Bacharach PCA 2 24-9448 manual

Product Leadership • T raining • Service • Reliability Portable Combustion Analyzer Instruction 24-9448 Operation & Maintenance Rev . 1 - October 2006[...]

W ARRANTY 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 opt[...]

Instruction 24-9448 i Contents Contents 1 I n t r o d u c t i o n .................................. 1 - 1 1. 1 P CA 2 Gen e ral Descr ip tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 1.2 Sales Co mbo & M od el Co n f igu ra t io ns . . . . . . . . . . . . . . . . . . . . . . 1 - 2 1 . 3 F e a t u r e s & B e n e[...]

Instruction 24-9448 ii Contents 4 Operation .................................... 4 - 1 4 . 1 O p e r a t i n g T i p s ......................................... 4 - 1 4. 2 T ur ni ng O N th e A na l yzer an d W arm Up . . . . . . . . . . . . . . . . . . .4 - 2 4 . 3 S e l e c t i n g a F u e l ....................................... 4 - 3 4 . 4 S a[...]

Instruction 24-9448 iii Contents 6 Maintenance .................................. 6 - 1 6 . 1 P C A 2 D i s a s s e m b l y .................................... 6 - 2 6. 2 W a ter Trap / Fi lte r Ma inte nance . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 6. 2. 1 Em pty ing the W ater Trap Chamb er . . . . . . . . . . . . . . . . . 6 - 6 [...]

Instruction 24-9448 iv Contents Notes:[...]

Instruction 24-9448 1-1 Introduction 1 Introduction 1 . 1 PC A 2 G eneral Des cription T h e PCA 2 is a comm ercia l- g ra d e hand -h e l d co mb ustio n and e m issi o ns ana l yzer d esi g n ed f o r on - d e mand s am p ling of light in dustria l, i nsti tu- tio nal, c o mm ercial a n d resi de n t ial f ur naces, a p pliances, a n d bo ile rs.[...]

Instruction 24-9448 1-2 Introduction 1 . 2 Sales C ombo & Model Configurations Sales Combo 24-8350 24-8351 24-8352 Sales Combo (Kit) 24-8370 24-8371 24-8372 Model T ype 225 235 245 PCA2 Only Part Number 24-7301 24-7302 24-7303 Measurements Oxygen (O 2 ) 333 Stack Temperature 333 Primary / Ambient Air Temperature 333 Carbon Monoxide Low (CO Low [...]

Instruction 24-9448 1-3 Introduction Sales Combo 24-8353 24-8354 24-8355 Sales Combo (Kit) 24-8373 24-8374 24-8375 Model T ype 255 265 275 PCA2 Only Part Number 24-7304 24-7305 24-7306 Measurements Oxygen (O 2 ) 3 3 3 Stack Temperature 3 3 3 Primary / Ambient Air Temperature 3 3 3 Carbon Monoxide Low (CO Low ) 3 3 3 Pressure / Draft 3 3 3 Carbon Mo[...]

Instruction 24-9448 1-4 Introduction 1 .3 F eatures & Benefit s • Po w e red b y 4 ‘ A A ’ a l kal ine b a tt eries, o r Ni M H rechargeab le b a t teries. A n op t io na l A C po w e r a da p ter p rovid es con tin uo us ope ra tion. • I n terna l charg i ng cir cuit allo ws rechargeab l e ba tter i es to be charged insid e the analyze[...]

Instruction 24-9448 1-5 Introduction 1 .4 Op erational Ov er view T h e PCA 2 is pow ered b y ei the r its 4 internal ba t teries, o r b y an op t io na l A C p o w er a da pte r tha t oper a tes fr o m an y con ve n ie nt so u rce of 1 0 0 – 24 0 V A C, 50 /6 0 Hz pow er . T he type of ba tter i es used can be ei the r dispos- ab le alk al ine o[...]

Instruction 24-9448 1-6 Introduction e miss i o n l ev els in th e sta ck ga s an d th e n dis p la y m eas ured an d calcula ted val ue s o n i ts LCD . V al u es are listed in Sectio n 2 S pecif ica tio ns. Du ri ng a test, the CO L ow senso r i s p rotected f rom high CO l ev els b y be ing a uto ma tica lly f l ush ed w i th fresh ai r w h e n [...]

Instruction 24-9448 1-7 Introduction T-STACK T-A IR F ig u re 1 - 1 . P CA 2 Com ponents LCD – 160 x 160 graphic display F1 / F2 / F3 – Soft Menu Buttons, whose functions are dened by labels appearing above them on LCD Arrow Buttons: – Moves cursor up the display , or increments an alphanumerical value – Moves cursor down the display , o[...]

Instruction 24-9448 1-8 Introduction 1 .5 .3 POW ER ( A C Adapter) T h e A C pow e r a da p ter P / N 2 4- 1 4 04 ca n be used as an externa l pow er su p - p l y , which wil l r un the analyze r o n a con ti n uo us bas is. W he n using rechargeab le NiM H b a t teries, th e AC po we r a da p ter can a lso be used to charge th e ba tter i es w h i[...]

Instruction 24-9448 1-9 Introduction 1 . 6 F ron t P an el B ut tons Descr i p tio ns of th e f ron t pane l bu t tons are g iv e n be lo w . Note tha t a c o n tro l ma y perfo rm m u l ti p le functions as d etermi n ed b y w hat scree n is being disp la yed a t the tim e. T h e fu ncti ons o f these b uttons are de f ined b y labels a p - pear i[...]

Instruction 24-9448 1-10 Introduction Sel ects a h ighlighted m en u. I n a d diti on, if cha ng es w ere ma d e to on e of the analyze r’ s ope ra ti ng parame t ers ( e.g ., da te, time, O 2 re f ere nce, etc. ), p ressing this b u tton con - f ir ms th ose cha nge s and sa ves th em in m e mo r y . Star ts a n d stop s a com busti o n test w h[...]

Instruction 24-9448 2-1 Specications 2 Specif ications The PCA 2 Directly Measures and Displays: T h e gases disp lay ed de pe n d o n th e ana l yzer’ s mod el n umber . R ef er to Se ctio n 1.2 . O x y g e n .............................................. 0 t o 2 0 . 9 % Stac k T e m pe ra tu re . . . . . . . . . . . . . . . . . . . . – 4 t[...]

Instruction 24-9448 2-2 Specications Normal Operating Conditions: T e m pe ra tu re: A na l yzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 1 0 4 º F (0 to 4 0 ºC ) P robe Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 4 72 ºF (80 0 º C ) Ma x. H um i dity: A na l yzer . . . . . . . . . . . [...]

Instruction 24-9448 2-3 Specications Power Requirements: F o ur d isposa b le ‘ A A ’ a lk al ine b atteries p rov i de a t l east 1 5 ho urs of con ti n u- o us op era tio n. Ni M H recha rgea b le b a t teries can als o be used, with th e op era ti ng tim e d ep en de n t on ba tter y ty pe and co nditio n. A n o p ti o nal A C p o w er a [...]

Instruction 24-9448 2-4 Specications Notes:[...]

Instruction 24-9448 3-1 Initial Setup 3 Initial Setup 3. 1 Scope Befo r e using th e P CA 2 , yo u M UST: • I nstal l ba tt e r i es, or p l ug in the o pti onal A C p o w er a dap t e r (Sect io n 3 .2) • C onn ect the p robe and h ose asse mb l y (Section 3.3) • C h eck, and if necessar y , make changes to th e ana l yzer’ s c o nf igu ra[...]

Instruction 24-9448 3-2 Initial Setup 3 .2 .2 U sin g the A C Pow e r A dapter T h e A C pow e r a da p ter is ca pa b le o f pow eri ng th e a na l yzer o n a con tin uo us bas is. T h e a d a p ter p lu gs into an ap pro p riate 1 0 0 –2 40 V A C, 5 0/6 0 Hz wal l o u tl et, and p rodu ces an ou tpu t of +9 V DC. T he a dap t er’ s ou tpu t c[...]

Instruction 24-9448 3-3 Initial Setup F ig u re 3- 2 . Con necting t he P robe a nd Hose Assem bl y to the PCA 2 POWER P T-ST ACK 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 Measureme[...]

Instruction 24-9448 3-4 Initial Setup 3.4 Op erating P arameter s T h e PCA 2 is set u p at th e factory for t h e fo l lo w ing ope ra ti ng parame t ers : F u e l ..................... N a t u r a l G a s T e m pe ra tu re U nits . . . . . . . . . ° F P ressure U nits . . . . . . . . . . . . I nc h es of W ater Co l u mn (in wc ) Po l l utio n U[...]

Instruction 24-9448 3-5 Initial Setup 3. 6 T emperature Un it s Selection Sel ect t o disp la y tem pera t ure i n ei the r °F or °C as fo l lo ws : 1. Disp la y the M A I N M EN U b y p ressing th e ME NU (F2 ) b u tton. If necessar y , press E SC until M EN U ap pears abov e F2 . 2. U se th e b u ttons to high ligh t SET U P , and th en p ress [...]

Instruction 24-9448 3-6 Initial Setup 3. 7 P ress ure U nits Selec tion Sel ect t o disp la y press ure i n Inch es o f W a ter Col um n (in w c ), mil libar (m b ), P asca ls ( Pa ), o r h ect oP asca ls ( hPa ) as f o llo ws : 1. D isp la y th e M A I N M EN U by p ressing the ME NU (F2 ) b u tton. If necessar y , press E SC until M EN U ap pears[...]

Instruction 24-9448 3-7 Initial Setup 3.8 P ollution U nits Select ion T h e PCA 2 is cap ab le o f c o n v erti ng th e meas ured p p m lev els of CO , NO , NO 2 , and SO 2 to var io us po llu tion units using CF R 40 Par t 6 0 emiss io n factors. N ote tha t the po l l u tio n-unit co n vers io ns fo r NO, N O 2 and N Ox a re based o n the m o le[...]

Instruction 24-9448 3-8 Initial Setup 3.9 Date Setu p T h e da te is stored in the f orma t: M M / DD/ Y Y . Its val u e is par t of th e date and tim e stam p that is sa ved alo ng with ea ch co m b usti on tes t record. Set th e ana l yzer’ s i n terna l cl ock to the cur ren t da te as fo l lo ws: 1. D isp la y th e M A I N M EN U by p ressing[...]

Instruction 24-9448 3-9 Initial Setup 3. 1 0 Time Setup T h e time is s tored in the f orma t: h h:mm: ss A M / P M. Its v alu e i s part of the da te a n d time stam p tha t is sav ed a lo ng w i th eac h com busti o n test record. Set th e ana l yzer’ s i n terna l cl ock to the cur ren t time as f ollo w s: 1. Disp la y the M A I N M EN U b y [...]

Instruction 24-9448 3-10 Initial Setup 3. 1 1 O 2 R eferen ce Setup T h e m easured val u es o f CO, N Ox , and SO 2 can be individ ua lly ref eren ced t o a speci f ic O 2 p erce n tage of be t w e e n 0 and 1 5%. Individ ual l y se t u p th e O 2 refe rence v alu e for ea ch of th e abov e gases as f ollo ws: 1. Disp la y the M A I N M EN U b y p[...]

Instruction 24-9448 3-1 1 Initial Setup 3. 1 2 P rint P ressure Selection Sel ect wh eth e r to pri n t o r no t pri n t th e p ress ure m easurem en t on th e co mb ustio n test p ri n tou t as fo l lo ws ( see F ig ure 4 -3 on P age 4-31 ): 1. Disp la y the M A I N M EN U b y p ressing th e ME NU (F2 ) b u tton. If necessar y , press E SC until M[...]

Instruction 24-9448 3-12 Initial Setup 3. 1 3 Zoom- Displa y Selection Z oom -d isp lay p rov i d es an ad d iti o nal comb ustio n test screen tha t sho ws th e test v alu es of O 2 , CO, and e ff icie ncy i n extra large characters, th us a l - lo w ing the o pe ra t or to v i e w th e disp la y of th ese val u es from a l on ge r dista nce . P r[...]

Instruction 24-9448 3-13 Initial Setup 3. 1 4 Bat ter y Char ger Select ion W he n using rechargeab le NiM H b a t teries, th e A C p o w er a da pte r can be used to cha rge th e ba t - teries w h ile insi de t h e ana l yzer . T he analyze r ’ s ra p i d -cha rge r cir cuit, ho we v er , m ust be f i rst tur ne d ON . IM PORT ANT : W hen using [...]

Instruction 24-9448 3-14 Initial Setup 3. 1 5 Loggin g Selection W he n th e l oggi ng function is a c tiv ated, u p to 5 0 0 com b ustio n test records wi ll be a u toma tical l y stored in m e m ory a t a p rese t interval ov er a p re - de t ermined l ength of time. R ef er to Se ctio n 4. 12 f or d etai led inform a t io n on ho w t o se l ect [...]

Instruction 24-9448 4-1 Operation 4 Operat ion 4. 1 Op erating T ips • W he n a n ana l yzer is b r o ugh t i n from a co l d v e hicl e, l e t i t w arm up sl ow ly to m in imi ze con de nsa tion. T em pera tu res bel ow freezi ng wi ll not dam - age th e a nalyze r; ho we v er , bring i ng a co l d ana l yzer in to a warm, h u mid en v ir o nme[...]

Instruction 24-9448 4-2 Operation 4. 2 T ur ni ng ON the Analyz er and W ar m Up 1. Connect th e p robe an d hos e asse mb ly , and make s ure that t h e ana lyze r is p rope r ly se t u p pe r Sec tio n 3 Ini tial Setup . IM PORT ANT : D O N OT insert pr obe i nto sta ck bef ore tu r ni ng ON the anal yzer ! 2. Place th e probe in an a rea tha t c[...]

Instruction 24-9448 4-3 Operation 4.3 Selec ting a F u el T h e top line o f th e Com b ustion T est H OL D screen sh o w s th e fue l cur ren tly se lected. I n the e x am p le sh o wn, the cur ren t f u e l is NAT U R A L GA S . If n ecessar y , change the fu e l as fo l lo ws : 1. Disp la y the M A I N M EN U b y p ressing th e ME NU (F2 ) b u t[...]

Instruction 24-9448 4-4 Operation 4. 4 Sampl ing P oint F ORCED AIR FURNA CE – F or a tm os p he r ic b urne r o r gra v i ty v en ted, fo rced air h ea ting eq u i p m e n t wit h a clam sh ell o r secti o nal h ea t e x chang er d e - si gn, test e ac h of t h e exha ust po rts a t th e top o f th e h ea t e xc ha ng e r . The p rob e s h o ul [...]

Instruction 24-9448 4-5 Operation 4.5 P er forming a Combus tion T est Ensure that t h e fo l lo w ing has been co m pl eted , and th en p r oceed w i th th e com b ustio n test as de scr ibed be lo w: • T u r n O N ana l yzer an d al lo w it to w arm up (Section 4.2) . • S el e ct fue l be ing burned (Sectio n 4. 3) . • I nset p r obe in t o[...]

Instruction 24-9448 4-6 Operation 4. Y o u can no w begi n b ur n er-se rv ice proced ures. T he analyze r rea di ngs wi l l change quic kly to sh o w changes in b ur ne r performance . CA UT ION: Position t h e W ater T rap wi th i ts gas-f low arro w poi nti ng upwa rd. Do n ot let w ater condensate go above t h e tip of t he ri ser tu be. Th e s[...]

Instruction 24-9448 4-7 Operation 4.6 Maki ng a Draf t / P ress ure Measu rement T h e di f f e ren ce in press ure ( ∆ P) be tw een tw o a reas ca n be m easur ed b y using th e ana l yzer’ s two p ressure ports a n d th e P RE S SU RE screen. By using th e – ∆ P port as the re f eren ce, th e p ressure a p p l i ed to the + ∆ P po rt wi[...]

Instruction 24-9448 4-8 Operation b . D isconn ect a n y hoses co nnected t o th e + ∆ P an d –∆P ports, a n d th e n p ress ENT to zero the p ressure senso r . c. R econnect an y h oses. W he n measuri ng d raf t, simp l y l ea ve th e –∆P p o rt o pe n to t h e a tm os p h e re an d c o nn ect t h e p ro be ’ s dr aft h os e to t h e [...]

Instruction 24-9448 4-9 Operation 4.8 Ending a C o mbustion T est W AR NIN G! Bu rn Hazar d. D o not touch the p ro be after re mov i ng it from t h e stack. A llo w the p ro be to cool be fo re handli ng ( abo ut 5 m inu tes ). 1. R e m ov e probe from s tack. 2. A l lo w the p ump to r un until a ll com b usti on g ases ha ve bee n f l ush ed fr [...]

Instruction 24-9448 4-10 Operation 4. 1 0 T urning OF F the Analy zer & P urging T ur n O F F th e a na l yzer b y press ing the I/O b u t - ton f or a t l east 2 secon ds , o r until two b eep s are h eard. T he unit wi ll c o un t do w n 5 secon d s be fo re sh u tting do wn , g i v ing th e ope rato r an op p o r tu - nity to kee p th e a na[...]

Instruction 24-9448 4-1 1 Operation 4. 1 2 Data Loggi ng W he n th e l oggi ng function is a c tiv ated, u p to 5 0 0 com b ustion tes t records wi l l be a u toma tical l y stored in m e mo r y a t a p reset in t erval (1 , 5, 1 0, 15, 30 se con ds, 1, 2 , 5 , 1 0 m in u tes ) ove r a pred ete rmi n ed d ura tio n (5, 1 0 , 1 5 , 30 m in u tes, 1,[...]

Instruction 24-9448 4-12 Operation 4 . 1 2 . 1 T urnin g ON Data Loggi ng IM PORT ANT : B ef o re tu r ni ng ON data l ogging and starti n g t he data l ogging p rocess, t he anal yzer should al ready b e set u p to perf or m a co m b ustion test per Section 4.5. T ur n ON da ta loggi ng as f o llo w s: 1. Disp la y the M A I N M EN U b y p ressing[...]

Instruction 24-9448 4-13 Operation 4 . 1 2 .2 Set ting th e L oggin g Inter val a nd Du r ati on T h e lo ggi ng inte r val is th e l e ng th of tim e betw een m easurem en ts, w hi le th e lo ggi ng d ura tio n is th e time alloca ted t o th e loggi ng p rocess. Set the lo ggi ng interval a n d dura tio n as f o llo w s: TIP: If t he du ratio n is[...]

Instruction 24-9448 4-14 Operation 4 . 1 2 .3 Star ting the Da ta Log ging P r ocess A f ter tur ni ng O N da ta lo gg ing and se tting the interval a n d dura tio n, th e ana l yzer wi ll pa use a t th e L O G GING SU M M A RY screen, wh ere th e cur ren tly se l e cted i n terval a n d d ura tio n time periods are d isp la ye d. P ress ENT to sta[...]

Instruction 24-9448 4-15 Operation 4 . 1 2 . 4 Ending th e Data L ogging P roce ss Da ta loggi ng wi ll st o p and th e pum p w il l tu rn O F F af ter th e p rescr ibed d urati o n, or af ter al l 50 0 me mo r y l ocati o ns are f i l l ed. To e xit th e C o mb ustio n T est L OG s creen, p ress th e RUN/ HOLD bu tt on t wice to d isp la y th e Co[...]

Instruction 24-9448 4-16 Operation 4 . 1 3. 1 Recalling Co mbu stion T est Data R eca ll i n d ivid ual com b usti o n test da ta records as f o llo ws : 1. Disp la y the M A I N M EN U b y p ressing th e ME NU (F2 ) b u tton. If necessar y , press E SC until M EN U ap pears abov e F2 . 2. U se th e b u ttons to high ligh t ME MOR Y , and th en p r[...]

Instruction 24-9448 4-17 Operation 4 . 1 3. 2 Recall ing L ogged T est Data R eca ll i n d ivid ual log ged co m b usti on tes t da ta records as fo l lo ws: 1. Disp la y the M A I N M EN U b y p ressing th e ME NU (F2 ) b u tton. If necessar y , press E SC until M EN U ap pears abov e F2 . 2. U se th e b u ttons to high ligh t ME MOR Y , and th en[...]

Instruction 24-9448 4-18 Operation 4 . 1 3. 3 Clearing Memor y W he n al l m e m ory (“sna p sh ot ” ) locati ons u sed to store individ ual com b usti o n test records ha ve been fi lled, th e nex t com busti o n test record sa ved wi l l o ve r w rite the o ld est. W he n al l lo ggi ng m e m ory loca t io ns i n th e lo ggi ng di rec tory a [...]

Instruction 24-9448 4-19 Operation 4. 1 4 Do wnl o ad in g St or ed D ata to a C omp ute r T h e co mb ustio n test da ta tha t was stored in ei the r th e ana l yzer’ s Me mo r y Di rect ory (Se ctio n 4. 7 ), o r L oggi ng Di rect ory (Sec tio n 4 . 12), can be do w n - lo a d ed to a com pu ter using th e PCA 2 Da t a Re cov er y P rogra m and[...]

Instruction 24-9448 4-20 Operation 4 . 1 4 . 1 PC A 2 Data Reco ver y Program Ins talla tio n T h e PCA 2 Da t a Re cov er y P rogra m is su pp l i ed with th e a nalyzer o n a C D ( P/ N 2 4- 1 4 25). Instal l this progra m as f o llo w s: 1. In se rt the PCA 2 CD i n t o the co mp ute r’ s CD -ROM dr iv e. 2. L oc a t e th e CD -RO M d rive in [...]

Instruction 24-9448 4-21 Operation 5. Click Install t o conf i rm th e d estina tio n f o l der an d use r in fo rma tion. 6. Click Finish af ter al l f iles ha ve bee n c o p ie d into th e d estina tio n f o l d er . 7 . At this ti m e th e P CA 2 Da ta R ecov ery P rog ram ico n sh o uld a ppear und er " Star t A l l P rog rams m e n u. 8. [...]

Instruction 24-9448 4-22 Operation 4 . 1 4 .2 Computer to PC A 2 Conn ection & USB D e vice Driver Installa tion Connect th e USB ca b l e ( P/ N 1 0 4 -4 032) tha t was su pp l i ed with th e P CA 2 , and, i f n ecessar y , insta ll the ana l yzer’ s USB de v ice dr i ve r as fo llo ws : 1. With bo th the PCA 2 and co mp uter turned O N, i n[...]

Instruction 24-9448 4-23 Operation 3. S e l ect “Ins tall fr o m a li st o r sp ecifi c l oc a ti o n (A dv an c e d )” an d c li c k Ne xt> . 4. Sel ect t o search fo r th e best dr i ve r a n d th en b row se to fo ld er C: P rog ram F i l es P CA 2 Da ta. C lick Ne x t> . 5. At th e Hardw a re I nstal la t io n w indo w , cl ic k C[...]

Instruction 24-9448 4-24 Operation 6. A f ter th e F o und N ew Hardw a re Wiza rd has f in ish ed instal li ng th e software, click Finish to cl ose th e Wizard. 4 . 1 4 . 3 Reco vering Data Befo r e da t a can be rec o ve red f rom th e a nalyzer , in stall the PCA 2 Da ta R ecov ery P rog ram, USB cab le, an d USB d ev ice dr iv er as described [...]

Instruction 24-9448 4-25 Operation Status line showing PCA 2 is successfully connected to the computer Use this section of window to Recover Logging Data Use this section of window to Recover Combustion Data Start the download process by clicking the desired Open Log / Data File button Select a pre-existing folder or create a new folder to store th[...]

Instruction 24-9448 4-26 Operation NOTE: Th e filename is automatical l y g iv en a CSV ( Com ma Separated V alue ) e xtension, allow ing t h e file t o be d i rect l y ope ned by most s pr ead sheet p rograms fo r an al ys is. 3. A f ter sel ec ting a fo ld er an d en teri ng th e f i le na m e, click Open and th en click Star t to beg in the d o [...]

Instruction 24-9448 4-27 Operation 4 . 1 4 . 4 Unplug ging th e USB C abl e CA UT ION: To a void poss ib l e elect ron i c damage to the ana- l yzer , it is not advisab le to un p lug t he U SB cab le withou t first t urn i ng OFF the PCA 2 U SB co nnection usi ng the “ Saf el y R emo ve H ar dwa re ” icon in t h e Windows X P sy ste m tra y . [...]

Instruction 24-9448 4-28 Operation 4. 1 5 Im po r ti n g S a v ed Da ta In to a S pr ea ds hee t Da ta that w as re cov ered and sa ved as an A SCI I t ext f ile with a “CS V ” extensi o n, as described in S ection 4. 1 4 , can easi l y be ope n ed f or vie w i ng in most s p rea dsh eet pro g rams b y sim pl y dou b le- clicking the fi l enam [...]

Instruction 24-9448 4-29 Operation TA BLE 4 -2 . DOW NL OA D ED D A TA FI ELD S Fie ld Col u m n N a me Da ta Nam e o r V a lu e 1 T im e T ime o f T est in 12 ho u r f orma t (A M / P M ) 2 Date Da t e of T est in mm / dd /y y 3 F ue l F u el N ame 4 %O2 Ox yg e n L ev el 5 C O Carbon M o no x id e L eve l ( see f ie ld 26) 6 pp m C O( O2) Carbon [...]

Instruction 24-9448 4-30 Operation 4. 1 6 Printin g T est Data Com b usti o n or p ressure data tha t is cu r re n tl y be ing d isp la y ed can be sen t to a pri n ter us ing I r DA p rotocol as d es cribed bel ow . Da ta that is sto red in me mory can a lso be p r inted b y f i rst di sp la y i ng th e stored test da ta as descr ibed in Sec tio n[...]

Instruction 24-9448 4-31 Operation F ig u re 4-3 . Pr in ter Alignme nt & Sam ple P rin tout BACHARACH, INC. PCA 2 SN: xxxxxx ===================== TIME 01:00:00 PM DA TE 10/06/06 FUEL NA TURAL GAS O2 4.0 % CO 12 ppm EFF 82.6 % CO2 9.5 % T -ST ACK 374 °F T -AIR 68.0 °F EA 21 % NO 18 ppm NO T emp 70.5 °F NO2 6 ppm NOX 24 ppm SO2 ∗∗∗ ppm[...]

Instruction 24-9448 4-32 Operation Notes:[...]

Instruction 24-9448 5-1 Calibration 5 Ca libration IM PORT ANT : B ef o re perf orm ing an y calib ration p rocedu re, ensu re t hat fresh bat teri es ar e instal led or use t he optio nal A C powe r ad ap ter . Al so ensu re t hat the anal yzer is at room tem per- atu re a nd wil l be sam p li ng f resh ai r when tu rned ON . 5. 1 Smar t Sens ors [...]

Instruction 24-9448 5-2 Calibration A n y errors d e tec ted d ur i ng w a rm- up wi ll be listed on th e d isp l a y immedia tel y f o l - lo w ing warm- up . F or exam p le, th e s creen to the righ t sh ows t ha t th e b a t tery is lo w . Corre ct an y errors be fo re proceed ing. Ref er to S ection 7 .3 fo r a listing of error m essa ges and t[...]

Instruction 24-9448 5-3 Calibration p la y the CA L I BR A TE P RE S SU R E screen. “Mea su red ” is the press u re val u e cu rren t l y bei ng detected by the pr e ssu re sensor , wh ile “ App lied ” i s a know n value of p ress u re t hat wi ll b e ap pl i ed f or cal ibr ation p u rposes. 4. W i th both th e – ∆ P and + ∆ P ports [...]

Instruction 24-9448 5-4 Calibration 5.4 T - Stack Ca libration T his procedure f irst zeros and th en spans th e stack -te m pe ra tu re chan n e l to k no w n tem pera tu re val u es. T h e use of an e l ectr o nic th erm o cou pl e sim ula tor is th e p ref erred me th od of p rodu c ing th e de sired ca libr a tio n t e m pera t ures. A lterna t[...]

Instruction 24-9448 5-5 Calibration 5. W ait un til the Meas ured rea d ing stab i l izes, and th en p ress ENT t o cal ib rate th e T S -Zero Meas ured valu e t o tha t of the Ap pli ed val u e ; af ter w hich th e messa ge “G ood Ca lib ra t i on ” sh o uld b r ie f l y a p pear fo l lo wed b y the CA L I BR ATE T S - SP A N screen. TS - Span[...]

Instruction 24-9448 5-6 Calibration 5. 5 T - A i r Ca li bra tio n T his procedure f irst zeros and th en spans th e a mb ie n t-te mpe ra tu re chan- n el to kno wn tem pera t ure valu es. T h e use of an e l ectr o nic th erm o cou pl e sim ula tor is th e p ref erred me th od of p rodu c ing th e de sired ca libr a tio n t e m pera t ures. A lte[...]

Instruction 24-9448 5-7 Calibration T he calib ration ra nge is from 3 2 to 4 1 °F ( 0 t o 5 °C) . An attem pt to cali b rate ou tside this ra nge w il l cause the message “ Ba d Cali b ration Wr ong CAL Entry ” to app ear i n the f ol l ow i ng step . 5. W ait un til the Meas ured rea d ing stab i l izes, and th e n p ress ENT to cal ib ra t[...]

Instruction 24-9448 5-8 Calibration 5. 6 C O - L O Sensor C alibration No te tha t th e CO -LO senso r also meas ures H 2 fo r th e pur pose of co m- pens a ting th e CO reading fo r th e p rese nce o f H 2 i n th e gas sam pl e. T his p rocedure f i rst s pans th e CO -LO senso r and, o pti o nal l y , sp ans the H 2 par t of th e senso r to k no [...]

Instruction 24-9448 5-9 Calibration If t he sensor ’s ou tp ut is t oo low to be usable, t hen the message “B a d Cali b ration Sensor End o f Li f e, Entry Not Saved ” will a ppea r . T h e sen - sor w il l now be mar k ed as being BA D in t he DI A GN OSTICS sc ree n. NOTE: H 2 cal ib ration can be by passed by pr essi n g t he ESC bu tton,[...]

Instruction 24-9448 5-10 Calibration 5. 7 SO 2 Sens or C ali bration T his procedure sp ans the o ptio na l sul fu r dioxid e senso r to a k no w n gas l ev el. Ma ter ia l Requir ed: Cal ib rati o n K it, P/ N 24 - 7059 Gas Cylind e r: 1 0 0 pp m S O 2 in Ni troge n, P/ N 24 - 1 158 Proce dur e : 1. I f no t al rea dy d on e, tur n ON th e a nalyz[...]

Instruction 24-9448 5-1 1 Calibration If t he sensor ’s ou tp ut is t oo low to be usable, t hen the message “B a d Cali b ration Sensor End o f Li f e, Entry Not Saved ” will a ppea r f ol lowe d by the CAL IBR ATION LI ST sc reen b ei ng re-disp l a ye d. T he sens or w il l now be mar k ed as being BA D in the D I A GNO STICS sc reen. 6. T[...]

Instruction 24-9448 5-12 Calibration b rief l y a ppear fo l lo w ed by th e CA L I BR ATIO N L IST s creen b eing re-d isp la yed. If t he sensor ’s ou tp ut is l ow , bu t sti ll usab l e, t hen the message “G ood Cali b ration W A RNI NG Low Sensor ” wi ll a ppea r . T h e sensor w il l now be mar k ed as being Low in t he DIAG NOSTI CS sc[...]

Instruction 24-9448 5-13 Calibration ca use t he me ss ag e “B ad C al ib ra tio n W ro ng C A L E n try ” to a p p ea r i n t he f o llo wi ng s te p . 5. Adjus t regu la tor f o r a f lo wme ter indica tion o f a p proxima tel y 2 S CF H. W ait un ti l th e M easured rea di ng stab i li zes ( ap pro ximate l y 3 minu tes ) , and th en p ress [...]

Instruction 24-9448 5-14 Calibration 4. Use th e and b u ttons to en t er an Ap p lied val u e tha t exactl y eq uals the co ncen - tra tio n stamped o n the CO cy li n d er . The ca l i b ra tio n r an g e is fr o m 2 5 0 to 1 1 ,000 p p m . An a tte mp t to ca li br ate o ut - si de t h is r an g e w i l l ca use t he m es sag e “B ad Cal ib ra[...]

Instruction 24-9448 6-1 Maintenance 6 Maintena nce Custom er mai n t enance o f th e PCA 2 is li mited to th e f o llo wi ng: Ba ttery rep lace me nt o r charg i ng us ing A C po w er a dap t er ( Sec tio n 3 .2) Sensor re-ca libra tio n (Section 5) W a ter tra p / f i lte r asse mb l y mai n t enance ( Se ctio n 6.2) Sensor re pla ce m e n t (Sect[...]

Instruction 24-9448 6-2 Maintenance 6. 1 PC A 2 Disassembly T h e f o llo wi ng p rocedure describes h ow to disassem bl e the ana l yzer , w hi le F ig ures 6 - 1 th r u 6 - 4 il l ustra te ho w th e ana l yzer is p ut toge th er . Too ls R equi red: Medi um Phi ll ip s Screw dr iv e r P rocedure: 1. Un pl ug al l th erm o cou pl es f ro m bottom [...]

Instruction 24-9448 6-3 Maintenance F ig u re 6- 2. Inside V iew wit h Rear Ca se Remov ed Sensor Positions 225 24-7301 235 24-7302 245 24-7303 255 24-7304 265 24-7305 275 24-7306 #1 O 2 O 2 O 2 O 2 O 2 O 2 #2 CO LO CO LO CO LO CO LO CO LO CO LO #3 SO 2 NO 2 SO 2 #4 NO CO HI NO NO Model P/N Position Sensor Retainer Purge Pump Gas Pump GAS Purge Air[...]

Instruction 24-9448 6-4 Maintenance F ig u re 6-3 . T ub i ng Connections Models 235 & 245 P/Ns 24-7302 & 24-7303 Model 255 P/N 24-7304 Models 265 & 275 P/Ns 24-7305 & 24-7306 Model 225 P/N 24-7301 PRESSURE SENSOR on printed circuit board –∆P +∆P –∆P (Bottom) +∆P (T op) PRESSURE PURGE AIR GAS Gas IN GAS PUMP PURGE PUMP G[...]

Instruction 24-9448 6-5 Maintenance F ig u re 6-4 . Wiring Solder (2 Places) Red dot on pump indicates positive (red wire) connection Battery to J14 Battery to J14 Gas Pump to J8 Purge Pump to J9 Sensor Connector (typical 4 places) Factory T est Connector LCD Connector (opposite side of board) Ribbon Cable Conection between LCD Assembly and Printed[...]

Instruction 24-9448 6-6 Maintenance F ig u re 6-5 . Di sassem b l ing t he W at er Trap / F il ter Assem b l y FIL TER ELEMENT “A” “B” Pry apart filter chamber using a small flat-blade screwdriver inserted into notch When reasse m- bling filte r cha mber , make sure s urfac es “A” a nd “B” cont act each other W A TER TRAP CHAMBER FI[...]

Instruction 24-9448 6-7 Maintenance 6.3 Smar t Sensor R eplacem ent Bacha rach ’ s Sma r t sensor t ech no logy a l lo ws ne w sensors to be in sta lled with o u t n eedi ng to be cal ib ra t ed insi d e th e ana l yzer . N OTE : Se ns o rs ma y be p u r c has ed wi t h an d w i t ho u t t he S ma rt se nso r te c h no lo g y PC B . See Se ct ion[...]

Instruction 24-9448 6-8 Maintenance 6.4 Sensor Only R eplacement A l l se nsors are rep laced in a simi la r manner . Do the f ollo wi ng to rep lace e i th er th e O2 , CO -LO, CO -HI , NO , NO2 , or SO2 se nso r . Refer to Sect ion 8. 1 Replac ement Pa r t s for list of sensors and par t numbers. T ur n O F F th e a na l yzer . R e m ov e the b a[...]

Instruction 24-9448 6-9 Maintenance 12 . Pl ug th e sensor in to an alyze r; and th en rea t tac h tub ing to gas cup . 1 3. Insta ll the se nsor re t ai n er an d b a t tery cove r . 12 . A l lo w the se nsor tha t was j ust in stalled time to stab i li ze in the circu i t bef ore con ti n u ing w i th this proced ure. Stab il iza tio n t im e fo [...]

Instruction 24-9448 6-10 Maintenance 6.5 Nitr ic Ox ide Sensor B at ter y Repla cement A singl e lithi um ba tter y , located o n th e NO S mar t Sensor ass e mb ly , ap pli es a bias v o l t ag e to the NO s enso r t o pre v e n t th e se nsor fro m de stab il izi ng w h e n th e ana l yzer is turned off. T h e NO b ias ba ttery is expec ted to la[...]

Instruction 24-9448 6-1 1 Maintenance 6.6 T hermocouple Repla cement U sing th e a pp ro p r ia t e th erm o cou p l e rep lace m en t kit listed bel ow , rep lace th e p robe’ s th erm o cou pl e as fo l lo ws: The rm oco upl e Repl ace me nt Ki ts: Part Number Replaces Thermocouple in a Probe with a T ube Length of . . . 24-8413 6 inches 24-841[...]

Instruction 24-9448 6-12 Maintenance 3. P u ll ol d the rmoco u p le from p robe bod y a n d dis card. 4. T he n e w th erm o cou p l e has been co iled f or ship ping p u r poses. Straigh ten th e the rm ocou pl e usi ng y o ur th umb an d ind ex f inger . 5. I f not alread y d on e, i nstal l su pp l i ed O-Ri ngs o n to the r m ocou pl e. 6. I n[...]

Instruction 24-9448 6-13 Maintenance 6. 7 Pump R eplacement Par t s & T oo ls Req uire d: R e p lacem en t P ump : Gas P um p P / N 2 4 - 1 3 93 P urge P um p P / N 3 0 15 - 1 71 6 Sol d ering I ron and So l d er Medi um Phi ll ip s Screw dr iv e r Small F lat B la d e Screw dr iv e r Proce dur e : 1. Ga in access to both th e gas an d p urge p[...]

Instruction 24-9448 6-14 Maintenance 6.8 C leani ng the P robe T h e p robe tu be and gas-s am p l e h ose wi ll bec o m e di r ty und er no rmal use. No te tha t th e w a t er tra p’ s f i lte r el em en t sho u l d p rev e n t s oot from rea ching th e ana l yzer’ s i n terna l com pon en ts. I f th e probe is n ot k ep t cl ea n, it co u l d[...]

Instruction 24-9448 6-15 Maintenance Notes:[...]

Instruction 24-9448 7-1 T roubleshooting 7 T roublesh ooting 7 . 1 Analyz er R epair I t is recomm en de d tha t f i e l d re pair of the PCA 2 be limited to: Checks o f p ri n ted ci rcuit board conn ect ors R e p laci ng th e probe asse mb ly R e p laci ng th e f i lte r el em en t in the w ate r tra p / f ilter ass e mb ly R e p laci ng se nsors[...]

Instruction 24-9448 7-2 T roubleshooting 7 .3 E rro r Me ss age s D is pla y ed A f ter W arm- Up If th e re w er e p rob le ms d etected d ur ing w a rm - up , erro r m essa ge s th a t d escrib e th e na ture of th e p ro b le ms are dis p la y ed imm ediate ly f o l lo wi ng th e analyz er’ s 60 seco n d warm -u p pe riod. If pro b l e ms w er[...]

Instruction 24-9448 7-3 T roubleshooting 7 .4 Dia gno sti cs a nd S tat us S cree ns T h e DI A GNOSTI CS scree n lists t h e curre n t sta tus o f all th e SM A RT gas se nso rs install ed an d th e O 2 se nsor s ta tus an d m V o u tp u t. T h e STA T US screen p rov i de s a quick re f e ren ce of k ey i tem s w he n trou b l eshooting . D IAG N[...]

Instruction 24-9448 7-4 T roubleshooting Notes:[...]

Instruction 24-9448 8-1 Parts & Service 8 P ar ts & Ser vice 8. 1 Re placement P ar ts Item (Fig. 8-1) Description Part No. 1 Main PCB Assembly ............................ 2 4 - 1 3 7 1 2 L C D M o d u l e ................................... 2 4 - 1 3 7 4 3 R e a r C a s e ..................................... 2 4 - 1 3 8 1 4 T o p C a s e[...]

Instruction 24-9448 8-2 Parts & Service Item (Fig. 8-1) Description Part No. 18 Sensors (NOT-calibrated): 18A O 2 .......................................... 2 4 - 0 7 8 8 O 2 sensor PCB only * . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1364 18B CO-H 2 ....................................... 2 4 - 0 7 8 9 18C CO HI .................[...]

Instruction 24-9448 8-3 Parts & Service F ig u re 8- 1 . Parts ( 1 of 2 ) 22 22 25 25 9 22 –∆P +∆P –∆P (Bottom) Pressure Sensor +∆P (T op) PRESSURE PURGE AIR GAS IN (Bottom) OUT (T op) OUT IN 23 25 26 24 16 (typical 4 places) 15 (typical 2 places) 14B (typical 2 places) 14A 14C (typical 3 places) 23 14 1 1 12 17A 18A 17C 18C 17C 18D[...]

Instruction 24-9448 8-4 Parts & Service 4 10 7 6 2 1 9 18 17 13 3 5 8 19 12 14 20 21 1 1 19 F ig u re 8- 1 . Parts ( 2 of 2 )[...]

Instruction 24-9448 8-5 Parts & Service 8. 2 A ccessories Stan dard Acce ssori es P ar t No. C a r r y i n g C a s e .......................................... 2 4 - 0 8 6 5 Ba tteries, ' A A ' A lka li ne ( 4 requi red) . . . . . . . . . . . . . . . . . . . . . . . . 20 4 - 0 0 0 4 12 " P robe, H ose, a n d W a ter Trap / Fi lte[...]

Instruction 24-9448 8-6 Parts & Service Opt ional Acc essori es P ar t No. A C Po w er A dap ter ( I np u t: 1 0 0 –24 0 V AC, 50/6 0 Hz; O u tpu t: 9 V DC @ 1 A) . . . . . . . . 24 - 1 4 0 4 PCA 2 P rotect i v e B oot with m agne t . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 1 4 09 A mb i e n t A i r Therm o cou pl es ( T -A I R[...]

Instruction 24-9448 8-7 Parts & Service 8.3 Ser vice Centers Unite d Stat es Bacharach Inc. 62 1 H u n t V a lle y Ci rcl e Ne w K e nsing ton, P A 1506 8 Pho ne : 724- 334 - 50 5 1 F ax: 724 -3 34 - 5 723 Emai l: h el p @bac harach - inc.co m Canada Bacharach o f Cana da, I nc. 25 0 Shie l d s Cour t U n i t # 3 Ma r kha m, On ta rio L3 R 9 W [...]

Notes:[...]

Headquarters: 621 Hunt V alley Circle, New Kensington, P A 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • T oll Free: 800-736-4666 Website: www .bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A. ISO 9001:2000[...]