Bacharach PCA 2 User manual

Product Leadership • Training • Service • Reliability
Portable Combustion Analyzer
Instruction 24-9448
Operation & Maintenance
Rev. 4 - July 2009

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 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 IM-
PLIED 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 ARIS-
ING 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 limita-
tion will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.
AInstruction 24-9448
Register Your Warranty by Visiting
www.bacharach-inc.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 © 2006, 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 companies.

Instruction 24-9448 i
Contents
Contents
1 Introduction.................................. 1-1
1.1 PCA2GeneralDescription...............................1-1
1.2 Sales Combo & Model Configurations . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 Features&Benefits ....................................1-4
1.4 OperationalOverview...................................1-5
1.5 ConnectorDescriptions..................................1-6
1.5.1 Probe Connections (Gas, Pressure, T-Stack) . . . . . . . . . . . .1-6
1.5.2 T-AIR (Primary Air Thermocouple). . . . . . . . . . . . . . . . . . .1-6
1.5.3 POWER(ACAdapter) .............................1-8
1.5.4 ∆P (Differential Pressure) ..........................1-8
1.5.5 USB (Computer Interface) . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.5.6 IrDA (Printer Interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.5.7 OPT(Option).....................................1-9
1.6 FrontPanelButtons ....................................1-9
2 Specications................................. 2-1
3 Initial Setup .................................. 3-1
3.1 Scope ................................................3-1
3.2 Power................................................3-1
3.2.1 Installing or Replacing Batteries. . . . . . . . . . . . . . . . . . . . .3-1
3.2.2 Using the AC Power Adapter . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Connecting the Probe and Hose Assembly. . . . . . . . . . . . . . . . . . .3-2
3.4 OperatingParameters.................................. 3-4
3.5 FuelSelection ........................................ 3-4
3.6 Temperature Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.7 PressureUnitsSelection................................ 3-6
3.8 PollutionUnitsSelection.................................3-7
3.9 DateSetup........................................... 3-8
3.10 TimeSetup.......................................... 3-9
3.11 O2ReferenceSetup...................................3-10
3.12 Print Pressure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3.13 Zoom-Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3.14 Battery Charger Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3.15 LoggingSelection ....................................3-14
3.16 ButtonSound........................................3-14
3.17 Test ID Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3.18 Username. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3.19 Language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.20 Cal Reminder Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3.21 Run/Hold Screen Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Instruction 24-9448
ii
Contents
4 Operation .................................... 4-1
4.1 OperatingTips.........................................4-1
4.2 Turning ON the Analyzer and Warm Up . . . . . . . . . . . . . . . . . . .4-2
4.3 SelectingaFuel....................................... 4-3
4.4 SamplingPoint ....................................... 4-4
4.5 Performing a Combustion Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6 PressureLabelSelection.................................4-7
4.7 Temperature Measurement Label . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.8 Making a Draft / Pressure Measurement . . . . . . . . . . . . . . . . . . 4-9
4.9 SavingTestData......................................4-10
4.10 Ending a Combustion Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.11 Emptying the Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.12 Turning OFF the Analyzer & Purging . . . . . . . . . . . . . . . . . . .4-12
4.13 LowBatteryAlarm...................................4-12
4.14 DataLogging........................................4-13
4.14.1 Turning ON Data Logging . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.14.2 Setting the Logging Interval and Duration. . . . . . . . . . .4-15
4.14.3 Starting the Data Logging Process . . . . . . . . . . . . . . . . .4-16
4.14.4 Ending the Data Logging Process . . . . . . . . . . . . . . . . . .4-17
4.15 Memory ............................................4-17
4.15.1 Recalling Combustion Test Data . . . . . . . . . . . . . . . . . . .4-18
4.15.2 Recalling Logged Test Data . . . . . . . . . . . . . . . . . . . . . . .4-19
4.15.3 Clearing Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.16 Downloading Stored Data to a Computer. . . . . . . . . . . . . . . . . .4-21
4.16.1 PCA 2 Data Recovery Program Installation . . . . . . . . . 4-22
4.16.2 Computer to PCA 2 Connection & USB Device
Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.16.3 RecoveringData............................... 4-26
4.17 Importing Saved Data Into a Spreadsheet . . . . . . . . . . . . . . . . . .4-29
4.18 PrintingTestData....................................4-31
5 Calibration ................................... 5-1
5.1 SmartSensors.........................................5-1
5.2 StartingaCalibration...................................5-1
5.3 Pressure Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 T-StackCalibration.................................... 5-4
5.5 T-AirCalibration...................................... 5-6
5.6 CO-LO Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7 SO2SensorCalibration.................................5-10
5.8 NOSensorCalibration .................................5-11
5.9 NO2SensorCalibration.................................5-12
5.10 CO-HI Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Instruction 24-9448 iii
Contents
6 Maintenance.................................. 6-1
6.1 PCA2Disassembly.................................... 6-2
6.2 Water Trap / Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.1 Emptying the Water Trap Chamber . . . . . . . . . . . . . . . . . 6-6
6.2.2 Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Smart Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6.4 SensorOnlyReplacement............................... 6-8
6.5 Nitric Oxide Sensor Battery Replacement . . . . . . . . . . . . . . . . . .6-10
6.6 Thermocouple Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6.7 PumpReplacement ....................................6-13
6.8 CleaningtheProbe....................................6-14
7 Troubleshooting .............................. 7-1
7.1 AnalyzerRepair........................................7-1
7.2 ErrorSymbols.........................................7-1
7.3 Error Messages Displayed After Warm-Up . . . . . . . . . . . . . . . . . .7-2
7.4 Diagnostics and Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
8 Parts & Service ............................... 8-1
8.1 ReplacementParts......................................8-1
8.2 Accessories........................................... 8-4
8.3 ServiceCenters....................................... 8-6

Instruction 24-9448
iv
Contents
Notes:

Instruction 24-9448 1-1
Introduction
1 Introduction
1.1 PCA 2 General Description
The PCA 2 is a commercial-grade hand-held combustion and emissions
analyzer designed for on-demand sampling of light industrial, institu-
tional, 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, Data
Download Software with USB cable and carrying case.
Because of the PCA 2’s ability to measure up to four gases simultaneously,
it is the perfect tool for service technicians, inspectors and boiler contrac-
tors who need to determine combustion efficiency, excess air, stack gas O2
and CO levels, stack temperature, draft, and differential pressure. The
analyzer can also directly measure and display NO, NO2and SO2with the
installation of the appropriate sensors. Combustion efficiency calculations
can be conducted for the following fuels: natural gas, oil #2, oil #4, oil #6,
propane, coal, wood, kerosene, bagasse, and digester gas. A large backlit
graphical display shows up to eight combustion test values simultaneously,
and includes a zoom capability that provides an extra large display.
Smart sensor technology allows a new sensor to be installed in the field
without having to calibrate the analyzer before use. New and innovative
probe and analyzer designs allow the PCA 2 to be easily serviced, thus
lowering the cost of ownership.
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.
An optional AC power adapter allows the analyzer to run continuously for
data logging purposes.
The optional sample conditioning probe is recommended when measuring
NO2and SO2to ensure the highest degree of measurement accuracy.

Instruction 24-94481-2
Introduction
1.2 Sales Combo & Model Configurations
Sales Combo 24-8350 24-8351 24-8352
Sales Combo (Kit) 24-8370 24-8371 24-8372
Model Type 225 235 245
PCA2 Only Part Number 24-7301 24-7302 24-7303
Measurements
Oxygen (O2)333
Stack Temperature 333
Primary / Ambient Air Temperature 333
Carbon Monoxide Low (COLow)333
Pressure / Draft 333
Carbon Monoxide High (COHigh)3
Nitric Oxide (NO) 3
Nitrogen Dioxide (NO2)
Sulfur Dioxide (SO2)
Calculations
Combustion Efciency 333
Excess Air 333
Carbon Dioxide (CO2)333
NOx (NOx = NO + NO2)
NOx referenced to %O2
CO referenced to %O2333
NO referenced to %O23
NO2referenced to %O2
SO2referenced to %O2
Refer to Section 8.2 for a listing of standard and optional accessories.

Instruction 24-9448 1-3
Introduction
Sales Combo 24-8353 24-8354 24-8355
Sales Combo (Kit) 24-8373 24-8374 24-8375
Model Type 255 265 275
PCA2 Only Part Number 24-7304 24-7305 24-7306
Measurements
Oxygen (O2)3 3 3
Stack Temperature 3 3 3
Primary / Ambient Air Temperature 3 3 3
Carbon Monoxide Low (COLow)3 3 3
Pressure / Draft 3 3 3
Carbon Monoxide High (COHigh)
Nitric Oxide (NO) 3 3
Nitrogen Dioxide (NO2)3
Sulfur Dioxide (SO2)3 3
Calculations
Combustion Efciency 3 3 3
Excess Air 3 3 3
Carbon Dioxide (CO2)3 3 3
NOx (NOx = NO + NO2)3
NOx referenced to %O23
CO referenced to %O23 3 3
NO referenced to %O23 3
NO2referenced to %O23
SO2referenced to %O23 3

Instruction 24-94481-4
Introduction
1.3 Features & Benefits
• Powered by 4 ‘AA’ alkaline batteries, or NiMH rechargeable batteries.
An optional AC power adapter provides continuous operation.
• Internal charging circuit allows rechargeable batteries to be charged
inside the analyzer with the use of the optional AC power adapter.
• O2and COLow measurement standard. Optional measurement of up to
two additional gases: COHigh, NO, NO2, or SO2.
• With the appropriate sensors installed, the analyzer optionally dis-
plays pollution conversions for CO, NO, NO2, and SO2. Pollution con-
versions include ppm, #/MBTU, mg/m3, and g/GJ.
• Smart sensor technology allows pre-calibrated sensors to be installed
in the field.
• Automatic zero of all sensing channels on ambient air when the ana-
lyzer is first turned ON.
• Automatic flushing of the COLow sensor with fresh air if the CO level
exceeds 4,000 ppm, thus protecting the COLow sensor from high CO
levels. To measure CO levels above 4,000 ppm, the analyzer automati-
cally switches to its COHigh sensor, if installed.
• Automatic purging of the gas-sample system if the detected gas levels
are abnormally high when the analyzer is turned OFF.
• Displays temperatures in either °F or °C.
• Displays pressure in either inwc, mb, Pa, or hPa.
• Backlit graphic LCD with zoom capabilities.
• Low battery alarm.
• Stores 500 individual combustion records, which can later be recalled
for viewing, printing, or downloading to a personal computer. Stores an
additional 500 data logged records.
• Wireless IrDA link used for printing current and stored combustion
records, pressure records, sensor calibration data, and diagnostic data.
• USB connectivity for downloading stored data to a personal computer.
• Field replaceable sensors and thermocouple.
• Two year warranty on analyzer and all gas sensors except the O2 sen-
sor which has a one (1) year warranty.

Instruction 24-9448 1-5
Introduction
•Language options including English, French, and Spanish
•Custom Display Formats
•Calibration Reminders - PCA2 can be set up to remind the user that
calibration is past due.
1.4 Operational Overview
The PCA 2 is powered by either its 4 internal batteries, or by an optional
AC power adapter that operates from any convenient source of 100–
240 VAC, 50/60 Hz power. The type of batteries used can be either dispos-
able alkaline or rechargeable NiMH. Note that rechargeable batteries can
be charged inside the analyzer using the optional AC power adapter.
The PCA 2 is controlled by 11 front panel push buttons, while a graphical
LCD is used to display all combustion and emission test data and analyzer
parameters.
A probe and hose assembly, with an integral thermocouple and filter/wa-
ter-trap connect to the bottom of the analyzer, thus providing the means of
drawing in gas samples, and for measuring stack temperature and draft.
The PCA 2 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 “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 display. To change the fuel: first, press the
MENU (F2) button; next, select FUEL from the menu; then use the but-
tons to highlight the fuel being burned; and finally, press the green ENT
button to select the highlighted fuel.
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

Instruction 24-94481-6
Introduction
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 ana-
lyzer will begin to continuously monitor the stack temperature, %O2and
emission levels in the stack gas and then display measured and calculated
values on its LCD. Values are listed in Section 2 Specifications.
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 CO-
High sensor, if installed, at CO levels starting at 4,001 ppm, thus providing
continuous CO readings up to 20,000 ppm.
A backlight enables a user to read the display in dimly-lit areas. Turn the
backlight ON and OFF by briefly pressing the I/O button.
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 analyz-
er 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.
1.5 Connector Descriptions
1.5.1 Probe Connections (Gas, Pressure, T-Stack)
Attach the probe and hose assembly to the analyzer by connecting its . . .
• stack-gas thermocouple to the analyzer's T-STACK connector,
• stack-gas hose to the analyzer's GAS connector,
• draft hose to the analyzer's +∆P connector.
Observe that the probe connectors are of different sizes and shapes, which
prevent incorrect connection to their associated connectors on the analyzer.

Instruction 24-9448 1-7
Introduction
T-STACK T-AIR
Figure 1-1. PCA 2 Components
LCD – 160 x 160
graphic display
F1 / F2 / F3 –
Soft Menu Buttons,
whose functions are
dened by labels
appearing above them
on LCD
Arrow Buttons:
– Moves cursor
up the display,
or increments an
alphanumerical value
– Moves cursor
down the display,
or decrements an
alphanumerical value
– Moves cursor left,
or moves to top of
menu list
– Moves cursor right,
or moves to bottom of
menu list
ENT:
•Selects a highlighted
menu item, or conrms the
entry of data
RUN / HOLD:
• Starts and stops a combustion
efciency test
• Pressing this button during
the 5 second turn-off period will
keep the analyzer turned ON
ESC – Displays previous menu
or previously viewed screen
I/O – Press from between
1 and 2 seconds to turn
analyzer ON and OFF
– With analyzer turned
ON, press briey to turn
backlight ON and OFF
POWER – AC power adapter
connector
OPT – Option external
measurement connector
T-STACK – Probe’s stack-gas
thermocouple connector
T-AIR – Primary /
ambient air thermo-
couple connector
GAS – Probe’s gas
hose connector
“+∆P” Probe’s draft
hose tting
“–∆P” Reference
pressure hose tting
USB – Computer
communications
connector
IrDA – Wireless printer
communications port

Instruction 24-94481-8
Introduction
1.5.2 T-AIR (Primary Air Thermocouple)
If thermocouple P/N 104-1797 (10 feet long) or Utility Wand P/N 104-1799
(12 inch ridged probe with handle and 5 foot coiled cable) is to be used
to measure the burner’s primary air temperature, then connect either of
these thermocouples to the analyzer’s T-AIR connector.
1.5.3 POWER (AC Adapter)
The AC power adapter P/N 24-1404 can be used as an external power sup-
ply, which will run the analyzer on a continuous basis.
When using rechargeable NiMH batteries, the AC power adapter can also
be used to charge the batteries while inside the analyzer. The analyzer’s
rapid-charger circuit, however, must first be turned ON per Section 3.16.
The rapid charger will charge a set of depleted batteries in approximately
2 - 3 hours.
When disposable alkaline batteries are used, the analyzer’s battery char-
ger circuit must be OFF to prevent the batteries from overheating. As a
precaution, the charger circuit is automatically toggled back to its OFF
state when the analyzer is turned OFF.
1.5.4 ∆P (Differential Pressure)
Draft is measured by connecting the probe’s draft hose to the +∆P fitting,
while leaving the –∆P fitting open to the atmosphere.
In addition to measuring draft, the “+” and “–” ∆P fittings can also be used
to measure the differential pressure between two areas by first connecting
a hose P/N 24-1103 to the –∆P fitting, and then inserting the open end of
this hose into the area being used as the reference pressure. The analyzer’s
probe is then inserted into the area where differential pressure is to be
measured. Refer to Section 4.6.
1.5.5 USB (Computer Interface)
Data that has been stored in the analyzer’s memory can be downloaded to
a personal computer by connecting USB data cable P/N 104-4032 between
the USB ports of the computer and analyzer. Refer to Section 4.14.2.
1.5.6 IrDA (Printer Interface)
Data that has been stored in the analyzer’s memory can be printed on a

Instruction 24-9448 1-9
Introduction
compatible IrDA wireless printer by aligning their IrDA communication
ports. Refer to Section 4.16.
1.5.7 OPT (Option)
The option connector is used for optional external measurement features.
1.6 Front Panel Buttons
Descriptions of the front panel buttons are given below. Note that a control
may perform multiple functions as determined by what screen is being
displayed at the time.
The functions of these buttons are defined by labels ap-
pearing above them on the LCD. The labels that appear
depend on the functions that can be performed in the
particular screen being displayed.
PRINT (F1): Transmits the data displayed on the screen
to a printer through the IrDA communications port.
MENU (F2): Displays the Main Menu.
SAVE (F3): Saves the data currently displayed on the
LCD in memory. Up to 500 individual Combustion Test
and Pressure records can be saved. After 500 records
have been saved, the memory must be cleared to continue
saving additional data. The analyzer will not overwrite
old data.
ZERO (F2): When viewing the Pressure screen, this
button zeros the pressure sensor to current atmospheric
conditions. When viewing the Temperature screen, this
button zeroes the temperature channel difference.
PAGE– (F1): When viewing the Memory or Logging
Directory, each press of this button pages down through
the directory. Holding this button down speeds up the
paging process.
PAGE+ (F3): When viewing the Memory or Logging
Directory, each press of this button pages up through
the directory. Holding this button down speeds up the
paging process.

Instruction 24-94481-10
Introduction
The arrow buttons move the cursor on the LCD in the di-
rection of the arrow. In screens that require the entry of
alphanumerical data, use the buttons to move cursor
across the screen and then use the buttons to incre-
ment and decrement the data. When viewing a menu, use
the buttons to quickly move to the top and bottom of
the menu.
Selects a highlighted menu. In addition, if changes were
made to one of the analyzer’s operating parameters (e.g.,
date, time, O2reference, etc.), pressing this button con-
firms those changes and saves them in memory.
Starts and stops a combustion test when the Combus-
tion Test screen is displayed. Pressing this button in any
other screen returns the analyzer to the Combustion Test
HOLD screen. Pressing this button during the 5 second
turn-off-delay period will abort the turn-off process and
also return the analyzer to the Combustion Test HOLD
screen.
Displays a previously viewed screen. In addition, if
changes were made to one of the analyzer’s operating
parameters (e.g., date, time, O2reference, etc.), pressing
this button aborts those changes, restores the old values,
and then displays the previously viewed screen.
Turns the analyzer ON and OFF, and is also used to
turn the backlight and button LEDs ON and OFF.
Note that when the analyzer is turned OFF, there is a
5 second delay, during which time an operator can keep
the analyzer turned ON by pressing the RUN / HOLD
button. Also note that if the measured emission levels
are above predetermined limits at the time the instru-
ment is turned OFF, the pump is automatically started
and purges the sensor compartment with fresh air until
the gas levels inside the analyzer are reduced. If desired,
the purging process can be aborted by again pressing the
I/O button.

Instruction 24-9448 2-1
Specications
2 Specifications
The PCA 2 Directly Measures and Displays:
The gases displayed depend on the analyzer’s model number.
Refer to Section 1.2.
Oxygen .............................................. 0to20.9%
Stack Temperature. . . . . . . . . . . . . . . . . . . . –4 to 2,192 ºF (–20 to 1,200 ºC)
Primary / Ambient Air Temperature . . . . . . . . –4 to 999 ºF (–20 to 537 ºC)
Carbon Monoxide (CO) (H2compensated). . . . . . . . . . . . . . . . 0 to 4,000 ppm
Pressure/Draft................................±72"H2O (±180 mb)
COHighRange ............................... 4,001to20,000ppm
NitricOxide(NO)...................................0to3,000ppm
Nitrogen Dioxide (NO2)............................... 0to500ppm
Sulfur Dioxide (SO2) ................................0to5,000ppm
The PCA 2 Calculates and Displays:
Calculations are performed only when the measured oxygen level is below
16.0%, and the stack temperature is below 2,000 °F (1,093 ºC).
CombustionEfficiency..................................0.1to100%
ExcessAir.............................................1to250%
Carbon Dioxide (dry basis). . . . . . . . . . 0.1 to fuel dependent maximum in %
NOx (NOx = NO + NO2)..............................0to3,500ppm
NOx referenced to %O2..............................0to9,999ppm
CO referenced to %O2................................0to9,999ppm
NO reference to %O2................................0to9,999ppm
NO2reference to %O2................................0to9,999ppm
SO2reference to %O2................................0to9,999ppm
Fuels Available for Combustion Calculations:
•Natural Gas •Coal
•Oil #2 •Wood
•Oil #4 •Kerosene
•Oil #6 •Bagasse
•Propane •Digester Gas

Instruction 24-94482-2
Specications
Normal Operating Conditions:
Temperature:
Analyzer ............................... 32to104ºF(0to40ºC)
ProbeTip.................................1,472ºF(800ºC)Max.
Humidity:
Analyzer . . . . . . . . . . . . . .15 to 90% Relative Humidity, non-condensing
Air Pressure:
Analyzer .........................................Atmospheric
Probe..................... 10"H2O (25 mb) draft max. at probe tip
Performance:
Accuracy:
O2.............................±0.3%O2on practical concentrations
of stack gas (mix of O2, CO2and N2)
CO . . . . . . . . . . . . . . . . . . . . . . . . . . ±5% of reading or ±10 ppm,
whichever is greater between
0–2,000 ppm, and ±10% of reading
between 2,001–20,000 ppm.
NO . . . . . . . . . . . . . . . . . . . . . . . . . . ±5% of reading or ±5 ppm,
whichever is greater between
0–2,000 ppm
NO2......................... ±5%ofreadingor±5ppm,
whichever is greater between
0–500 ppm
SO2......................... ±5%ofreadingor±10ppm,
whichever is greater between
0–2,000 ppm
Stack 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)
Primary / Ambient Air Temp.. . . . . ±2 ºF between 32 and 212 ºF
(±1 °C between 0 and 100 °C)
Pressure / Draft. . . . . . . . . . . . . . . . ±2% of reading or ±0.02 "H2O
(±0.05 mb), whichever is greater
System Flow Rate with Probe . . . . . . . 200 cc/min minimum

Instruction 24-9448 2-3
Specications
Power Requirements:
Four disposable ‘AA’ alkaline batteries provide at least 15 hours of continu-
ous operation. NiMH rechargeable batteries can also be used, with the
operating time dependent on battery type and condition.
An optional AC power adapter, which runs from any convenient source of
100–240 VAC, 50/60 Hz power, can be used to power the analyzer on a con-
tinuous basis. If using rechargeable batteries, the AC power adapter can also
be used to charge the batteries while inside the analyzer.
Warm-Up Time:
60 seconds. Sensors are checked and auto zeroed during warm-up.
Memory:
• 500 complete combustion test records
• 500 complete logged combustion test records
Interfaces:
• Printer – Infrared (IrDA) communications
• Computer – USB
Dimensions:
9H x 3W x 2.5D inches (22.9 x 7.6 x 6.3 cm)
Weight:
• Analyzer – 1.4 lb (0.6 kg) w/ batteries
• Probe & Hose Assembly – 1 lb (0.5 kg)

Instruction 24-94482-4
Specications
Notes: