Bacharach 300 User manual

INSTRUCTION 24-9223
MODEL 300
COMBUSTION ANALYZER
(Standard Efficiency Equations,
Siegert Efficiency Equations,
and NSX Version)
Operation/Maintenance
Rev. 2 – November 1999
Bacharach, Inc.
625 Alpha Drive, Pittsburgh, PA 15238
Phone: [phone] • FAX: [phone] • Web: www.bacharach-inc.com
Printed in U.S.A. ® Registered Trademark

MODEL 300 COMBUSTION ANALYZER
A
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 warranty set forth in paragraph 1 does not apply to parts the Operating Instructions
designate as having a limited shelf-life or as being expended in normal use.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND AC-
CEPTED 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
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTACT 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: O-Rings and Gaskets are considered consumable items and are
excluded from the terms of this warranty.

MODEL 300 COMBUSTION ANALYZER
WARNINGS!
• Burn hazard. DO NOT touch the Model 300 Combustion Analyzer probe
after it is removed from a stack. Allow the probe to cool before han-
dling.
• Burn hazard. When emptying filter/trap bowl and particulate trap, be
aware that both traps may contain hot and mildly corrosive water. Take
the necessary precautions to avoid being burned.
• Burn hazard. All of the sensors contain corrosive chemicals. DO NOT
puncture or take them apart.
CAUTIONS:
• To avoid damaging the probe assembly due to excessive heat, remove
probe from stack at or before the prescribed time listed below. Allow
probe to cool to room temperature before reinserting it back into the
stack.
100–1000°F (38–538°C) ....... Unlimited
1000–1200°F (538–649°C) ....... 30 mins. per exposure
1200–1400°F (649–760°C) ....... 10 mins. per exposure
Note that the high-temperature extended-probe options have unlimited
exposure times up to 2000°F (1093°C)
• Allow probe to cool before placing it in case.
• DO NOT store the Model 300 Combustion Analyzer at temperatures
below – 4°F (– 20°C).
Instruction 24-9223 i

MODEL 300 COMBUSTION ANALYZER
TABLE OF CONTENTS
ii Instruction 24-9223
1 INTRODUCTION ................................................................................ 1-1
1.1 Scope of Manual .......................................................................... 1-1
1.2 Basic Features ............................................................................. 1-2
1.3 Optional Features ....................................................................... 1-3
1.4 Basic Panel Functions & Displays .............................................. 1-4
1.4.1 CAL, FUEL, and RUN Keys ............................................ 1-4
1.4.2 Left Display and Select Key ........................................... 1-5
1.4.3 Middle Display and Select Key ........................................ 1-7
1.4.4 Right Display and Select Key .......................................... 1-8
1.5 Optional Auxiliary Panel Functions & Displays ........................ 1-9
1.5.1 Left Display - Clock .......................................................... 1-9
1.5.2 Middle Display - ppm NOX .............................................. 1-9
1.5.3 Right Display - ppm SO2 ................................................. 1-9
2 SET-UP ................................................................................................. 2-1
2.1 230 VAC Plug Installation .......................................................... 2-2
2.2 Printer Paper Installation .......................................................... 2-2
2.3 Filter/Trap Installation ............................................................... 2-2
2.4 Probe Connection ........................................................................ 2-3
2.5 Initial Start-up and Adjustment ................................................. 2-4
2.6 Sensor Checks ............................................................................. 2-7
2.7 Optional Clock Setting ................................................................ 2-8
2.8 Optional Analyzer Configuration ............................................. 2-10
3 OPERATION ........................................................................................ 3-1
3.1 Performing an Efficiency Test .................................................... 3-3
3.2 Gas Sampling Points ................................................................... 3-6
3.3 Installing the Probe ..................................................................... 3-6
3.4 Printer Operation ........................................................................ 3-7
3.5 Error, Warning and Overrange Displays ................................... 3-9
3.5.1 Basic Error, Warning and Overrange Displays .............. 3-9
3.5.2 Optional Error, Warning, and Overrange Displays ..... 3-10
3.6 Recalibration after an Efficiency Test ...................................... 3-14
3.7 Changing Fuels ......................................................................... 3-15
3.8 Combustion Analyzer Shutdown and Storage ......................... 3-15
3.9 Charging the Battery Pack ....................................................... 3-18

MODEL 300 COMBUSTION ANALYZER
Instruction 24-9223 iii
4 CALIBRATION .................................................................................... 4-1
4.1 Sensor and/or Control Panel Removal........................................ 4-3
4.2 Ambient Temperature Calibration - R24 ................................... 4-5
4.3 Toxic Gas Span Calibration ........................................................ 4-7
4.3.1 CO Span Calibration - R9 ................................................ 4-7
4.3.2 Optional NOX & SO2 Span Calibration .......................... 4-9
4.4 Thermocouple Span Calibration - R19 ....................................... 4-9
4.4.1 Low-Range Thermocouple Calibration ........................... 4-9
4.4.2 High-Range Thermocouple Calibration ........................ 4-11
4.5 Oxygen Sensor Calibration ....................................................... 4-14
5 MAINTENANCE .................................................................................. 5-1
5.1 Oxygen Sensor Replacement ...................................................... 5-1
5.2 Toxic Sensor Replacement .......................................................... 5-3
5.3 Filter/Trap Filter Replacement .................................................. 5-5
5.4 Cleaning the Gas Sampling System ........................................... 5-7
5.4.1 Cleaning the Probe and its Sampling Hose .................... 5-7
5.4.2 Cleaning the Analyzer’s Sampling System ................... 5-10
5.5 Leak Testing .............................................................................. 5-12
5.6 Printer Paper Replacement ...................................................... 5-13
5.7 Optional Sensor Bias Battery Replacement ............................. 5-14
5.8 Optional DIP Switch Settings ................................................... 5-15
6 REPLACEMENT PARTS, ACCESSORIES, AND DIAGRAMS ......... 6-1
6.1 Replacement Parts List ............................................................... 6-1
6.2 Accessories List ........................................................................... 6-3
6.3 Wiring Diagram ........................................................................... 6-4
GLOSSARY OF TERMS .......................................................................... G-1
BACHARACH SERVICE CENTERS ...................................................... G-3
TABLE OF CONTENTS (Cont.)

MODEL 300 COMBUSTION ANALYZER
SPECIFICATIONS
GENERAL
Size .................................... Carrying Case: 18" x 14" x 8"
(45.7 x 35.6 x 20.3 cm)
Standard Probe: 11.5" (29.2 cm)*
Hose - 22' (6.7 m)*
Weight ................................ 15 lbs. (6.8 kg)
Materials ............................ HDPE Case, medium gray; polycarbonate
membrane switch; stainless steel probe
Calibration Interval ........... 60 seconds
Storage Environment ......... – 4 to 122°F (–20 to 50°C),
0 to 100% relative humidity
Operating Environment .... 32 to 104°F (0 to 40°C),
0 to 99% relative humidity, non-condensing.
Sample Gas Flow ............... 0.7 to 1.5 liters/min
Power source ...................... Either 120 VAC, 240 VAC, or internal battery
pack per sales order
BATTERY PACK SPECIFICATIONS
(A battery-powered unit may be run off the charger, if required.)
Output Voltage: .................. 5 VDC
Charging Input Voltage: .... 8 VDC from Bacharach Charger
(Refer to Section 6 for part numbers)
Charging Time: .................. 5-6 hours
Operating Time ................. At least 200 sequential combustion tests, or 4
to 6 hours (min.). The analyzer will operate an
addtional 1 hour (min.) after the BATTERY
STATUS light goes out. These discharge times
are based on worst-case-continuous-operating
conditions, which include printing every
20 minutes. A typical discharge time of a fully
charged battery pack is between 12 and
16 hours.
iv Instruction 24-9223

MODEL 300 COMBUSTION ANALYZER
ACCURACY (68°F [20°C], 45% RELATIVE HUMIDITY)
Stack Temperature ........ ±1% full scale
Oxygen ............................ ±0.6% O2
Carbon Monoxide ........... ±5% reading or ±10 ppm, whichever is greater
NOX(Optional) ............... ±5% reading or ±10 ppm, whichever is greater
SO2(Optional) ................ ±5% reading or ±10 ppm, whichever is greater
PROBE TEMPERATURE EXPOSURE LIMITS
The time and temperature limits for the probe assembly (24-7131) are
listed below.
Stack Temperature Probe Exposure Time Limit
100–1000°F (38–538°C) Unlimited
1000–1200°F (538–649°C) 30 mins. per exposure
1200–1400°F (649–760°C) 10 mins. per exposure
NOTE: The high-temperature extended-probe options have
unlimited exposure times up to 2000°F (1093°C).
FUNCTIONS
Directly Measures and Displays:
• Stack Temperature (up to 2000°F [1093°C])
• Carbon Monoxide level: (0–3700 ppm over 32–104°F [0– 40°C])
• Oxygen level (0.1 to at least 23.5%)
• Oxygen Sensor output in millivolts
•NO
Xlevel (0-1999 ppm) (NSX units)
•SO
2level (0-1999 ppm) (NSX units)
Instruction 24-9223 v

MODEL 300 COMBUSTION ANALYZER
FUNCTIONS (Cont.)
Computes and Displays:
• Combustion Efficiency (1 to 99.9%)
• Stack Loss (1 to 99.9%)
• Carbon Dioxide Level (1 to 20%)
• Excess Air (1 to 250%)
Additionally Displays:
• Fuel selected:
Standard Efficiency Equations
NGAS - Natural Gas
OIL2 - Number Two Fuel Oil
OIL6 - Number Six Fuel Oil
LPG - Liquid Propane
COAL - Coal
WOOD - Wood (17% Moisture)
BAGA - Bagasse (from vegetable matter)
Siegert Efficiency Equations
NG+F - Natural Gas w/ Fan
NG–F - Natural Gas w/o Fan
LOIL - Light Oil
HOIL - Heavy Oil
LPG - Liquid Propane
KOKS - Coal Gas
LEG - Low Energy Gas
* Custom fuels available upon factory request.
vi Instruction 24-9223

MODEL 300 COMBUSTION ANALYZER
FUNCTIONS (Cont.)
Additionally Displays (Cont.):
• Analyzer errors or warnings
Main Display
OK - No errors or warnings to report.
W*CO - CO channel warning.
E*O2 - Oxygen channel error.
E*TC - Thermocouple channel error.
E*AM - Ambient temperature channel error.
OR/A - Ambient sensor overrange.
OR/T - Thermocouple overrange.
OR/C - CO sensor overrange.
OR/O - O2 sensor overrange.
Auxiliary Display, NSX Units
LOW BATT - NOX /SO2sensor bias batteries low.
BATT FAIL - NOX /SO2sensor bias batteries dead.
W*NO - NOXsensor out of calibration.
W*SO - SO2sensor out of calibration.
E*NO - NOXsensor failure.
E*SO - SO2sensor failure.
**** - Clock module battery dead.
Additional Printouts (NSX units only):
• Serial number of analyzer
• Time and date of test
•NO
Xppm level (if NOXsensor is installed)
•SO
2ppm level (if SO2sensor is installed)
Instruction 24-9223 vii

MODEL 300 COMBUSTION ANALYZER
Figure A. Model 300 Combustion Analyzer
(Typical Configuration)
viii Instruction 24-9223