Bacharach Portable Combustion Analyzer Specifications

Portable Combustion Analyzer Operation and Maintenance Manual Instruction 0024-9472 Rev. 3 – August 2014 Product Leadership • Training

PCA3 Manual 10 0024-9472 Rev 3 “ERRORS DETECTED” is displayed along with a list of the errors. These errors must be corrected before proceeding

PCA3 Manual 100 0024-9472 Rev 3 World Headquarters 621 Hunt Valley Circle, New Kensington, Pennsylvani

PCA3 Manual 0024-9472 Rev 3 11 1.6. Features and Benefits • Powered by 4 ‘AA’ alkaline batteries or NiMH rechargeable batteries. An optional

PCA3 Manual 12 0024-9472 Rev 3 1.7. Sales Combo and Model Configurations Sales Combo (0024-xxxx) 8440 8441 8442 8443 8444 8445 8446 Sales Comb

PCA3 Manual 0024-9472 Rev 3 13 1.8. Specifications Measurement (Based on Installed Sensors) Display Range Oxygen 0.1 to 20.9% Stack Temperat

PCA3 Manual 14 0024-9472 Rev 3 Reading Performance Accuracy O2 ±0.3% O2 on practical concentrations of stack gas (mix of O2, CO2, and N2) CO G

PCA3 Manual 0024-9472 Rev 3 15 CHAPTER 2. HARDWARE 2.1. Overview Figure 2-1. Front and Bottom Views Showing Key Components

PCA3 Manual 16 0024-9472 Rev 3 2.2. Front Panel Buttons The PCA®3 is controlled by various buttons, while a color graphic LCD (with automatic

PCA3 Manual 0024-9472 Rev 3 17 For example, the functions of the F1, F2, and F3 buttons are defined by labels appearing above them on the LCD.

PCA3 Manual 18 0024-9472 Rev 3 Figure 2-3. Battery Compartment Figure 2-4. Bottom View Showing Connectors 2.6. Probe Connectors (Gas, Press

PCA3 Manual 0024-9472 Rev 3 19 Figure 2-5. Probe Connectors GAS, +∆P, and T-STACK 2.7. Differential Pressure Connector (∆P) Draft is measure

PCA3 Manual 2 0024-9472 Rev 3 WARRANTY POLICY Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from d

PCA3 Manual 20 0024-9472 Rev 3 CHAPTER 3. INITIAL SETUP 3.1. Overview Before configuring or using the PCA®3, you MUST: • provide power •

PCA3 Manual 0024-9472 Rev 3 21 3.3. Connecting the Probe and Hose Assembly To attach the probe and hose assembly to the analyzer follow the st

PCA3 Manual 22 0024-9472 Rev 3 Figure 3-2. Connecting the Probe to the Analyzer

PCA3 Manual 0024-9472 Rev 3 23 CHAPTER 4. CONFIGURATION PROCEDURES 4.1. Default Operating Parameters The PCA®3 is set up at the factory for

PCA3 Manual 24 0024-9472 Rev 3 4. Press ENT to save the selection and display the Combustion Test HOLD screen. Observe that the name of the se

PCA3 Manual 0024-9472 Rev 3 25 Figure 4-2. Auto/Manual Zero Selection NOTE: The PCA®3 performs a zero function during warm-up. Among other

PCA3 Manual 26 0024-9472 Rev 3 Figure 4-3. Temperature Units Selection 4.5. Pressure Units Selection Select to display pressure

PCA3 Manual 0024-9472 Rev 3 27 4.6. Pollution Units Selection The PCA®3 is capable of converting the measured ppm levels of CO, NO, NO2, and S

PCA3 Manual 28 0024-9472 Rev 3 5. Repeat Step 4 until the values for month, day, and year have been set. 6. Press ENT to save the selection

PCA3 Manual 0024-9472 Rev 3 29 Figure 4-7. Time Setup 4.9. O2 Reference Setup The measured values of CO, NOx, and SO2 can be individ

PCA3 Manual 0024-9472 Rev 3 3 TABLE OF CONTENTS CHAPTER 1. INTRODUCTION ...

PCA3 Manual 30 0024-9472 Rev 3 4.10. Print Pressure Selection Select whether to print or not print the pressure measurement on the combustion

PCA3 Manual 0024-9472 Rev 3 31 Figure 4-10. Zoom Display Selection 4.12. Logging Selection When the logging function is activated,

PCA3 Manual 32 0024-9472 Rev 3 Figure 4-12. Button Sound Selection 4.14. Test ID Information Test records can be identified (e.g., c

PCA3 Manual 0024-9472 Rev 3 33 8. At this time, either return to Step 6 to choose another line to edit, or end this procedure by highlighting E

PCA3 Manual 34 0024-9472 Rev 3 All Records3. Press ESC to end this procedure and return to the Test ID menu or press the RUN/HOLD key to return

PCA3 Manual 0024-9472 Rev 3 35 7. At this time, either return to Step 4 to choose another line to edit, or end this procedure by highlighting E

PCA3 Manual 36 0024-9472 Rev 3 4.16. Language Information on the display screen can be shown in English, French, or Spanish. Select the desir

PCA3 Manual 0024-9472 Rev 3 37 NOTE: The date and time settings must be correct to get accurate calibration reminders. Figure 4-19.

PCA3 Manual 38 0024-9472 Rev 3 NOTE: Stars (***) appear in measurement and calculation fields of sensors that are not installed. Change the o

PCA3 Manual 0024-9472 Rev 3 39 4. Use the ▲▼ buttons to highlight RESET FORMAT, then press ENT to display the Reset Format screen. 5. Use the

PCA3 Manual 4 0024-9472 Rev 3 4.8. Time Setup ...

PCA3 Manual 40 0024-9472 Rev 3 CHAPTER 5. OPERATION 5.1. Operating Tips • When an analyzer is brought in from a cold vehicle, let it warm u

PCA3 Manual 0024-9472 Rev 3 41 5.2. Turning On the Analyzer Connect the probe and hose assembly, and make sure that the analyzer is properly s

PCA3 Manual 42 0024-9472 Rev 3 5.3. Low Battery Alarm When the batteries are nearly depleted, an empty battery icon appears in the upper right

PCA3 Manual 0024-9472 Rev 3 43 90% Efficiency Condensing Furnace 80% Efficiency Fan Assist or Power Vented Furnace Atmospheric/Gravity Vented Bo

PCA3 Manual 44 0024-9472 Rev 3 Figure 5-7. Performing a Combustion Test 1. Press the RUN/HOLD button to start the test. You should hear the p

PCA3 Manual 0024-9472 Rev 3 45 List of Combustion Test Data Display Name Description of Measurement or Calculation O2 % Oxygen CO Carbon Mono

PCA3 Manual 46 0024-9472 Rev 3 Figure 5-8. Selecting a Pressure Label 5.7. Temperature Label Selection and Measurement The difference in

PCA3 Manual 0024-9472 Rev 3 47 5.8. Performing a Draft / Pressure Measurement The difference in pressure (∆P) between two areas can be mea

PCA3 Manual 48 0024-9472 Rev 3 differential pressure between the two areas is now displayed on the PRESSURE screen. If the pressure at the +∆P p

PCA3 Manual 0024-9472 Rev 3 49 5.10. Ending a Combustion Test WARNING: Burn Hazard. Do not touch the probe after removing it from the stack

PCA3 Manual 0024-9472 Rev 3 5 5.14. Downloading Stored Data to a Computer ... 57 5.15. Importing

PCA3 Manual 50 0024-9472 Rev 3 Figure 5-14. Emptying the Water Trap 5.12. Data Logging 5.12.1. Overview When the logging function is activ

PCA3 Manual 0024-9472 Rev 3 51 Logging Intervals and Durations Logging Intervals Logging Durations 1 second 5 minutes 5 second 10 minut

PCA3 Manual 52 0024-9472 Rev 3 Figure 5-15. Turning On Data Logging 5.12.3. Setting the Logging Interval and Duration The logging i

PCA3 Manual 0024-9472 Rev 3 53 5.12.4. Starting the Data Logging Process After turning ON data logging and setting the interval and duration,

PCA3 Manual 54 0024-9472 Rev 3 NOTE: If the logging process was stopped by pressing ESC, it cannot be resumed without first turning logging b

PCA3 Manual 0024-9472 Rev 3 55 NOTE: The recalled combustion test data can be printed by pressing the PRINT (F1) button. Refer to Printing

PCA3 Manual 56 0024-9472 Rev 3 Figure 5-19. Recalling Logged Test Data 5.13.4. Clearing Memory When all memory locations used to st

PCA3 Manual 0024-9472 Rev 3 57 5.14. Downloading Stored Data to a Computer The combustion test data that was stored in either the analyzer’s M

PCA3 Manual 58 0024-9472 Rev 3 Downloaded Data Fields Field Column Name Data Name or Value 1 Date Date of Test in mm/dd/yy 2 Time Time of Test i

PCA3 Manual 0024-9472 Rev 3 59 5.16. Printing Test Data Combustion or pressure data that is currently being displayed can be sent to a printer

PCA3 Manual 6 0024-9472 Rev 3 7.3. Emptying the Water Trap Chamber ... 83 7.4. Replaci

PCA3 Manual 60 0024-9472 Rev 3 Figure 5-21. Printer Alignment and Sample Printout

PCA3 Manual 0024-9472 Rev 3 61 5.17. Turning Off the Analyzer and Purging Turn OFF the analyzer by pressing the I/O button for at least 2 seco

PCA3 Manual 62 0024-9472 Rev 3 CHAPTER 6. CALIBRATION IMPORTANT: Before performing any calibration procedure ensure that new batteries are i

PCA3 Manual 0024-9472 Rev 3 63 5. Before calibration can begin a 4-character alphanumeric password must be entered. Use the ▲▼ and ◄► buttons

PCA3 Manual 64 0024-9472 Rev 3 Bacharach also offers a convenient exchange program that allows the customer to regularly send in old sensors and

PCA3 Manual 0024-9472 Rev 3 65 NOTE: The calibration range is from –6 to –2 inwc (–15 to -5 mb). An attempt to calibrate outside this range w

PCA3 Manual 66 0024-9472 Rev 3 The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temp

PCA3 Manual 0024-9472 Rev 3 67 which the message “Good Calibration” should briefly appear followed by the CALIBRATE TS-SPAN screen. Fi

PCA3 Manual 68 0024-9472 Rev 3 1. Set thermocouple simulator to room temperature and plug its output into the T-AIR connector located at the bo

PCA3 Manual 0024-9472 Rev 3 69 6.6.3. TA-Span Procedure 1. Set thermocouple simulator to 212 °F (100 °C), and then use the ▲▼ and ◄► buttons t

PCA3 Manual 0024-9472 Rev 3 7 CHAPTER 1. INTRODUCTION 1.1. About This Manual Thank you for investing in a Bacharach PCA®3 Combustion Analyz

PCA3 Manual 70 0024-9472 Rev 3 6.7.2. Procedure 1. If not already done, turn ON the analyzer and display the CALIBRATION LIST screen (refer to

PCA3 Manual 0024-9472 Rev 3 71 NOTE: If the sensor’s output is too low to be usable, then the message “Bad Calibration Sensor End of Life, Ent

PCA3 Manual 72 0024-9472 Rev 3 NOTE: A CO-only calibration can be done by pressing F3 in Step 5 (instead of ENT). 6.8. SO2 Sensor Calibratio

PCA3 Manual 0024-9472 Rev 3 73 and then press ENT to calibrate the SO2 Measured value to that of the applied value. The message “Good Calibratio

PCA3 Manual 74 0024-9472 Rev 3 Figure 6-10. NO Sensor Calibration 5. Adjust regulator for a flow meter indication of approximately 2  SC

PCA3 Manual 0024-9472 Rev 3 75 NOTE: “Measured” is the current NO2 reading, while “Applied” is a known NO2 level that will be applied for cal

PCA3 Manual 76 0024-9472 Rev 3 6.11. COHIGH Sensor Calibration This procedure spans the optional carbon monoxide high sensor (4,001 to 20,000 

PCA3 Manual 0024-9472 Rev 3 77 NOTE: The calibration range is from 250 to 11,000 ppm. An attempt to calibrate outside this range will cause th

PCA3 Manual 78 0024-9472 Rev 3 CHAPTER 7. MAINTENANCE 7.1. Overview Customer maintenance of the PCA®3 is limited to the following: • Batte

PCA3 Manual 0024-9472 Rev 3 79 Figure 7-1. Removing the Rear Case Sensor Position Model Number and Corresponding Sensor Configuration 225

PCA3 Manual 8 0024-9472 Rev 3 CAUTION: Do not store instrument or its sensors with solvents or products that contain solvents. CAUTION: Exc

PCA3 Manual 80 0024-9472 Rev 3 Figure 7-2. Inside View with Rear Case Removed

PCA3 Manual 0024-9472 Rev 3 81 Figure 7-3. Tubing Connections - Main Figure 7-4. Tubing Connections - Sensors

PCA3 Manual 82 0024-9472 Rev 3 Figure 7-5. Wire Routing, Connectors, and Solder Connections

PCA3 Manual 0024-9472 Rev 3 83 7.3. Emptying the Water Trap Chamber The water trap chamber should be emptied after every test, or when the wat

PCA3 Manual 84 0024-9472 Rev 3 7.5. Sensor Replacement All sensors are replaced in a similar manner. Do the following to replace either the O2

PCA3 Manual 0024-9472 Rev 3 85 Figure 7-7. Sensor Assembly 12. Allow the sensor that was just installed time to stabilize in the circu

PCA3 Manual 86 0024-9472 Rev 3 7.6. Nitric Oxide (NO) Sensor Battery Replacement A single lithium battery, located on the NO Smart Sensor asse

PCA3 Manual 0024-9472 Rev 3 87 7.7. Cleaning the Probe The probe tube and gas sample hose will become dirty under normal use. NOTE: The wat

PCA3 Manual 88 0024-9472 Rev 3 CHAPTER 8. TROUBLESHOOTING 8.1. Error Symbols Error symbols are shown in the data fields of the Combustion Te

PCA3 Manual 0024-9472 Rev 3 89 8.3. Accessing the Diagnostic Menu 1. Display the MAIN MENU by pressing the MENU (F2) button. If necessary, pre

PCA3 Manual 0024-9472 Rev 3 9 1.4. General Description The PCA®3 is a commercial-grade hand-held combustion and emissions analyzer designed fo

PCA3 Manual 90 0024-9472 Rev 3 O2 Sensor Missing Oxygen sensor not installed. Install oxygen sensor. Refer to Sensor Replacement on page 84. BAD

PCA3 Manual 0024-9472 Rev 3 91 Item Description Part No. assembly, including O-rings) 14A O-Ring, Pressure Fitting 0105-5103 14B O-Ring, Ga

PCA3 Manual 92 0024-9472 Rev 3 Figure 8-3. Replacement Parts Main PCB Assembly (Replacement Part Not Available)

PCA3 Manual 0024-9472 Rev 3 93 Figure 8-3. Replacement Parts (Continued) 8.7. Accessories Standard Accessories Description Part No. Carryin

PCA3 Manual 94 0024-9472 Rev 3 Figure 8-4. Hose and Probe Assembly (Parts) Optional Accessories Description Part No. AC Power Adapter: (Inp

PCA3 Manual 0024-9472 Rev 3 95 Description Part No. Thermocouple Replacement Kit, 36 in. 0024-8416 Sample Conditioning Probe, Compact (recomme

PCA3 Manual 96 0024-9472 Rev 3 CHAPTER 9. DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer of the products covered by t

PCA3 Manual 0024-9472 Rev 3 97

PCA3 Manual 98 0024-9472 Rev 3

PCA3 Manual 0024-9472 Rev 3 99