Bacharach 450 Installation and operation manual

Environmental Combustion Analyzer
Model 450
Instruction 0024-9400
Operation & Maintenance
Rev. 6 – June 2013
Product Leadership • Training • Service • Reliability

ii Instruction 0024-9400
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, 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
one (1) year after the date of delivery of this Product by Bacharach, Inc.
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 OBLIGA-
TION, 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.
Note: The probe is considered a consumable item and is therefore not covered under the terms of this warranty.
HAZARDOUS AREA WARNING:
This instrument has not been designed to be intrinsically
safe for use in areas classified as hazardous locations. For your safety, DO NOT
use it in
hazardous (classified) locations.
COMBUSTIBLE/FLAMMABLE GAS WARNING: This is NOT a safety device. Some flue
gases which this instrument can measure may be combustible/flammable. This instrument
should not be used to monitor combustible flue gases at or above their respective lower
explosive limits (LEL). Immediately correct those conditions in the appliance (e.g. boiler,
furnace…) causing unfired combustible gases before proceeding with the flue gas
measurements.
Register Your Warranty By Visiting
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.
Copyright © 2000−2013, Bacharach, Inc., all rights reserved.
BACHARACH® is a registered trademark of Bacharach, Inc. All other trademarks, trade names,
service marks and logos referenced herein belong to their respective owners.

ECA 450 Contents
Instruction 0024-9400 iii
Table of Contents
1Introduction.................................................................................................................... 1
1.1 General Description ...................................................................................................................................1
1.2 Features .....................................................................................................................................................1
1.3 Technical Data............................................................................................................................................2
1.4 Operation Overview...................................................................................................................................5
1.5 Front Panel Connections and Controls ......................................................................................................6
1.5.1 GAS, PRESSURE, T-STACK (Probe) ..............................................................................................6
1.5.2 T-AIR (Primary Air Thermocouple).............................................................................................7
1.5.3 POWER (AC Adapter) .................................................................................................................7
1.5.4 ∆P REF (Differential Pressure) ...................................................................................................7
1.5.5 RS232 (Computer Interface) ......................................................................................................7
1.5.6 OPT (Option) ..............................................................................................................................7
1.6 Front Panel Keypad Controls .....................................................................................................................8
2Operation ..................................................................................................................... 11
2.1 Turning On the Analyzer ..........................................................................................................................11
2.2 Turning Off the Analyzer ..........................................................................................................................11
2.3 Fuel Selection ...........................................................................................................................................12
2.4 Performing a Combustion Test ................................................................................................................13
2.5 Ending a Combustion Test .......................................................................................................................15
2.6 Performing a Draft Measurement ...........................................................................................................15
2.7 Saving Test Data.......................................................................................................................................16
2.8 Clearing Memory .....................................................................................................................................16
2.9 Recalling Test Data Stored in Memory.....................................................................................................17
2.10 Printing Data ............................................................................................................................................19
2.11 Downloading Data to a Personal Computer ............................................................................................20
2.12 Data Logging ............................................................................................................................................22
2.12.1 Turning Data Logging On..........................................................................................................22
2.12.2 Turning Data Logging Off .........................................................................................................24
2.13 Importing Saved Data Into a Spreadsheet ...............................................................................................25
2.14 Primary Air Temperature Measurement .................................................................................................27
2.14.1 Thermocouple Method ............................................................................................................27
2.14.2 Probe Thermocouple Method .................................................................................................27
2.14.3 Thermometer Method .............................................................................................................29
2.14.4 Internal Temperature Sensor Method.....................................................................................30
2.15 Differential Pressure Measurement ........................................................................................................31
2.16 Statistics Mode.........................................................................................................................................32
2.17 Setting Up the Analyzer ...........................................................................................................................35
2.17.1 Temperature Units...................................................................................................................36
2.17.2 Pressure Units ..........................................................................................................................36
2.17.3 Pollution Units .........................................................................................................................36
2.17.4 Language..................................................................................................................................37
2.17.5 Date..........................................................................................................................................37
2.17.6 Time .........................................................................................................................................38
2.17.7 O2Reference ............................................................................................................................38
2.17.8 Test ID ......................................................................................................................................39
2.17.8.1 Enter / Edit Test ID Information .........................................................................39
2.17.8.2 Select Test ID ......................................................................................................40
2.17.8.3 Transmit Test ID..................................................................................................41
2.17.8.4 Clearing Test ID Information ..............................................................................42
2.17.9 Display Timeout .......................................................................................................................43
2.17.10 Display Format .........................................................................................................................43
2.17.10.1 Changing Display Format ....................................................................................44

Contents ECA 450
iv Instruction 0024-9400
2.17.10.2 Resetting Display Format Back to Factory Default .............................................44
2.17.11 Primary Air ...............................................................................................................................45
2.17.12 Data Logging ............................................................................................................................45
2.17.13 Statistics...................................................................................................................................45
2.17.14 User Name ...............................................................................................................................45
2.17.14.1 Enter / Edit User Name Information...................................................................45
2.17.14.2 Clear User Name Information.............................................................................46
2.17.15 Keypad Sound ..........................................................................................................................46
2.17.16 High Resolution NOx Enable ....................................................................................................47
2.17.17 Print Pressure...........................................................................................................................48
2.17.18 Information ..............................................................................................................................48
3Calibration .................................................................................................................... 49
3.1 Initial Sensor Check..................................................................................................................................49
3.2 Calibration Fixtures ..................................................................................................................................50
3.3 Starting and Ending a Calibration Procedure...........................................................................................51
3.4 Calibrate Pressure Sensor ........................................................................................................................51
3.5 Calibrate T-Stack (Stack Temperature) Channel ......................................................................................52
3.6 Calibrate T-Air (Ambient Temperature) Channel.....................................................................................53
3.7 Calibrate HC Sensor .................................................................................................................................54
3.8 Calibrate CO-LO Sensor............................................................................................................................55
3.9 Calibrate SO2Sensor ................................................................................................................................57
3.10 Calibrate NO Sensor.................................................................................................................................58
3.11 Calibrate NO2Sensor................................................................................................................................59
3.12 Calibrate CO-HI Sensor.............................................................................................................................60
4Maintenance................................................................................................................. 61
4.1 Battery Charging ......................................................................................................................................61
4.2 Water-Trap / Filter Assembly...................................................................................................................62
4.3 Printer Paper Replacement......................................................................................................................63
4.4 Sensor Replacement ................................................................................................................................64
4.4.1 O2, CO, NO, NO2, & SO2Sensor Replacement ..........................................................................65
4.4.2 Nitric Oxide Sensor Battery Replacement................................................................................66
4.4.3 HC Sensor Replacement...........................................................................................................67
4.5 Replacing Internal Particulate Filter.........................................................................................................68
4.6 Cleaning the Probe and Sampling Hoses .................................................................................................69
4.7 Resetting the Microprocessor..................................................................................................................70
5Troubleshooting............................................................................................................ 72
5.1 Analyzer Repair ........................................................................................................................................72
5.2 Problem Messages Displayed After Warm-Up.........................................................................................72
5.3 Error Symbols...........................................................................................................................................73
5.4 Troubleshooting Guide ............................................................................................................................74
6Parts & Service .............................................................................................................. 79
6.1 Replacement Parts ...................................................................................................................................79
6.2 Accessories...............................................................................................................................................80
6.3 Service Centers ........................................................................................................................................81

ECA 450 Introduction
Instruction 0024-9400
1
1 Introduction
1.1 General Description
The Bacharach Environmental Combustion Analyzer Model 450 (hereafter
referred to as the ECA 450) is an industrial grade environmental and
combustion efficiency analyzer that is designed for the testing of fuel-burning
combustion equipment. This analyzer is for furnace and boiler technicians
who need to determine combustion safety, environmental compliance, and
efficiency of small to large commercial industrial heating systems.
1.2 Features
•Measures and displays O2and CO in the flue gas, pressure (draft),
primary air temperature, and stack temperature.
•Calculates combustion efficiency, excess air, and CO2.
•Optionally measures and displays NO, NO2, SO2, HC (methane equivalent
combustibles), and CO (in the high range of 4,000 to 80,000 ppm).
•Optionally calculates NOx (the combination of NO and NO2), and
calculates CO, SO2, and NOx individually referenced to a user defined
Oxygen level of between 0 and 15%.
•Automatically purges the low-range CO sensor with fresh air if the CO
level exceeds 4,000 ppm. At this time the analyzer also automatically
switches over to its optional high-range CO sensor, if installed.
•Automatically zeros all sensing channels on ambient air when the
analyzer is first turned on.
•Displays temperature in either °C or °F.
•Displays pressure in either inches of water column (inwc), millibars (mb),
Pascals (Pa), or hecto Pascals (hPa).
•Optionally displays pollution conversions for CO, NO, NO2, and SO2.
Pollution conversions include parts per million (ppm), pounds of pollutant
per million BTU (#/MBTU), milligrams of pollutant per cubic meter of gas
(mg/m3), and grams of pollutant per gigajoule (g/GJ).
•Low battery warning message.
•Stores over 1000 individual combustion and/or pressure test records,
which can later be recalled for viewing or printing.
•Stored test records can be downloaded to a personal computer in comma-
delimited format, which can be captured as a text file and then opened in a
spreadsheet program.

Introduction ECA 450
2 Instruction 0024-9400
•Performs data logging. A series of combustion tests can be automatically
started at user-defined intervals, and the data saved for reviewing at the
conclusion of the logging period. The data can be stored in either the
analyzer’s internal memory, sent to a personal computer, or both.
•Utilizes four sources of primary-air temperature information in the
following priority: 1) A thermocouple can be inserted into the primary-air
stream and plugged into the analyzer’s front panel T-AIR connector. 2) A
primary-air temperature reading can be made with the probe’s
thermocouple and stored in memory. 3) An external thermometer can be
used to take a primary-air temperature reading and then entered into
memory using the analyzer’s front panel keypad. 4) If no other primary-air
temperature source is available, the analyzer defaults to an internal case
temperature that is measured the on printed circuit board.
•Stores test identification that is manually entered by an operator. This
information is added to the test records as they are saved, and appears
within each test record when printed.
•Stores user name information that is manually entered by the owner or
user of the analyzer. This information appears at the top of each printout.
•Displays information in either English, French, or Spanish.
•Can be set up to automatically turn off the front-panel display to conserve
battery life.
1.3 Technical Data
The ECA 450 Directly Measures and Displays:
•Oxygen content in flue gas in the range of 0.1 to 20.9% O2.
•Stack gas temperature in the range of –4 to 2400 ºF (–20 to 1315 ºC).
•Primary-air in the range of –4 to 999 ºF (–20 to 999 ºC).
•Pressure in the range of ±27.7 inches of water column (±69 mb).
•Carbon Monoxide content in flue gas in the range of 0 to 4,000 ppm CO
(corrected for the presence of Hydrogen).
Optionally . . .
•Carbon Monoxide in the range of 4,000 to 80,000 ppm CO.
•Nitric Oxide in the range of 0 to 3,500 ppm NO.
•Nitrogen Dioxide in the range of 0 to 500 ppm NO2.
•Sulfur Dioxide in the range of 0 to 4,000 ppm SO2.
•Combustibles in the range of 0 to 5% gas.
The ECA 450 Calculates and Displays:
The following is true only when the measured Oxygen level is not above 16.0%,
and the Stack (Flue Gas) temperature is not above 2192 °F (1200 ºC)
•Combustion efficiency in the range of 0.1 to 100%.
•Excess Air in the range of 1 to 250%.
•Carbon Dioxide content in flue gas in the range of 0.1 to a fuel dependent
maximum CO2value in percent.
•Carbon Monoxide content referenced to a user defined percentage of
Oxygen in the range of 0 to 99,999 ppm CO.
•Differential pressure in the range of ±27.7 inches of water column
(±69 mb).

ECA 450 Introduction
Instruction 0024-9400
3
Optionally . . .
•NOx content in the range of 0 to 4,000 ppm NOx.
•NOx content referenced to a user defined percentage of Oxygen in the
range of 0 to 17,000 ppm NOx.
•Nitric Oxide content referenced to a user defined percentage of Oxygen
in the range of 0 to 14,900 ppm NO.
•Nitrogen Dioxide content referenced to a user defined percentage of
Oxygen in the range of 0 to 2,100 ppm NO2.
•Sulfur Dioxide content referenced to a user defined percentage of Oxygen
in the range of 0 to 17,000 ppm SO2.
Fuels Available for Combustion Calculations:
•Natural Gas •Propane
•Oil #2 •Coal
•Oil #4 •Wood
•Oil #5 •Kerosene
•Oil #6 •Bagasse
Normal Operating Environment:
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" H2O (25 mb) negative pressure max. at probe tip.
Accuracy:
Oxygen....................................±0.3% O2, on a practical concentration of flue
gas (mixtures of O2, CO2and N2)
Carbon Monoxide ..................±5% of reading or ±10 ppm, whichever is
greater, between 0 and 2,000 ppm CO, and
±10% of reading between 2,001 and
40,000 ppm CO
Nitric Oxide............................±5% of reading or ±5 ppm, whichever is greater,
between 0 and 2,000 ppm NO
Nitrogen Dioxide....................±5% of reading or ±5 ppm, whichever is greater,
between 0 and 500 ppm NO2
Sulfur Dioxide........................±5% of reading or ±10 ppm, whichever is
greater, between 0 and 2,000 ppm SO2
Combustibles..........................±5% of full scale
Stack Temperature................±4 °F between 32 and 255 °F
(±2 °C between 0 to 124 °C)
±6 °F between 256 and 480 °F
(±3 °C between 125 to 249 °C)
±8 °F between 481 and 752 °F
(±4 °C between 250 to 400 °C)
Primary Air / Ambient
Temperature .......................±2 °F between 32 and 212 °F
(±1 °C between 0 to 100 °C)
Pressure .................................±2% of reading or ±0.05 mB (0.02 inches of H2O),
whichever is greater.

Introduction ECA 450
4 Instruction 0024-9400
Front Panel Controls and Indicators:
Sixteen embossed push-button switches with tactile feedback (refer to
Section 1.6). One POWER LED.
Display:
2¼" ×8", 20 character by 4 line alphanumeric vacuum-fluorescent
display panel.
Power Requirements:
Internal 7.2V battery pack, or AC adapter (100–240 VAC, 50/60 Hz).
Operating Time:
A fully charged battery pack will provide at least 8 hours of continuous
operation with the pump running. Unlimited operating time when using the
AC adapter.
Warm Up Time:
60 seconds.
Printer:
Internal, 2¼" wide paper, 20 characters.
Materials:
•High impact ABS plastic briefcase with storage for the standard probe,
instruction manual, and AC adapter.
•Nickel plated, brass quick-connect hose fittings.
•Stainless steel probe.
Dimensions:
Height: 13.5 in. (343 mm).
Width: 18.5 in. (470 mm).
Depth: 9 in. (229 mm).
Weight:
Approximately 25 lbs (11.34 kg).

ECA 450 Introduction
Instruction 0024-9400
5
1.4 Operation Overview
The ECA 450 is microprocessor controlled, allowing it to be easily operated
and configured to suit each operator’s individual needs. Using a system of
menu selections, the operator is guided through the proper operation and set-
up procedures, signaling the appropriate action, and waiting until the correct
steps are taken.
The analyzer is powered by either its internal battery pack, or by an AC
adapter that operates from any convenient source of 100–240 VAC, 50/60 Hz
power. The analyzer’s control panel consists of a bright and easy-to-read 2¼"
×8" blue vacuum-fluorescent display, sixteen pushbuttons, and one POWER
LED. A sampling probe and hose assembly with an integral thermocouple
and water/filter trap provides the means of drawing in gas samples, and for
measuring stack temperature and pressure.
A burner’s combustion efficiency is calculated by first entering the fuel being
burned and then allowing the analyzer to measure the burner’s primary air
temperature, stack temperature, and percent Oxygen in the flue gas. This
information is processed by the analyzer, resulting in the display of all the
measured and calculated values that are listed in Section 1.3 Technical Data.
For analyzer models that are equipped for environmental monitoring of
combustion by-products, the gas sample that was drawn into the analyzer
through its probe is applied to an array of electrochemical gas sensors. The
results of the analyzer’s gas analyses are shown on the front panel display.

Introduction ECA 450
6 Instruction 0024-9400
1.5 Front Panel Connections and Controls
Figure 1-1. ECA 450 Components
RS 232
POWER
OPT T-STACK T-AIR
PRESSUREGAS
P REF
ECA 450
SET UP
CALIBRATE
MEMORY
FUEL
MENU
PRINT
POWER
I/O
RUN
SAVE
ENTER
V
ESC
PRESSURE
PRINT – Prints contents of either the
Combustion Test or Pressure screen
on local printer.
SAVE – Saves to memory the contents
of the Combustion Test or Pressure
screen. Saved data can later be
recalled for viewing on the display, or
downloaded to a personal computer.
MENU – Steps display from the
Combustion Test screen through the
Setup List, Calibrate, Fuel, Pressure,
and Memory menu screens.
Alternately, a particular menu screen
can be directly displayed by pressing
its associated shortcut key.
I/O – Turns analyzer ON and OFF.
RUN – Starts and stops a combustion
efficiency test.
SET UP – Displays Setup List
screen.
CALIBRATE – Displays Calibrate
screen.
FUEL – Displays Fuel screen.
PRESSURE – Displays Pressure
screen.
MEMORY – Displays Memory
screen.
ESC – Displays previous menu or previously
viewed screen.
– Moves cursor left.
– Moves cursor up through screen, or
increments an alphanumerical value.
– Moves cursor down through screen, or
decrements an alphanumerical value.
– Moves cursor right.
ENTER – Chooses a menu item that has been
selected by the cursor's position.
VACUUM FLUORESCENT
DISPLAY PANEL
(4 Lines by 20 Characters)
PRINTER
BATTERY CHARGER/
AC ADAPTER CONNECTOR
RS 232 CONNECTOR
P REF – Differential pressure
reference hose connector
GAS – Probe's stack hose connector
PRESSURE – Probe's draft hose
connector
T-STACK – Probe's Flue-gas
thermocouple connector
T-AIR – Primary air thermocouple
connector
OPT – Option connector
STORAGE COMPARTMENT
6" x 18" x 3"
SENSOR COMPARTMENT
SHORTCUT MENU KEYS:
P / P
1.5.1 GAS, PRESSURE, T-STACK (Probe)
Attach the supplied probe to the analyzer by connecting its . . .
•flue-gas thermocouple to the analyzer’s T-STACK connector,
•flue-gas hose (yellow band) to the analyzer’s GAS connector,
•draft hose (blue band) to the analyzer’s PRESSURE connector.
Observe that the probe’s connectors are of different sizes and shapes, which
prevent misconnection to their associated connectors on the analyzer.