Bacharach Portable Combustion Analyzer 24-9351 User Manual
Portable Combustion
Analyzer (PCA)
INSTRUCTION 24-9351
Operation & Maintenance
Rev. 11 – May 2004
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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 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 officer of Bacharach.
Register Your Warranty by Visiting
www.bacharach-inc.com
PCA
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 © 1999–2004, 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.
A
Instruction 24-9351
PCA
Contents
Contents
1.0 INTRODUCTION ............................................................................ 1-1
1.1 The Portable Combustion Analyzer........................................... 1-1
1.2 Displayed Data ........................................................................... 1-2
1.3 Sensor Configurations ................................................................ 1-3
2.0 TECHNICAL CHARACTERISTICS ............................................ 2-1
3.0 SETTING UP THE PCA................................................................. 3-1
3.1 Scope........................................................................................... 3-1
3.2 Power.......................................................................................... 3-1
3.2.1 Checking and Replacing the Batteries ........................... 3-1
3.2.2 Using the Optional Power Supply .................................. 3-2
3.3 Connecting the Probe ................................................................ 3-2
3.4 Configuring the PCA ................................................................. 3-4
4.0 OPERATION.................................................................................... 4-1
4.1 Key Pad Functions..................................................................... 4-1
4.2 Sampling Hole Location ............................................................ 4-2
4.3 Combustion Test ........................................................................ 4-3
4.3.1 Analyzer Turn On and Warm Up .................................. 4-3
4.3.2 Installing Probe in the Stack ......................................... 4-4
4.3.3 Performing a Combustion Test ...................................... 4-5
4.3.4 Ending a Combustion Test............................................. 4-5
4.3.5 Turning Off the Analyzer and Purging the CO Sensor.... 4-6
4.4 Differential Pressure Measurement ......................................... 4-7
4.5 Warm-up Screen ........................................................................ 4-8
4.6 Sensor Status Screen................................................................. 4-9
4.7 Combustion Test Screen.......................................................... 4-10
4.8 Fuel Selection Screen .............................................................. 4-11
4.9 Draft Screens ........................................................................... 4-12
4.10 Memory Directory Screen ..................................................... 4-13
4.11 Memory to PC Screen ............................................................ 4-14
4.12 ID Setup Screens ................................................................... 4-17
4.13 Temperature Setup Screen ................................................... 4-19
4.14 Draft Unit Setup Screen ....................................................... 4-20
4.15 Language Setup Screen......................................................... 4-21
4.16 Display Mode Setup Screen .................................................. 4-22
4.17 Time/Date Setup Screen........................................................ 4-23
4.18 Printer Setup Screen ............................................................. 4-24
4.19 Maintenance Password Screen ............................................. 4-25
4.20 Maintenance Screen .............................................................. 4-26
4.21 User Name Screens ............................................................... 4-27
Instruction 24-9351
i
Contents
PCA
4.22 Saving Test Data ................................................................... 4-28
4.23 Printing Test Data................................................................. 4-29
4.24 Clear Memory Screen ............................................................ 4-31
4.25 Resetting the Microprocessor................................................ 4-31
5.0 CALIBRATION................................................................................ 5-1
5.1 Sensor Check ............................................................................. 5-1
5.2 Calibration Fixtures .................................................................. 5-2
5.3 Calibrate Menu Screen.............................................................. 5-3
5.4 Calibrate TA-Zero...................................................................... 5-4
5.5 Calibrate TA-Span..................................................................... 5-5
5.6 Calibrate TL-Zero ...................................................................... 5-6
5.7 Calibrate TL-Span ..................................................................... 5-7
5.8 Calibrate NX .............................................................................. 5-8
5.9 Calibrate CO .............................................................................. 5-9
5.10 Calibrate Draft....................................................................... 5-11
6.0 MAINTENANCE.............................................................................. 6-1
6.1 Routine Maintenance ................................................................ 6-1
6.2 Disassembly ............................................................................... 6-2
6.3 Cleaning the Probe .................................................................... 6-4
6.4 Water Trap/Filter Assembly Maintenance............................... 6-5
6.5 Replacing the Particulate Filter ............................................... 6-6
6.6 Replacing the Oxygen Sensor ................................................... 6-7
6.7 Replacing the Nitric Oxide Sensor ........................................... 6-8
6.7.1 Replacing the Nitric Oxide Sensor Filter ...................... 6-8
6.7.2 Replacing the Nitric Oxide Sensor Bias Battery .......... 6-9
6.8 Replacing the Carbon Monoxide Sensor................................. 6-10
6.8.1 Replacing the Carbon Monoxide Sensor Filter ........... 6-11
6.9 Replacing the Pump Assembly ............................................... 6-12
7.0 TROUBLESHOOTING.................................................................... 7-1
7.1 Analyzer Repair ......................................................................... 7-1
7.2 Error Codes ................................................................................ 7-2
7.3 Troubleshooting Guide .............................................................. 7-3
8.0 PARTS & SERVICE........................................................................ 8-1
8.1 Replacement Parts..................................................................... 8-1
8.2 Accessories ................................................................................. 8-2
8.3 Sales/Service Centers ................................................................ 8-6
APPENDIX A – Display Screen Translations...................................A-1
APPENDIX B – Printout Translations ..............................................B-1
ii
Instruction 24-9351
PCA
Introduction
1.0 INTRODUCTION
1.1 The Portable Combustion Analyzer
The Portable Combustion Analyzer (PCA) (Figure 1-1) is a commercial
grade, hand held, combustion efficiency analyzer that is designed for
continuous (on demand) sampling of light industrial and residential
furnaces, appliances, and boilers. The basic instrument is supplied with a
probe, instruction manual, batteries, and carrying case.
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Instruction 24-9351
M E N U
P C A
Figure 1-1. PCA
1-1
Introduction
PCA
1.2 Displayed Data
The PCA directly measures, displays, and stores the following data:
• Room Temperature in °C or °F (Primary Air/Ambient Temperature)
• Flue Gas Oxygen Content in %
• Flue Gas Temperature in °C or °F
• Flue Gas Carbon Monoxide Content (H2 Compensated) in ppm
(For analyzers having a Carbon Monoxide sensor)
• Flue Gas Nitric Oxide content in ppm
(For analyzers having a Nitric Oxide sensor)
• Pressure/Draft in Millibars, Pascals, or Inches of Water Column
(For analyzers having a draft sensor)
• Differential Pressure in Millibars, Pascals, or Inches of Water Column
(For analyzers having a draft sensor)
The PCA will compute, display, and store the following data for any of the
standard fuels:
• Stack Loss in %
• Lambda
• Flue Gas Carbon Dioxide Content in %
• Flue Gas Carbon Monoxide Content referenced to 0% Oxygen in ppm
(For analyzers having a Carbon Monoxide sensor)
• Flue Gas Nitric Oxide Content referenced to 0% Oxygen in ppm
(For analyzers having a Nitric Oxide sensor)
The standard fuels are:
• Natural Gas
• Oil #2
• Oil #6
• LPG
• Koks
• Low Energy Gas
• P-Coal (available in English, German, Dutch, French, Italian,
Polish, and Spanish languages)
• Biofuel (available in Danish, Finnish, and Swedish languages)
The PCA continuously monitors flue-gas-exhaust conditions and updates
the above displayed values during a combustion test. If the analyzer is
equipped with an optional pressure sensor, draft measurements can be
made simultaneously with the combustion test, or made separately.
The analyzer has the ability to store data that was collected during a
combustion test or draft measurement. The stored data can then either be
viewed on the PCA’s display, printed using an optional printer, or downloaded to a computer.
1-2
Instruction 24-9351
PCA
Introduction
1.3 Sensor Configurations
TABLE 1-1. PCA SENSOR CONFIGURATIONS
PCA Models Sensors Installed
Standard Advanced
PCA Part No.* Part No.** PCA Part No.* Part No.** Stack Temp., CO NX Draft
Model 24- 24- Model 24- 24- Air Temp. & O
10 7181 7281 40 7241 7251 X
15 7182 7282 45 7242 7252 X X
20 7183 7283 50 7243 7253 X X
25 7184 7284 55 7244 7254 X X X
30 7185 7285 60 7245 7255 X X X
35 7186 7286 65 7246 7256 X X X X
* English, Danish, Dutch, German, Finnish & Swedish languages
** English, French, German, Italian, Polish & Spanish languages
2
PCA 10 & 40
These basic instruments have the capability of measuring, displaying,
and storing combustion tests. They will also display flue gas Oxygen
content, flue gas Carbon Dioxide (CO2) content, air temperature, flue gas
temperature, stack loss, Lambda, and the current fuel selected. The
‘standard’ PCA 10 stores up to 10 combustion tests, while the ‘advanced’
PCA 40 can store up to 100 tests.
(
∆∆
∆P)
∆∆
PCA 15 & 45 with Draft
In addition to the features of the basic PCAs described above, these instruments have the added capability of measuring, displaying, and saving draft
or differential pressure in either Millibars, Pascals, or Inches-of-Water
Column.
PCA 20 & 50 with Carbon Monoxide Measurement
In addition to the features of the basic PCAs described above, these
instruments have the added capability of measuring, displaying, and
saving Carbon Monoxide (CO) content, as well as calculating CO referenced to 0% Oxygen.
PCA 25 & 55 with Draft and CO Measurement
These instruments combine the features of all the PCAs listed above.
PCA 30 & 60 with CO and Nitric Oxide Measurement
In addition to the features of the basic PCAs with CO measurement, these
instruments have the added capability of measuring, displaying, and
saving Nitric Oxide (NX) content, as well as calculating NX referenced to
0% Oxygen.
Instruction 24-9351
1-3
Introduction
PCA
PCA 35 & 65 with Draft, CO & NX
These instruments are capable of measuring, displaying, and saving all
measurements as previously described.
Printout Capability
All PCAs have the ability to print the latest test data, or any of the saved
tests, to an optional printer using HP, IrDA or RS-232 protocol.
Advanced PCA Model Features
‘Advanced’ models of the PCA contain the following features that are in
addition to the features of their corresponding ‘standard’ PCAs:
• 100 memory locations
• RS232 output for transferring saved data to a Personal Computer
• Ability to enter three lines of user-identification information that is
printed at the top of each printout
• Ability to enter three lines of customer-identification information that
is printed with each test record.
• Automatic CO sensor purge on analyzers equipped with a CO sensor
Instruction 24-93511-4
PCA
Technical Characteristics
2.0 TECHNICAL CHARACTERISTICS
The PCA Directly Measures and Displays:
• Oxygen content in flue gas in the range of 0.1 to 20.9 % O
• Flue gas temperature in the range of –18 to 1200 ºC (0 to 2192 ºF)
• Primary-air / ambient temperature is in the range of –18 to 999 ºC
(0 to 999 ºF)
Optional . . .
• Differential pressure/draft in the range of ±70.0 mb (±28" H2O)
• Carbon Monoxide* content in flue gas in the range of 0 to 4000 ppm
• Nitric Oxide* content in flue gas in the range of 0 to 1000 ppm
The PCA Computes and Displays:
(When the measured oxygen level is not above 18.8%, and the Stack (Flue
Gas) temperature is not above 1200 ºC (2192 °F)
• Stack loss in the range of 0.1 to 99.9%
• Carbon Dioxide content in flue gas from 0.1 to a fuel dependent
maximum value in percent
• Lambda in the range of 1 to 9.95
• Carbon Monoxide* content referenced to 0% Oxygen in the range of
0 to 9,999 ppm on analyzers equipped with a CO sensor.
• Nitrix Oxide* content referenced to 0% Oxygen in the range of 0 to
9,999 ppm on analyzers equipped with a NX sensor.
2
Standard Fuels** Available for
Combustion Calculations:
• Natural Gas
• Koks
• LEG
• LPG
• Oil #2
• Oil #6
• P-Coal (available in English, German, Dutch, French, Italian,
Polish, and Spanish languages)
• Biofuel (available in Danish, Finnish, and Swedish languages)
* For the PCA 30, 35, 60, & 65, the display can be set up to show either
measured values of Carbon Monoxide and Nitric Oxide (CO & NX), or
show the calculated values of these gases (CU & NU) referenced to
0% Oxygen. In either case, all values are listed on the printout of
analzyers equipped with a printer.
** Custom fuels available upon request. Contact factory for details.
Instruction 24-9351
2-1
Technical Characteristics
Normal Operating Conditions:
Temperature:
Analyzer ...................0 to 40 ºC (32 to 104 ºF)
Probe.........................800 ºC (1472 ºF) Max.
Humidity:
Analyzer ...................15 to 90% Relative Humidity, Non-Condensing
Air Pressure:
Analyzer ...................Atmospheric
Probe.........................25 mb (10" H2O) draft max at probe tip
Performance:
Accuracy:
Oxygen*....................±0.3% O
Carbon Monoxide.....±5% of reading or ±10 ppm, whichever is greater
between 0 – 2000 ppm, and ±10% of reading
between 2001 – 4000 ppm.
Nitric Oxide..............±5% of reading or ±5 ppm, whichever is greater
Flue Gas Temp......... ±2 ºC between 0 and 124 ºC
±3 ºC between 125 and 249º C
±4 °C between 250 and 400 °C
Ambient Temp. ........±1 °C between 0 and 100° C
Pressure ...................±2% of reading or ±0.05 mb (±0.02 inches of
Water Column), whichever is greater
2
(±4 ºF between 32 and 255 ºF)
(±6 ºF between 256 and 480 ºF)
(±8 ºF between 481 and 752 ºF)
(±2 ºF between 32 and 212 ºF)
PCA
System Flow Rate:
With probe................200 cc/min minimum
Front Panel Controls:
Seven embossed push-button switches with tactile feedback (refer to
Section 4.1)
* Accuracy referenced in practical flue gas concentrations
(mixtures of O2, CO2 and N2)
2-2
Instruction 24-9351
PCA
Technical Characteristics
Display:
20 character by 4 line alphanumeric LCD panel with a green backlight.
Power Requirements:
Four disposable AA alkaline batteries. Battery backup for the real-time
clock, RAM, and bias voltage for the Nitric Oxide sensor are provided by
internal lithium batteries. Optional AC Power Supplies (110 VAC &
230 VAC) are also available.
Operating Time:
A fresh set of four disposable AA alkaline batteries provides at least
8 hours of continuous operation with the pump running and the backlight
turned on.
Warm Up Time:
60 seconds.
Printer Interface:
Infrared & RS-232 Communications (refer to Section 4.23).
Materials:
• High impact ABS plastic case
• Polycarbonate window over the display
• Nickel plated, brass quick-connect hose fitting
• Stainless steel probe
Dimensions:
Height:.................. 215 mm (8.5 in.)
Width: ................... 96 mm (3.8 in.) at display (75 mm [3.0 in.] at controls)
Depth:................... 50 mm (2 in.)
Weight:
With Batteries:..... Approximately 0.7 Kg (1.5 lbs)
Instruction 24-9351
2-3
Technical Characteristics
Agency Approvals:
_ TÜV Agency Approved (1.BImSchV - First Ordinance of the German
Federal Emissions Law)
Approval Number: TÜV By RgG 168
_ CE declaration of conformity
Manufacturer's name: Bacharach, Inc.
Manufacturer's address: 621 Hunt Valley Circle
New Kensignton, PA 15068
European operations: Bacharach Instruments
Sovereign House, Queensway
Royal Leamington Spa
Warwickshire CV31 3JR
United Kingdom
Product name: Portable Combustion Analyzer (PCA)
conforms to the following CE
requirements:
EN 50081-1, January 1992 (Emissions)
EN 50082-1, January 1992 (Immunity)
Equations
PCA
2
×=
max
COC2
()
TLTAqA
21
=
LA
2
−
O21
×=
COCU
×=
NONU
2-4
2
O21
−
21
21
2A
×−=
21
−
−
O21
O21
2
−
()
O21
2
2
Where:
= Measured Oxygen in percent
O
2
TA = Measured stack temperature in °C
TL = Measured primary air temperature in °C
CO = Measured Carbon Monoxide in ppm
+
B
NO = Measured Nitric Oxide in ppm
C2 = Calculated Carbon Dioxide in percent
qA = Calculated stack loss in percent
LA = Calculated Lambda
CU = Calculated Carbon Monoxide referenced
to 0% Oxygen
NU = Calculated Nitric Oxide referenced to 0%
Oxygen
CO2max, A2, and B are constants (see below)*:
Fuel CO2max A2 B
NG 11.8 0.66 0.009
KOKS 10.2 0.60 0.011
LEG 13.1 0.63 0.011
LPG 13.8 0.63 0.008
Oil#2 15.4 0.68 0.007
Oil#6 15.9 0.68 0.007
P-Coal 18.7 0.60 0.007
Biofuel 20.4 0.70 0.012
* Some constants vary for Danish, Italian, and Polish fuels
Instruction 24-9351
PCA
Setup
3.0 SETTING UP THE PCA
3.1 Scope
Before using the PCA, you MUST:
• Check the batteries or plug in an optional Power Supply (Section 3.2)
• Connect the probe to the analyzer (Section 3.3)
• Check the analyzer’s configuration (Section 3.4)
3.2 Power
3.2.1 Checking and Replacing the Batteries
A fresh set of batteries is supplied with the PCA. Install the batteries as
described below. Check for a sufficient charge prior to each use. If a
LOWBATTERY message is displayed, replace the batteries.
1. Remove the battery cover from the back of the PCA (Figure 3-1).
2. Remove (and properly dispose of) the old batteries.
3. Install a new set of four AA alkaline batteries, making sure to properly orient them as indicated by the “+” and “–” terminals in the
battery compartment.
4. Replace the battery cover.
Figure 3-1. Battery Replacement
Instruction 24-9351
3-1
Setup
PCA
3.2.2 Using the Optional Power Supply
If an Optional Power Supply is to be used:
1. Connect the output plug of the Optional Power Supply to the
analyzer’s power supply jack (Figure 3-2).
2. Plug the Optional Power Supply into an appropriate AC wall outlet.
The analyzer will now operate and function normally.
3.3 Connecting the Probe
To attach the probe to the analyzer (Figure 3-2):
1. Push the yellow-banded, quick-connect Flue Gas Hose (giving a slight
twist) onto the analyzer’s GAS sample-inlet fitting.
2. Push the blue-banded, quick-connect Draft Hose (giving a slight twist)
onto the analyzer’s DRAFT sample-inlet fitting.
3. Push the Flue Gas Thermocouple into the T-STACK jack (connector
fits in only one way).
NOTE: The PCA has a built in room-air thermocouple.
Perform Step 4 only if the Optional Room Air/Primary Air
Thermocouple is used.
4. Push the Optional Room Air/Primary Air Thermocouple into the
T-AIR jack (connector fits in only one way).
NOTE: In order for the PCA to correctly calculate combustion efficiency when the burner’s primary-air temperature is
not the same as room temperature, the primary-air temperature should be measured using the optional Primary Air
Thermocouple.
Inspect all the hoses for cracks. If any hose is defective, replace the entire
probe assembly. Check that the water trap is dry and the filter is not
dirty or saturated with water.
3-2
Instruction 24-9351
PCA
POWER
Setup
Reset Button
T-AIR
RESET
T-STACK
GAS
Room Air /
Primary Air
Thermocouple
(Optional)
Power Supply
110V/60Hz
230V/50Hz
(Optional)
Flue Gas
Thermocouple
Water
Trap / Filter
Assembly
Pressure Reference
Port (Used in the
Measurement of
Differential Pressure)
Draft Hose
Flue Gas
Hose
Probe Tube
Adjustable
Probe Stop
Figure 3-2. Connecting the Probe to the Analyzer
Instruction 24-9351
Flue
Gas
Hose
Probe
Handle
3-3
Setup
PCA
3.4 Configuring the PCA
The PCA is configured at the factory for the parameters shown below, but
can be changed by following the instructions in the associated sections.
Function Parameters To Change,
Refer to . . .
Fuel Natural Gas Section 4.8
Temperature ºC Section 4.13
Optional Draft MB Section 4.14
Language English Section 4.15
Display Mode* CO & NX Section 4.16
Time HR:MIN:SEC Section 4.17
Date** DD.MM.YY Section 4.17
Printer IrDA Section 4.18
* Available only on the PCA 30, 35, 60, & 65
** The year displays as two digits on the instrument, and
four digits on the printout.
3-4
Instruction 24-9351
PCA
Operation
4.0 OPERATION
4.1 Key Pad Functions
Descriptions of the key pad functions are given below. Note that most of
the front panel key pad buttons perform multiple functions as determined
by what screen is being displayed at the time.
Turns the analyzer ON and OFF. Note that there is a 5 second
delay before the instrument actually turns OFF, thus allowing an
operator to turn the instrument back ON by pressing the key
to prevent the accidental loss of test data.
Moves the cursor [z] in front of a menu item up through the
displayed items. This key also increases alphanumeric values in
screens requiring a value change.
Moves the cursor [z] in front of a menu item down through the
displayed items. This key also decreases alphanumeric values in
screens requiring a value change.
Chooses the highlighted item (the item with the cursor [z] in front
of it) in all menus and screens. This key also causes the cursor to
enter the number field in the Maintenance Password Screen, and
causes the cursor to advance to the next field position in screens
requiring multiple alphanumeric entries.
Starts and stops a combustion test when the Combustion Test
Screen is displayed. Pressing this key in any other screen almost
always returns the instrument to the Combustion Test Screen.
However, there are four situations where this key behaves as an
enter key: 1) After entering a correct password in the Password
Screen, press the key to display the first calibration screen.
2) After entering an offset or span value in any of the Calibration
Edit Screens, press the key to store the new values. 3) After
entering a time or date value in the Time/Date Setup Screen,
press the key to store the new values and return the cursor to
the left side of the display. 4) After entering text in either the ID
Setup or User Name Screens, press the key to store the text.
Advances the display to the next menu screen.
Turns the backlight ON and OFF.
Instruction 24-9351
4-1
Operation
PCA
4.2 Sampling Hole Location
The analyzer requires that a 13 mm (½ in.) diameter sampling hole be
made in the furnace stack to accommodate the probe stop on the Probe
and Hose Assembly.
Locate the sampling hole downstream from the last heat exchanger,
and upstream from any source of dilution, such as a draft diverter
(Figure 4-1).
IMPORTANT! As the distance between the last heat exchanger and sampling point increases, stack loss will falsely
decrease due to heat loss by convection from the flue or stack.
For residential and light-commercial combustion-equipment applications,
the following recommendations are applicable:
• Oil Gun Burners – Locate sampling
hole at least 30 cm (12 in.) downstream from the furnace breaching,
and at least 15 cm (6 in.) upstream
from the furnace side of the draft
regulator.
• Gas Burners – Locate sampling hole
at least 15 cm (6 in.) upstream from
the furnace side of the draft diverter
on gas-converted units. For gasdesigned equipment, the probe may
be inserted down into the flue
through the draft diverter or hood.
FLUE GAS FLOW
(Downstream)
DRAFT
DIVERTER/
REGULATOR
SAMPLE
POINT
(Upstream)
FURNACE
BREECHING
Figure 4-1. Sampling Hole Location
4-2
Instruction 24-9351
PCA
Operation
4.3 Combustion Test
IMPORTANT! Large rapid changes in the temperature of
the analyzer can affect its accuracy. This is important to
know if the analyzer is stored in a cold place (such as an
unheated vehicle in the winter) and then taken into a warm
furnace area. For the most accurate test results, allow the
analyzer to warm up to room temperature before use (about
10 minutes).
4.3.1 Analyzer Turn On and Warm Up
IMPORTANT! Be sure the probe is at room temperature
before performing the following steps.
1. Make sure that the analyzer is properly set up per Section 3.0.
2. Place probe in an area of fresh, ambient air; then press the analyzer’s
key.
3. Wait for the analyzer to countdown through its 60 second warmup
period; then perform one of the following:
• If no errors were detected during warmup, the Combustion
Test Screen will be displayed. Skip Step 4, and go to Section 4.3.2.
• If an error was detected during warmup, proceed with Step 4.
4. If one or more errors were detected by the microprocessor during
warmup, these errors will be displayed at the bottom of the Sensor
Status Screen. Address any problems now per Section 7.2; then repeat
this procedure starting with Step 1.
NOTE: If the error detected is not critical to your test, the
instrument can still perform any test not using the function
disabled by the error.
Instruction 24-9351
4-3
Operation
4.3.2 Installing Probe in the Stack
1. After making a sampling hole in the stack (Section 4.2), and turning
on the analyzer (Section 4.3.1), screw the probe stop supplied with the
Probe and Hose Assembly into the sampling hole (Figure 4-2).
2. Insert the probe through the hole in the probe stop, then position the
probe tip inside the stack, near its center. Tighten the thumbscrew on
the probe stop to secure the probe.
PROBE STOP
PCA
4-4
THUMBSCREW
Figure 4-2. Installing the Probe
Instruction 24-9351
PCA
Operation
4.3.3 Performing a Combustion Test
IMPORTANT: If the burner’s primary-air temperature is
not the same as the room temperature, then be sure the
Optional Room Air / Primary Air Thermocouple is installed
per Section 3.3.
1. With the Combustion Test Screen displayed and the probe installed in
the stack, press the key to start a combustion test (refer to Section 4.7).
2. Once all sensor readings are indicated on the screen: A) Loosen the
thumbscrew on the probe stop. B) Move the probe in and out of the
stack until the stack’s core temperature (hot spot) is located.
C) Tighten the thumbscrew to prevent further movement of the probe.
Locating the highest stack temperature is very important for accurate
combustion calculations.
3. You can now begin burner-service procedures. The readings on the
analyzer change quickly to show changes in burner performance.
CAUTION
With the Water Trap / Filter Assembly stood up on its Outlet
End, do not let water condensate build up beyond the tip of
the riser tube. The sensors could be damaged if water would
enter the analyzer. Drain the water condensate after every
combustion test (refer to Section 6.4).
4. Pressing the key will save the Combustion Test Screen readings
while a test is in progress. Moving the cursor (z) in front of the print
( P) function using the s key, and then pressing will print the test
information to an optional printer.
4.3.4 Ending a Combustion Test
1. Press the key to end a combustion test.
WARNING!
Burn hazard! Allow a hot probe to cool for about 5 minutes
before handling.
Instruction 24-9351
4-5
Operation
CAUTION:
Do not place a hot probe inside the instrument’s carrying case.
Allow the probe to cool before storage.
2. Loosen the thumbscrew on the probe stop; then remove the probe and
probe stop from the stack.
3. If data was saved during the combustion test, you can turn off the
analyzer and review or print the stored data at a later time as described in Sections 4.10 and 4.23.
4.3.5 Turning Off the Analyzer and Purging the CO Sensor
Turn off the analyzer by pressing the key.
If the key is pressed while the CO reading is 100 ppm or higher, the
pump will automatically turn on (if not already running) to purge the
analyzer of CO.
IMPORTANT! The analyzer’s probe must be removed from
the stack during the purging process to allow fresh air to be
drawn through the analyzer.
PCA
The following message is displayed while the analyzer is being purged.
PURGING CO SENSOR
As soon as the CO level falls below 100 ppm, the pump turns off and the
analyzer starts its normal 5 second turn-off sequence.
To abort the purging process and immediately start the analyzer’s turn-off
sequence, press the key.
NOTE: Turning the analyzer off initiates a 5-second delay,
during which time the unit can be turned on again without
any warmup time. You can turn the analyzer back on during
this 5-second delay by pressing the key.
4-6
Instruction 24-9351
PCA
Operation
4.4 Differential Pressure Measurement
The difference in pressure (∆P) between two areas can be measured by
using the PCA’s two pressure ports and DRAFT Screen. By using Pressure Port 2 (–) as the reference, the pressure applied to Port 1 (+) will be
displayed on the DRAFT Screen as the differential pressure between the
two ports.
1. Turn on the analyzer by pressing the key; wait for the warmup cycle
to complete; then press the MENU key until the first DRAFT Screen is
displayed (refer to Section 4.9). If a TA-SENSOR ERROR is displayed
because the probe’s thermocouple is not plugged into the analyzer, then
press the key to acknowledge the error before pressing the MENU
key.
2. While the first DRAFT Screen is displayed, remove any hoses connected to Pressure Ports 1 and 2; then press the key to zero these
ports at atmospheric pressure.
3. Connect two sampling hoses to
Pressure Ports 1 and 2
(Figure 4-3). Then place the open
end of each hose into the areas
DRAFT
DRAFT – 2.25 MB
HOT SPOT ---- °C P
«S
being measured.
4. The differential pressure between the two areas is now displayed on
the third DRAFT Screen. If the pressure at Port 1 is higher than
Port 2, then the pressure difference will be positive. But if the pressure at Port #1 is lower, then the pressure difference will be negative.
The reading shown in this example indicates that the pressure at
Port 1 is 2.25 mb lower than the pressure at Port 2.
Sampling Hoses with quickconnect fittings are available
as an optional accessory.
Refer to Section 8.2.
Pressure Port 2(–)
Pressure Port 1(+)
Reference
Figure 4-3. Differential Pressure Hose Connections
Instruction 24-9351
4-7
Operation
PCA
4.5 Warmup Screen
BACHARACH, INC.
PCA xx
WARMUP yy
Where: xx = Instrument Model Number
yy = Counts down from 60 seconds
As soon as the key is pressed, the instrument’s serial number and
software version number are displayed for approximately 3 seconds. To
continuously display these items, hold down the key at start-up. The
warmup cycle continues after the key is released.
The Warmup Screen is displayed during the analyzer’s 60 second warmup
cycle, during which time the “Warmup” value (yy) counts down to zero.
After the warmup cycle is complete (and if the unit is working correctly)
the instrument will flash NO ERRORS DETECTED and go directly to
the Combustion Test Screen (Section 4.7). If there is a problem, however,
with one or more of the sensors, the Sensor Status Screen (Section 4.6) is
displayed with error message(s) appearing at the bottom of the screen.
Front Panel Key Functions:
– No Action
– No Action
– No Action
– No Action
– No Action
– Toggle Backlight ON/OFF*
– Turn analyzer OFF*
* The button will always turn the backlight on and off, and the key will
always turn the analyzer on and off. These two keys will not be mentioned
in the remainder of this section.
4-8
Instruction 24-9351
PCA
Operation
4.6 Sensor Status Screen
BACHARACH, INC.
PCA xx
WARMUP 0
z
Where: xx = Instrument Model Number
z = Sensor(s) in error
If there is problem with one or more of the sensors, the Sensor Status
Screen will be displayed after the analyzer has gone through its warmup
cycle (refer to Section 7.2 for a listing of the error codes).
Front Panel Key Functions:
– No Action
– No Action
– No Action
– Go to Combustion Test Screen
– No Action
Instruction 24-9351
4-9
Operation
4.7 Combustion Test Screen
PCA models 10–25, 40–55 PCA models 30, 35, 60, & 65
O2 4.0 CO 12 HLD O2 4.0 CO 12 HLD
C2 9.5 CU 15 NG C2 9.5 NX 10 NG
TL 20.0 TA 190 P TL 20.0 TA 190 P
qA 8.1 LA 1.24
«S qA 8.1 LA 1.24 «S
PCA
This screen shows:
O2 ...............Oxygen content in flue gas (%)
C2 ...............Carbon Dioxide content
present in flue gas (%)
TL ...............Primary/Ambient air temp. (°F)
qA ...............Stack Loss
CO* .............Carbon Monoxide content in flue gas (ppm)
CU*............. Carbon Monoxide content referenced to 0% Oxygen (ppm)
TA ............... Stack (Flue gas) temperature (°F)
LA ............... LAMBDA
NX*.............Nitric Oxide content in flue gas (ppm)
NU* ............Nitric Oxide content referenced to 0% Oxygen (ppm)
HLD/RUN ..PCA on hold / PCA running test
NG .............. Fuel code for natural gas (see Section 4.8 for other codes)
P.................. Print Data
S..................Save Data
O2 4.0 CU 15 HLD
C2 9.5 NU 12 NG
TL 20.0 TA 190 P
qA 8.1 LA 1.24 «S
- OR -
* For PCA models 30, 35, 60 and 65, you have the option of displaying either
CO & NX, or CU & NU. Refer to Section 4.16 for setup instructions.
NOTE: Refer to Section 7.3 if stars (****) , dashes (----) , or
Xs (XXXX) appear in the display.
Front Panel Key Functions:
– Move cursor (z) up
4-10
– Move cursor (z) down
– Save or Print screen data
– Run test / Stop test
– Go to Fuel Selection Screen
Instruction 24-9351
PCA
Operation
4.8 Fuel Selection Screen
«NATGAS FUEL
KOKS OIL NO.2
LEG OIL NO.6
LPG P-COAL
This screen is displayed by pressing the MENU key from the Combustion
Test Screen. This screen is used to select the fuel being burned.
To select a fuel, first use the st keys to move the cursor (z) in front of the
desired fuel, and then press the key.
NOTE: The fuel selected is saved as the default, and remains in memory after the PCA is turned off.
The fuel codes as displayed in the Combustion Test Screen:
NG = Natural Gas O#6 = Oil No. 6
KOK = Coal Gas PC = P-Coal (English, German, Dutch,
LPG = Propane French, Italian, Polish, and Spanish) or Biofuel
O#2 = Oil No. 2 (Danish, Finnish, and Swedish)
Front Panel Key Functions:
– Move cursor (z) up
– Move cursor (z) down
– Select Fuel
– Go to Combustion Test Screen
– Go to Draft Screens
Instruction 24-9351
4-11
Operation
4.9 Draft Screens
PCA
The first Draft Screen is displayed by
repeatedly pressing the MENU key
from the Combustion Test Screen.
To measure draft, first zero the
analyzer’s pressure sensor to atmospheric pressure by disconnecting the
draft hose from the bottom of the
instrument, and then pressing the
key. Reconnect the draft hose after
the second Draft Screen appears
(shown for 3 seconds). The third
screen shows the current values of
draft and stack temperature as
measured by the analyzer.
When using the analyzer to make a
differential pressure measurement
(Section 4.4), the differential pressure
value will be displayed on the third
Draft Screen.
To save (S) or print (P) the screen
data, first use the st keys to move
the cursor (z) in front of the desired
function, and then press the key.
DRAFT
DISCONNECT DRAFT
HOSE
PRESS ±
DRAFT
RECONNECT DRAFT
HOSE
DRAFT
DRAFT – 0.25 XX
HOT SPOT 190 °C P
«S
Where: xx = Unit of measure.
Default is millibars (MB). See
Optional Draft SETUP Screen
(Section 4.14) for other choices.
Front Panel Key Functions:
– Move cursor (z) up
– Move cursor (z) down
– Save or Print screen data
– Go to Combustion Test Screen
– Go to Memory Directory Screen
4-12
Instruction 24-9351
PCA
Operation
4.10 Memory Directory Screen
‘Standard’ PCA Screen ‘Advanced’ PCA Screen
MEMORY DIRECTORY MEMORY DIRECTORY
«M8 28.7.97 15:45 «98 28.7.97 15:45
M9 MEMORY EMPTY 99 MEMORY EMPTY
CLEAR MEMORY CLEAR MEMORY
The Memory Directory Screen is displayed by repeatedly pressing the
MENU key from the Combustion Test Screen. This screen is used to select
a memory location that contains saved data which an operator can review.
NOTE: A ‘standard’ PCA has 10 memory locations numbered M0 thru M9, while an ‘advanced’ PCA has 100 memory
locations numbered 0 thru 99.
To select a data-memory location, first use the st keys to move the
cursor (z) in front of the desired memory location; then press the key.
The saved data is now displayed in either the Combustion Test Screen or
Draft Screen, depending on whether the chosen memory location contains
combustion or draft information. To print the saved data, refer to Section 4.23.
After viewing or printing the saved data, use the st keys to move the
cursor (z) to the exit (E) function; then press . This will redisplay the
memory directory.
Selecting the CLEAR MEMORY function displays the Clear Memory
Screen from where all saved data can be erased (refer to Section 4.24).
Front Panel Key Functions:
– Move cursor (z) up
– Move cursor (z) down
– Display the data saved at the chosen memory location
– Go to Combustion Test Screen
– Go to Temperature Setup Screen, or the
Memory To PC Screen for Advanced units
Instruction 24-9351
4-13
Operation
PCA
4.1 1 Memory to PC Screen
(For ‘Advanced’ PCA Models 40, 45, 50, 55, 60 & 65)
MEMORY TO PC
«TRANSMIT DATA
CLEAR MEMORY
The Memory To PC Screen is displayed by repeatedly pressing the MENU key
from the Combustion Test Screen. Use this screen to either transmit all
stored memory locations to a computer, or clear all memory locations.
TRANSMIT DATA
Before data can be transmitted to a personal computer, the PCA’s RS-232
output must first be connected to an unused COM port on the computer
using serial data cable Part No. 24-1073 (see Figure 4-4). Also, a communications program (i.e., ProcommPlus®, Windows 3.x Terminal, or Windows 9x Hyper Terminal) must be installed, and its communications
parameters configured for: 9600 baud, 8 data bits, 1 stop bit, no parity,
and no handshaking.
4-14
A t t a c h D B 9 C o n n e c t o r t o c o m p u t e r ' s
C O M 1 o r C O M 2 p o r t . I f n e c e s s a r y ,
u s e a 2 5 - p i n t o 9 - p i n a d a p t e r .
S e r i a l D a t a C a b l e
P a r t N o . 2 4 - 1 0 7 3
T - A I R
R E S E T
T - S T A C K
P O W E R
G A S
R S - 2 3 2 C o n n e c t o r
Figure 4-4. Connecting the Serial Data Cable
Instruction 24-9351
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