Bacharach PCA3 Manuale utente

Portable Combustion Analyzer

(Siegert Version)

Operation and Maintenance Manual

Instruction 0024-9473

Rev. 3 – August 2012

Product Leadership •Training •Service •Reliability

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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 specifications. Bacharach’s liability and Buyer’s remedy under this warranty are

limited to the repair or replacement, at Bacharach’s option, of this Product or parts thereof

returned to Seller at the factory of manufacture and shown to Bacharach Inc.’s reasonable

satisfaction to have been defective; provided that written notice of the defect shall have

been given by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this

Product by Bacharach, Inc. The Oxygen (O2) sensor has a limited warranty of one (1) year.

Routine service and calibration are excluded from this warranty.

Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s

liability and Buyer’s remedy under this warranty of title are limited to the removal of any title

defects or, at the election of Bacharach, to the replacement of this Product or parts thereof

that are defective in title.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED

IN LIEU OF (I) ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,

INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY

OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT,

WHETHER OR NOT 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.

www.MyBacharach.com

NOTICE

Product improvements and enhancements are continuous, therefore the specifications and

information contained in this document may change without notice.

Bacharach, Inc. shall not be liable for errors contained herein or for incidental or

consequential damages in connection with the furnishing, performance, or use of this

material.

No part of this document may be photocopied, reproduced, or translated to another

language without the prior written consent of Bacharach, Inc.

BACHARACH, PCA, B-SMART, and FYRITE are registered trademarks of Bacharach, Inc.

All other trademarks, trade names, service marks and logos referenced herein belong to

their respective companies.

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TABLE OF CONTENTS

CHAPTER 1. INTRODUCTION ........................................................................7

1.1. About This Manual ....................................................................................... 7

1.2. Conventions ................................................................................................. 7

1.3. Safety ........................................................................................................... 7

1.4. General Description ..................................................................................... 9

1.5. Operation Overview..................................................................................... 9

1.5.1. Turning On the PCA®3 ...................................................................... 9

1.5.2. The Combustion Test..................................................................... 10

1.5.3. Turning Off the PCA®3.................................................................... 10

1.6. Features and Benefits ................................................................................ 10

1.7. Sales Combo and Model Configurations .................................................... 12

1.8. Specifications ............................................................................................. 13

CHAPTER 2. HARDWARE ............................................................................ 16

2.1. Overview .................................................................................................... 16

2.2. Front Panel Buttons ................................................................................... 17

2.3. Backlit Display ............................................................................................ 18

2.4. Battery Compartment ................................................................................ 18

2.5. AC Adapter Connector (POWER)................................................................ 18

2.6. Probe Connectors (Gas, Pressure, T-Stack)................................................ 19

2.7. Differential Pressure Connector (∆P)......................................................... 20

2.8. Primary Air Thermocouple Connector (T-AIR) ........................................... 20

2.9. Computer Interface (USB) .......................................................................... 20

2.10. Wireless Printer Port (IrDA) ..................................................................... 20

2.11. Options Connector (OPT) ......................................................................... 20

CHAPTER 3. INITIAL SETUP .........................................................................21

3.1. Overview .................................................................................................... 21

3.2. Power ......................................................................................................... 21

3.3. Connecting the Probe and Hose Assembly ................................................ 22

3.4. Preparing to Configure the PCA®3.............................................................. 22

CHAPTER 4. CONFIGURATION PROCEDURES ..............................................24

4.1. Default Operating Parameters ................................................................... 24

4.2. Fuel Selection ............................................................................................. 24

4.3. Auto/Manual CO Zero Selections............................................................... 26

4.4. Temperature Units Selection ..................................................................... 27

4.5. Pressure Units Selection ............................................................................ 27

4.6. Pollution Units Selection ............................................................................ 28

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4.7. Smoke Number .......................................................................................... 29

4.8. Oil Derivative.............................................................................................. 30

4.9. Boiler Temperature .................................................................................... 30

4.10. Date Setup................................................................................................ 31

4.11. Time Setup ............................................................................................... 32

4.12. O2Reference Setup .................................................................................. 32

4.13. Print Pressure Selection ........................................................................... 33

4.14. Zoom Display Selection ............................................................................ 34

4.15. Logging Selection ..................................................................................... 35

4.16. Button Sound Selection............................................................................ 35

4.17. Test ID Information .................................................................................. 36

4.17.1. Entering or Editing a Test ID ........................................................ 36

4.17.2. Selecting a Test ID ....................................................................... 37

4.17.3. Clearing Test ID Information........................................................ 37

4.18. User Name ............................................................................................... 38

4.18.1. Entering a User Name.................................................................. 38

4.18.2. Clearing a User Name .................................................................. 39

4.19. Language .................................................................................................. 39

4.20. Calibration Reminder Period.................................................................... 40

4.21. Run/Hold Screen Format.......................................................................... 41

CHAPTER 5. OPERATION ............................................................................44

5.1. Operating Tips............................................................................................ 44

5.2. Turning On the Analyzer ............................................................................ 45

5.3. Low Battery Alarm ..................................................................................... 45

5.4. Locating Sampling Points ........................................................................... 46

5.5. Performing a Combustion Test .................................................................. 47

5.6. Selecting a Pressure Label.......................................................................... 50

5.7. Temperature Label Selection and Measurement ...................................... 50

5.8. Performing a Draft / Pressure Measurement ............................................ 51

5.9. Saving Test Data......................................................................................... 52

5.10. Ending a Combustion Test........................................................................ 53

5.11. Emptying the Water Trap......................................................................... 53

5.12. Data Logging............................................................................................. 54

5.12.1. Overview...................................................................................... 54

5.12.2. Turning On Data Logging ............................................................. 55

5.12.3. Setting the Logging Interval and Duration................................... 56

5.12.4. Starting the Data Logging Process ............................................... 57

5.12.5. Ending the Data Logging Process................................................. 57

5.13. Memory Functions ................................................................................... 58

5.13.1. Overview...................................................................................... 58

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5.13.2. Recalling Combustion Test Data.................................................. 58

5.13.3. Recalling Logged Test Data.......................................................... 59

5.13.4. Clearing Memory ......................................................................... 60

5.13.5. Print Average ............................................................................... 60

5.14. Downloading Stored Data to a Computer................................................ 61

5.15. Importing Saved Data into a Spreadsheet ............................................... 62

5.16. Printing Test Data..................................................................................... 63

5.17. Turning Off the Analyzer and Purging...................................................... 65

CHAPTER 6. CALIBRATION.......................................................................... 66

6.1. B-Smart Sensors ......................................................................................... 66

6.2. Starting a Calibration ................................................................................. 66

6.3. B-Smart®Sensor Replacement and Calibration.......................................... 67

6.4. Pressure Sensor Calibration ....................................................................... 68

6.4.1. Material Required.......................................................................... 68

6.4.2. Procedure ...................................................................................... 68

6.5. T-Stack Calibration ..................................................................................... 69

6.5.1. Material Required.......................................................................... 70

6.5.2. TS-Zero Procedure ......................................................................... 70

6.5.3. TS-Span Procedure ........................................................................ 71

6.6. T-Air Calibration ......................................................................................... 71

6.6.1. Material Required.......................................................................... 71

6.6.2. TA-Zero Procedure......................................................................... 71

6.6.3. TA-Span Procedure ........................................................................ 73

6.7. COLOW Sensor Calibration ........................................................................... 73

6.7.1. Material Required.......................................................................... 73

6.7.2. Procedure ...................................................................................... 74

6.8. SO2Sensor Calibration ............................................................................... 76

6.8.1. Material Required.......................................................................... 76

6.8.2. Procedure ...................................................................................... 76

6.9. NO Sensor Calibration ................................................................................ 77

6.9.1. Material Required.......................................................................... 77

6.9.2. Procedure ...................................................................................... 77

6.10. NO2Sensor Calibration............................................................................. 78

6.10.1. Material Required........................................................................ 78

6.10.2. Procedure .................................................................................... 78

6.11. COHIGH Sensor Calibration......................................................................... 80

6.11.1. Material Required........................................................................ 80

6.11.2. Procedure .................................................................................... 80

CHAPTER 7. MAINTENANCE .......................................................................82

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7.1. Overview .................................................................................................... 82

7.2. PCA®3 Disassembly..................................................................................... 82

7.2.1. Tools Required............................................................................... 82

7.2.2. Procedure ...................................................................................... 82

7.3. Emptying the Water Trap Chamber ........................................................... 87

7.4. Replacing the Filter Element ...................................................................... 87

7.4.1. Material Required.......................................................................... 87

7.4.2. Procedure ...................................................................................... 87

7.5. Sensor Replacement .................................................................................. 88

7.6. Nitric Oxide (NO) Sensor Battery Replacement ......................................... 90

7.6.1. Material Required.......................................................................... 90

7.6.2. Procedure ...................................................................................... 90

7.7. Cleaning the Probe..................................................................................... 91

7.7.1. Equipment Required...................................................................... 91

7.7.2. Procedure ...................................................................................... 91

CHAPTER 8. TROUBLESHOOTING ...............................................................92

8.1. Error Symbols............................................................................................. 92

8.2. Diagnostics and Status Screens.................................................................. 92

8.3. Accessing the Diagnostic Menu ................................................................. 93

8.4. Accessing the Status Menu ........................................................................ 93

8.5. Error Messages (After Warm-up)............................................................... 93

8.6. Replacement Parts ..................................................................................... 94

8.7. Accessories................................................................................................. 97

8.8. Analyzer Repair .......................................................................................... 99

8.9. Service Centers........................................................................................... 99

CHAPTER 9. DECLARATION OF CONFORMITY ........................................... 100

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CHAPTER 1. INTRODUCTION

1.1. About This Manual

Thank you for investing in a Bacharach PCA®3 Combustion Analyzer. To assure

operator safety and the proper use of the PCA®3, please read the contents of this

manual for important information on the operation and maintenance of the

analyzer.

1.2. Conventions

WARNING:

A warning statement denotes a potential hazard

associated with the use of this equipment. Failure to follow this

information could result in serious personal injury or death.

CAUTION: A caution statement indicates a potentially hazardous

situation which, if not avoided, may result in minor or moderate

injury. Caution statements may also be used to alert against unsafe

practices.

IMPORTANT: An impor

tant statement provides emphasis of an

important feature, operation, etc. Failure to follow this information

could void your warranty, result in improper operation, or cause

equipment damage.

NOTE: A note statement provides emphasis of a feature, operation,

practice, etc.

1.3. Safety

WARNING:

This analyzer is not intended to be used as a safety

device.

WARNING: When testing an appliance, a full visual inspection of

the appliance should be performed to ensure its safe operation.

CAUTION:

This analyzer is not intended to be used on a

continuous basis.

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CAUTION: Do not store instrument or its sensors with solvents or

products that contain solvents.

CAUTION: Exce

pt 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.

HAZARDOUS AREA WARNING: This instrument has not been

designed to be intrinsically sa

fe for use in areas classified as

hazardous locations. For your safety, DO NOT use it in hazardous

(classified) locations.

CAUTION: When the instrument is used in an inefficient furnace or

boiler application where there is a high emission of soot, the probe’s

sample filter may become clogged. Before every use check the filter

to confirm that it is clean or replace it with a new filter.

To prevent this from occurring, a smoke test should be performed

before operating under such conditions. This ensur

es that the

furnace or boiler is burning at a level appropriate for the use of this

instrument.

When the CO2level exceeds the allowable threshold, a warning will

appear prompting the user to consider performing a smoke test (see

Figure 1-1

). This screen is removed by pressing the ENT button.

Once the warning is cleared, it will not be displayed again for that

particular test. If a new test is started (by pressing the HOLD

button), the warning will be displayed again if the limit has been

exceeded.

Figure 1-1. High CO2Warning

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1.4. General Description

The PCA®3 is a commercial-grade hand-held combustion and emissions

analyzer designed for on-

demand sampling of light industrial, institutional,

commercial and residential furnaces, appliances, and boilers.

The basic instrument is supplied with

a probe and hose assembly,

instruction manual, factory calibrated

smart sensors, 4 ‘AA’ alkaline

batteries, boot, Fyrite®User

Software, USB cable, and carrying

case. Refer to Figure 1-2.

The PCA®3 can measure up to four

gases simultaneously, so it is the

perfect tool for service technicians,

inspectors, and boiler contractors

who need to determine combustion

efficiency, excess air, stack gas O2

and CO levels, stack temperature,

draft, and differential pressure.

Figure 1-2. A Typical PCA®3 Kit

The analyzer can also directly measure and display NO, NO2and SO2with the

installation of the appropriate sensors. Combustion efficiency calculations can be

conducted for a variety of fuels (see Specifications later in this chapter).

Combustion analysis is performed in accordance with EN50379.

B-Smart®sensor technology allows a new sensor to be installed in the field

without having to calibrate the analyzer with gas before use.

Advanced data storage and communication features allow the operator to store

up to 500 individual combustion test records, which can later be recalled for

viewing, printing, or downloading to a personal computer. In its data logging

mode, the analyzer can store an additional 500 data logged records.

The optional AC power adapter allows the analyzer to run for extended periods of

time while data logging.

The optional sample conditioning probe is recommended when measuring NO2

and SO2to ensure the highest degree of measurement accuracy.

A probe and hose assembly with an integral thermocouple and filter/water trap

connect to the bottom of the analyzer, providing the means of drawing in gas

samples and for measuring stack temperature and draft.

1.5. Operation Overview

1.5.1. Turning On the PCA®3

The PCA®3 is turned ON by pressing its red I/O button. A warm-up period of 60

seconds then begins, during which time the analyzer performs self diagnostics.

At the end of the warm-up period, if no errors were detected the instrument will

display the Combustion Test HOLD screen. If errors were detected, the message

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“ERRORS DETECTED” is displayed along with a list of the errors. These errors

must be corrected before proceeding with the combustion test.

Before starting a test be sure to select the fuel being burned. The default fuel

selected is Natural Gas. Note that the name of the fuel being burned is indicated

at the top of the run/hold screen.

1.5.2. The Combustion Test

To assure correct combustion efficiency calculations, the analyzer must know the

burner’s primary-air temperature. The analyzer normally uses its internal

temperature sensor for the primary-air temperature value, but this method is only

acceptable if the burner is using ambient room air. If the burner is drawing in cold

outside air, we recommend that the optional T-AIR thermocouple be used. This

thermocouple plugs into the bottom of the analyzer and is placed in the burner’s

primary-air stream.

Begin the combustion test by first inserting the analyzer’s probe tube into the

stack-gas stream of the appliance under test, and then pressing the RUN/HOLD

button to display the Combustion Test RUN screen. The analyzer will begin to

continuously monitor the stack temperature, %O2and emission levels in the

stack gas and then display measured and calculated values on its display. The

recommended time required to achieve a stable measurement is a minimum of 3

minutes.

During a test, the COLOW sensor is protected from high CO levels by being

automatically flushed with fresh air when the detected CO level exceeds

4,000 ppm. The analyzer will automatically start using its optional COHIGH sensor,

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

readings up to 20,000 ppm.

A keypad backlight enables a user to read the keypad in dimly-lit areas. Turn the

keypad backlight ON and OFF by briefly pressing the I/O button.

1.5.3. Turning Off the PCA®3

The analyzer is turned OFF by pressing and holding down the I/O button for at

least 2 seconds. Note that there is a 5-second delay before the analyzer actually

turns OFF, during which time the analyzer can be turned back ON by pressing

the RUN/HOLD button. In addition, there is a gas-purge feature that keeps the

analyzer’s pump running if the gas level inside the sensor chambers is

abnormally high at shutdown. With the probe removed from the stack and

sampling fresh air, the analyzer purges itself until the detected gas

concentrations drop below predetermined levels.

1.6. Features and Benefits

•Powered by 4 ‘AA’ alkaline batteries or NiMH rechargeable batteries. An

optional AC adapter provides extended operation.

•O2and Hydrogen-compensated COLow measurements are standard.

Optional measurement of up to two additional gases, including COHigh, NO,

NO2, or SO2.

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