Bacharach PCA400 Operating Manual
Combustion Analyzer
for Commercial & Light Industrial Use
®
Combustion & Emissions
P/N: 0024-9551 | February 2019 Revision 2
User
Manual
PCA® 400 User Manual
WARRANTY POLICY
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 specications. 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 IMPORTANT of the defect shall have been given by buyer to Bacharach, Inc.
within one (1) year after the date of delivery of this product by Bacharach, Inc.
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 ARISING 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 limitation will be binding upon Bacharach, Inc. unless in writing,
signed by a duly authorized ocer of Bacharach.
Register Your Warranty by Visiting: www.mybacharach.com
SERVICE POLICY
Bacharach, Inc. maintains a service facility at the factory. Some Bacharach distributors / agents may also have repair
facilities; however, Bacharach assumes no liability for service performed by anyone other than Bacharach personnel.
Repairs are warranted for 90 days after date of shipment (sensors, pumps, lters and batteries have individual warranties).
Should your analyzer require non-warranty repair, you may contact the distributor from whom it was purchased or
you may contact Bacharach directly.
If Bacharach is to do the repair work, send the monitor, prepaid, to the closest service center.
Prior to shipping equipment to Bacharach, visit www.mybacharach.com for an Returned Merchandise Authorization
Number (RMA #). All returned goods must be accompanied with an RMA #. Pack the equipment securely (in its original
packing, if possible), as Bacharach cannot be held responsible for any damage incurred during shipping to our facility.
Always include your RMA #, shipping address, telephone number, contact name, billing information and a description
of the defect as you perceive it. You will be contacted with a cost estimate for expected repairs prior to the performance
of any service work. For liability reasons, Bacharach has a policy of performing all needed repairs to restore the
monitor to full operating condition.
IMPORTANT
Product improvements and enhancements are on-going, therefore the specications and information contained in
this document may change without IMPORTANT.
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 © 2019, Bacharach, Inc., All Rights Reserved.
BACHARACH, PCA, B-SMART, and FYRITE are registered trademarks of Bacharach, Inc. All other trademarks, trade names, service marks and logos
2
referenced herein belong to their respective companies.
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Table of Contents
Introduction ..................................................... 6
1.1 About this Manual ........................................................................................................... 6
1.2 Conventions ...................................................................................................................... 6
1.2.1 Short Form Instructions...............................................................................................................................6
1.2.2 Iconography .................................................................................................................................................. 7
1.3 General Safety Statements ............................................................................................. 7
1.4 Product Overview ............................................................................................................ 8
1.5 North America (NA) vs. Siegert (S) Combustion Equations .......................................... 9
Product Description ....................................... 10
2.1 Combustion & Emissions Analyzer .............................................................................. 11
2.1.1 Overview ......................................................................................................................................................11
2.1.2 Keypad .........................................................................................................................................................12
2.1.3 Display .........................................................................................................................................................12
2.1.4 Instrument Connections ............................................................................................................................14
2.1.5 Interfaces ....................................................................................................................................................15
2.1.6 Components ...............................................................................................................................................16
2.2 Sample Line & Probe Assembly .................................................................................... 17
2.3 PowerCongurations .................................................................................................... 18
Operation ........................................................ 19
3.1 Setup................................................................................................................................ 19
3.1.1 Operation Tips ............................................................................................................................................19
3.1.2 Inspection / Prerequisites ..........................................................................................................................21
3.1.3 Connecting Probe Assembly ......................................................................................................................22
3.2 Performing Combustion Test ....................................................................................... 23
3.2.1 Combustion User Preferences ..................................................................................................................23
3.2.2 Combustion Analysis .................................................................................................................................24
3.2.3 Additional Settings .....................................................................................................................................27
3.2.4 Combustion Average Test ..........................................................................................................................31
3.3 Performing Pressure Test ............................................................................................. 32
3.3.1 Pressure User Preferences ........................................................................................................................32
3.3.2 Pressure Analysis ........................................................................................................................................32
3.4 Performing Leak Tests (Siegert Only) ............................................................................ 34
3.4.1 Let-by Test ...................................................................................................................................................34
3.4.2 Tightness Test .............................................................................................................................................35
3.5 Performing Temperature Test ..................................................................................... 36
3.5.1 Temperature User Preferences .................................................................................................................36
3.5.2 Temperature Analysis ................................................................................................................................37
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Settings & Features ........................................ 39
4.1 Language Selection ........................................................................................................ 39
4.2 Date & Time .................................................................................................................... 39
4.3 Username ....................................................................................................................... 40
4.4 Button Sound ................................................................................................................. 41
4.5 Inactivity Timeout .......................................................................................................... 41
4.6 Post-Purge Period .......................................................................................................... 41
4.7 Carbon Monoxide (CO) Zero ......................................................................................... 41
4.8 Sensor Setup ................................................................................................................... 42
4.9 Bluetooth® Setup ........................................................................................................... 43
4.10 Printer Setup ..................................................................................................................44
4.11 Onboard Data Logging ..................................................................................................45
4.12 Memory File Management ............................................................................................46
4.13 Fresh Air Purge without Removing Probe ..................................................................47
4.14 Sensor Protection / Dilution Mode ..............................................................................48
4.15 Smoke Number Test ...................................................................................................... 49
4.16 Oil Derivative Test ..........................................................................................................50
4.17 Boiler Temperature Test ............................................................................................... 50
4.18 Combustion Equations .................................................................................................. 50
Care & Maintenance ...................................... 51
5.1 Emptying the Water Trap .............................................................................................. 51
5.2 Replacing the Filter Element ........................................................................................ 52
5.3 Cleaning the Probe Assembly ....................................................................................... 53
5.4 Sensor Replacement ...................................................................................................... 54
5.5 B-Smart® Sensor Calibration ........................................................................................ 57
5.5.1 B-Smart® Sensors .......................................................................................................................................57
5.5.2 Starting a Calibration ................................................................................................................................58
5.5.3 B-Smart® Sensor Calibration ....................................................................................................................58
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5.6 Manual Sensor Calibration ........................................................................................... 61
5.6.1 Starting a Calibration ................................................................................................................................61
5.6.2 CO
5.6.3 SO2 Sensor Calibration ..............................................................................................................................65
5.6.4 NO Sensor Calibration ...............................................................................................................................66
5.6.5 NO2 Sensor Calibration .............................................................................................................................67
5.6.6 CO
Sensor Calibration ..........................................................................................................................62
LOW
Sensor Calibration ..........................................................................................................................69
HIGH
5.7 Troubleshooting ............................................................................................................. 70
5.7.1 Error Codes .................................................................................................................................................70
5.7.2 Error Symbols .............................................................................................................................................71
5.7.3 Diagnostics & Status Screens ....................................................................................................................71
Additional Information ................................. 73
6.1 TechnicalSpecications ................................................................................................ 73
6.1.1 Instrument Details .....................................................................................................................................73
6.1.2 Approvals ....................................................................................................................................................74
6.1.3 Measurement Range & Accuracy ..............................................................................................................74
6.1.4 Calculated Readings ..................................................................................................................................75
6.2 PCA® Reporting Software .............................................................................................. 76
6.2.1 Downloading Stored Data to a Computer ...............................................................................................76
6.2.2 Importing Saved Data ................................................................................................................................76
6.3 Bacharach Combustion App ......................................................................................... 79
Parts & Accessories ........................................ 80
7.1 Part Numbers ................................................................................................................. 80
7.2 Service Center Locations ............................................................................................... 82
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1. Introduction
1.1 About this Manual ............................................................................................................ 6
1.2 Conventions ....................................................................................................................... 6
1.2.1 Short Form Instructions...............................................................................................................................6
1.2.2 Iconography .................................................................................................................................................. 7
1.3 General Safety Statements .............................................................................................. 7
1.4 Product Overview ............................................................................................................. 8
1.5 North American (NA) vs. Siegert (S) Combustion Equations ....................................... 9
1.1 About this Manual
Thank you for investing in a Bacharach PCA® 400 Combustion Analyzer. To ensure operator
safety and the proper use of the PCA® 400, please read the contents of this manual for
important information on the operation and maintenance of the analyzer.
IMPORTANT: Before using this product, carefully read and strictly follow the
instructions in the manual.
1.2 Conventions
1.2.1 Short Form Instructions
This document uses a short form for describing steps (e.g. executing a command).
Example:
Selecting fuel type of application being tested.
Short Form Instructions:
f To select Fuel Type: Main Menu Fuel Menu (
being tested.
Steps Required:
1. Open the Main Menu.
2. Select Fuel Menu (indicated by the
icon
) select the fuel used in the application
).
3. Select desired fuel type from the listed options.
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1.2.2 Iconography
Alert Icon Description
DANGER
WARNING
WARNING
WARNING
CAUTION
IMPORTANT
Imminently hazardous situation which, if not avoided, will result
in death or serious injury.
Potentially hazardous situation which, if not avoided, could
result in death or serious injury.
Potential electrical shock hazard which, if not avoided, could
result in death or serious injury.
Hot surface which, if not avoided, could result in physical injury
or damage to the product.
Potentially hazardous situation which, if not avoided, could result
in physical injury or damage to the product or environment. It
may also be used to alert against unsafe practices.
Additional information on how to use the product.
1.3 General Safety Statements
WARNING: This analyzer is not intended to be used as a safety device.
WARNING: When testing an appliance, a full visual inspection should be performed to
ensure its safe operation.
WARNING: This analyzer has not been designed to be intrinsically safe for use in areas
classied as being hazardous locations. For your safety, DO NOT use it in hazardous
(classied) locations.
CAUTION: This analyzer is designed for on-demand and / or semi-continuous sampling
and is not intended to be used on a continuous basis.
CAUTION: Do not store instrument or its sensors with solvents or products which
contain solvents.
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CAUTION: Except for sensor and battery replacement, this analyzer should only be
opened and / or serviced by authorized Bacharach personnel. Failure to comply may void
the warranty.
CAUTION: When the instrument is used in an inecient furnace or boiler application
where there is a high soot concentration, the probe’s sample lter may become
clogged. Before every use check the lter to conrm that it is clean or replace it with
a new lter.
CAUTION: Never disconnect the probe from the instrument until purging is complete.
Otherwise, leftover target gas (for example, CO) may remain in the probe and cause
inaccurate zeroing at power up that could lead to inaccurate gas measurements
afterwards.
1.4 Product Overview
The PCA® 400 is an industrial-grade, hand-held combustion and emissions analyzer
for on-demand and / or semi-continuous sampling of commercial and light industrial
appliances (furnaces, boilers and engines).
Standard Product Conguration
The base instrument is supplied with a probe and hose assembly, factory calibrated / installed
sensors, printer interface, hard carry case, lters, USB cable, PC Software (digital download),
AC adapter and a rechargeable lithium-ion battery pack. The reporting kit version (in addition
®
to the base) includes an IrDA + Bluetooth
printer and printer paper.
Intended Product Applications
The intended purpose of the measuring device is for:
• Engineerings servicing / monitoring industrial combustion plants process systems,
power stations
• Emissions inspectors, Engine manufacturers and operators, service engineers &
mechanics of burner /boiler manufacturers in the industrial sector.
®
Typical measuring tasks and particular characters of the PCA
400 include:
• Measurement on industrial engines (CO / NO dilution)
• Measurement on gas turbines (High precision CO and NO plus optional dilution).
• Emissions measurements (integrated ow speed and dierential pressure measurement)
The PCA® 400 has not been designed for and SHOULD NOT be used for the following:
• Continuous measurements over 5-hours
• As a safety (alarm) instrument.
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1.5 North American (NA) vs. Siegert (S)
Combustion Equations
Though the combustion process is fairly standardized across the globe, a combustion
analyzer intended for worldwide use demands a degree of exibility for a few regional
preferences.
IMPORTANT: Detailed dierences between North American and Siegert
congurations are noted where appropriate in this manual.
IMPORTANT: The Combustion Equations setting is used to congure the
instrument to use either North American combustion equations or Siegert
combustion equations. Changing this setting resets memory and the values of
other settings.
Feature North American (NA) vs. Siegert (S) Conguration
Countries
Heating Values
Fuels Dierent fuel sets and composition.
Dierent RUN
Parameters
Extra Siegert Parameters
CO
Max In the Siegert conguration, the user can set a CO2 Max number for the fuel.
2
Languages
®
The PCA
400 provides a North American (NA) conguration and a Siegert (S) conguration
Typical North American (NA) Users
Asia, Australia, Latin America,
North America, South America
For combustion calculations, Siegert uses the fuel’s lower heating value; NA
uses the higher value.
EFF (NA) vs. Stack loss and ETA (S)
Excess Air (NA) vs. Lambda (S)
(Lambda is similar to excess air)
CO/CO
displayed for Siegert only.
3 for the North American (NA) conguration and 8 for the Siegert (S)
conguration.
ratio, boiler temperature, smoke number, and oil derivative are
2
Typical Siegert (S) Users
Belgium, Denmark, France,
Germany, Italy, Netherlands,
Poland, Spain, United Kingdom
to address these and other needs, which are detailed in the table above.
f To change Combustion Equations: Main Menu Settings ( ) Combustion Eqns.
select Standard or Siegart (European).
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2. Product Description
2.1 Combustion & Emissions Analyzer ............................................................................... 11
2.1.1 Overview ......................................................................................................................................................11
2.1.2 Keypad .........................................................................................................................................................12
2.1.3 Display .........................................................................................................................................................12
2.1.4 Instrument Connections ............................................................................................................................14
2.1.5 Interfaces ....................................................................................................................................................15
2.1.6 Components ...............................................................................................................................................16
2.2 Sample Line & Probe Assembly ..................................................................................... 17
2.3 PowerCongurations ..................................................................................................... 18
Fig. 2-1: Product Features
IrDA + Bluetooth® Communications
Wireless communications allow users to
conveniently stream data to printers and
compatible devices.
10 Standard Fuel Calculations
Combustion calculations for 10 common
fuel types and optional custom fuels.
4.3" Color Touch Display
Backlit display and resistive touch
make operation simple and intuitive
in the eld.
Enhanced Data Viewing
View data in list, tile or trending formats
making it easier to interpret results.
®
B-Smart
Pre-calibrated sensors eliminate
the need for costly down-time or
calibration gases.
Sensor Technology
Extended Probe Options
Probe assembly is available in 12",
The analyzer can be powered by a
rechargeable lithium-ion battery
pack, 4 × AA batteries or an AC
Stored analysis data can be
downloaded to a PC as a
Comma or Semicolon Separated
Sample Line Options
Sample line assembly is available with
Buna-N or Viton
in lengths of 7.5' and 15'.
24"and 36" lengths.
+
Hour Run Time
12
power adapter.
500 Memory Locations
Value (CSV) text le.
®
tubing construction
10
One-Step Connection
Keyed connectors ensure a quick, reliable
connection between the sample line
assembly and other components.
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2.1 Combustion & Emissions Analyzer
The PCA® 400 is designed for use in commercial and light industrial applications.
The analyzer is capable of measuring O2, CO, NO, NO2 or SO2, stack / ambient
temperatures, and pressure. The PCA® 400 also calculates CO2, NOx, combustion
eciency and excess air.
2.1.1 Overview
CAUTION: The analyzer contains strong magnets which may damage other
instruments. KEEP AWAY from products which could be damaged by magnetic
elds (e.g. monitors, computers, heart pacemakers, credit cards).
Fig. 2-2: Combustion & Emissions Analyzer
Infrared Printer Interface (top)
Integrated Magnetic Boot (rear) - High impact ABS
plastic with molded-in magnets protects the analyzer
and allows for hands-free use .
LCD Touch Display - 4.3" full color, backlit liquid-crystal
display with resistive touch panel.
Interfaces: USB, T-Air (side)
Tactile Keypad
Instrument Connections (bottom)
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2.1.2 Keypad
Fig. 2-3: Navigation Keypad
Back Key - Displays the previously viewed screen. In
addition, if changes have been made to one of the
analyzer’s operating parameters (e.g., date, time, O2
reference, etc.), pressing this button aborts any changes,
restores the old values and displays the previously
viewed screen.
Home Key - Displays the Main Menu. In addition, if
changes have been made to one of the analyzer’s
operating parameters (e.g., date, time, O2 reference, etc.),
pressing this button aborts any changes, restores the
old values and displays the Main Menu.
Power Key - Turns the analyzer ON and OFF.
Navigation Keys - Move the cursor on the display. When
viewing a directory, use the buttons to open and
close sub-directories.
2.1.3 Display
DANGER: Display contains liquid crystal which is poisonous. If liquid crystal comes
in contact with skin, wash immediately with soap and water. If ingested, immediately
contact the local poison control center.
CAUTION: DO NOT subject display to excessive shock.
CAUTION: Periodic cleaning with a lightly moistened soft cloth is recommended.
DO NOT wipe display with a dry cloth, as it may scratch the surface.
CAUTION: DO NOT use organic solvents or detergents to clean the display, as they
may cause damage to the screen.
Enter Key - Selects a highlighted item. In addition,
if changes have been made to one of the analyzer’s
operating parameter (e.g., date, time, O2 reference, etc.),
pressing this button conrms those changes and saves
them in memory.
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Status Icons
Icon Name Description
x
Battery / Power Status
Pump OFF Sample pump is idle
Pump ON Sample pump is operating
100% Charge
75% Charge
50% Charge
25% Charge
Bluetooth® Active Bluetooth® is enabled and compatible devices may be connected
Preference Icons
Icon Name Description
Display table / list format
Display Options
Display trending / line graph format
Display tile format
Settings Display conguration parameters
Memory Set le structure and naming conventions for data storage
Fuel Types Display list from which to select current test’s combustion fuel
Status Display device status, device information and main diagnostics
Options
Context-sensitive parameters; touch to adjust run/hold format,
low / high limits, features, options, etc.
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Function Icons
Icon Name Description
Measure Touch to select test to perform (combustion, pressure, temperature)
Turn On Pump Touch to turn on pump; used with to toggle RUN / HOLD mode
Stop Pump Touch to stop pump; used with to toggle RUN / HOLD mode
Print Touch to print data to IrDA + Bluetooth® printer
Save Touch to save data to default selected folder
Calibrate Touch to perform calibration functions
2.1.4 Instrument Connections
Fig. 2-4: Sample Line Connection Port
Stack Gas Type-K Thermocouple / T-STACK Port
Gas Sample Port
Pressure High Side (+∆P) Port
Pressure Low Side (-∆P) Port
Quick-Connector - keyed to t specic components:
gray analyzer, blue probe handle.
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2.1.5 Interfaces
Computer Interface
Data that has been stored in the analyzer’s onboard memory can be uploaded to a personal
computer by connecting the included Micro-B USB Cable between the USB ports of the
computer and the analyzer.
Fig. 2-5: Micro-B USB Port
Micro-B USB Port
Type-K Ambient Air Thermocouple / T-AIR Port
Micro-B USB Cable
Printer Interfaces
The PCA® 400 is capable of wirelessly transmitting data to compatible IrDA (Infrared Data
Associated) or IrDA + Bluetooth® Printers. The IrDA Interface is located at the top of the
device (Figure 2-2).
IMPORTANT: Interference can be caused by devices that are transmitting on the
same frequency band.
WARNING: Use of radio connection may not be permitted in some locations
(e.g. airplanes, hospitals). User assumes responsibility for complying with rules
governing the use of radio connections.
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Fig. 2-6: IrDA Communication Range
Fig. 2-7: Bluetooth® Communication Range
60°
max.
4" to 16"
(10 to 30 cm)
2.1.6 Components
CAUTION: Except for sensor and battery replacement, this analyzer should only
be opened and / or serviced by authorized Bacharach personnel. Failure to comply
may void the warranty.
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30'
(9.1 m)
PCA® 400 User Manual
Fig. 2-8: Sensor & Battery Positions
Sensor Position 1 - O
Sensor Position 2 - CO
2
LOW
or CO
Sensor Position 3 - NO2 or SO
HIGH
2
Sensor Position 4 - NO
Battery Compartment
2.2 Sample Line & Probe Assembly
The PCA® 400’s sample line and probe are modular, allowing users to quickly swap
out dierent sized probe lengths, sample lines and the optional sample conditioner.
Fig. 2-9: Sample Line & Probe Assembly
17
Probe Tube - available in multiple lengths.
Probe Stop
Probe Handle
Water Trap / Filter Assembly
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Sample Line - available in multiple
lengths and construction types.
Quick-Connector - keyed to t specic
components: gray analyzer, blue probe
handle.
PCA® 400 User Manual
IMPORTANT: Replacement parts and accessories are sold separately. See Part
Numbers (Section 7.1) for more information.
2.3 Power Congurations
The PCA® 400 comes standard with a rechargeable lithium-ion battery pack which is
capable of powering the analyzer for up to 12-hours. Users may also run the analyzer
on 4 × AA batteries or via the supplied Micro-B USB cable and AC power adapter.
WARNING: DO NOT disassemble battery pack or short battery contacts, as this
may result in electrical shock.
DANGER: Batteries may pose risk of explosion, re or chemical burns if mistreated:
• NEVER dispose of batteries in a re or incinerator.
• NEVER expose batteries to corrosive liquids.
• DO NOT attempt to charge batteries which are swollen or bulging.
CAUTION: Lithium-Ion batteries contain elements that may pose health risks to
individuals if they are allowed to leach into the ground water supply. Always dispose
of batteries in accordance with local regulations.
IMPORTANT: Operating the analyzer with the AC power adapter DOES NOT charge
its rechargeable batteries. To recharge the analyzer’s batteries, supply power via
the AC power adapter when the analyzer is turned OFF.
Fig. 2-10: Congurations for Li-ion Battery Pack and 4 × AA Batteries
AA Battery Tray
Li-ion Battery Pack Connection
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3. Operation
3.1 Setup ................................................................................................................................ 19
3.1.1 Operation Tips ............................................................................................................................................19
3.1.2 Inspection / Prerequisites ..........................................................................................................................21
3.1.3 Connecting Probe Assembly ......................................................................................................................22
3.2 Performing Combustion Test ....................................................................................... 23
3.2.1 Combustion User Preferences ..................................................................................................................23
3.2.2 Combustion Analysis .................................................................................................................................24
3.2.3 Additional Settings .....................................................................................................................................27
3.2.4 Combustion Average Test ..........................................................................................................................31
3.3 Performing Pressure Test ............................................................................................. 32
3.3.1 Pressure User Preferences ........................................................................................................................32
3.3.2 Pressure Analysis ........................................................................................................................................32
3.4 Performing Leak Tests (Siegert Only) ............................................................................ 34
3.4.1 Let-by Test ..................................................................................................................................................34
3.4.2 Tightness Test .............................................................................................................................................35
3.5 Performing Temperature Test ..................................................................................... 36
3.4.1 Temperature User Preferences .................................................................................................................36
3.4.2 Temperature Analysis ................................................................................................................................37
3.1 Setup
Properly preparing the analyzer is critical to accurate analysis and safe operation. Be
sure to read the following instructions prior to use of this instrument.
3.1.1 Operation Tips
Allow Analyzer to Warm-up Slowly
When an analyzer is brought in from a cold vehicle, allow it to warm-up slowly to minimize
condensation. Temperatures below freezing will not damage the analyzer.
CAUTION: Although the analyzer itself is not damaged by extremely cold
temperatures, the electrochemical sensors may sustain damage. The O2 sensor’s
electrolyte will freeze at approximately -13ºF (-25ºC), and the other sensors at
approximately -94ºF (-70ºC). If the analyzer is exposed to extremely cold conditions,
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 surrounding PCB assemblies.
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Start Analyzer in Fresh Air
Ensure that the analyzer is sampling fresh air during initial 60-second warm-up period.
Pulling a stack gas sample through the analyzer during its warm-up period will not damage
the analyzer, but it will result in incorrect sensor readings, and may result in sensor error
messages appearing after the warm-up cycle completes.
Inspect Water Trap / Filter Assembly
Before each use, inspect the lter element of the water trap / lter assembly. Replace the
lter if it looks dirty. See Replacing the Filter Element (Section 5.2) for more information.
Keep Analyzer Above Water Trap Assembly
When sampling ue gas, keep the analyzer above the water trap, and keep the trap in a
vertical position. This will maximize the eectiveness of the trap and keep liquid condensate
from being drawn directly into the analyzer. (Flue gas condensate can be acidic and very corrosive.
Do not to allow the analyzer’s internal components to come in contact with condensate.)
Don’t Allow Water Trap to Become Full
When liquid condensate is seen inside the water trap, empty the trap before it becomes full.
See Emptying the Water Trap (Section 5.1) for more information.
Fig. 3-1: Water Trap / Filter Assembly
To Gas Port on Analyzer
Ensure that lter is clean.
Never allow the water level
to rise above tip of riser tube
during operation.
Stack Gas from Probe
20
CAUTION: Use the Water Trap / Filter Assembly in a vertical position with the gas
ow arrow pointing up as shown in the illustration above.
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Purge Analyzer After Each Use
The analyzer should be purged after performing a combustion test. After removing probe
from the stack, let the pump run for at least 10-minutes to remove any stack gases and dry
any condensate from inside the sensor chamber and probe assembly.
Remove Moisture from Water Trap Before Storing
When storing the analyzer, it is recommended that users empty the water trap and leave it
open to prevent damage associated with prolonged exposure to moisture. See Emptying
the Water Trap (Section 5.1) for more information.
Maintain Sensor Calibration
Calibrate the analyzer every 6-months to 1-year to ensure its accuracy. See Calibration
(Sections 5.5 and 5.6) for more information.
3.1.2 Inspection / Prerequisites
Before performing any tests with the analyzer, verify the following:
Thewatertrap/lterassemblyisempty,clean,andthearrowispointingUP.
Check for obvious signs of splits and or cracks in the sample line and other tubing.
Perform routine maintenance (replacing sensors, calibrating, etc.) as outlined in Care &
Maintenance.
Ensurethattheanalyzerhassucientchargebeforeoperation.Ifindoubt,recharge
Li-ion battery pack, replace disposable batteries or provide power via the AC adapter
and USB cable.
Fig. 3-2: Acceptable Battery Levels
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3.1.3 Connecting Probe Assembly
1. Connect Analyzer to Sample Line
Firmly insert the gray quick-connector into the base of the analyzer. Users will hear a click
once a secure connection has been made.
Fig. 3-3: Insert Gray Quick-Connector into Analyzer
2. Connect Probe to Sample Line
Firmly insert the blue quick-connector into the base of the probe handle. Users will hear a
click once a secure connection has been made.
Fig. 3-4: Insert Blue Quick-Connector into Probe Handle
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3. Turn On Analyzer
Press the POWER button to begin a 60-second warm-up period. Users will hear the pump
begin operation and splash screen should appear on the analyzer’s display.
Fig. 3-5: Press Power Button
60-SECOND
WARM-UP
CAUTION: Ensure that the analyzer is sampling fresh air during the warm-up.
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.
3.2 Performing Combustion Test
3.2.1 Combustion User Preferences
Temperature Units
Select to display temperature in Fahrenheit (ºF) or Celsius (ºC).
f To change Temperature Units: Main Menu Settings ( ) Temperature Units select
Fahrenheit or Celsius.
Pollution Units
®
The PCA
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.)
400 is capable of converting the measured ppm levels of CO, NO, NO2, and SO2
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f To change Pollution Units: Main Menu Settings ( ) Pollution Units select ppm, lb/
MBtu, mg/m3 or g/GJ.
IMPORTANT: After saving changes to Temperature and Pollution Units, they will
become the analyzer’s default values for all future testing.
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3.2.2 Combustion Analysis
1. Select Folder / Memory Location (User Discretion)
®
The PCA
viewing and downloads.
f To change Folder / Memory Location: Main Menu Memory ( ) use navigation keys
to highlight the desired folder Options (
2. Select Fuel Type
400 gives users the ability to organize their records in a folder structure for later
) select Target.
f To select Fuel Type: Main Menu Fuel Menu (
) select the fuel used in the application
being tested.
NA (Standard) Siegert
Natural Gas Natural Gas
Oil #2 KOKS
Oil #4 LEG
Oil #6 Propane
Propane Oil #2
Coal Oil #6
Wood Coal
Kerosene BioFuel
Bagasse LPG
Digester Gas Butane
If your combustion application requires a fuel type not listed in the Fuel menu, contact
Bacharach for information on additional fuel codes. Custom fuel codes may developed by
Bacharach at a customer’s request and can be loaded into the instrument using the PCA
Reporting Software.
IMPORTANT: Custom fuel codes are specific to the combustion equations that
are being used, so be sure to include your combustion equation type (North
American or Siegert) with any custom fuel code requests.
3. CO2 Max Value (Siegert Only)
When using the PCA® 400’s Siegert conguration, additional settings allow one to adjust the
CO2 max value to account for fuel variations. Adjusted CO2 Max values are stored with the
saved combustion records and
f To change the CO2 Max: Main Menu Fuel Menu ( ) select the fuel used in the
application being tested Adjust insert the desired CO2 Max press Save ( ).
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4. Select Measurement Type
f To select Measurement Type: Main Menu Measure (
) select Combustion.
5. Insert Probe Tube into Measurement Area
After identifying the ue / exhaust stack, select a safe and convenient location from which
to draw the sample.
f Select length-appropriate probe.
f Set probe stop to ensure that the probe is inserted into the center of the ue / exhaust
stack / measurement area. (The probe stop also acts to secure the probe in the measurement
area during analysis.)
Fig. 3-6: Probe Placed in Center of Measurement Area
CAUTION: When the instrument is used in an inecient furnace or boiler application
where there is a high soot concentration, the probe’s sample lter may become
clogged. Before every use check the lter to conrm that it is clean or replace it with
a new lter (Section 5.2).
6. Run Sample Pump
After starting the pump, allow readings to stabilize for a minimum of 3-minutes or as long
as required by manufacturer specications / compliance testing procedures.
f To start the pump: press Run / Hold (
).
f To stop the pump: press Run / Hold ( ).
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