Bacharach PCA 55 Specifications

Portable Combustion AnalyzerInstruction 0024-9472Operation & MaintenanceRev. 0 - August 2010

PCA®3101.4 Features & Benefi ts• Powered by 4 ‘AA’ alkaline batteries or NiMH rechargeable batteries. An optional AC adapter provides extended op

PCA®3100Access the Diagnostic menu as follows:1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC until MENU appears a

PCA®31018 Parts & Service8.1 Replacement PartsItem Description Part No.1 Main PCB Assembly 0024-15232 LCD Module 0024-15203 Rear Case 0024-13814

PCA®310216K Sensor, NOT-calibrated, NO20024-102716L Sensor, NOT-calibrated, SO20024-099817 Screw, #4 x 1/2” LG 0002-214418 Battery Clip, Single 0004-1

PCA®31034 10 7 6 2 1 9 16 15 13 3 5817121418191117

PCA®31048.2 AccessoriesStandard AccessoriesDescription Part No.Carrying Case 0024-0865Batteries, ‘AA’ Alkaline 0204-000412” Probe, Hose, and Water Tra

PCA®3105Optional AccessoriesDescription Part No.AC Power Adapter:(Input: 100-240 VAC, 50/60 Hz; Output: 6 VDC @ 1 A)0024-1254Ambient Air Thermocouple

PCA®31068.3 Service CentersUnited StatesBacharach, Inc.621 Hunt Valley CircleNew Kensington, PA 15068Phone: 724-334-5051Fax: 724-334-5723Email: help@M

PCA®3107NOTES

World Headquarters621 Hunt Valley Circle, New Kensington, PA 15068Ph: 724-334-5000 • Toll Free: 800-736-4666 • Fax: 724-334-5001Website: www.MyBachara

PCA®3111.5 Operational OverviewThe PCA®3 is powered by either its four internal batteries or by an optional AC power adapter that operates from any co

PCA®312During a test, the COLow sensor is protected from high CO levels by being automatically fl ushed with fresh air when the detected CO level excee

PCA®313T-STACK T-AIRFigure 1-1. PCA®3 ComponentsF1 / F2 / F3 – Soft Menu Buttons, whose functions are defi ned by labels appearing above them on LCD Ar

PCA®3141.6.2 T-AIR (Primary Air Thermocouple)If thermocouple P/N 0104-1797 (10 feet long) or Utility Wand P/N 0104-1799 (12-inch ridged probe with han

PCA®3151.7 Front Panel ButtonsDescriptions of the front panel buttons are given below. Note that a control may perform multiple functions as determin

PCA®316Selects a highlighted item. In addition, if changes were made to one of the analyzer’s operating parameters (e.g., date, time, O2 reference, et

PCA®3172.0 Specifi cationsThe PCA®3 Directly Measures and Displays:The gases displayed depend on the sensors installed in the analyzer. Refer to Sectio

PCA®318Normal Operating Conditions:Temperature:Analyzer 32 to 104 °F (0 to 40 °C)Probe Tip 1,472 °F (800 °C) Max.Humidity:Analyzer 15 to 90% Relative

PCA®319Power Requirements:Four disposable ‘AA’ alkaline batteries provide a minimum of 10 hours of continuous operation. NiMH rechargeable batteries c

WARRANTYBacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in mater ial and manufac ture and will c

PCA®3203.0 Initial Setup3.1 ScopeBefore using the PCA®3, you MUST:• Install batteries, or plug in the optional AC power adapter (Section 3.2)• Conne

PCA®3213.2.2 Using the AC Power AdapterThe AC power adapter is capable of powering the analyzer on a continuous basis. The adapter plugs into an appro

PCA®322POWERPT-STACK T-AIRGASDifferentialPressure Hose(— ∆P) (Optional)ProbeHandleWater Trap /Filter AssemblyStack GasThermocoupleConnector(T-STACK)AC

PCA®3233.4 Operating ParametersThe PCA®3 is set up at the factory for the following operating parameters:Fuel ...N

PCA®3244. Press ENT to save the selection and display the Combustion Test HOLD screen. Observe that the name of the selected fuel should now appear at

PCA®3253.7 Pressure Units SelectionSelect to display pressure in Inches of Water Column (inwc), millibar (mb), Pascals (Pa), or hectoPascals (hPa) as

PCA®3263.8 Pollution Units SelectionThe PCA®3 is capable of converting the measured ppm levels of CO, NO, NO2, and SO2 to various pollution units usi

PCA®3273.9 Date SetupThe date is stored in the format: MM/DD/YY. Its value is part of the date and time stamp that is saved along with each combustion

PCA®3283.10 Time SetupThe time is stored in the format: hh:mm:ss AM/PM. Its value is part of the date and time stamp that is save along with each comb

PCA®3293.11 O2 Reference SetupThe measured values of CO, NOx, and SO2 can be individually referenced to a specifi c O2 percentage of between 0 and 15%.

Contents1.0 Introduction ... 6 1.1 About This Manual ...

PCA®3303.12 Print Pressure SelectionSelect whether to print or not print the pressure measurement on the combustion test printout as follows:1. Displ

PCA®3313.13 Zoom-Display SelectionCombustion test data in the Run/Hold screen can be shown with enlarged characters to make viewing easier. The oper

PCA®3323.14 Logging SelectionWhen the logging function is activated, up to 500 combustion test records will be automatically stored in memory at a pr

PCA®3333.16 Test ID InformationTest records can be identifi ed (e.g. customer’s name, burner number, and location) by manually entering up to three li

PCA®3348. At this time, either return to Step 6 to choose another line to edit, or end this procedure by highlighting Edit Complete and pressing the

PCA®3353.17 UsernameThe name of the user or owner of the analyzer (e.g. company name, address, phone number) can be stored in memory by manually enter

PCA®3368. Press ESC to go to the Main Menu or the RUN/HOLD key to return to the Run/Hold screen.To Clear a Username proceed as follows:1. Display the

PCA®3373.18 LanguageInformation on the display screen can be shown in English, French, or Spanish. Select the desired language as follows:1. Display

PCA®3383.19 Cal Reminder PeriodThe analyzer can be set to indicate a calibration reminder during the 60 second warm-up period. Calibration reminders

PCA®3393.20 Run/Hold Screen FormatPCA®3 test data is located in the Run/Hold screen. By pressing the RUN/HOLD key, you should hear the pump running a

4 Operation ... 42 4.1 Operating Tips ...

PCA®340Change the order in which data is displayed as follows: 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, press ESC un

PCA®341Reset Display format back to factory default settings as follows:1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, pres

PCA®3424 Operation4.1 Operating Tips• When an analyzer is brought in from a cold vehicle, let it warm up slowly to minimize condensation. Temperatur

PCA®343• When storing the analyzer, it’s a good idea to empty the water trap and leave it open to further dry it out.• Calibrate the analyzer every

PCA®3444.3 Sampling PointFORCED AIR FURNACE: For atmospheric burner or gravity vented, forced air heating equip ment with a clamshell or sectional he

PCA®3454.4 Performing a Combustion TestEnsure that the following has been completed, and then proceed with the combustion test as described below:•

PCA®3464. Pressing the RUN/HOLD button holds all readings, stops the pump and displays the Combustion-Test HOLD screen. Press the ▲▼ buttons to scroll

PCA®3474.5 Pressure Label SelectionThe pressure measurement can be labeled with types including, differen-tial across heat exchanger, draft reading, a

PCA®3484.6 Temperature Label Selection & MeasurementThe difference in temperature between two areas can be measured by using the analyzer’s two t

PCA®3494.7 Making a Draft / Pressure MeasurementThe difference in pressure (∆P) between two areas can be measured by using the analyzer’s two pressur

6 Maintenance ... 85 6.1 PCA®3 Disassembly ...

PCA®350• To measure draft, simply insert the probe into the stack and observe the draft reading on the PRESSURE screen.• To measure differential pre

PCA®3514.9 Ending a Combustion TestWARNING! Burn Hazard. Do not touch the probe after removing it from the stack. Allow the probe to cool before han

PCA®3524.11 Turning OFF the Analyzer & PurgingTurn OFF the analyzer by pressing the I/O button for at least 2 seconds, or until two beeps are hea

PCA®353The stored logged data can either be viewed on the display using the analyzer’s memory function (refer to Section 4.14), or downloaded to a per

PCA®3544.13.2 Setting the Logging Interval and DurationThe logging interval is the length of time between measurements, while the logging duration is

PCA®3554.13.3 Starting the Data Logging ProcessAfter turning ON data logging and setting the interval and duration, the analyzer will pause at the LO

PCA®3564.14 MemoryThere are two memory banks, each containing 500 memory locations. The fi rst bank is used to store combustion test data as described

PCA®3574.14.1 Recalling Combustion Test DataRecall individual combustion test data records as follows:1. Display the MAIN MENU by pressing the MENU

PCA®3584.14.2 Recalling Logged Test DataRecall individual logged combustion test data records as follows:1. Display the MAIN MENU by pressing the ME

PCA®3594.14.3 Clearing MemoryWhen all memory locations used to store individual combustion test records have been fi lled, the next combustion test re

PCA®361.0 Introduction1.1 About This ManualThank you for investing in a Bacharach PCA®3 Combustion Analyzer. To assure operator safety and the proper

PCA®3604.15 Downloading Stored Data to a ComputerThe combustion test data that was stored in either the analyzer’s Memory Directory (Section 4.8), or

PCA®3614.15.1 Fyrite® User Software InstallationWindows XP:1. Insert the Fyrite® User Software CD into the computer’s disc drive.2. After the CD is

PCA®3624. Click “Next”Windows Vista:1. Insert the Fyrite® User Software CD into the computer’s disc drive.2. After the CD is loaded, the Security wi

PCA®363Click “Finish”Click “Continue”After the installation:1. Open Fyrite® User Software via the desktop icon.2. Connect instrument to the PC with U

PCA®3644.16 Fyrite® User Software DescriptionFyrite User SoftwareSet Instrument Time Sync instrument with computers timeCalibration Password Change 4

PCA®365Table 4-2 — Downloaded Data FieldsField Column Name Data Name or Value1 Date Date of Test in mm/dd/yy2 Time Time of Test in 12 hour format (AM/

PCA®3664.18 Printing Test DataCombustion or pressure data that is currently being displayed can be sent to a printer using IrDA protocol as described

PCA®367PRINT MENU SAVE8 to 16 in.(20.32 to 40.64 cm)BACHARACH, INC.PCA 3SN: xxxxxx=====================TIME 01:00:00 PMDATE 08/04/10

PCA®3685 CalibrationIMPORTANT: Before performing any calibration procedure ensure that fresh batteries are installed or use the optional AC power adap

PCA®3695.2 Starting a CalibrationStart any calibration procedure by doing the following:1. Place the probe in an area of fresh air, turn ON the anal

PCA®371.2 PCA®3 General DescriptionThe PCA®3 is a commercial-grade hand-held combustion and emissions analyzer designed for on-demand sampling of ligh

PCA®3705.3 B-Smart® Sensor Replacement & CalibrationTo replace a B-Smart® sensor and calibrate, do the following:1. Enter the CALIBRATION MENU pe

PCA®3715.4 Pressure Sensor CalibrationThis procedure calibrates the pressure sensor to a known pressure value.Material Required:• Bellows• Manometer•

PCA®3726. Use the ▲▼ and ◄► buttons to enter an Applied value that exactly equals the manometer reading. The calibration range is from –6 to –2 inwc (

PCA®3735.5 T-Stack CalibrationThis procedure fi rst zeros and then spans the stack-temperature channel to known temperature values. The use of an elect

PCA®3744. Set thermocouple simulator to 32 °F (0 °C), and then use the ▲▼ and ◄► buttons to enter an Applied value that exactly equals the setting of

PCA®3755.6 T-Air CalibrationThis procedure fi rst zeros and then spans the ambient-temperature channel to known temperature values. The use of an elec

PCA®3764. Set thermocouple simulator to 32 °F (0 °C), and then use the ▲▼ and ◄► buttons to enter an Applied value that exactly equals the setting of

PCA®3775.7 COLow Sensor CalibrationNote that the COLow sensor also measures H2 for the purpose of com-pensating the CO reading for the presence of H2

PCA®3785. Adjust the regulator for a fl owmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximate-ly 3 minut

PCA®379If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life” will appear followed by the CALIBRATION L

PCA®381.3 Sales Combo & Model Confi gurationsSales Combo 0024-8440 0024-8441 0024-8442Sales Combo (Kit) 0024-8447 0024-8448 0024-8449Model Type 22

PCA®3805. Adjust regulator for a fl owmeter indication of approximately 2 SCFH. Wait until the Measured reading stabilizes (approximate-ly 3 minutes),

PCA®381The calibration range is from 9 to 900 ppm. An attempt to calibrate outside this range will cause the message “Bad Calibration Wrong CAL Entry”

PCA®3825.10 NO2 Sensor CalibrationThis procedure spans the optional nitrogen dioxide sensor to a known gas level.Material Required:• Calibration Kit

PCA®383If the sensor’s output is low, but still usable, then the message “Good Calibration WARNING Low Sensor” will appear. The sensor will now be ma

PCA®384Figure 5-2. Gas Sensor Calibration Equipment5. Adjust regulator for a fl owmeter indication of approximately 2 SCFH. Wait until the Measured re

PCA®3856 MaintenanceCustomer maintenance of the PCA®3 is limited to the following:• Battery replacement (Section 3.2.1)• Sensor re-calibration (Sect

PCA®3866.1 PCA®3 DisassemblyThe following procedure describes how to disassemble the analyzer, while Figures 6-1 thru 6-4 illustrate how the analyzer

PCA®387Sensor PositionsModelPosition225 235 245 255 265 275#1 O2O2O2O2O2O2#2 COLowCOLowCOLowCOLowCOLowCOLow#3 SO2NO2SO2#4 NO COHighNO NOSensor Retaine

PCA®388Models 235 & 245P/Ns 0024-7321 & 0024-7322Model 255P/N 0024-7323Models 265 & 275P/Ns 0024-7324 & 24-7325Model 225P/N 0024-7320E

PCA®389Solder(2 Places)Red dot on pump indicates positive (red wire) connectionBatteryto J14Batteryto J14GasPumpto J8PurgePumpto J9Sensor Connector(ty

PCA®39Sales Combo 0024-8443 0024-8444 0024-8445 0024-8446Sales Combo (Kit) 0024-8450 0024-8451 0024-8452 0024-8453Model Type 255 265 275 285PCA®3 Only

PCA®3906.2 Water Trap / Filter Maintenance6.2.1 Emptying the Water Trap ChamberThe water trap chamber should be emptied after every test, or when th

PCA®3916.3 Sensor ReplacementAll sensors are replaced in a similar manner. Do the following to replace either the O2, COLow, COHigh, NO, NO2, or SO2

PCA®3929. Attach the gas cup to new sensor, making sure that when the sensor assembly is plugged into the analyzer’s main board, the tubing connectio

PCA®3934. Re-install the Smart Sensor assembly.5. Before powering up and using the analyzer, allow the Nitric Oxide sensor to stabilize as described

PCA®3946.5 Thermocouple ReplacementUsing the appropriate thermocouple replacement kit listed below, replace the probe’s thermocouple as follows:Thermo

PCA®3953. Pull old thermocouple from probe body and discard.4. The new thermocouple has been coiled for shipping purposes. Straighten the thermocoup

PCA®3966.6 Cleaning the ProbeThe probe tube and gas-sample hose will become dirty under normal use. Note that the water trap’s fi lter element should

PCA®3977 Troubleshooting7.1 Analyzer RepairIt is recommended that fi eld repair of the PCA®3 be limited to:• Checks of printed circuit board connector

PCA®3987.3 Error Messages Displayed After Warm-UpIf there were problems detected during warm-up, error messages that describe the nature of the probl

PCA®399 Stack or Air temperature channel is measuring temperature outside the range of -4 to 212 °F at startup. Make sure that the Stack and Air the