Bacharach Portable Combustion Analyzer Manual de usuario

Portable Combustion

Analyzer (PCA)

Instruction 0024-9219

Operation & Maintenance

Rev. 10 – May 2010

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,atBacharach’soption,ofthisProductorpartsthereofreturned

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)

yearafterthedateofdeliveryofthisProductbyBacharach,Inc.TheOxygen

) Sensor has a limited warranty of one (1) year. Routine service and/or

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

IMPLIEDWARRANTIESOF MERCHANTABILITYANDFITNESSFORA

PARTICULAR

PURPOSE:

AND

(II)

ANY

OBLIGATION,

LIABILITY,

RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR

NOT

ARISING

FROM

BACHARACH’S

NEGLIGENCE,

ACTUAL

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.

To Register Your Warranty, Visit

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

is a registered trademark of Bacharach, Inc.

All other trademarks are the property of their respective owners.

Instruction 0024-9219

PCA

Contents

1.0

INTRODUCTION

............................................................................

1.1 The Portable Combustion A

nalyzer

........................................... 1-1

1.2 Displayed

Data

........................................................................... 1-2

1.3 PCA Model

Configurations

......................................................... 1-3

2.0 TECHNICAL

CHARACTERISTICS

.............................................

3.0 SETTING UP

THE PCA

..................................................................

3.1 Scope

............................................................................................ 3-1

3.2 PCA

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 Key Pad

Functions

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

4.2 Sampling Hole

Location

............................................................. 4-2

4.3 Performing a

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 Starting 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 Sel

ection 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 S

creen

........................................................ 4-20

4.15 O

Reference Setup Screen

..................................................... 4-21

4.16 Language S

etup S

creen

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

4.17 Display M

ode Setup Screen

................................................... 4-23

4.18 Time / Dat

e Setup Scr

een

....................................................... 4-24

4.19 Printer /

Setup Screen ............................................................ 4-25

4.20 Calibration / Maintenance

Password Screen ........................ 4-26

4.21 Maint

enance Screen

............................................................... 4-27

Instruction 0024-9219

Contents

PCA

4.22 User Na

me Screens

................................................................ 4-28

4.23 Saving Test

Data

.................................................................... 4-29

4.24 Printing Test

Data

.................................................................. 4-30

4.25 Clear

Memory Screen

............................................................. 4-32

4.26 Resetting the

Microprocessor

................................................. 4-32

5.0 CALIBRATION

..................................................................................

5.1 Sensor

Check

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

5.2 Calibration

Fixtures

................................................................... 5-2

5.3 Calibrate Menu

Screen

............................................................... 5-3

5.4 Calibrate

TS-Zero ....................................................................... 5-4

5.5 Calibrate

TS-Span

...................................................................... 5-5

5.6 Calibrate

TA-Zero

....................................................................... 5-6

5.7 Calib

rate TA-Span

...................................................................... 5-7

5.8 Calibrate

............................................................................... 5-8

5.9 Calibrate

CO ............................................................................... 5-9

5.10 Calibrate

Draft

........................................................................ 5-11

6.0 MAINTENANCE

................................................................................

6.1 Routine

Maintenance

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

6.2 Disassembly

................................................................................ 6-2

6.3 Cleaning the

Probe

..................................................................... 6-4

6.4 Water Trap/Fil

ter Assembly Mai

ntenance

................................ 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 Oxi

de 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 Analyzer

Repair

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

7.2 Error

Codes

................................................................................. 7-2

7.3 Troubleshooting Guide

............................................................... 7-3

8.0 PARTS & SERVICE

..........................................................................

8.1 Replacement

Parts

...................................................................... 8-1

8.2 Accessories

.................................................................................. 8-2

8.3 Service

Centers

........................................................................... 8-6

APPENDIX A – Display Screen Translations

.....................................

APPENDIX B – Printout Translations

.................................................

Instruction 0024-9219

PCA

1.0 INTRODUCTION

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.

Figure 1-1. PCA

Instruction 0024-9219

1-1

Introduction

1.2 Displayed Data

PCA

The PCA directly measures, displays, and stores the following data:

•

Room Temperature in °F or °C (Primary Air/Ambient Temperature)

•

Flue Gas Oxygen Content in %

•

Flue Gas Temperature in

°F or °C

•

Flue Gas Carbon Monoxide Content (H

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

seven standard fuels:

•

Combustion Efficiency in %

•

Excess Air in %

•

Flue Gas Carbon Dioxide Content in %

•

Flue Gas Carbon Monoxide Content referenced to Oxygen in ppm

(For analyzers having a Carbon Monoxide sensor)

•

Flue Gas Nitric Oxide Content referenced to Oxygen in ppm

(For analyzers having a Nitric Oxide sensor)

The seven standard types of fuels that can be selected are:

•

Natural Gas

•

Oil #2

•

Oil #4

•

Oil #6

•

Kerosene

•

Propane

•

Coal

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, then draft measurements can

be made simultaneously with the combustion test, or made separately.

The analyzer has the capability of storing data that was collected during

a combustion test or draft measurement. The stored data can then at a

later date be either viewed on the PCA’s display, printed using an op-

tional printer, or downloaded to a computer.

1-2

Instruction 0024-9219

PCA

1.3 PCA Model Configurations

Introduction

TABLE 1-1. PCA SENSOR CONFIGURATIONS

PCA Models

Standard Advanced

Sensors Installed

PCA Part No. PCA Part No. Stack Temp., CO NX Draft

Model 24- Model 24- Air Temp. & O

(



10 8040 40 8140 X

15 8041 45 8141 X X

20 8042 50 8142 X X

25 8043 55 8143 X X X

30 8044 60 8144 X X X

35 8045 65 8145 X X X X

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 (CO

) content, air temperature, flue gas

temperature,

combustion efficiency, excess air

, 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.

PCA 15 & 45 with Draft

In addition to the features of the basic PCAs described above, these instru-

ments 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 a CO level

that is referenced to Oxygen. The ‘standard’ PCA 20 calculates CO refer-

enced to 0% Oxygen, while the ‘advanced’ PCA

50 calculates CO refer-

enced to a user selected Oxygen level of between 0–15%.

PCA 25 & 55 with Draft and CO Measurement

These instruments combine the features of all the PCAs listed above.

Instruction 0024-9219

1-3

Introduction

PCA

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 a NX level that is

referenced to Oxygen. The ‘standard’ PCA 30 calculates NX referenced to

0% Oxygen, while the ‘advanced’ PCA

60 calculates NX referenced to a

user selected Oxygen level of between 0–15%.

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 via an infrared link.

CO Sensor Purge

On all PCAs that measure CO, if

the

ON/OFF

is pressed while the CO

reading is 100 ppm or higher, the analyzer will attempt to purge itself of

CO before turning off.

Advanced PCA Model Features

‘Advanced’ models of the PCA contain the following features that are in

addition to the features of their corresponding ‘standard’ units:

•

100 memory locations

•

RS232 output for transferring saved data to a personal computer

•

Ability to enter three lines of user-identification information which is

printed at the top of each printout

•

Ability to enter three lines of customer-identification information

which is printed with each test record

•

Ability to set the Oxygen reference level from 0 to 15% for CO and NX

measurements on analyzers equipped with a CO or NX sensor

1-4

Instruction 0024-9219

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 0 to 2192 ºF (–18 to 1200 ºC)

•

Primary-air / ambient temperature is in the range of 0 to 999 ºF

(–18 to 999 ºC)

Optional . . .

•

Differential Pressure and Draft in the range of ±28" H

O (±70.0 mb)

•

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 16.0%, and the Stack (Flue

Gas) temperature is not above 1832 °F (1000 ºC)

•

Efficiency in the range of 0.1 to 99.9%

•

Excess Air in the range of 1 to 250%

•

Carbon Dioxide content in flue gas from 0.1 to a fuel dependent

maximum value in percent

•

Carbon Monoxide* content referenced to a percentage of Oxygen in

the range of 0

to 9,999 ppm on analyzers equipped with a CO sensor.

•

Nitrix Oxide* content referenced to a percenage of Oxygen in the

range of 0 to 9,999

ppm on analyzers equipped with a NX sensor.

Standard Fuels** Available for

Combustion Calculations:

•

Natural Gas

•

Oil #2

•

Oil #4

•

Oil #6

•

Kerosene

•

Propane

•

Coal

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 (CF & NF)

referenced to 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 0024-9219

2-1

Technical Characteristics

PCA

Normal Operating Conditions:

Temperature:

Analyzer

...................

32 to

104 ºF (0 to 40 ºC)

Probe Tip

..................

1472 ºF

(800 ºC) Max.

Humidity:

Analyzer

...................

15 to

90% Relative Humidity, Non-Condensing

Air Pressure:

Analyzer

...................

Atmospheric

Probe.........................

10"

O (25 mb) draft max at probe

tip

Performance:

Accuracy:

Oxygen*

....................±0.3% O2

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.

........

±4 ºF between 32 and 255 ºF

(±2 ºC between 0 and 124 ºC)

±6 ºF between 256 and 480 ºF

(±3 ºC between 125 and 249 ºC)

±8 ºF between 481 and 752 ºF

(±4 °C between 250 and 400 °C)

Ambient

Temp.

........

±2 ºF between 32 and 212 ºF

(±1 °C between 0 and 100 °C)

Pressure

...................

±2% of reading or ±0.02 inches of Water Column

(±0.05 mb), whichever is greater

System Flow Rate:

With

probe................200

cc/min minimum

Front Panel

Controls:

Seven embossed pushbutton switches with tactile feedback (refer to

Section 4.3)

Display:

20 character by 4 line alphanumeric LCD panel with a green backlight.

Accuracy referenced in practical flue gas concentrations

(mixtures of O

and N

)

2-2

Instruction 0024-9219

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