe Connections (Gas, Pressure, T-Stack) . . . . . . . . . . . .1-6

1.5.2 T-AIR (Primary Air Thermocouple) . . . . . . . . . . . . . . . . . . .1-6

1.5.3 POWER (AC Adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.5.4 ∆P (Differential Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.5.5 USB (Computer Interface) . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.5.6 IrDA (Printer Interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.5.7 OPT (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.6 Front Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

2 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2.1 Installing or Replacing Batteries . . . . . . . . . . . . . . . . . . . . .3-1

3.2.2 Using the AC Power Adapter . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.3 Connecting the Probe and Hose Assembly . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.5 Fuel Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.6 Temperature Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.7 Pressure Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.8 Pollution Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3.9 Date Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.10 Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.11 O2 Reference Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3.12 Print Pressure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3.13 Zoom-Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3.14 Battery Charger Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3.15 Logging Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3.16 Button Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Instruction 24-9448

Contents

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 Turning ON the Analyzer and Warm Up . . . . . . . . . . . . . . . . . . .4-2

4.3 Selecting a Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 Sampling Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.5 Performing a Combustion Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.6 Making a Draft / Pressure Measurement . . . . . . . . . . . . . . . . . . .4-7

4.7 Saving Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.8 Ending a Combustion Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.9 Emptying the Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.10 Turning OFF the Analyzer & Purging. . . . . . . . . . . . . . . . . . . .4-10

4.11 Low Battery Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4.12 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.12.1 Turning ON Data Logging . . . . . . . . . . . . . . . . . . . . . . . .4-12

4.12.2 Setting the Logging Interval and Duration . . . . . . . . . .4-13

4.12.3 Starting the Data Logging Process . . . . . . . . . . . . . . . . .4-14

4.12.4 Ending the Data Logging Process . . . . . . . . . . . . . . . . . .4-15

4.13 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.13.1 Recalling Combustion Test Data . . . . . . . . . . . . . . . . . . .4-16

4.13.2 Recalling Logged Test Data . . . . . . . . . . . . . . . . . . . . . . .4-17

4.13.3 Clearing Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4.14 Downloading Stored Data to a Computer . . . . . . . . . . . . . . . . . .4-19

4.14.1 PCA 2 Data Recovery Program Installation . . . . . . . . . 4-20

4.14.2 Computer to PCA 2 Connection & USB Device Driver In-

stallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4.14.3 Recovering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4.14.4 Unplugging the USB Cable . . . . . . . . . . . . . . . . . . . . . . . .4-27

4.15 Importing Saved Data Into a Spreadsheet . . . . . . . . . . . . . . . . . .4-28

4.16 Printing Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Smart Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Starting a Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3 Pressure Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 T-Stack Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 T-Air Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.6 CO-LO Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.7 SO2 Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5.8 NO Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5.9 NO2 Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5.10 CO-HI Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Instruction 24-9448

Contents

6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 PCA 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Water Trap / Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.2.1 Emptying the Water Trap Chamber . . . . . . . . . . . . . . . . . 6-6

6.2.2 Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3 Smart Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.4 Sensor Only Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.5 Nitric Oxide Sensor Battery Replacement . . . . . . . . . . . . . . . . . .6-10

6.6 Thermocouple Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6.7 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6.8 Cleaning the Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Analyzer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Error Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.3 Error Messages Displayed After Warm-Up . . . . . . . . . . . . . . . . . .7-2

7.4 Diagnostics and Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

8 Parts & Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.3 Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7

Instruction 24-9448

iii

Contents

Notes:

Instruction 24-9448

Introduction

1 Introduction

1.1 PCA 2 General Description

The PCA 2 is a commercial-grade hand-held combustion and emissions analyzer designed for on-demand sampling of light industrial, institutional, commercial and residential furnaces, appliances, and boilers. The basic instrument is supplied with a probe and hose assembly, instruction manual, factory calibrated smart sensors, 4 'A A' alkaline batteries, Data Download Software with USB cable and carrying case.

Because of the PCA 2’s ability to measure up to four gases simultaneously, it is the perfect tool for service technicians, inspectors and boiler contractors who need to determine combustion efficiency, excess air, stack gas O2 and CO levels, stack temperature, draft, and differential pressure. The analyzer can also directly measure and display NO, NO2 and SO2 with the installation of the appropriate sensors. Combustion efficiency calculations can be conducted for the following fuels: natural gas, oil #2, oil #4, oil #6, propane, coal, wood, kerosene, bagasse, and digester gas. A large backlit graphical display shows up to eight combustion test values simultaneously, and includes a zoom capability that provides an extra large display of just the O2, CO, and combustion efficiency values.

Smart sensor technology allows a new sensor to be installed in the field without having to calibrate the analyzer before use. New and innovative probe and analyzer designs allow the PCA 2 to be easily serviced, thus lowering the cost of ownership.

Advanced data storage and communication features allow the operator to store up to 500 individual combustion test records, which can later be recalled for viewing, printing, or downloading to a personal computer. In its data logging mode, the analyzer can store an additional 500 data logged records.

An optional AC power adapter allows the analyzer to run continuously for data logging purposes.

The optional sample conditioning probe is recommended when measuring NO2 and SO2 to ensure the highest degree of measurement accuracy.

Instruction 24-9448 1-1

Introduction

1.2 Sales Combo & Model Configurations

Sales Combo 24-8350 24-8351 24-8352

Sales Combo (Kit) 24-8370 24-8371 24-8372

Model Type 225 235 245

PCA2 Only Part Number 24-7301 24-7302 24-7303

Measurements

Oxygen (O2)

Stack Temperature

Primary / Ambient Air Temperature

Carbon Monoxide Low (CO

Low

)

Pressure / Draft

Carbon Monoxide High (CO

High

)

Nitric Oxide (NO)

Nitrogen Dioxide (NO

)

Sulfur Dioxide (SO2)

Calculations

Combustion Efciency

Excess Air

Carbon Dioxide (CO

)

NOx (NOx = NO + NO2)

NOx referenced to %O

CO referenced to %O

NO referenced to %O

NO2 referenced to %O

SO2 referenced to %O

3 3 3

Refer to Section 8.2 for a listing of standard and optional accessories.

Instruction 24-94481-2

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 (O2)

Stack Temperature

Primary / Ambient Air Temperature

Carbon Monoxide Low (CO

Low

)

Pressure / Draft

Carbon Monoxide High (CO

High

)

Nitric Oxide (NO)

Nitrogen Dioxide (NO

Sulfur Dioxide (SO

)

3 3 3

3 3

Calculations

Combustion Efciency

Excess Air

Carbon Dioxide (CO

)

NOx (NOx = NO + NO2)

NOx referenced to %O

CO referenced to %O

NO referenced to %O

NO2 referenced to %O

SO2 referenced to %O

3 3 3

3 3

Instruction 24-9448 1-3

Introduction

1.3 Features & Benefits

• Powered by 4 ‘AA’ alkaline batteries, or NiMH rechargeable batteries. An optional AC power adapter provides continuous operation.

• Internal charging circuit allows rechargeable batteries to be charged inside the analyzer with the use of the optional AC power adapter.

• O2 and CO two additional gases: CO

measurement standard. Optional measurement of up to

Low

, NO, NO2, or SO2.

High

• With the appropriate sensors installed, the analyzer optionally displays pollution conversions for CO, NO, NO2, and SO2. Pollution conversions include ppm, #/MBTU, mg/m3, and g/GJ.

• Smart sensor technology allows pre-calibrated sensors to be installed in the field.

• Automatic zero of all sensing channels on ambient air when the analyzer is first turned ON.

• Automatic flushing of the CO exceeds 4,000 ppm, thus protecting the CO

sensor with fresh air if the CO level

Low

sensor from high CO

Low

levels. To measure CO levels above 4,000 ppm, the analyzer automatically switches to its CO

sensor, if installed.

High

• Automatic purging of the gas-sample system if the detected gas levels are abnormally high when the analyzer is turned OFF.

• Displays temperatures in either °F or °C.

• Displays pressure in either inwc, mb, Pa, or hPa.

• Backlit LCD and push buttons.

• Low battery alarm.

• Stores 500 individual combustion records, which can later be recalled for viewing, printing, or downloading to a personal computer. Stores an additional 500 data logged records.

• Wireless IrDA link used for printing current and stored combustion records, pressure records, sensor calibration data, and diagnostic data.

• USB connectivity for downloading stored data to a personal computer.

• Field replaceable sensors and thermocouple.

• Two year warranty on analyzer and all gas sensors except the O2 sensor which has a one (1) year warranty.

Instruction 24-94481-4

Introduction

1.4 Operational Overview

The PCA 2 is powered by either its 4 internal batteries, or by an optional AC power adapter that operates from any convenient source of 100– 240 VAC, 50/60 Hz power. The type of batteries used can be either disposable alkaline or rechargeable NiMH. Note that rechargeable batteries can be charged inside the analyzer using the optional AC power adapter.

The PCA 2 is controlled by 11 front panel push buttons, while a graphical LCD is used to display all combustion and emission test data and analyzer parameters.

A probe and hose assembly, with an integral thermocouple and filter/water-trap connect to the bottom of the analyzer, thus providing the means of drawing in gas samples, and for measuring stack temperature and draft.

The PCA 2 is turned ON by pressing its red I/O button. A warm-up period of 60 seconds then begins, during which time the analyzer performs self diagnostics. At the end of the warm-up period, if no errors were detected the message “NO ERRORS DETECTED” is briefly displayed followed by the display of the Combustion Test HOLD screen. If errors were detected, the message “ERRORS DETECTED” is displayed along with a list of the errors. These errors must be corrected before proceeding with the combustion test.

Before starting a test be sure to select the fuel being burned. The default fuel selected is Natural Gas. Note that the name of the fuel being burned is indicated at the top of the display. To change the fuel: first, press the MENU (F2) button; next, select FUEL from the menu; then use the but- tons to highlight the fuel being burned; and finally, press the green ENT button to select the highlighted fuel.

To assure correct combustion-efficiency calculations, the analyzer must know the burner’s primary-air temperature. The analyzer normally uses its internal temperature sensor for the primary-air temperature value, but this method is only acceptable if the burner is using ambient room air. If the burner is drawing in cold outside air, we recommend that the optional TAIR thermocouple be used. This thermocouple plugs into the bottom of the analyzer and is placed in the burner’s primary-air stream.

Begin the combustion test by first inserting the analyzer’s probe tube into the stack-gas stream of the appliance under test, and then pressing the RUN/HOLD button to display the Combustion Test RUN screen. The analyzer will begin to continuously monitor the stack temperature, %O2 and

Instruction 24-9448 1-5

Introduction

emission levels in the stack gas and then display measured and calculated values on its LCD. Values are listed in Section 2 Specifications.

During a test, the CO automatically flushed with fresh air when the detected CO level exceeds 4,000 ppm. The analyzer will automatically start using its optional CO-

sensor, if installed, at CO levels starting at 4,001 ppm, thus providing

High

continuous CO readings up to 20,000 ppm.

A backlight enables a user to read the display in dimly-lit areas. Turn the backlight ON and OFF by briefly pressing the I/O button.

The analyzer is turned OFF by pressing and holding down the I/O button for at least 2 seconds. Note that there is a 5-second delay before the analyzer actually turns OFF, during which time the analyzer can be turned back ON by pressing the RUN/HOLD button. In addition, there is a gas-purge feature that keeps the analyzer’s pump running if the gas level inside the sensor chambers is abnormally high at shutdown. With the probe removed from the stack and sampling fresh air, the analyzer purges itself until the detected gas concentrations drop below predetermined levels.

sensor is protected from high CO levels by being

Low

1.5 Connector Descriptions

1.5.1 Probe Connections (Gas, Pressure, T-Stack)

Attach the probe and hose assembly to the analyzer by connecting its . . .

• stack-gas thermocouple to the analyzer's T-STACK connector,

• stack-gas hose to the analyzer's GAS connector,

• draft hose to the analyzer's +∆P connector.

Observe that the probe connectors are of different sizes and shapes, which prevent incorrect connection to their associated connectors on the analyzer.

1.5.2 T-AIR (Primary Air Thermocouple)

If thermocouple P/N 104-1797 (10 feet long) or Utility Wand P/N 104-1799 (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 of these thermocouples to the analyzer’s T-AIR connector.

Instruction 24-94481-6

Introduction

T-STACK T-AIR

IrDA – Wireless printer communications port

ENT:

• Selects a highlighted

menu item, or conrms 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

efciency test

• Pressing this button during the 5 second turn-off period will keep the analyzer turned ON

ESC – Displays previous menu or previously viewed screen

I/O – Press from between 1 and 2 seconds to turn analyzer ON and OFF

– With analyzer turned

ON, press briey to turn

backlight ON and OFF

LCD – 160 x 160 graphic display

F1 / F2 / F3 – Soft Menu Buttons, whose functions are

dened by labels

appearing above them on LCD

USB – Computer communications connector

Arrow Buttons:

– Moves cursor up the display, or increments an alphanumerical value

– Moves cursor down the display, or decrements an alphanumerical value

– Moves cursor left, or moves to top of menu list

– Moves cursor right, or moves to bottom of menu list

T-STACK – Probe’s stack-gas thermocouple connector

OPT – Option external measurement connector

T-AIR – Primary /

POWER – AC power adapter

connector

ambient air thermocouple connector

GAS – Probe’s gas hose connector

“+∆P” Probe’s draft

hose tting

“–∆P” Reference

pressure hose tting

Figure 1-1. PCA 2 Components

Instruction 24-9448 1-7

Introduction

1.5.3 POWER (AC Adapter)

The AC power adapter P/N 24-1404 can be used as an external power supply, which will run the analyzer on a continuous basis.

When using rechargeable NiMH batteries, the AC power adapter can also be used to charge the batteries while inside the analyzer. The analyzer’s rapid-charger circuit, however, must first be turned ON per Section 3.14. The rapid charger will charge a set of depleted batteries in approximately 2 - 3 hours.

When disposable alkaline batteries are used, the analyzer’s battery charger circuit must be OFF to prevent the batteries from overheating. As a precaution, the charger circuit is automatically toggled back to its OFF state when the analyzer is turned OFF.

1.5.4 ∆P (Differential Pressure)

Draft is measured by connecting the probe’s draft hose to the +∆P fitting, while leaving the –∆P fitting open to the atmosphere.

In addition to measuring draft, the “+” and “–” ∆P fittings can also be used to measure the differential pressure between two areas by first connecting a hose P/N 24-1103 to the –∆P fitting, and then inserting the open end of this hose into the area being used as the reference pressure. The analyzer’s probe is then inserted into the area who’s differential pressure is to be measured. Refer to Section 4.6.

1.5.5 USB (Computer Interface)

Data that has been stored in the analyzer’s memory can be downloaded to a personal computer by connecting USB data cable P/N 104-4032 between the USB ports of the computer and analyzer. Refer to Section 4.14.2.

1.5.6 IrDA (Printer Interface)

Data that has been stored in the analyzer’s memory can be printed on a compatible IrDA wireless printer by aligning their IrDA communication ports. Refer to Section 4.16.

1.5.7 OPT (Option)

The option connector is used for optional external measurement features.

Instruction 24-94481-8

Introduction

1.6 Front Panel Buttons

Descriptions of the front panel buttons are given below. Note that a control may perform multiple functions as determined by what screen is being displayed at the time.

The functions of these buttons are defined by labels appearing above them on the LCD. The labels that appear depend on the functions that can be performed in the particular screen being displayed.

PRINT (F1): Transmits the data displayed on the screen to a printer through the IrDA communications port.

MENU (F2): Displays the Main Menu.

SAVE (F3): Saves the data currently displayed on the

LCD in memory. Up to 500 individual Combustion Test and Pressure records can be saved. After which, the oldest data will be overwritten.

ZERO (F2): When viewing the Pressure screen, this button zeros the pressure sensor to current atmospheric conditions.

PAGE– (F1): When viewing the Memory or Logging Directory, each press of this button pages down through the directory. Holding this button down speeds up the paging process.

PAGE+ (F3): When viewing the Memory or Logging Directory, each press of this button pages up through the directory. Holding this button down speeds up the paging process.

The arrow buttons move the cursor on the LCD in the direction of the arrow. In screens that require the entry of alphanumerical data, use the buttons to move cursor across the screen and then use the buttons to increment and decrement the data. When viewing a menu, use the buttons to quickly move to the top and bottom of the menu.

Instruction 24-9448 1-9

Introduction

Selects a highlighted menu. In addition, if changes were made to one of the analyzer’s operating parameters (e.g., date, time, O2 reference, etc.), pressing this button confirms those changes and saves them in memory.

Starts and stops a combustion test when the Combustion Test screen is displayed. Pressing this button in any other screen returns the analyzer to the Combustion Test HOLD screen. Pressing this button during the 5 second turn-off-delay period will abort the turn-off process and also return the analyzer to the Combustion Test HOLD screen.

Displays a previously viewed screen. In addition, if changes were made to one of the analyzer’s operating parameters (e.g., date, time, O2 reference, etc.), pressing this button aborts those changes, restores the old values, and then displays the previously viewed screen.

Turns the analyzer ON and OFF, and is also used to turn the backlight and button LEDs ON and OFF.

Note that when the analyzer is turned OFF, there is a 5 second delay, during which time an operator can keep the analyzer turned ON by pressing the RUN / HOLD button. Also note that if the measured emission levels are above predetermined limits at the time the instrument is turned OFF, the pump is automatically started and purges the sensor compartment with fresh air until the gas levels inside the analyzer are reduced. If desired, the purging process can be aborted by again pressing the I/O button.

Instruction 24-94481-10

Specications

2 Specifications

The PCA 2 Directly Measures and Displays:

The gases displayed depend on the analyzer’s model number. Refer to Section 1.2.

Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 20.9%

Stack Temperature . . . . . . . . . . . . . . . . . . . . –4 to 2,192 ºF (–20 to 1,200 ºC)

Primary / Ambient Air Temperature . . . . . . . . –4 to 999 ºF (–20 to 537 ºC)

Carbon Monoxide (CO) (H2 compensated) . . . . . . . . . . . . . . . .0 to 4,000 ppm

Pressure / Draft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±72 "H2O (±180 mb)

CO High Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,001 to 20,000 ppm

Nitric Oxide (NO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 to 3,000 ppm

Nitrogen Dioxide (NO2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 500 ppm

Sulfur Dioxide (SO2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 to 5,000 ppm

The PCA 2 Calculates and Displays:

Calculations are performed only when the measured oxygen level is below

16.0%, and the stack temperature is below 2,000 °F (1,093 ºC).

Combustion Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.1 to 100%

Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 250%

Carbon Dioxide (dry basis) . . . . . . . . . . 0.1 to fuel dependent maximum in %

NOx (NOx = NO + NO2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 3,500 ppm

NOx referenced to %O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 9,999 ppm

CO referenced to %O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 9,999 ppm

NO reference to %O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 9,999 ppm

NO2 reference to %O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 9,999 ppm

SO2 reference to %O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 9,999 ppm

Fuels Available for Combustion Calculations:

• Natural Gas • Coal

• Oil #2 • Wood

• Oil #4 • Kerosene

• Oil #6 • Bagasse

• Propane • Digester Gas

Instruction 24-9448 2-1

Specications

Normal Operating Conditions:

Temperature:

Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 104 ºF (0 to 40 ºC)

Probe Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,472 ºF (800 ºC) Max.

Humidity:

Analyzer . . . . . . . . . . . . . .15 to 90% Relative Humidity, non-condensing

Air Pressure:

Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Atmospheric

Probe . . . . . . . . . . . . . . . . . . . . . 10" H2O (25 mb) draft max. at probe tip

Performance:

Accuracy:

O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .±0.3% O2 on practical concentrations

of stack gas (mix of O2, CO2 and N2)

CO . . . . . . . . . . . . . . . . . . . . . . . . . . ±5% of reading or ±10 ppm,

whichever is greater between 0–2,000 ppm, and ±10% of reading between 2,001–20,000 ppm.

NO . . . . . . . . . . . . . . . . . . . . . . . . . . ±5% of reading or ±5 ppm,

whichever is greater between 0–2,000 ppm

NO2 . . . . . . . . . . . . . . . . . . . . . . . . . ±5% of reading or ±5 ppm,

whichever is greater between 0–500 ppm

SO2 . . . . . . . . . . . . . . . . . . . . . . . . . ±5% of reading or ±10 ppm,

whichever is greater between 0–2,000 ppm

Stack Gas Temp. . . . . . . . . . . . . . . . ±4 ºF between 32 and 255 ºF

(±2 ºC between 0 and 124 ºC) ±6 ºF between 256 and 480 ºF (±3 ºC between 125 and 249 ºC) ±8 ºF between 481 and 752 ºF (±4 °C between 250 and 400 °C)

Primary / Ambient Air Temp. . . . . . ±2 ºF between 32 and 212 ºF

(±1 °C between 0 and 100 °C)

Pressure / Draft . . . . . . . . . . . . . . . . ±2% of reading or ±0.02 "H2O

(±0.05 mb), whichever is greater

System Flow Rate with Probe . . . . . . . 200 cc/min minimum

Instruction 24-94482-2

Specications

Power Requirements:

Four disposable ‘AA’ alkaline batteries provide at least 15 hours of continuous operation. NiMH rechargeable batteries can also be used, with the operating time dependent on battery type and condition.

An optional AC power adapter, which runs from any convenient source of 100–240 VAC, 50/60 Hz power, can be used to power the analyzer on a continuous basis. If using rechargeable batteries, the AC power adapter can also be used to charge the batteries while inside the analyzer.

Warm-Up Time:

60 seconds. Sensors are checked and auto zeroed during warm-up.

Memory:

• 500 complete combustion test records

• 500 complete logged combustion test records

Interfaces:

• Printer – Infrared (IrDA) communications

• Computer – USB

Dimensions:

9H x 3W x 2.5D inches (22.9 x 7.6 x 6.3 cm)

Weight:

• Analyzer – 1.4 lb (0.6 kg) w/ batteries

• Probe & Hose Assembly – 1 lb (0.5 kg)

Instruction 24-9448 2-3

Specications

Notes:

Instruction 24-94482-4

Initial Setup

Release and then remove battery cover by pushing latch up

3 Initial Setup

3.1 Scope

Before using the PCA 2, you MUST:

• Install batteries, or plug in the optional AC power adapter (Section 3.2)

• Connect the probe and hose assembly (Section 3.3)

• Check, and if necessary, make changes to the analyzer’s configuration (Section 3.4)

3.2 Power

3.2.1 Installing or Replacing Batteries

Either alkaline or NiMH rechargeable batteries can used to power the analyzer. Note that if rechargeable batteries are used, they can be recharged while installed inside the analyzer using the optional AC power adapter (refer to Section 3.2.2).

Install or replace the batteries as described below:

1. Remove battery cover from back of unit (Figure 3-1.)

2. Remove (and properly dispose of) any old batteries.

3. Install a set of four ‘AA’ alkaline or NiMH batteries, per the “+” and “–” markings inside the battery compartment.

4. Replace battery cover.

Figure 3-1. Installing Batteries

Instruction 24-9448 3-1

Initial Setup

3.2.2 Using the AC Power Adapter

The AC power adapter is capable of powering the analyzer on a continuous basis. The adapter plugs into an appropriate 100–240 VAC, 50/60 Hz wall outlet, and produces an output of +9 VDC. The adapter’s output connector plugs into the analyzer’s POWER jack located on the bottom of the unit (Figure 3-2).

If NiMH rechargeable batteries are used, the adapter can also rapid charge these batteries in approximately 2 - 3 hours while still inside the analyzer. For the batteries to be charged, however, the analyzer’s battery charger circuit must be turned ON per Section 3.14.

3.3 Connecting the Probe and Hose Assembly

Do the following to attach the probe and hose assembly to the analyzer (Figure 3-2):

1. Push the gas-sample hose connector, the larger of the two connectors (giving a slight twist), onto the analyzer’s GAS fitting.

2. Push the draft-hose connector, the smaller connector (giving a slight twist), onto the analyzer’s +∆P fitting.

3. Push the stack-gas thermocouple connector into the T-STACK jack (connector fits in only one way).

NOTE: The analyzer has a built-in temperature sensor for measuring ambient temperature. Perform Step 4 only if the optional primary / ambient air thermocouple is used.

4. Push the optional primary / ambient air thermocouple into the T-AIR jack (connector fits in only one way).

IMPORTANT: To assure the accurate calculation of combustion efficiency, the optional primary / ambient air thermocouple must be used when the burner’s primary-air temperature is not the same as the room temperature.

5. Inspect all hoses for cracks. If any hose is found to be defective, replace the entire probe and hose assembly. Check that the water trap is empty, and that the filter is not dirty or saturated with water.

Instruction 24-94483-2

Initial Setup

POWER

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

Connector

(Optional External Measurement)

Draft Hose

(+ ∆P)

Gas Sample

Hose

(GAS)

Probe Tube

Probe Stop

Primary /

Ambient Air

Thermocouple (T-AIR) (Optional)

Figure 3-2. Connecting the Probe and Hose Assembly to the PCA 2

Instruction 24-9448 3-3

Initial Setup

MAIN MENU

FUEL

PRESSURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

FUEL MENU NATURAL GAS OIL #2 OIL #4 OIL #6

PROPANE

COAL WOOD

(more)

F1 F2 F3

3.4 Operating Parameters

The PCA 2 is set up at the factory for the following operating parameters:

Fuel . . . . . . . . . . . . . . . . . . . . .Natural Gas

Temperature Units . . . . . . . . . °F

Pressure Units . . . . . . . . . . . .Inches of Water Column (inwc)

Pollution Units . . . . . . . . . . . .ppm

Date . . . . . . . . . . . . . . . . . . . . . Current MM/DD/YY

Time . . . . . . . . . . . . . . . . . . . . Current EST HH:MM AM/PM

O2 Reference . . . . . . . . . . . . . .0%

Print Pressure . . . . . . . . . . . .No

Zoom . . . . . . . . . . . . . . . . . . . .No

Battery Charger . . . . . . . . . . .OFF

Logging . . . . . . . . . . . . . . . . . . No

Button Sound . . . . . . . . . . . . .ON

To change any of these parameters, perform the associated procedure provided in Sections 3.5 thru 3.16.

3.5 Fuel Selection

To assure the accurate calculation of combustion efficiency, select the fuel being burned as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight FUEL, and then press ENT to display the FUEL MENU.

3. Use the buttons to scroll through the list of available fuels until the desired fuel is highlighted. In the example shown, PROPANE has been selected.

TIP: Use the buttons to quickly scroll to the bottom and top of the list.

4. Press ENT to save the selection and display the Combustion Test HOLD screen. Observe that the name of the selected fuel should now appear at the top of the screen.

Instruction 24-94483-4

3.6 Temperature Units Selection

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU

TEMP UNITS

PRESSURE UNITS POLLUTION UNITS DATE TIME O2 REF PRINT PRESSURE

(more)

F1 F2 F3

TEMP UNITS MENU Celsius

Fahrenheit

F1 F2 F3

05/26/06 09:25:30 AM

Select to display temperature in either °F or °C as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight TEMP UNITS, and then press ENT to display the TEMP UNITS MENU.

4. Use the buttons to highlight the desired temperature units. In the example shown, Fahrenheit has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Initial Setup

Instruction 24-9448 3-5

Initial Setup

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

PRESSURE UNITS MENU

InchesWater

milliBar Pascals hectoPascals

F1 F2 F3

05/26/06 09:25:30 AM

SETUP MENU TEMP UNITS

PRESSURE UNITS

POLLUTION UNITS DATE TIME O2 REF PRINT PRESSURE

(more)

F1 F2 F3

3.7 Pressure Units Selection

Select to display pressure in Inches of Water

Column (inwc), millibar (mb), Pascals (Pa), or

hectoPascals (hPa) as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight PRESSURE UNITS, and then press ENT to display the PRESSURE UNITS MENU.

4. Use the buttons to highlight the desired pressure units. In the example shown, InchesWater has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Instruction 24-94483-6

3.8 Pollution Units Selection

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU TEMP UNITS PRESSURE UNITS

POLLUTION UNITS

DATE TIME O2 REF PRINT PRESSURE

(more)

F1 F2 F3

POLLUTION UNITS MENU

ppm

#/Mbtu mg/m3 g/GJ

F1 F2 F3

05/26/06 09:25:30 AM

The PCA 2 is capable of converting the measured ppm levels of CO, NO, NO2, and SO2 to various pollution units using CFR40 Part 60 emission factors. Note that the pollution-unit conversions for NO, NO2 and NOx are based on the molecular weight of NO2.

Select to display pollution units in parts per million (ppm), pounds of pollutant per million BTU (#/Mbtu), milligrams of pollutant per cubic meter of gas (mg/m3), or grams of pollutant per gigajoule (g/GJ) as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

Initial Setup

3. Use the buttons to highlight POLLUTION UNITS, and then press ENT to display the POLLUTION UNITS MENU.

4. Use the buttons to highlight the desired pollution units. In the example shown, ppm has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Instruction 24-9448 3-7

Initial Setup

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU TEMP UNITS PRESSURE UNITS POLLUTION UNITS

DATE

TIME O2 REF PRINT PRESSURE

(more)

F1 F2 F3

DATE MENU

DATE 05/26/06

05/26/06 09:25:30 AM

F1 F2 F3

3.9 Date Setup

The date is stored in the format: MM/DD/Y Y. Its

value is part of the date and time stamp that is

saved along with each combustion test record.

Set the analyzer’s internal clock to the current

date as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight DATE, and then press ENT to display the DATE MENU.

4. First use the buttons to move the cursor across the screen until it is over the digit to be changed, and then press the buttons until the desired value is displayed.

5. Repeat Step 4 until the values for month, day, and year have been set.

6. Press ENT to save the displayed date values and re-display the SETUP MENU, or press ESC to abort this procedure and retain the old date values.

Note: The Date and Time real time clock is powered by the main batteries and is maintained by a supercap on the Main PCB for approximately 1-2 days in the absence of batteries. The supercap is intended to maintain the real time clock when the batteries are changed when exhausted. If the batteries are removed for extended periods of time such as when the PCA2 is not in use (off-season storage), simply reset the time and date after fresh batteries are installed when it is placed back in service.

Instruction 24-94483-8

3.10 Time Setup

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU TEMP UNITS PRESSURE UNITS POLLUTION UNITS DATE

TIME

O2 REF PRINT PRESSURE

(more)

F1 F2 F3

TIME MENU

TIME 09:25 AM

05/26/06 09:25:30 AM

F1 F2 F3

The time is stored in the format: hh:mm:ss AM/PM. Its value is part of the date and time stamp that is saved along with each combustion test record.

Set the analyzer’s internal clock to the current time as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight TIME, and then press ENT to display the TIME MENU.

4. First use the buttons to move the cursor across the screen until it is over the digit to be changed, and then press the buttons until the desired value is displayed.

Initial Setup

5. Repeat Step 4 until the values for hour, minute, and meridiem have been set.

NOTE: The value for seconds cannot be en-

tered, but are displayed and stored as part of the combustion test record.

6. Press ENT to save the displayed time values and re-display the SETUP MENU, or press ESC to abort this procedure and retain the old time values.

Instruction 24-9448 3-9

Initial Setup

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU TEMP UNITS PRESSURE UNITS POLLUTION UNITS DATE TIME

O2 REF

PRINT PRESSURE

(more)

F1 F2 F3

O2 REFERENCE

CO Ref to O2

NOx Ref to O2 SO2 Ref to O2

05/26/06 09:25:30 AM

F1 F2 F3

CO REF TO O2

00%

05/26/06 09:25:30 AM

F1 F2 F3

3.11 O2 Reference Setup

The measured values of CO, NOx, and SO2 can be individually referenced to a specific O2 percentage of between 0 and 15%.

Individually set up the O2 reference value for each of the above gases as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight O2 REF, and then press ENT to display the O2 REFERENCE screen.

4. Use the buttons to highlight the desired measurement, and then press ENT to display the REF TO O2 screen for that measurement. In the example shown, CO has been selected.

5. First use the buttons to move the cursor across the screen until it is over the digit to be changed, and then press the buttons until the desired value is displayed.

6. Press ENT to save the displayed value and redisplay the O2 REFERENCE screen, or press ESC to abort this procedure and retain the old O2 reference value.

7. If the O2 reference value for more than one gas is being set, then repeat Steps 4, 5, and 6 for each measurement.

Instruction 24-94483-10

3.12 Print Pressure Selection

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU

(more) TIME O2 REF

PRINT PRESSURE

DIAGNOSTICS BATTERY CHARGER LOGGING BUTTON SOUND

F1 F2 F3

PRINT PRESSURE

Yes

05/26/06 09:25:30 AM

F1 F2 F3

Select whether to print or not print the pressure measurement on the combustion test printout as follows (see Figure 4-3 on Page 4-31):

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight PRINT PRESSURE, and then press ENT to display the PRINT PRESSURE screen.

4. Use the buttons to highlight either No (do not print pressure) or Yes (print pressure). In the example shown, Yes has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Initial Setup

Instruction 24-9448 3-11

Initial Setup

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU

(more) TIME O2 REF PRINT PRESSURE

ZOOM

BATTERY CHARGER LOGGING BUTTON SOUND

F1 F2 F3

ZOOM

Yes

05/26/06 09:25:30 AM

F1 F2 F3

O2 4.0 %

CO 12 ppm

EFF 82.6%

PRINT MENU SAVE

F1 F2 F3

3.13 Zoom-Display Selection

Zoom-display provides an additional combustion test screen that shows the test values of O2, CO, and efficiency in extra large characters, thus allowing the operator to view the display of these values from a longer distance.

Pressing the ENT button while performing a combustion efficiency test will now show the zoomdisplay. Refer to Section 4.5.

Turn zoom-display ON and OFF as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight ZOOM, and then press ENT to display the ZOOM screen.

4. Use the buttons to highlight either No (turn zoom OFF) or Yes (turn zoom ON). In the example shown, Yes has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Instruction 24-94483-12

3.14 Battery Charger Selection

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU

(more) TIME O2 REF PRINT PRESSURE ZOOM

BATTERY CHARGER

LOGGING BUTTON SOUND

F1 F2 F3

BATTERY CHARGER OFF

05/26/06 09:25:30 AM

F1 F2 F3

When using rechargeable NiMH batteries, the AC power adapter can be used to charge the batteries while inside the analyzer. The analyzer’s rapid-charger circuit, however, must be first turned ON.

IMPORTANT: When using disposable alkaline batteries, the analyzer’s battery charger circuit should be OFF to prevent the batteries from overheating.

As a precaution, the charger circuit is automatically toggled to its OFF state when the analyzer is turned OFF, thus requiring the operator to turn the charger back ON when needed.

Note: The PCA2 must be left turned ON to charge the batteries.

Turn the battery charger circuit ON and OFF as follows:

Initial Setup

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight BATTERY CHARGER, and then press ENT to display the BATTERY CHARGER screen.

4. Use the buttons to highlight either OFF (turn charger OFF) or ON (turn charger ON). In the example shown, ON has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Instruction 24-9448 3-13

Initial Setup

SETUP MENU

(more) TIME O2 REF PRINT PRESSURE ZOOM BATTERY CHARGER

LOGGING

BUTTON SOUND

F1 F2 F3

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU

(more) TIME O2 REF PRINT PRESSURE ZOOM BATTERY CHARGER LOGGING

BUTTON SOUND

F1 F2 F3

BUTTON SOUND

OFF

05/26/06 09:25:30 AM

F1 F2 F3

3.15 Logging Selection

–

When the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a preset interval over a predetermined length of time.

Refer to Section 4.12 for detailed information on how to select the logging function; how to set the interval and duration time periods; and how to view or download the stored data.

3.16 Button Sound

The audible sound used to signal when a button is pressed can be turned OFF and ON as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight BUTTON SOUND, and then press ENT to display the BUTTON SOUND screen.

4. Use the buttons to highlight either OFF (turn sound OFF) or ON (turn sound ON). In the example shown, OFF has been selected.

5. Press ENT to save the selection and re-display the SETUP MENU.

Instruction 24-94483-14

Operation

4 Operation

4.1 Operating Tips

• When an analyzer is brought in from a cold vehicle, let it warm up slowly to minimize condensation. Temperatures below freezing will not damage the analyzer; however, bringing a cold analyzer into a warm, humid environment may cause condensate to form inside the case.

CAUTION: Although the analyzer itself is not damaged by an extremely cold environment, the electrochemical sensors may be damaged. The O2 sensor's electrolyte will freeze at approximately -20 ºF and the other sensors at approximately -94 ºF. If the analyzer is exposed to an extremely cold condition, it is strongly suggested that the sensor housings be examined for hairline cracks. Be aware that a leaking sensor can cause chemical burns to the skin and possibly damage the PCB assemblies.

• Ensure that the analyzer is sampling fresh air when turned ON. 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.

• Note that flue-gas condensate is acidic and very corrosive. It is important not to allow the analyzer’s internal components to come in contact with condensate for long periods of time.

• Before each use, inspect the filter element of the water-trap / filter assembly. Replace the filter if it looks dirty. Refer to Section 6.2.

• When sampling flue-gas, keep the analyzer above the water-trap, and keep the trap in a vertical position. This will maximize the effectiveness of the trap and keep liquid condensate from being drawn directly into the analyzer.

• When liquid condensate is seen inside the water trap, empty the trap before it becomes full. Refer to Section 4.9.

• It is recommended that the analyzer be purged after performing a combustion test. Once the probe is removed from the stack, let the pump run for 10 minutes or so to completely remove any remaining stack gases and dry any condensate from inside the sensor chamber and probe assembly. If the analyzer is turned OFF with high levels of flue gas remaining in the analyzer, then the pump will continue to run and the message “PURGING SENSORS” will appear on the display until all flue gas levels fall below predetermined levels.

• When storing the analyzer, it’s a good idea to empty the water trap and leave it open to further dry it out.

• Calibrate the analyzer every

Instruction 24-9448 4-1

6 months to assure its accuracy.

Operation

Warm Up 60

Warm Up Complete

NO ERRORS DETECTED

O2 Value: Good

ERRORS DETECTED Low Battery

MENUMENU

PCA 2

FIRMWARE VERSION

x.xx

MODEL xxx SERIAL # x xxxxxx

4.2 Turning ON the Analyzer and Warm Up

1. Connect the probe and hose assembly, and make sure that the analyzer is properly set up per Section 3 Initial Setup.

IMPORTANT: DO NOT insert probe into stack before turning ON the analyzer!

2. Place the probe in an area that contains fresh air. This ensures that the sensors will be properly zeroed during the warm-up cycle.

3. Turn ON the analyzer by pressing the I/O button for at least 1 second, or until a single beep is heard. Observe that the analyzer’s firmware version, model and serial numbers are briefly displayed followed by the Warm Up screen.

4. Wait for the analyzer to count down its 60 second warm-up period; after which, the message “NO ERRORS DETECTED” along with the oxygen sensor’s output voltage is briefly displayed followed by the display of the Combustion Test HOLD screen.

TIP: The O2 value at the end of warm-up is reported as "Good, Low or BAD". Consider replacing the oxygen sensor when its value is reported as "Low".

If problems were detected during warm up, the message “ERRORS DETECTED” is displayed along with a list of those errors. As an example, the screen to the right shows that the battery is low. Refer to Section 7.3 for a listing and possible remedy for the errors displayed.

TIP: If the sensors in error are not critical to the combustion test, then press the RUN/HOLD button to display the Combustion Test HOLD screen and proceed with the test.

Instruction 24-94484-2

4.3 Selecting a Fuel

HOLD NATURAL GAS O2 20.9 % CO 0 ppm EFF --- % CO2 --- %

T-STK 71.5 °F T-AIR 71.5 °F EA --- % CO(0) --- ppm

PRINT MENU SAVE

F1 F2 F3

MAIN MENU

FUEL

PRESSURE MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

FUEL MENU NATURAL GAS OIL #2 OIL #4 OIL #6

PROPANE

COAL WOOD

(more)

F1 F2 F3

HOLD PROPANE O2 20.9 % CO 0 ppm EFF --- % CO2 --- %

T-STK 71.5 °F T-AIR 71.5 °F EA --- % CO(0) --- ppm

PRINT MENU SAVE

F1 F2 F3

The top line of the Combustion Test HOLD screen shows the fuel currently selected. In the example shown, the current fuel is NATURAL GAS. If necessary, change the fuel as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button.

2. Use the buttons to highlight FUEL, and then press ENT to display the FUEL MENU.

3. Use the buttons to scroll through the list of available fuels until the desired fuel is highlighted. In the example shown, PROPANE has been selected.

TIP: Use the buttons to quickly scroll to the bottom and top of the list.

4. Press ENT to save the selection and return to the Combustion Test HOLD screen. The newly selected fuel should now appear in the top line of the display.

Operation

Instruction 24-9448 4-3

Operation

O2, CO, Stack Temp.

Undiluted Flue Gas Sample Taken Under Draft Diverter in Top of Fire Tube

O2, CO, Stack Temp.

Combustion Air Sampling Point

O2, CO, Stack Temp.

4.4 Sampling Point

FORCED AIR FURNACE – For atmospheric burner

or gravity vented, forced air heating equipment with a clamshell or sectional heat exchanger design, test each of the exhaust ports at the top of the heat exchanger. The probe should be inserted back into each of the exhaust ports to obtain a flue-gas sample, before any dilution air is mixed in.

HOT WATER TANK – Domestic hot water tanks with the ‘bell’ shaped draft diverter can be accurately tested by inserting the probe tip directly into the top of the fire tube below the diverter.

80% EFFICIENCY FAN ASSIST OR POWER VENTED – Combustion testing of fan assist or power vented, furnaces/boilers should be done through a hole drilled in the vent immediately above the inducer fan.

90% EFFICIENCY CONDENSING – Condensing furnaces/boilers can be tested through a hole drilled in the plastic vent pipe (when allowed by the manufacturer or local authority of jurisdiction) or taken from the exhaust termination.

Forced Air Furnace

ATMOSPHERIC OR GRAVITY VENTED BOILER – Boilers, which have a ‘bell’ shaped draft diverter on top, should be tested directly below the diverter through a hole drilled in the vent connector.

80% Eff. Fan Assist or

90% Eff. Condensing

Power Vented

Hot Water Tank

Atmospheric or Gravity

Vented Boiler

Instruction 24-94484-4

Operation

RUN NATURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

PRINT MENU SAVE

F1 F2 F3

RUN NATURAL GAS NO 18 ppm NO2 6 ppm NOx 24 ppm NO(3) 19 ppm NO2(3) 1 ppm NOx(3) 25 ppm

PRINT MENU SAVE

F1 F2 F3

O2 4.0 %

CO 12 ppm

EFF 82.6%

PRINT MENU SAVE

F1 F2 F3

4.5 Performing a Combustion Test

Ensure that the following has been completed, and then proceed with the combustion test as described below:

• Turn ON analyzer and allow it to warm up (Section 4.2).

• Select fuel being burned (Section 4.3).

• Inset probe into stack (Section 4.4).

• If necessary, insert optional primary air thermocouple into combustionair stream of burners that use an outside source of combustion air.

1. Press the RUN/HOLD button to start the test. You should hear the pump start running and see the word RUN appear at the top of the Combustion Test screen.

2. Press the ENT button to view the various combustion test screens that contain the data listed in Table 4-1 on Page 4-6.

The screens to the right show typical combus-

tion test data for an analyzer equipped with O2, CO

TIP: Use the zoom-display to show only the values of O2, CO, and efficiency in large characters. Refer to Section 3.13.

, NO and NO2 sensors.

LOW

Sensor Indicators: The following indicators

appear in the sensor's data field depending on certain conditions:

(∗ ∗ ∗) Sensor that is not calibrated or defective.

(XXX) Sensor overrange (

- - -

) The calculated data cannot be displayed because the measured data necessary to make the calculation is out of range (i.e., oxygen level above 16%).

3. Press ENT until T-STK is displayed. Loosen thumbscrew on probe stop and move probe in and out of the stack until the stack’s core temperature (hot spot) is located as indicated by the highest T-STK reading; then tighten thumbscrew to prevent further probe movement. Locating the highest stack temperature

is very important for accurate efficiency calculations.

Instruction 24-9448 4-5

Operation

4. You can now begin burner-service procedures. The analyzer readings will change quickly to show changes in 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. The sensors could be damaged if water would enter the analyzer. Empty the Water Trap after every combustion test (refer to Section 4.9)

5. Pressing the RUN/HOLD button freezes all readings, stops the pump and displays the Combustion-Test HOLD screen. Press the ENT button to view all test values at the moment the RUN/HOLD button was pressed. Press- ing RUN/HOLD again restarts the pump and resumes testing.

TABLE 4-1. LIST OF COMBUSTION TEST DATA

Display Name

CO Carbon Monoxide

Description of Measurement or Calculation

% Oxygen

(1)

EFF % Combustion Efficiency

% Carbon Dioxide

T-STK Stack Temperature

T-AIR Primary / Ambient Air Temperature as measured either in-

ternally or by an optional external thermocouple plugged into the analyzer’s T-AIR connector

EA % Excess Air

CO(n) Carbon Monoxide ppm level referenced to a % of oxygen

NO Nitric Oxide

Nitrogen Dioxide

NOx Oxides of Nitrogen (combination of NO and NO2)

Sulfur Dioxide

(1)

NO(n) Nitric Oxide ppm level referenced to a % of oxygen

NO2(n) Nitrogen Dioxide ppm level referenced to a % of oxygen

NOx(n) Oxides of Nitrogen ppm level referenced to a % of oxygen

SO2(n) Sulfur Dioxide ppm level referenced to a % of oxygen

(2)

NO Temp Nitric Oxide Sensor Temperature (3)

(1) Pollution unit of measure selected per Section 3.8 (2) The letter “n” represents the oxygen reference level of between 0 and 15% as

selected per section 3.11

(3) Shown only on printout, not on LCD display.

Instruction 24-94484-6

Operation

PRESSURE

Measured:

0.00 inwc

PRINT ZERO SAVE

F1 F2 F3

MAIN MENU FUEL

PRESSURE

MEMORY SETUP CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

POWER

T-STACK T-AIR

GAS

— ∆P (Pressure Reference Port)

+∆P (Pressure Measurement Port)

4.6 Making a Draft / Pressure Measurement

The difference in pressure (∆P) between two areas can be measured by using the analyzer’s two pressure ports and the PRESSURE screen. By using the –∆P port as the reference, the pressure applied to the +∆P port will be displayed on the PRESSURE screen as the differential pressure between the two ports.

Perform a draft / pressure measurement as follows:

1. Turn ON the analyzer and allow it to complete its warm-up cycle (Section 4.2).

TIP: The pressure units of measure is selected per Section 3.7.

2. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

3. Use the buttons to highlight PRESSURE, and then press ENT to display the PRESSURE screen.

4. Before taking a measurement, the pressure sensor may need to be re-zeroed if it is not already displaying zero with both pressure ports open to the atmosphere. If necessary, zero the pressure sensor as follows:

a. Press the ZERO (F2) button.

Sampling Hoses with quick

connect ttings are available

as an optional accessory. Refer to Section 8.2.

Instruction 24-9448 4-7

Figure 4-1. Draft / Pressure Measurement Hose Connections

Operation

PRESSURE ZERO

Disconnect hose then press ENTER

PRINT ZERO SAVE

F1 F2 F3

PRESSURE ZERO

Reconnect hose

PRINT ZERO SAVE

F1 F2 F3

RUN NATURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

PRINT MENU SAVE

F1 F2 F3

b. Disconnect any hoses connected to the

+∆P and –∆P ports, and then press ENT to zero the pressure sensor.

c. Reconnect any hoses. When measuring

draft, simply leave the –∆P port open to

the atmosphere and connect the probe’s draft hose to the +∆P port (see Figure 3-2 on Page 3-3).

5. Do one of the following to measure draft or differential pressure:

• To measure draft, simply insert the probe into the stack and observe the draft reading on the PRESSURE screen.

• To measure differential pressure, connect two sampling hoses to the +∆P and –∆P ports, and place the open end of each hose into the areas being measured. The differential pressure between the two areas is now displayed on the PRESSURE screen. If the pressure at the +∆P port is higher than the –∆P port, then the pressure reading will be positive. If it is lower, then the reading will be negative.

4.7 Saving Test Data

Up to 500 individual sets (“snap shots”) of combustion-test or pressure data can be saved in memory, which can later be recalled for viewing from the Memory Directory (Section 4.13.1).

1. First display the screen that contains the data to be saved. In the example to the right, all data associated with the Combustion Test RUN screen will be saved.

2. Press the SAVE (F3) button to save the test data in the next available memory location.

NOTE: When memory is full, the next reading saved will overwrite the oldest reading.

Instruction 24-94484-8

Operation

To Gas Port on Analyzer

Gas Flow

Do not allow water level to go above tip of riser tube

Stack Gas From Probe

To empty water, pull apart using a slight twisting motion

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 until all combustion gases have been flushed from the analyzer as indicated by the O2 reading returning to 20.9%.

4.9 Emptying the Water Trap

The Water Trap / Filter Assembly removes stack-gas condensate, and also prevents soot from contaminating the internal components of the analyzer.

IMPORTANT: Use the Water Trap / Filter Assembly in a vertical position with the gas-flow arrow pointing up as shown in the illustration to the right.

Empty the water trap chamber after each combustion test, or stop the test and empty the chamber if the liquid condensate level approaches the tip of the riser tube.

To empty the trap, first pull apart the two halves of the Water Trap using a slight twisting motion; empty the water trap chamber; and then reassemble the trap.

After each combustion test, also check the Water Trap’s filter element. If it looks dirty, replace the filter per Section 6.2.

Instruction 24-9448 4-9

Operation

RUN NATURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

PRINT MENU SAVE

F1 F2 F3

Low Batter y Alarm Empty Battery Icon

SHUTDOWN IN 5 sec

PURGING SENSORS

4.10 Turning OFF the Analyzer & Purging

Turn OFF the analyzer by pressing the I/O button for at least 2 seconds, or until two beeps are heard. The unit will count down 5 seconds before shutting down, giving the operator an opportunity to keep the analyzer turned ON by pressing the RUN/HOLD button.

If the PCA 2 was not purged with fresh air as described in Section 4.8, then the analyzer may remain ON with its pump running and display the message “PURGING SENSORS” as the result of combustion gases still being present inside the analyzer. At this time the operator should ensure that the probe is removed from the stack, allowing the analyzer to purge itself with fresh air. The 5-second-shutdown sequence will not begin until the gas levels inside the analyzer drop below predetermined levels:

TIP: Although not recommended, the purging process can be bypassed by pressing the I/O button a second time.

4.11 Low Battery Alarm

When the batteries are nearly depleted, an empty battery icon appears in the upper-right corner of the display, and a short beep is sounded every 10 seconds.

After a low battery alarm occurs, the analyzer will continue to operate for only a few minutes. The amount of operating time that remains depends on many factors (e.g., pump and backlight being ON or OFF, and the type and condition of the batteries).

Instruction 24-94484-10

Operation

4.12 Data Logging

When the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a preset interval (1, 5, 10, 15, 30 seconds, 1, 2, 5, 10 minutes) over a predetermined duration (5, 10, 15, 30 minutes, 1, 2, 5, 10, 24, 48 hours).

The maximum duration that data can be collected is determined by the interval. For example, if the interval is set to 10 seconds, then the maximum selectable length of time in which data can be collected to fill 500 memory locations would be 1 hour (500 x 10 seconds = 5000 seconds or 83 minutes). If the operator chooses a duration that is longer than possible for the interval chosen, then the analyzer automatically selects the highest duration possible for the selected interval.

The stored logged data can either be viewed on the display using the analyzer’s memory function (refer to Section 4.13), or downloaded to a personal computer using the supplied PCA 2 data recovery software and USB cable (refer to Section 4.14). Downloaded data is stored on the computer’s hard drive as a comma-separated-value ASCII text file with a CSV extension, which can be opened by most spreadsheet programs for analysis.

TIP: The latest PCA 2 data recovery software can be downloaded from http://www.bacharach-inc.com/downloads.

Instruction 24-9448 4-11

Operation

MAIN MENU FUEL PRESSURE MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

SETUP MENU

(more) TIME O2 REF PRINT PRESSURE ZOOM BATTERY CHARGER

LOGGING

BUTTON SOUND

F1 F2 F3

LOGGING

YES

nnn MEMORY

LOCATIONS OPEN

F1 F2 F3

Where: “nnn” is the number of memory locations available to store data.

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 logging as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight SETUP, and then press ENT to display the SETUP MENU.

3. Use the buttons to highlight LOGGING, and then press ENT to display the LOGGING screen.

TIP: The amount of memory available for storing new data is displayed in the LOGGING screen (maximum of 500 locations). If previous logging sessions are stored, and additional memory is needed, clear the logging memory per Section 4.13.3.

NOTE: At no time will new logging data over write old data.

4. Use the buttons to highlight YES (turn logging ON).

5. Press ENT to make the selection and display the LOGGING INTERVAL screen.

Instruction 24-94484-12

Operation

LOGGING INTERVAL 1 sec 5 sec 10 sec 15 sec 30 sec

1 min

2 min

(more)

F1 F2 F3

LOGGING DURATION 5 min 10 min 15 min 30 min 1 hr

2 hr

5 hr

(more)

F1 F2 F3

4.12.2 Setting the Logging Interval and Duration

The logging interval is the length of time between measurements, while the logging duration is the time allocated to the logging process. Set the logging interval and duration as follows:

TIP: If the duration is set for more than 10 hours, we recommend using the optional AC power adapter to power the analyzer.

1. As soon as logging is turned ON as described in Section 4.12.1, the LOGGING INTERVAL screen appears.

2. Use the buttons to highlight the desired interval, and then press ENT to make the selection and display the LOGGING DURATION screen. In this example, 1 minute has been selected

3. Use the buttons to highlight the desired duration, and then press ENT to make the selection and display the LOGGING SUMMARY screen. In this example, 2 hours has been selected.

NOTE: If the selected duration requires more memory than is currently available, then the analyzer will automatically select the longest duration possible for the selected interval.

Instruction 24-9448 4-13

Operation

LOGGING SUMMARY

Interval 1 min Duration 2 hr

Press ENTER to Start

F1 F2 F3

LOG NATURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

Log Entry xx

F1 F2 F3

Where: “xx” is the memory location where the current log entry is being saved.

4.12.3 Starting the Data Logging Process

After turning ON data logging and setting the interval and duration, the analyzer will pause at the LOGGING SUMMARY screen, where the currently selected interval and duration time periods are displayed.

Press ENT to start the combustion test and logging process. At this time the Combustion Test LOG screen will appear, indicating that the analyzer is now performing a combustion test and the data is being stored in memory.

Note the following:

• At the bottom of the screen, the memory location where the current log entry is being saved is displayed. This number also represents the total number of test records that are stored in memory.

• If there were previously stored log entries, each new logging session will start to store data in the next available memory location.

• At no time will new data overwrite old data.

• The ENT button can be pressed while logging to view the other Combustion Test screens.

Instruction 24-94484-14

Operation

LOG NATURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

yy Entries Stored

F1 F2 F3

Where: “yy” is the number of log entries stored during the last logging session.

4.12.4 Ending the Data Logging Process

Data logging will stop and the pump will turn OFF after the prescribed duration, or after all 500 memory locations are filled.

To exit the Combustion Test LOG screen, press the RUN/HOLD button twice to display the Combustion Test HOLD screen.

Note the following:

• To end the logging process at any time, press the ESC button.

• At the end of the logging period, or if the ESC button was pressed, the total number of log entries that were stored during that period appear at the bottom of the screen.

• If the logging process was stopped by pressing ESC, it cannot be resumed without first turning logging back ON per Section 4.12.1.

4.13 Memory

There are two memory banks, each containing 500 memory locations. The first bank is used to store combustion test data as described in Section 4.7., while the second bank is used to store logged combustion test data as described in Section 4.12. Each bank is independent of each other, and cannot share data or be combined.

Individual memory locations in each memory bank can be recalled for viewing on the display or printed (refer to Sections 4.13.1 & 4.13.2), or the entire contents of each memory bank can be individually downloaded to a computer and viewed in a spreadsheet program for analysis (refer to Section 4.14).

Instruction 24-9448 4-15

TIP: When displaying the contents of either memory bank, the operator can quickly page through the screens by pressing the PAGE– (F1) and PAGE+ (F3) buttons. Or move to the first or last memory location by pressing the buttons, respectively.

Operation

MAIN MENU FUEL PRESSURE

MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

MEMORY MENU

MEMORY DIRECTORY

LOGGING DIRECTORY

CLEAR MEMORY DATA CLEAR LOGGING DATA

CLEAR ALL MEMORY

F1 F2 F3

MEMORY DIRECTORY

1 05/23/06 10:00:00

2 05/23/06 10:30:14 3 05/23/06 11:45:38 4 05/23/06 01:50:10 5 05/23/06 03:35:25 6 EMPTY 7 EMPTY

(more)

F1 F2 F3

PAGE- MENU PAGE+

Mem: 1 NATURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

PRINT MENU

F1 F2 F3

4.13.1 Recalling Combustion Test Data

Recall individual combustion test data records as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight MEMORY, and then press ENT to display the MEMORY MENU.

3. Use the buttons to highlight MEMORY DIRECTORY, and then press ENT to display the MEMORY DIRECTORY screen.

4. Use the buttons to highlight the desired memory location to be recalled. Each memory location is identified by the date and time at which data was saved. The word EMPTY signifies that the memory location does not contain data.

5. Press ENT to display the data contained in the selected memory location.

Note the following:

• The top line of the recalled combustion test data screen shows the memory location being viewed. In this example, “MEM: 1” is being displayed

• The ENT button can be pressed to view other memory test data screens.

• The recalled combustion test data can be printed by pressing the PRINT (F1) button (refer to Section 4.16).

Instruction 24-94484-16

4.13.2 Recalling Logged Test Data

MAIN MENU FUEL PRESSURE

MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

MEMORY MENU

MEMORY DIRECTORY

LOGGING DIRECTORY

CLEAR MEMORY DATA CLEAR LOGGING DATA

CLEAR ALL MEMORY

F1 F2 F3

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 O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 %

T-STK 374 °F T-AIR 68.0 °F EA 21.3 % CO(3) 13 ppm

PRINT MENU

F1 F2 F3

Recall individual logged combustion test data records as follows:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight MEMORY, and then press ENT to display the MEMORY MENU.

3. Use the buttons to highlight LOGGING DIRECTORY, and then press ENT to display the LOGGING DIRECTORY screen.

4. Use the buttons to highlight the desired data logging location to be recalled. Each logging location is identified by the date and time at which the data was saved. The word EMPTY signifies that the logging location does not contain data.

5. Press ENT to display the logging data contained in the selected memory location.

Operation

Note the following:

• The top line of the log test data screen shows the log location being viewed. In this example, “Log: 6” is being displayed.

• The ENT button can be pressed to view other log test data screens.

• The recalled logged test data can be printed by pressing the PRINT (F1) button (refer to Section 4.16).

Instruction 24-9448 4-17

Operation

MAIN MENU FUEL PRESSURE

MEMORY

SETUP

CALIBRATION DIAGNOSTICS STATUS

F1 F2 F3

MEMORY MENU

MEMORY DIRECTORY LOGGING DIRECTORY

CLEAR MEMORY DATA

CLEAR LOGGING DATA

CLEAR ALL MEMORY

F1 F2 F3

CLEAR MEMORY DATA

YES

F1 F2 F3

CLEAR MEMORY DATA

WAIT

Erasing memory

F1 F2 F3

4.13.3 Clearing Memory

When all memory (“snap shot”) locations used to store individual combustion test records have been filled, the next combustion test record saved will overwrite the oldest.

When all logging memory locations in the logging directory are full, they must be manually cleared in order to store new data. At no time will the logging process overwrite older data.

Each memory bank can be individually cleared, or all memory locations in both banks can be cleared simultaneously.

Do the following to clear memory:

1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears above F2.

2. Use the buttons to highlight MEMORY, and then press ENT to display the MEMORY MENU.

3. Use the buttons to highlight one of the following:

• CLEAR MEMORY DATA clears only the individual saved combustion test records.

• CLEAR LOGGING DATA clears only the combustion test records that were saved during the logging process.

• CLEAR ALL MEMORY clears all memory locations in both memory banks.

4. Press ENT to display the CLEAR MEMORY, LOGGING, or ALL DATA conformation screen. Highlight YES to confirm that memory is to be cleared, and then press ENT to actually clear memory as evidenced by the display of the “WAIT Erasing memory” screen.

Instruction 24-94484-18

Operation

4.14 Downloading Stored Data to a Computer

The combustion test data that was stored in either the analyzer’s Memory Directory (Section 4.7), or Logging Directory (Section 4.12), can be downloaded to a computer using the PCA 2 Data Recovery Program and USB cable that are supplied with the analyzer.

The following procedures assume that the operator is familiar with creating folders and navigating the file structure of the Windows operating system. If necessary, consult the Windows help files for instructions on how to perform these procedures.

The downloaded data is stored on the computer’s hard drive – or removable media of the operator’s choosing – as a comma-separated-value ASCII text file with a CSV extension. This type of file can be opened by most spreadsheet programs for analysis.

Computer requirements:

• Windows 98SE or higher

• CD ROM drive

• USB 1.1 or USB 2.0 port

• 12 MB of hard drive space for the PCA 2 data recovery program, plus up to an additional 350 KB for each download

Instruction 24-9448 4-19

Operation

4.14.1 PCA 2 Data Recovery Program Installation

The PCA 2 Data Recovery Program is supplied with the analyzer on a CD (P/N 24-1425). Install this program as follows:

1. Insert the PCA 2 CD into the computer’s CD-ROM drive.

2. Locate the CD-ROM drive in Windows Explorer and open the PCA2 folder. Double-click the Setup.exe program to start the installation process.

3. Click Next on the “Welcome to the InstallShield Wizard for PCA2” window.

4. Click

Next to accept the default destination folder, or click Change to

install to a different folder.

Default Installation Folder

Click to change installation folder

Instruction 24-94484-20

Operation

5. Click Install to confirm the destination folder and user information.

6. Click

Finish after all files have been copied into the destination folder.

7. At this time the PCA2 Data Recovery Program icon should appear under "Start All Programs menu.

8. This completes the installation of the software. Remove CD from drive.

Instruction 24-9448 4-21

Operation

4.14.2 Computer to PCA 2 Connection &

USB Device Driver Installation

Connect the USB cable (P/N 104-4032) that was supplied with the PCA 2, and, if necessary, install the analyzer’s USB device driver as follows:

1. With both the PCA 2 and computer turned ON, insert the appropriate ends of the USB cable into the USB connectors on the PCA 2 and computer as shown in Figure 4-2.

2. If this is the first time the PCA 2 is being connected to the computer, then the “Found New Hardware Wizard” should shortly appear. Select “No, not this time” and click Next>.

NOTE: The USB device driver only needs to be installed once. It does not require to be re-installed each time the PCA 2 is connected to the computer.

Do not search for software.

Figure 4-2. Computer to PCA 2 Connection

Instruction 24-94484-22

Operation

3. Select “Install from a list or specific location (Advanced)” and click Next>.

Name of new USB hardware

Select (Advanced).

4. Select to search for the best driver and then browse to folder C:\Program Files\PCA2Data. Click

Select to search for driver in folder C:\Program Files\ PCA2Data

Next>.

5. At the Hardware Installation window, click

Continue Anyway.

Our driver has been thoroughly tested in Windows for stability. This message appears because Microsoft has not tested this product through WHQL certification.

Instruction 24-9448 4-23

Operation

6. After the Found New Hardware Wizard has finished installing the software, click Finish to close the Wizard.

4.14.3 Recovering Data

Before data can be recovered from the analyzer, install the PCA 2 Data Recovery Program, USB cable, and USB device driver as described in Sections 4.14.1 and 4.14.2.

Recover either the logging or combustion data as follows:

1. Start the program by either double-clicking the PCA2 icon on the Windows desktop, or clicking the PCA2 shortcut in start menu. The “Bacharach PCA 2 Data Recovery Program” window should appear.

Observe that the window is divided into two sections. The left-hand

section is used to recover logging data, while combustion data is recovered from the right-hand section.

In the following steps, the logging data will be recovered. The same

procedure can be used to recover combustion data using the right-hand section of the window.

2. Select where the downloaded file containing the recovered data will be located and give it a filename by clicking the Open Log File button. The following example screens show that the downloaded file will be placed into a pre-existing PCA2 Logging Data folder and given the filename Customer XYZ.

Instruction 24-94484-24

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 le

Enter lename

File type preset

to *.cvs

Use this section of window to Recover Combustion Data

Start the download process by clicking the desired Open Log / Data File button

Click here to create a new folder

Click Open after selecting a folder and entering a

lename

Location of

downloaded le

Click Start

to begin the

download

process

Total number

of records

received out of

512 total

Status line

showing les

are currently

being received

Instruction 24-9448 4-25

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 selecting a folder and entering the filename, click Open and then click Start to begin the download process.

While recovering the stored data, observe that the “Records received”

line displays the total number of records currently downloaded. And after all records have been received, the Status line will read “Log files finished.”

NOTE: The “Records received” line will shown that 512 files have been received, regardless of how many memory locations actually contained data. This occurs because the program checks for data in all 500 memory locations, including 12 additional locations that contain sensor calibration data.

Note that the 12 files that contain sensor calibration data are saved in a separate “CalibrationData.csv” file. This file is automatically created and placed in the same folder that was selected in Step 2.

4. This completes the process of recovering logging data. Either click Exit to close the program, or proceed to recover the combustion data by starting over at Step 2, but this time using the right-hand section of the “Bacharach PCA 2 Data Recovery Program” window.

NOTE: Once either the logging data or combustion data has been recovered, that portion of the recovery program’s window will turn gray.

Status line

showing

recovery

process has

nished

Click Exit to end the program

Instruction 24-94484-26

4.14.4 Unplugging the USB Cable

Safely Remove Hardware Icon

CAUTION: To avoid possible electronic damage to the analyzer, it is not advisable to unplug the USB cable without first turning OFF the PCA 2 USB connection using the “Safely Remove Hardware” icon in the Windows XP system tray.

Do the following before unplugging the USB cable:

1. Double-click the “Safely Remove Hardware” icon in the Windows XP system tray.

2. If more than one USB device is plugged into the computer, select the device labeled “Bacharach PCA2 USB driver” and then click Stop.

3. Click OK to confirm that the device is to be stopped.

Operation

4. Wait until “Bacharach PCA2 USB driver” is removed from the screen, and then click Close.

5. The USB cable can now be safely unplugged.

Instruction 24-9448 4-27

Operation

4.15 Importing Saved Data Into a Spreadsheet

Data that was recovered and saved as an ASCII text file with a “CSV” extension, as described in Section 4.14, can easily be opened for viewing in most spreadsheet programs by simply double-clicking the filename. For example: double-clicking the filename Customer XYZ.csv should automatically open the spreadsheet program and display the contents of the file.

If the spreadsheet program does not recognize the “CSV” file extension, then refer to the spreadsheet’s documentation for information on how to manually import comma-delimited text files.

Table 4-2 contains a listing and description of the 27 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 “N/A” (Not Applicable). For example: if the analyzer does not contain an SO2 sensor, then “N/A” will appear in data fields 19 and 20.

Instruction 24-94484-28

TABLE 4-2. DOWNLOADED DATA FIELDS

Field Column Name Data Name or Value

1 Time Time of Test in 12 hour format (AM / PM) 2 Date Date of Test in mm/dd/yy 3 Fuel Fuel Name 4 %O2 Oxygen Level 5 CO Carbon Monoxide Level (see field 26) 6 ppm CO(O2) Carbon Monoxide Level referenced to a

% of O2 (see field 21) 7 %Efficiency Combustion Efficiency 8 %CO2 Carbon Dioxide Level

9 TStk Stack Temperature

10 TAir Primary / Ambient Air Temperature 11 TempUnit Temperature Units

12 %EA Excess Air

13 NO Nitric Oxide Level (see field 26) 14 ppm NO(O2) Nitric Oxide Level referenced to a % of O

(see field 22)

15 NO2 Nitrogen Dioxide Level (see field 26) 16 ppm NO2(O2) Nitrogen Dioxide Level referenced to a

% of O

(see field 22)

17 NOx Nitrogen Oxides (NO + NO2) (see field 26)

18 ppm NOx(O2) Nitrogen Oxides Level referenced to a

% of O

(see field 22)

19 SO2 Sulfur Dioxide (see field 26)

20 ppm SO2(O2) Sulfur Dioxide Level referenced to a

% of O

21 CO_O2Ref %O2 Reference for CO 22 NOx_O2Ref %O2 Reference for NOx 23 SO2_O2Ref %O2 Reference for SO

(see field 23)

(1)

24 Pressure Pressure (Draft) Value 25 Pressure Units Pressure Units of Measure 26 Pollution Units Pollution Units of Measure

(2)

(3)

27 PS Voltage Power Supply Voltage 28 NO Temp Nitric Oxide Sensor Temperature (4)

Operation

(1) %O2 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

(4) Shown only on printout, not on LCD display.

Instruction 24-9448 4-29

Operation

4.16 Printing Test Data

Combustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described below.

Data that is stored in memory can also be printed by first displaying the stored test data as described in Sections 4.13.1 & 4.13.2.

In addition to printing combustion and pressure data, the contents of any screen that shows the label “PRINT” above the F1 button can be printed. For example, the information shown in the DIAGNOSTIC screen can be printed.

1. Turn ON printer. Refer to the printer’s instruction manual for detailed operating information. If not already done, set up the printer for:

• 8 bit

• No parity

• 9600 baud

• IrDA is set to IrDA-SIR

• DTR handshaking

2. Align the printer with the top of the analyzer as shown in Figure 4-6.

3. Press the PRINT (F1) button to begin printing.

The printout shown in Figure 4-6 shows typical combustion-test results of an analyzer containing O2, CO that since the CO

and SO2 sensors are not installed, three stars

HIGH

, NO, and NO2 sensors. Note

LOW

(∗∗∗) appear in their data fields.

Instruction 24-94484-30

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 NO2(3) 6 ppm NOX(3) 25 ppm SO2(3) ∗∗∗ ppm

PRESSURE – 0.25 inwc

COMMENTS:

PRINT MENU SAVE

3 to 18 in.

(7.62 to 45.72 cm)

Operation

Optional pressure printout as selected per Section 3.12.

NOTES: Three stars (∗∗∗) appear in the data

eld of sensors that are not calibrated or defective, and in the data elds of

that sensor’s related calculated values.

Three hyphens or dashes (- - -) indicate that the calculated data cannot be displayed because the measured data necessary to make the calculation is out of range (i.e., oxygen level above 16%).

Three (XXX) indicate sensor overrange.

Figure 4-3. Printer Alignment & Sample Printout

Instruction 24-9448 4-31

Operation

Notes:

Instruction 24-94484-32

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 temperature and will be sampling fresh air when turned ON.

5.1 Smart Sensors

The PCA 2 uses Bacharach’s new “Smart Sensor” technology, meaning that the calibration data for each sensor is stored in nonvolatile memory on the sensor’s printed circuit board.

Benefits of Smart Sensors:

New sensors can be installed without needing to be calibrated.

• Sensors can be pre-calibrated and installed when needed.

• Sensors can be moved from one analyzer to another.

• The analyzer’s diagnostics screen shows what sensors are installed,

• and their current end-of-life condition (Good, Low, Bad). Each sensor stores its calibration history and operating parameters,

• which can be downloaded to a computer and analyzed. This information is useful in determining when the sensor was last calibrated, and predicting its end-of-life.

The smart sensors should be calibrated by an authorized Bacharach Service Center (Section continues to meet its published accuracy specifications. The smart sensors, however, can be calibrated in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in the following sections of this instruction manual.

8.3) every 6 months to assure that the analyzer

5.2 Starting a Calibration

Start any calibration procedure by doing the following:

1. Place the probe in an area of fresh air, turn ON the analyzer, allowing it to cycle through its 60 second warm-up period. During warm-up, the analyzer’s operation is checked and the sensors are set to the following ambient conditions:

Oxygen sensor spanned to 20.9%

• All gas sensors are zeroed

• The pressure sensor is zeroed

•

Instruction 24-9448 5-1

Calibration

MAIN MENU FUEL PRESSURE MEMORY SETUP

CALIBRATION

DIAGNOSTICS STATUS

F1 F2 F3

ERRORS DETECTED Low Battery

F1 F2 F3

Any errors detected during warm-up will

be listed on the display immediately following warm-up. For example, the screen to the right shows that the battery is low. Correct any errors before proceeding. Refer to Section 7.3 for a listing of error messages and their meaning.

2. Display the MAIN MENU by pressing the

MENU (F2) button. If necessary, press ESC

until MENU appears above F2.

3. Use the buttons to highlight CALIBRATION, and then press ENT to display the CALIBRATION LIST screen.

4. Use the buttons to highlight the sensor to be calibrated, and then perform the calibration procedure for that sensor as described in the following sections.

5.3 Pressure Sensor Calibration

This procedure calibrates the pressure sensor to a known pressure value.

Material Required:

Bellows

• Manometer

•

Range: ±8 in. of water column (±20 mb)

Accuracy: ±0.01 in. of water column (±0.025 mb)

Procedure:

NOTE: The unit-of-measure for pressure is selected per

Section 3.7. 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 calibration equipment as shown in Figure 5-1, but DO NOT connect the analyzer to the calibration equip-

ment at this time.

2. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

3. Use the buttons to highlight Pressure, and then press ENT to dis-

Instruction 24-94485-2

play the CALIBRATE PRESSURE screen.

POWER

T-STACK T-AIR

GAS

4 3 2 1 0

-1

-2

-3

-4

Parts:

1. 3/16" I.D. Tubing

2. Tee

3. Barbed Hose Connector

4. Bellows

5. Manometer

CALIBRATE PRESSURE Measured 0.00 inwc Applied -4.00 inwc

06/27/06 11:55:30 PM

F1 F2 F3

CALIBRATION LIST

Pressure

T-Stack T-Air CO-LO SO2 NO NO2

(more)

F1 F2 F3

“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 reading should be 0 ±0.01 inwc. If necessary, zero the pressure sensor per Section 4.6, and repeating Steps 2 thru 4.

5. Connect the hose from the manometer to the +∆P port and apply a negative pressure to this port by adjusting the bellows for a manometer reading of –4.00 ±2.00 inwc.

6. Use the and buttons to enter an Applied value that exactly equals the manometer reading.

The calibration range is from –6 to –2 inwc

(–15 to –5 mb). An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

Calibration

7. Wait until the Measured reading stabilizes, and then press ENT to calibrate the pressure sensor’s Measured value to that of the Applied value; after which the message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

8. Remove calibration equipment.

Instruction 24-9448 5-3

Figure 5-1. Pressure Sensor Calibration Equipment

Calibration

CALIBRATION LIST Pressure

T-Stack

T-Air CO-LO SO2 NO NO2

(more)

F1 F2 F3

5.4 T-Stack Calibration

This procedure first zeros and then spans the stack-temperature channel to known temperature values.

The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures. Alternatively, containers of ice water and boiling water can be used.

Material Required:

Thermocouple Simulator (K-type)

• Range: 0 to 600 °F

Accuracy: ±0.5 °F

(Alternatively) Ice-Water, Boiling Water, Thermometer

•

TS-Zero Procedure:

1. Set thermocouple simulator to room temperature and plug its output into the T-STACK connector located at the bottom of the analyzer.

Alternatively: Plug the probe’s thermocouple into the T-STACK con-

nector located at the bottom of the analyzer. DO NOT attach the

probe’s gas hose to the analyzer’s GAS port; otherwise water will be drawn into the analyzer!

2. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

3. Use the buttons to highlight T-Stack, and then press ENT to display the CALIBRATE TS-ZERO screen.

“Measured” is the current temperature read-

ing, while “Applied” is a known temperature that will be applied for calibration purposes.

4. Set thermocouple simulator to 32 °F (0 °C), and then use the and buttons to enter an Applied value that exactly equals the setting of the simulator.

Alternatively: Submerge probe tip into an ice-water bath with a ther-

mometer, wait several minutes, and then use the and buttons to enter an Applied value that exactly equals the thermometer reading.

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.

Instruction 24-94485-4

5. Wait until the Measured reading stabilizes,

CALIBRATE TS-ZERO Measured 34 °F Applied 032 °F

06/27/06 11:55:30 PM

F1 F2 F3

CALIBRATE TS-SPAN Measured 574 °F Applied 572 °F

06/27/06 11:55:30 PM

F1 F2 F3

and then press ENT to calibrate the TS-Zero Measured value to that of the Applied value; after which the message “Good Calibration” should briefly appear followed by the CALIBRATE TS-SPAN screen.

TS-Span Procedure:

6. Set thermocouple simulator to 572 °F (300 °C), and then use the and buttons to enter an Applied value that exactly equals the setting of the simulator.

Alternatively: Submerge probe tip into a con-

tainer of boiling water with a thermometer, wait several minutes, and then use the and buttons to enter an Applied value that exactly equals the thermometer reading.

The calibration range is from 175 to 625 °F

(80 to 330 °C). An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

Calibration

7. Wait until the Measured reading stabilizes, and then press ENT to calibrate the TS-Span Measured value to that of the Applied value; after which the message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

Instruction 24-9448 5-5

Calibration

CALIBRATION LIST Pressure T-Stack

T-Air

CO-LO SO2 NO NO2

(more)

F1 F2 F3

CALIBRATE TA-ZERO Measured 33 °F Applied 032 °F

06/27/06 11:55:30 PM

F1 F2 F3

5.5 T-Air Calibration

This procedure first zeros and then spans the ambient-temperature channel to known temperature values.

The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures. Alternatively, containers of ice water and boiling water can be used.

Material Required:

Thermocouple Simulator (K-type)

• Range: 0 to 600 °F

Accuracy: ±0.5 °F

(Alternatively) Ice-Water, Boiling Water, Thermometer

•

TA-Zero Procedure:

1. Set thermocouple simulator to room temperature and plug its output into the T-AIR connector located at the bottom of the analyzer.

Alternatively: Plug the probe’s thermocouple into the T-AIR connector

located at the bottom of the analyzer. DO NOT attach the probe’s

gas hose to the analyzer’s GAS port; otherwise water will be drawn into the analyzer!

2. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

3. Use the buttons to highlight T-Air, and then press ENT to display the CALIBRATE TA-ZERO screen.

“Measured” is the current temperature read-

ing, while “Applied” is a known temperature that will be applied for calibration purposes.

4. Set thermocouple simulator to 32 °F (0 °C), and then use the and buttons to enter an Applied value that exactly equals the setting of the simulator.

Alternatively: Submerge probe tip into an ice-

water bath with a thermometer, wait several minutes, and then use the and buttons to enter an Applied value that exactly equals the thermometer reading.

Instruction 24-94485-6

Calibration

CALIBRATE TA-SPAN Measured 210 °F Applied 212 °F

06/27/06 11:55:30 PM

F1 F2 F3

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. Wait until the Measured reading stabilizes, and then press

ENT to

calibrate the TA-Zero Measured value to that of the Applied value; after which the message “Good Calibration” should briefly appear followed by the CALIBRATE TA-SPAN screen.

TA-Span Procedure:

6. Set thermocouple simulator to 212 °F (100 °C), and then use the and buttons to enter an Applied value that exactly equals the setting of the simulator.

Alternatively: Submerge probe tip into a con-

tainer of boiling water with a thermometer, wait several minutes, and then use the and buttons to enter an Applied value that exactly equals the thermometer reading.

The calibration range is from 194 to 230 °F (90 to 110 °C). An attempt

to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

7. Wait until the Measured reading stabilizes, and then press

ENT to

calibrate the TA-Span Measured value to that of the Applied value; after which the message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

Instruction 24-9448 5-7

Calibration

CALIBRATION LIST Pressure T-Stack T-Air

CO-LO

SO2 NO NO2

(more)

F1 F2 F3

CALIBRATE CO Measured 480 PPM Applied 500 PPM

06/27/06 11:55:30 PM

F1 F2 F3

5.6 CO-LO Sensor Calibration

Note that the CO-LO sensor also measures H2 for the purpose of compensating the CO reading for the presence of H2 in the gas sample. This procedure first spans the CO-LO sensor and, optionally, spans the H2 part of the sensor to known gas levels.

Material Required:

Calibration Kit, P/N 24-7059

• Gas Cylinder: 500 ppm CO in air, P/N 24-0492

• Gas Cylinder: 1,000 ppm CO & 1,000 ppm H2 in Nitrogen, P/N 24-0794

•

Procedure:

1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

2. Use the buttons to highlight CO-LO, and then press ENT to display the CALIBRATE CO screen.

“Measured” is the current CO reading, while

“Applied” is a known CO level that will be applied for calibration purposes.

3. Attach a 500 ppm CO cylinder to the regulator of the calibration fixture shown in Figure 5-2 on Page 5-14.

4. Use the and buttons to enter an Applied value that exactly equals the concentration stamped on the CO cylinder.

The calibration range is from 250 to

1,000 ppm. An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

5. Adjust the regulator for a flowmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximately 3 minutes), and then press ENT to calibrate the CO Measured value to that of the Applied value. The message “Good Calibration” should briefly appear followed by the TEST GAS CO/H2 screen.

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.

Instruction 24-94485-8

Calibration

TEST GAS CO/H2 Enter CO VALUE 1000 PPM

06/27/06 11:55:30 PM

F1 F2 F3

CALIBRATE H2 Measured 1000 PPM Applied 1000 PPM

06/27/06 11:55:30 PM

F1 F2 F3

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 sensor will now be marked as being BAD in the DIAGNOSTICS screen.

NOTE: H2 calibration can be bypassed by pressing the ESC button, after which the CALIBRATION LIST screen is re-displayed. Skip to Step 10 if the ESC button was pressed.

6. Turn OFF the regulator of calibration fixture and remove the CO cylinder.

7. Attach a combination 1,000 ppm CO and 1,000 ppm H2 cylinder to the regulator of the calibration fixture, and then use the and

buttons to enter an Applied value that exactly equals the CO concentration stamped on the cylinder.

8. Adjust the regulator for a flowmeter indication of approximately 2 SCFH, and then press

ENT to display the CALIBRATE H

screen.

The calibration range is from 400 to 1,500 ppm. An attempt to cali-

brate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

9. Wait until the Measured reading stabilizes (approximately 3 minutes), and then press

ENT to calibrate the H

Measured value to

that of the Applied value; after which the message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

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” will appear followed by the CALIBRATION LIST screen being re-displayed. The sensor will now be marked as being BAD in the DIAGNOSTICS screen.

10. Turn OFF the regulator and remove the gas cylinder.

Instruction 24-9448 5-9

Calibration

CALIBRATION LIST Pressure T-Stack T-Air CO-LO

SO2

NO NO2

(more)

F1 F2 F3

CALIBRATE SO2 Measured 98 PPM Applied 100 PPM

06/28/06 11:55:30 PM

F1 F2 F3

5.7 SO2 Sensor Calibration

This procedure spans the optional sulfur dioxide sensor to a known gas level.

Material Required:

Calibration Kit, P/N 24-7059

• Gas Cylinder: 100 ppm SO2 in Nitrogen, P/N 24-1158

•

Procedure:

1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

2. Use the buttons to highlight SO2, and then press ENT to display the CALIBRATE SO2 screen.

“Measured” is the current SO2 reading, while

“Applied” is a known SO2 level that will be applied for calibration purposes.

3. Attach a 100 ppm SO

cylinder to the regu-

lator of the calibration fixture shown in Figure 5-2 on Page 5-14.

4. Use the and buttons to enter an Applied value that exactly equals the concentration stamped on the SO2 cylinder.

The calibration range is from 9 to 150 ppm.

An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

5. Adjust regulator for a flowmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximately 3 minutes), and then press ENT to calibrate the SO2 Measured value to that of the Applied value. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

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.

Instruction 24-94485-10

Calibration

CALIBRATION LIST Pressure T-Stack T-Air CO-LO SO2

NO2

(more)

F1 F2 F3

CALIBRATE NO Measured 245 PPM Applied 250 PPM

06/28/06 11:45:30 PM

F1 F2 F3

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. Turn OFF regulator and remove gas cylinder.

5.8 NO Sensor Calibration

This procedure spans the optional nitric oxide sensor to a known gas level.

Material Required:

Calibration Kit, P/N 24-7059

• Gas Cylinder: 250 ppm NO in Nitrogen, P/N 24-1156

•

Procedure:

1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

2. Use the buttons to highlight NO, and then press ENT to display the CALIBRATE NO screen.

“Measured” is the current NO reading, while

“Applied” is a known NO level that will be applied for calibration purposes.

3. Attach a 250 ppm NO cylinder to the regulator of the calibration fixture shown in Figure 5-2 on Page 5-14.

4. Use the and buttons to enter an Applied value that exactly equals the concentration stamped on the NO cylinder.

The calibration range is from 9 to 550 ppm.

An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

5. Adjust regulator for a flowmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximately 3 minutes), and then press ENT to calibrate the NO Measured value to that of the Applied value. The message “Good Calibration” should

Instruction 24-9448 5-11

Calibration

CALIBRATION LIST

(more) T-Air CO-LO SO2 NO

NO2

CO-HI T-Ref

F1 F2 F3

CALIBRATE NO2 Measured 96 PPM Applied 100 PPM

06/28/06 11:45:30 AM

F1 F2 F3

briefly appear followed by the CALIBRATION LIST screen being re-displayed.

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” 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. Turn OFF regulator and remove gas cylinder.

5.9 NO2 Sensor Calibration

This procedure spans the optional nitrogen dioxide sensor to a known gas level.

Material Required:

Calibration Kit, P/N 24-7059

• Gas Cylinder: 100 ppm NO2 in Nitrogen, P/N 24-1157

•

Procedure:

1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

2. Use the buttons to highlight NO2, and then press ENT to display the CALIBRATE NO2 screen.

“Measured” is the current NO2 reading, while

“Applied” is a known NO2 level that will be applied for calibration purposes.

3. Attach a 100 ppm

NO2 cylinder to the regulator of the calibration fixture shown in Figure 5-2 on Page 5-14.

4. Use the and buttons to enter an Applied value that exactly equals the concentration stamped on the NO2 cylinder.

The calibration range is from 9 to 150 ppm.

An attempt to calibrate outside this range will

Instruction 24-94485-12

Calibration

CALIBRATION LIST

(more) T-Air CO-LO SO2 NO NO2

CO-HI

T-Ref

F1 F2 F3

cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

5. Adjust regulator for a flowmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximately 3 minutes), and then press ENT to calibrate the NO2 Measured value to that of the Applied value. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

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” 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. Turn OFF regulator and remove gas cylinder.

5.10 CO-HI Sensor Calibration

This procedure spans the optional carbon monoxide high sensor (4,001 to 20,000 ppm) to a known gas level.

Material Required:

Calibration Kit, P/N 24-7059

• Gas Cylinder: 4,000 ppm CO in Air, P/N 24-1155

•

Procedure:

1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen per Section 5.2.

2. Use the buttons to highlight CO-HI, and then press ENT to display the CALIBRATE CO-HI screen.

“Measured” is the current CO reading, while

“Applied” is a known CO level that will be applied for calibration purposes.

3. Attach a 4,000 ppm CO cylinder to the regulator of the calibration fixture shown in Figure 5-2 on Page 5-14.

Instruction 24-9448 5-13

Calibration

CALIBRATE CO-HI Measured 3895 PPM Applied 4000 PPM

06/28/06 09:45:30 AM

F1 F2 F3

Parts:

1. Gas Cylinder

2. Regulator *

3. 3/16" I.D. Tubing *

4. Tee *

5. Flowmeter *

6. Barbed Hose Connector * * Part of Calibration Kit 24-7059

POWER

T-STACK T-AIR

GAS

Leave Top Port Open

GAS Port

4. Use the and buttons to enter an Applied value that exactly equals the concentration stamped on the CO cylinder.

The calibration range is from 250 to

11,000 ppm. An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry” to appear in the following step.

5. Adjust regulator for a flowmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximately 3 minutes), and then press ENT to calibrate the CO Measured value to that of the Applied value. The message “Good Calibration” should briefly appear followed by the CALIBRATION LIST screen being re-displayed.

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” 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. Turn OFF regulator and remove gas cylinder.

Figure 5-2. Gas Sensor Calibration Equipment

Instruction 24-94485-14

Maintenance

6 Maintenance

Customer maintenance of the PCA 2 is limited to the following:

Battery replacement or charging using AC power adapter (Section 3.2)

• Sensor re-calibration (Section 5)

• Water trap / filter assembly maintenance (Section 6.2)

• Sensor replacement (Section 6.3)

• Probe thermocouple replacement (Section 6.6)

• Pump (gas or purge) replacement (Section 6.7)

• Cleaning the probe (Section 6.8)

•

All other maintenance should be performed by an authorized Bacharach Service Center. Refer to Section 8.3.

Instruction 24-9448 6-1

Maintenance

Rear Case Screws (typical 4 places)

Release and then remove battery cover by pushing latch up

6.1 PCA 2 Disassembly

The following procedure describes how to disassemble the analyzer, while Figures 6-1 thru 6-4 illustrate how the analyzer is put together.

Tools Required:

Medium Phillips Screwdriver

•

Procedure:

1. Unplug all thermocouples from bottom of analyzer.

2. Remove battery cover and then remove batteries.

TIP: In Step 3, if the sensors are not being replaced, leave the tubing connected to each sensor’s gas cap, being careful not to put unnecessary strain on the tubing during the disassembly process.

3. Pull off sensor retainer; and

Figure 6-1. Removing Rear Case

then unplug all sensors.

4. Lay analyzer face down on a padded work surface; and then using a medium Phillips screwdriver, remove the unit’s four rear-case screws.

5. Lift rear case from analyzer and set aside.

6. Unplug electrical connectors J8, J9, and J14 from printed circuit board.

CAUTION: In Step 7, note that there is tubing connected between the bottom hose-connector plate and the pressure sensor on the printed circuit board. Do not put unnecessary strain on this tubing during the disassembly process.

7. Carefully lift battery-and-pump chassis, along with the bottom hose-

8. Lift printed circuit board from analyzer.

connector plate, from analyzer.

Instruction 24-94486-2

Sensor Positions

Sensor Retainer

Purge Pump

Gas Pump

GAS

Purge Air In

Pressure

+∆P

–∆P

Battery & Pump Chassis

Hose Connector Plate

Purge Pump Motor Connector

Gas Pump Motor Connector

Sensors

Type and position determined by model number

Battery Connector on printed circuit board

Pressure Sensor on printed circuit board

+∆P (Top) –∆P (Bottom)

Model P/N

Position

#1 O

#2 COLOCOLOCOLOCOLOCOLOCO

#3 SO2NO2SO

#4 NO CO

225

24-7301

235

24-7302

245

24-7303

255

24-7304

265

24-7305

NO NO

Maintenance

275

24-7306

Figure 6-2. Inside View with Rear Case Removed

Instruction 24-9448 6-3

Maintenance

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

PRESSURE SENSOR

on printed circuit board

–∆P

+∆P

–∆P (Bottom)

+∆P (Top)

PRESSURE

PURGE AIR

GAS

Gas IN

GAS PUMP

PURGE PUMP

Gas OUT

OUTIN

To Sensors

Figure 6-3. Tubing Connections

Instruction 24-94486-4

Maintenance

Solder

(2 Places)

Red dot on pump indicates positive (red wire) connection

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 Cable Conection

between LCD Assembly and

Printed Circuit Board

Lock Tabs (both ends)

J14

Wire Routing

Solder Connections

Connectors

Instruction 24-9448 6-5

Figure 6-4. Wiring

Maintenance

FILTER ELEMENT

“A” “B”

Pry apart filter chamber using a small flat-blade screwdriver inserted into notch

When reassembling filter chamber, make sure surfaces “A” and “B” contact each other

WATER TRAP CHAMBER

FILTER CHAMBER

Pull apart using a twisting motion.

DO NOT rock back and forth!

6.2 Water Trap / Filter Maintenance

6.2.1 Emptying the Water Trap Chamber

The water trap chamber should be emptied after every test, or when the water condensate approaches the tip of the riser tube (refer to Section 4.9).

1. Remove water trap chamber per Figure 6-5.

2. Pour out liquid condensate, and then reassemble trap.

6.2.2 Replacing the Filter Element

Replace the filter element when it becomes visibly dirty or becomes saturated with water.

Material Required: • Filter Element, P/N 07-1644

• Small Flat Blade Screwdriver

1. Remove water trap chamber per Figure 6-5.

2. Pry apart filter chamber using a small flat-blade screwdriver. Remove and discard old filter.

3. Install new filter and reassemble filter chamber, making sure that surfaces “A” and “B” contact each other.

4. Reassemble trap.

Figure 6-5. Disassembling the Water Trap / Filter Assembly

Instruction 24-94486-6

Maintenance

Gas Cup

Sensor Retainer

Sensor and Printed Circuit Board

Twist gas cap bayonet fitting counterclockwise to release

Sensor electrical connector mates with pins on analyzer’s main board

6.3 Smart Sensor Replacement

Bacharach’s Smart sensor technology allows new sensors to be installed without needing to be calibrated inside 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. Refer to Section 8.1 Replacement Parts for list of sensors and part numbers of both types.

Replace the oxygen sensor when its automatic calibration fails and the analyzer displays an O2 sensor error at the end of warm up. Refer to Section 4.2.

NOTE: The O2 sensor and PCB is not Smart sensor technology. Only the sensor itself, not the PCB, needs to be purchased when the sensor needs replaced.

Replace a gas sensor when it can no longer be calibrated, as evidenced by “Bad Calibration Sensor End of Life” being displayed during its calibration procedure. Refer to Sections 5.6 thru 5.10.

Refer to Section 8.1 for a listing of sensor part numbers. Also, see Figure 6-2 on page 6-3 for sensor positions.

Do the following to replace a Smart sensor:

1. Turn OFF the analyzer.

2. Remove the battery cover.

3. Remove the sensor retainer.

4. Remove the tubing from the gas cup of sensor being replaced.

5. Unplug the sensor along with its printed circuit board from the analyzer’s main board.

6. Remove the sensor’s gas cup by twisting its bayonet fitting counterclockwise, and then pulling the cup straight up.

7. Attach the gas cup to new sensor, making sure that when the sensor is plugged into analyzer’s main board, the tubing connections on top of gas cup are aligned as shown in Figure 6-3 on page 6-4.

8. Plug the sensor into analyzer; and then reattach tubing to gas cup.

9. Install the sensor retainer and battery cover.

10. Turn ON the analyzer and confirm that no sensor errors occur during warm up.

Instruction 24-9448 6-7

Maintenance

Gas Cup

Sensor Retainer

Sensor

Twist gas cap bayonet fitting counterclockwise to release

Sensor electrical connector mates with pins on analyzer’s main board

Printed Circuit Board

Adhesive foam disk

Be sure to remove any shorting spring from the new sensor pins before installing! There is no shorting spring on the O2 or NO sensors.

6.4 Sensor Only Replacement

All sensors are replaced in a similar manner. Do the following to

1. replace either 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 battery cover.

Remove the sensor retainer.

Remove the tubing from the gas cup of sensor being replaced.

Unplug the sensor along with its printed circuit board from the analyz-

6. er’s main board.

Remove the sensor’s gas cup by twisting its bayonet fitting counter-

7. clockwise, and then pulling the cup straight up.

Carefully remove the old sensor from the Smart sensor PCB, keeping

8. in mind that there is an adhesive foam disk in between the PCB and sensor. Gently remove any adhesive from from the PCB.

Important! When replacing the O2 sensor, be sure that the “+” sensor pin plugs into the PCB socket that is also marked “O2+”.

When replacing an NO sensor, also replace the bias battery.

9. Remove the replacement sensor from its plastic canister. Note that the CO-LO, CO-HI, SO2, and NO2 sensors have a shorting-spring installed between two of their pins. Remove and discard this spring before installing the sensor.

10. Place the adhesive disk on the bottom of the new sensor and plug the new sensor into the sensor PCB.

11. Attach the gas cup to new sensor, making sure that when the sensor assembly is plugged into the analyzer’s main board, the tubing connections on top of gas cup are aligned as shown in Figure 6-3 on page 6-4.

Instruction 24-94486-8

Maintenance

12. Plug the sensor into analyzer; and then reattach tubing to gas cup.

13. Install the sensor retainer and battery cover.

12. Allow the sensor that was just installed time to stabilize in the circuit before continuing with this procedure. Stabilization time for all sensors (except for the NO sensor) is about 1 hour. The NO sensor baseline technically requires several days to stabilize but should be sufficiently stabilized for use in approximately 4 hours.

13. Turn ON the analyzer and confirm that no sensor errors occur during warm up.

Note: Discard an old sensor in accordance with local and federal hazardous waste disposal laws.

14. Calibrate the new sensor(s) per Section 5 (except the O2 sensor which does not require calibration).

Instruction 24-9448 6-9

Maintenance

6.5 Nitric Oxide Sensor Battery Replacement

A single lithium battery, located on the NO Smart Sensor assembly, applies a bias voltage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off. The NO bias battery is expected to last at least the life of the NO sensor.

Note: It is recommended that the bias battery be replaced whenever the NO sensor is replaced.

Material Required:

• Bias battery (refer to Section 8.1 Replacement Parts)

Procedure:

1. Follow the instructions in Section 6.3 Smart Sensor Replacement to remove the Smart Sensor assembly from position 4.

2. Remove the old battery from its holder on the Nitric Oxide printed circuit board.

3. Insert the new battery with the positive side facing away from the sensor (the battery contact is stamped with a + symbol) .

4. Re-install the Smart Sensor assembly.

5. Before powering up and using the analyzer, allow the Nitric Oxide sensor to stabilize as described below. Note that recalibration of the Nitric Oxide sensor is not required after replacing its bias battery. Depending on how long the Nitric Oxide sensor was without bias voltage, the time required for the sensor to completely stabilize varies from less than a minute to several days. Typical stabilization times are shown below. Generally, however, the sensor is sufficiently stable after 4 hours for measurement purposes.

Bias battery removed for . . . Stabilization time

Less than 15 minutes Less than 1 minute

Less than 1 hour Less than 5 minutes

Less than 2 days Less than 4 hours

Greater than 2 days Up to 2 days

Instruction 24-94486-10

Maintenance

Probe Handle Screws

6.6 Thermocouple Replacement

Using the appropriate thermocouple replacement kit listed 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 inches 24-8414 12 inches 24-8415 24 inches 24-8416 36 inches

Each kit contains a thermocouple assembly, two O-rings, and two wiresplice connectors.

Tools Required:

• Small Flat Blade Screwdriver

• Wire Cutter

• Wire Stripper

• Slip Joint Pliers

Procedure:

1. Gain access to the thermocouple connections by first removing three screws from probe handle, and then separating the two handle pieces.

2. Cut wires attached to old crimp connectors, leaving behind as much of the probe’s thermocouple-connector wire as possible.

Figure 6-6. Probe Handle Disassembly

Instruction 24-9448 6-11

Maintenance

O-Rings

Thermocouple Assembly

Ensure end of Thermocouple is in front of plastic rib in handle

Wire-Splice Connectors

Red and Yellow Thermocouple Wires

Cut away view of Thermocouple inserted into Probe Body

When reassembling probe handle, ensure that the thermocouple wires do not become pinched around screw hole or edge of handle

3. Pull old thermocouple from probe body and discard.

4. The new thermocouple has been coiled for shipping purposes. Straighten the thermocouple using your thumb and index finger.

5. If not already done, install supplied O-Rings onto thermocouple.

6. Insert thermocouple into probe body until it “bottoms out.”

7. Strip 1/4 inch of insulation from each of the probe’s thermocouple connector wires.

IMPORTANT: In Step 8, the thermocouple wires must first be twisted together and then crimped.

8. Twist both red thermocouple wires together; insert them into the supplied wire-splice connector; and then crimp the connector using a pair of pliers. Repeat this step for the yellow thermocouple wires.

9. Reassemble the probe handle, being careful not to pinch the thermocouple wires between the handle pieces. In addition, ensure that the end of the thermocouple is in front of the rib molded into the bottom handle piece; otherwise, the handle pieces will not fit tightly together.

Figure 6-7. Thermocouple Installation and Wiring

Instruction 24-94486-12

Maintenance

–∆P

+∆P

–∆P (Bottom)

+∆P (Top)

PRESSURE

PURGE AIR

GAS

Gas IN

GAS PUMP LATCH

GAS PUMP

PURGE PUMP

Gas OUT

OUTIN

6.7 Pump Replacement

Parts & Tools Required:

Replacement Pump:

• Gas Pump P/N 24-1393

Purge Pump P/N 3015-1716

Soldering Iron and Solder

• Medium Phillips Screwdriver

• Small Flat Blade Screwdriver

•

Procedure:

1. Gain access to both the gas and purge pumps by removing the rear case. Refer to Section 6.1.

2. Unsolder the red and black wires from pump being replaced. Note that during installation of the new pump, the red dot on the pump motor indicates the positive (red wire) connection.

3. Do one of the following:

• Gas Pump Removal: Push pump latch toward bottom of analyzer and lift gas pump out from its mounting location.

• Purge Pump Removal: Insert a small f lat blade screwdriver between the purge pump motor and the pump chassis, and then pry the pump out from its mounting location.

4. Remove tubing from pump.

3. Install new pump by reversing this procedure.

To Sensors See Figure 6-3

Figure 6-8. Pump Tubing Connections

Instruction 24-9448 6-13

Maintenance

6.8 Cleaning the Probe

The probe tube and gas-sample hose will become dirty under normal use. Note that the water trap’s filter element should prevent soot from reaching the analyzer’s internal components. If the probe is not kept clean, it could become clogged and restrict the flow of gas into the analyzer, resulting in incorrect combustion test readings and calculations.

NOTE: An analyzer that is used to test natural gas furnaces normally requires less frequent cleaning than an analyzer used for testing coal or oil fired furnaces.

Equipment Required:

Alcohol

• Aerosol Can of Automotive Carburetor Cleaner

• Clean Rag

• Source of Compressed Air (optional)

•

Procedure:

1. Remove gas-sample hose from top of water trap.

CAUTION: Carburetor cleaner attacks plastic components! Take precautions not to spray cleaner onto the probe handle or analyzer.

2. Insert the plastic-spray tube of the carburetor cleaner into the gassample hose, and then liberally spray carburetor cleaner through the hose and out the probe tube.

3. After spraying, remove all the residual cleaner by repeatedly flushing the gas hose and probe tube with alcohol.

4. Wipe off the surfaces of the probe and tubing with a clean rag.

5. Allow the parts to dry completely. If available, blow compressed air through the probe to expedite the drying process.

6. Reconnect gas-sample hose to top of water trap.

Instruction 24-94486-14

Notes:

Maintenance

Instruction 24-9448 6-15

Troubleshooting

7 Troubleshooting

7.1 Analyzer Repair

It is recommended that field repair of the PCA 2 be limited to:

Checks of printed circuit board connectors

• Replacing the probe assembly

• Replacing the filter element in the water trap / filter assembly

• Replacing sensors

• Replacing either the gas or purge pump

•

Information on how to perform these repairs is provided in Section 6.

All other repairs should be performed by an authorized Bacharach Service Center (refer to Section 8.3). Any repairs performed by an unauthor- ized service organization will void the analyzer’s warranty and release Bacharach, Inc. of any implied or written product liability.

7.2 Error Symbols

Error symbols are shown in the data fields of the Combustion Test screens and on the printout to indicate the following:

“- - -” Three hyphens or dashes indicates that the calculated data can-

not 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).

“∗ ∗ ∗” Three stars appear in the data field of sensors that are not

installed, defective, or found to be in overrange during warmup, and also in the data fields of that sensor’s related calculated values. For example, if the data field of either the NO or NO2 sensor contains three stars, then the NOx data field will also contain three stars.

"X X X" Indicates sensor overrange.

Instruction 24-9448 7-1

Troubleshooting

7.3 Error Messages Displayed After Warm-Up

If there were problems detected during warm-up, error messages that describe the nature of the problems are displayed immediately following the analyzer’s 60 second warm-up period.

If problems were detected, the analyzer will not automatically switch to the Combustion Test HOLD screen after warm-up. The analyzer, however, can still be used to perform any test that does not depend on the sensor that is in error. Press the RUN button to manually display the Combustion Test HOLD screen, and then continue using the analyzer.

The following is a list of the error messages that may appear following warm-up and their suggested remedies:

Low Battery – Battery voltage is low. Only several minutes of operating time remain. Replace or charge batteries per Section 3.2.

O2 No Sensor – Oxygen sensor not installed, or has become unplugged from its electrical connector. Install oxygen sensor per Figure 6-2 on Page 6-3.

O2 BAD Sensor – The oxygen sensor’s output is below 24 mV, signifying that the sensor is depleted and needs replaced. Refer to Section 6.3.

No Smart Sensors – No gas sensors are installed. Install sensors per Section 6.3.

Pressure Overrange – Pressure sensor measured a pressure that was outside the range of ±3 inwc during warm-up. Ensure that probe tip is open to the atmosphere during warm-up.

Ts Error – The probe’s thermocouple is not connected to the analyzer’s TSTACK connector.

Ts Overrange – The temperature measured during warm-up was outside the range of –4 to 2,192 °F (–20 to 1,200 °C). Ensure that the probe is correctly connected to the analyzer per Figure 3-2 on Page 3-3, and that the probe is at room temperature during warm-up.

Ta Overrange – The temperature measured during warm-up by the optional primary / ambient air thermocouple plugged into the analyzer's T-AIR connector was outside the range of –4 to 212 °F (–20 to 100 °C). Ensure that this thermocouple is at room temperature during warm-up.

UNCALIBRATED SENSORS – List of sensors that do not have a calibration history stored on their printed circuit board. Calibrate each of the sensors listed per Section 5.

Instruction 24-94487-2

Troubleshooting

DIAGNOSTICS

O2 Value: 41mv Good

Smart Sensors

COLO cal Good Sensor

F1 F2 F3

PRINT MENU

STATUS Firmware Ver 1.00 Model 225 Serial # LN1000 1 Smart Sensors Battery Volt: 4.38 v Ref Temp: 79.5 °F No Errors 09/11/06 04:55:18 PM

PRINT MENU

7.4 Diagnostics and Status Screens

The DIAGNOSTICS screen lists the current status of all the SMART gas sensors installed and the O2 sensor status and mV output.

The STATUS screen provides a quick reference of key items when troubleshooting.

Instruction 24-9448 7-3

Troubleshooting

Notes:

Instruction 24-94487-4

Parts & Service

8 Parts & Service

8.1 Replacement Parts

Item (Fig. 8-1) Description Part No.

1 Main PCB Assembly

2 LCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1374

3 Rear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1381

4 Top Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1382

5 Battery Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1383

6 Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1385

7 LCD Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1386

8 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1387

9 Chassis, Battery & Pump . . . . . . . . . . . . . . . . . . . . . . . .24-1388

10 Lens, Infrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1391

11 Pump, Sample Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1393

12 Pump, Purge 13 Sensor Retainer

14 Hose Connector Plate (complete assembly) . . . . . . . . . .24-1419

14A Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1416

14B Pressure Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1415

14C Retaining ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-2886

15 O-Ring, Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .105-5102

16 O-Ring, Pressure Fitting . . . . . . . . . . . . . . . . . . . . . . . .105-5103

17 Gas Covers:

17A O2 / SO2 / NO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1421

17B CO-H2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1422

17C NO / COHI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1420

18 Smart Sensors (pre-calibrated):

18B CO-H2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1395

18C COHI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1397

18D NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1401

18E NO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1399

18F SO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1398

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3015-1716

. . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1371

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1418

Instruction 24-9448 8-1

Bacharach PCA 2 24-9448 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual