Bacharach PCA3 User manual

Portable Combustion Analyzer
(Siegert Version)
Operation and Maintenance Manual
Instruction 0024-9473
Rev. 3 – August 2012
Product Leadership •Training •Service •Reliability
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WARRANTY POLICY
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 IMPLIED 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 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.
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 © 2012, Bacharach, Inc., all rights reserved.
BACHARACH, PCA, B-SMART, and FYRITE are registered trademarks of Bacharach, Inc.
All other trademarks, trade names, service marks and logos referenced herein belong to
their respective companies.

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TABLE OF CONTENTS
CHAPTER 1. INTRODUCTION ........................................................................7
1.1. About This Manual ....................................................................................... 7
1.2. Conventions ................................................................................................. 7
1.3. Safety ........................................................................................................... 7
1.4. General Description ..................................................................................... 9
1.5. Operation Overview..................................................................................... 9
1.5.1. Turning On the PCA®3 ...................................................................... 9
1.5.2. The Combustion Test..................................................................... 10
1.5.3. Turning Off the PCA®3.................................................................... 10
1.6. Features and Benefits ................................................................................ 10
1.7. Sales Combo and Model Configurations .................................................... 12
1.8. Specifications ............................................................................................. 13
CHAPTER 2. HARDWARE ............................................................................ 16
2.1. Overview .................................................................................................... 16
2.2. Front Panel Buttons ................................................................................... 17
2.3. Backlit Display ............................................................................................ 18
2.4. Battery Compartment ................................................................................ 18
2.5. AC Adapter Connector (POWER)................................................................ 18
2.6. Probe Connectors (Gas, Pressure, T-Stack)................................................ 19
2.7. Differential Pressure Connector (∆P)......................................................... 20
2.8. Primary Air Thermocouple Connector (T-AIR) ........................................... 20
2.9. Computer Interface (USB) .......................................................................... 20
2.10. Wireless Printer Port (IrDA) ..................................................................... 20
2.11. Options Connector (OPT) ......................................................................... 20
CHAPTER 3. INITIAL SETUP .........................................................................21
3.1. Overview .................................................................................................... 21
3.2. Power ......................................................................................................... 21
3.3. Connecting the Probe and Hose Assembly ................................................ 22
3.4. Preparing to Configure the PCA®3.............................................................. 22
CHAPTER 4. CONFIGURATION PROCEDURES ..............................................24
4.1. Default Operating Parameters ................................................................... 24
4.2. Fuel Selection ............................................................................................. 24
4.3. Auto/Manual CO Zero Selections............................................................... 26
4.4. Temperature Units Selection ..................................................................... 27
4.5. Pressure Units Selection ............................................................................ 27
4.6. Pollution Units Selection ............................................................................ 28

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4.7. Smoke Number .......................................................................................... 29
4.8. Oil Derivative.............................................................................................. 30
4.9. Boiler Temperature .................................................................................... 30
4.10. Date Setup................................................................................................ 31
4.11. Time Setup ............................................................................................... 32
4.12. O2Reference Setup .................................................................................. 32
4.13. Print Pressure Selection ........................................................................... 33
4.14. Zoom Display Selection ............................................................................ 34
4.15. Logging Selection ..................................................................................... 35
4.16. Button Sound Selection............................................................................ 35
4.17. Test ID Information .................................................................................. 36
4.17.1. Entering or Editing a Test ID ........................................................ 36
4.17.2. Selecting a Test ID ....................................................................... 37
4.17.3. Clearing Test ID Information........................................................ 37
4.18. User Name ............................................................................................... 38
4.18.1. Entering a User Name.................................................................. 38
4.18.2. Clearing a User Name .................................................................. 39
4.19. Language .................................................................................................. 39
4.20. Calibration Reminder Period.................................................................... 40
4.21. Run/Hold Screen Format.......................................................................... 41
CHAPTER 5. OPERATION ............................................................................44
5.1. Operating Tips............................................................................................ 44
5.2. Turning On the Analyzer ............................................................................ 45
5.3. Low Battery Alarm ..................................................................................... 45
5.4. Locating Sampling Points ........................................................................... 46
5.5. Performing a Combustion Test .................................................................. 47
5.6. Selecting a Pressure Label.......................................................................... 50
5.7. Temperature Label Selection and Measurement ...................................... 50
5.8. Performing a Draft / Pressure Measurement ............................................ 51
5.9. Saving Test Data......................................................................................... 52
5.10. Ending a Combustion Test........................................................................ 53
5.11. Emptying the Water Trap......................................................................... 53
5.12. Data Logging............................................................................................. 54
5.12.1. Overview...................................................................................... 54
5.12.2. Turning On Data Logging ............................................................. 55
5.12.3. Setting the Logging Interval and Duration................................... 56
5.12.4. Starting the Data Logging Process ............................................... 57
5.12.5. Ending the Data Logging Process................................................. 57
5.13. Memory Functions ................................................................................... 58
5.13.1. Overview...................................................................................... 58

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5.13.2. Recalling Combustion Test Data.................................................. 58
5.13.3. Recalling Logged Test Data.......................................................... 59
5.13.4. Clearing Memory ......................................................................... 60
5.13.5. Print Average ............................................................................... 60
5.14. Downloading Stored Data to a Computer................................................ 61
5.15. Importing Saved Data into a Spreadsheet ............................................... 62
5.16. Printing Test Data..................................................................................... 63
5.17. Turning Off the Analyzer and Purging...................................................... 65
CHAPTER 6. CALIBRATION.......................................................................... 66
6.1. B-Smart Sensors ......................................................................................... 66
6.2. Starting a Calibration ................................................................................. 66
6.3. B-Smart®Sensor Replacement and Calibration.......................................... 67
6.4. Pressure Sensor Calibration ....................................................................... 68
6.4.1. Material Required.......................................................................... 68
6.4.2. Procedure ...................................................................................... 68
6.5. T-Stack Calibration ..................................................................................... 69
6.5.1. Material Required.......................................................................... 70
6.5.2. TS-Zero Procedure ......................................................................... 70
6.5.3. TS-Span Procedure ........................................................................ 71
6.6. T-Air Calibration ......................................................................................... 71
6.6.1. Material Required.......................................................................... 71
6.6.2. TA-Zero Procedure......................................................................... 71
6.6.3. TA-Span Procedure ........................................................................ 73
6.7. COLOW Sensor Calibration ........................................................................... 73
6.7.1. Material Required.......................................................................... 73
6.7.2. Procedure ...................................................................................... 74
6.8. SO2Sensor Calibration ............................................................................... 76
6.8.1. Material Required.......................................................................... 76
6.8.2. Procedure ...................................................................................... 76
6.9. NO Sensor Calibration ................................................................................ 77
6.9.1. Material Required.......................................................................... 77
6.9.2. Procedure ...................................................................................... 77
6.10. NO2Sensor Calibration............................................................................. 78
6.10.1. Material Required........................................................................ 78
6.10.2. Procedure .................................................................................... 78
6.11. COHIGH Sensor Calibration......................................................................... 80
6.11.1. Material Required........................................................................ 80
6.11.2. Procedure .................................................................................... 80
CHAPTER 7. MAINTENANCE .......................................................................82

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7.1. Overview .................................................................................................... 82
7.2. PCA®3 Disassembly..................................................................................... 82
7.2.1. Tools Required............................................................................... 82
7.2.2. Procedure ...................................................................................... 82
7.3. Emptying the Water Trap Chamber ........................................................... 87
7.4. Replacing the Filter Element ...................................................................... 87
7.4.1. Material Required.......................................................................... 87
7.4.2. Procedure ...................................................................................... 87
7.5. Sensor Replacement .................................................................................. 88
7.6. Nitric Oxide (NO) Sensor Battery Replacement ......................................... 90
7.6.1. Material Required.......................................................................... 90
7.6.2. Procedure ...................................................................................... 90
7.7. Cleaning the Probe..................................................................................... 91
7.7.1. Equipment Required...................................................................... 91
7.7.2. Procedure ...................................................................................... 91
CHAPTER 8. TROUBLESHOOTING ...............................................................92
8.1. Error Symbols............................................................................................. 92
8.2. Diagnostics and Status Screens.................................................................. 92
8.3. Accessing the Diagnostic Menu ................................................................. 93
8.4. Accessing the Status Menu ........................................................................ 93
8.5. Error Messages (After Warm-up)............................................................... 93
8.6. Replacement Parts ..................................................................................... 94
8.7. Accessories................................................................................................. 97
8.8. Analyzer Repair .......................................................................................... 99
8.9. Service Centers........................................................................................... 99
CHAPTER 9. DECLARATION OF CONFORMITY ........................................... 100

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CHAPTER 1. INTRODUCTION
1.1. About This Manual
Thank you for investing in a Bacharach PCA®3 Combustion Analyzer. To assure
operator safety and the proper use of the PCA®3, please read the contents of this
manual for important information on the operation and maintenance of the
analyzer.
1.2. Conventions
WARNING:
A warning statement denotes a potential hazard
associated with the use of this equipment. Failure to follow this
information could result in serious personal injury or death.
CAUTION: A caution statement indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate
injury. Caution statements may also be used to alert against unsafe
practices.
IMPORTANT: An impor
tant statement provides emphasis of an
important feature, operation, etc. Failure to follow this information
could void your warranty, result in improper operation, or cause
equipment damage.
NOTE: A note statement provides emphasis of a feature, operation,
practice, etc.
1.3. Safety
WARNING:
This analyzer is not intended to be used as a safety
device.
WARNING: When testing an appliance, a full visual inspection of
the appliance should be performed to ensure its safe operation.
CAUTION:
This analyzer is not intended to be used on a
continuous basis.

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CAUTION: Do not store instrument or its sensors with solvents or
products that contain solvents.
CAUTION: Exce
pt for sensor and battery replacement, this
analyzer should only be opened and/or serviced by authorized
Bacharach personnel. Failure to comply may void the warranty.
HAZARDOUS AREA WARNING: This instrument has not been
designed to be intrinsically sa
fe for use in areas classified as
hazardous locations. For your safety, DO NOT use it in hazardous
(classified) locations.
CAUTION: When the instrument is used in an inefficient furnace or
boiler application where there is a high emission of soot, the probe’s
sample filter may become clogged. Before every use check the filter
to confirm that it is clean or replace it with a new filter.
To prevent this from occurring, a smoke test should be performed
before operating under such conditions. This ensur
es that the
furnace or boiler is burning at a level appropriate for the use of this
instrument.
When the CO2level exceeds the allowable threshold, a warning will
appear prompting the user to consider performing a smoke test (see
Figure 1-1
). This screen is removed by pressing the ENT button.
Once the warning is cleared, it will not be displayed again for that
particular test. If a new test is started (by pressing the HOLD
button), the warning will be displayed again if the limit has been
exceeded.
Figure 1-1. High CO2Warning

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1.4. General Description
The PCA®3 is a commercial-grade hand-held combustion and emissions
analyzer designed for on-
demand sampling of light industrial, institutional,
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, boot, Fyrite®User
Software, USB cable, and carrying
case. Refer to Figure 1-2.
The PCA®3 can measure up to four
gases simultaneously, so it is the
perfect tool for service technicians,
inspectors, and boiler contractors
who need to determine combustion
efficiency, excess air, stack gas O2
and CO levels, stack temperature,
draft, and differential pressure.
Figure 1-2. A Typical PCA®3 Kit
The analyzer can also directly measure and display NO, NO2and SO2with the
installation of the appropriate sensors. Combustion efficiency calculations can be
conducted for a variety of fuels (see Specifications later in this chapter).
Combustion analysis is performed in accordance with EN50379.
B-Smart®sensor technology allows a new sensor to be installed in the field
without having to calibrate the analyzer with gas before use.
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.
The optional AC power adapter allows the analyzer to run for extended periods of
time while data logging.
The optional sample conditioning probe is recommended when measuring NO2
and SO2to ensure the highest degree of measurement accuracy.
A probe and hose assembly with an integral thermocouple and filter/water trap
connect to the bottom of the analyzer, providing the means of drawing in gas
samples and for measuring stack temperature and draft.
1.5. Operation Overview
1.5.1. Turning On the PCA®3
The PCA®3 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

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“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 run/hold screen.
1.5.2. The Combustion Test
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 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 analyzer will begin to
continuously monitor the stack temperature, %O2and emission levels in the
stack gas and then display measured and calculated values on its display. The
recommended time required to achieve a stable measurement is a minimum of 3
minutes.
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 COHIGH sensor,
if installed, at CO levels starting at 4,001 ppm, thus providing continuous CO
readings up to 20,000 ppm.
A keypad backlight enables a user to read the keypad in dimly-lit areas. Turn the
keypad backlight ON and OFF by briefly pressing the I/O button.
1.5.3. Turning Off the PCA®3
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 analyzer 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.
1.6. Features and Benefits
•Powered by 4 ‘AA’ alkaline batteries or NiMH rechargeable batteries. An
optional AC adapter provides extended operation.
•O2and Hydrogen-compensated COLow measurements are standard.
Optional measurement of up to two additional gases, including COHigh, NO,
NO2, or SO2.

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•With the appropriate sensors installed, the analyzer optionally displays
pollution conversions for CO, NO, NO2, and SO2. Pollution conversions
include ppm, #/MBTU, mg/m3, and g/GJ.
•B-Smart® sensor technology allows pre-calibrated sensors to be installed in
the field. Sensors are provided with data that can be entered through the
PCA®3 software, or instrument calibration menus, for easy calibration.
•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 automatically 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 °C or °F.
•Displays pressure in either inwc, mb, Pa, or hPa.
•Backlit color 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 for printing current and stored combustion records,
pressure records, calibration data, and diagnostic data.
•USB connectivity for downloading data to personal computer.
•Field replaceable sensors and thermocouple.
•Two year warranty on analyzer and all gas sensors except the O2sensor
which has a one (1) year warranty.
•Language options including English, French, Spanish, German, Italian,
Danish, Polish, and Dutch.
•Custom Display Formats.
•Calibration Reminders - PCA®3 can be set up to remind the user that
calibration is past due.
•Auto/manual zeroing option allows the operator to select the start-up mode.
Auto-zero determines the zero reading of the CO channel in fresh air and
provides an offset for the CO measurements. Also, all sensing channels are
automatically zeroed on ambient air when the analyzer is first turned ON.
Manual zero is used to detect CO that may be present during start-up.

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1.7. Sales Combo and Model Configurations
Sales Combo
(0024-xxxx)
8460 8461 8462 8463
8464
8465
8466
Sales Combo Kit
(0024-xxxx)
8467 8468 8469 8470
8471
8472
8473
Model Type
225 235 245 255 265 275 285
PCA®3 Only Part Number
(0024-xxxx)
7330
7331
7332
7333
7334
7335
7336
Measurements
Oxygen (O2) •••••••
Stack Temperature •••••••
Primary/Ambient Air Temperature •••••••
Carbon Monoxide Low (COLOW) •••••••
Pressure/Draft •••••••
Carbon Monoxide High (COHIGH) ••
Nitric Oxide (NO) ••••
Nitrogen Dioxide (NO2) •
Sulfur Dioxide (SO2) ••
Calculations
Stack Loss •••••••
Lambda •••••••
ETA – Efficiency Relative to Lower
Heating Values •••••••
EFF – Efficiency Relative to Higher
Heating Values •••••••
Carbon Dioxide (CO2) •••••••
NOx(NOx= NO + NO2) •
NOxreferenced to % O2•
CO referenced to % O2•••••••
NO referenced to % O2••••
NO2referenced to % O2•
SO2 referenced to % O2••
CO/CO2•••••••

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1.8. Specifications
Measurement (Based on Installed Sensors) Display Range
Oxygen 0.1 to 20.9%
Stack Temperature -20 to 1,200 °C (-4 to 2,192 °F)
Primary/Ambient Air Temperature -20 to 537 °C (-4 to 999 °F)
Carbon Monoxide (CO) (H2compensated) 0 to 4,000 ppm
Pressure/Draft ±179 mb (±72 inwc)
CO High Range 4,001 to 20,000 ppm
Nitric Oxide (NO) 0 to 3,000 ppm
Nitrogen Dioxide (NO2) 0 to 500 ppm
Sulfur Dioxide (SO2) 0 to 5,000 ppm
Calculated Value (Based on Installed Sensors) Display Range
Stack Loss (qA) 0.1 to 100%
Carbon Dioxide (dry basis) 0.0 to fuel-dependent max in %
Lambda 1 to 9.55
EFF (HHV) 0.1 to 100%
ETA (LHV) 0.1 to 112% (fuel dependent)
CO/CO2ratio 0.0001 to a fuel dependent max
(Approximately 8.000)
CO referenced to %O20 to 9,999 ppm
NO referenced to %O20 to 9,999 ppm
NO
x
referenced to %O
2
0 to 9,999 ppm
NO
2
referenced to %O
2
0 to 9,999 ppm
SO2referenced to %O20 to 9,999 ppm
NOTE:
Calculations are performed only when the measured
oxygen level is below 18.8% and the stack temperature is below
1,093 °C (2,000 °F).

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Equations (Some calculations vary by country)
( )
Definitions
O2= Measured oxygen (in %)
TSTK = Measured stack temp (in °C)
TAIR = Measured primary air temp (in °C)
CO = Measured carbon monoxide (in ppm)
CO2= Calculated carbon dioxide (in ppm)
qA = Calculated stack loss (in %)
Lambda = Calculated excess air
EFF = Efficiency based on HHV (in %)
ETA = Efficiency based on LHV (in %)
CO2max = Constant (see table below)
A2= Constant (see table below)
B = Constant (see table below)
Fuel Constants (Some fuel constants vary by country)
FUEL CO2 max A2B T0(
°
C) kF
Natural Gas 11.8 0.66 0.009 59 9.6
KOKS 10.2 0.60 0.011 62 11.2
LEG 13.1 0.63 0.011 61 10.3
LPG 13.8 0.63 0.008 55 7.6
Oil #2 15.4 0.68 0.007 49 5.3
Oil #6 15.9 0.68 0.007 46 4.7
Coal 18.7 0.60 0.007 36 3.4
Biofuel 20.4 0.70 0.012 59 6.0

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Reading Performance Accuracy
O2±0.3% O2on practical concentrations of stack gas
(mix of O2, CO2, and N2)
CO Greater of ±5% of reading or ±10 ppm, between 0-2,000 ppm.
±10% of reading between 2,001 and 4,000 ppm.
NO Greater of ±5% of reading or 5 ppm between 0 and 2,000 ppm
NO
2
Greater of ±5% of reading or ±5 ppm between 0-500 ppm
SO2Greater of ±5% of reading or ±10 ppm between 0-2,000 ppm
Flue Gas Temp
±2 °C (±4 °F) between 0 and 124 °C (32 and 255 °F)
±3 °C between 125 and 249 °C (±6 °F between 256 and 480 °F)
±4 °C between 250 and 400 °C (±8 °F between 481 and 752 °F)
Primary/Ambient
Air Temp ±1 °C (±2 °F) between 0 and 100 °C (32 and 212 °F)
Pressure/Draft
±0.05 mB from -2.49 to +2.49 mB (±0.02 inwc from -1 to 1 inwc)
±2% of reading from -24.9 to 24.9 mB (±2% from -10 to 10 inwc)
±3% of reading from -100 to 100 mB (±3% from -40 to 40 inwc)
System Flow Rate
with Probe 200 cc/min minimum
General Specification Description
Dimensions (H x W x D) 22.9 x 7.6 x 6.3 cm (9.0 x 3.0 x 2.5 inches)
Weight Analyzer with Batteries: ........................... 0.6 kg (1.4 lb)
Probe/Hose Assembly: ............................ 0.5 kg (1.0 lb)
Fuels Available for
Combustion Calculations
•Natural Gas •Biofuel
•Coal •KOKS
•Oil #2 •Propane
•LEG •LPG
•Oil #6 •Butane
Warm-up Time 60 seconds (Sensors checked and auto zeroed)
Power
4 “AA” Batteries
(Disposable)
Alkaline:.............................. 10 hours of operation (min)
NiMH Rechargeable: ................... Operating time varies
AC Adapter
(Optional) 100-240 VAC; 50/60 Hz: ....................... Continuous use
Operating Temperature Analyzer: ................................ 0 to 40 °C (32 to 104 °F)
Probe Tip:..................................800 °C (1,472 °F) Max.
Operating Humidity Analyzer: ......................15 to 90% RH, non-condensing
Operating Air Pressure Analyzer: ...................................................Atmospheric
Probe:............... 25 mb (10 inwc) draft max. at probe tip
Memory 500 complete combustion test records
500 complete logged combustion test records
Interfaces Printer:..........................Infrared (IrDA) communications
Computer:...........................USB 2.0 (mini-B connector)

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CHAPTER 2. HARDWARE
2.1. Overview
Figure 2-1. Front and Bottom Views Showing Key Components

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2.2. Front Panel Buttons
The PCA®3 is controlled by various buttons, while a color graphic LCD (with
automatic dimming feature) is used to display all combustion and emission test
data and analyzer parameters. Descriptions of the front panel buttons are given
below.
F1
PRINT Transmits the data displayed on the screen to a printer
through the IrDA communications port.
PAGE- 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.
F2
MENU Displays the Main Menu.
ZERO 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.
F3
SAVE Saves the data currently displayed on the LCD in
memory. Up to 500 individual Combustion Test,
Temperature, 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.
PAGE+ When viewing the Memory or Logging Directory, each
press of this button pages through the directory. Holding
this button speeds the paging process.
▲
▼
◄
►
The arrow buttons move the cursor on the LCD. In screens that
require the entry of alphanumerical data, use the◄► buttons to
move cursor across the screen and then use the▲▼ buttons to
increment and decrement the data. When viewing a menu, use the
◄► buttons to quickly move to the top and bottom of the menu.
ENT
Selects a highlighted item. In addition, if changes were made to
one of the analyzer’s operating parameters (e.g., date, time, O2
reference, etc.), pressing this button confirms those changes and
saves them in memory.
RUN/
HOLD
Starts and stops a combustion test when the Combustion 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.
ESC
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.
I/O Turns the analyzer ON and OFF, and is also used to turn the
keypad LEDs ON and OFF.

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Note that a button may perform multiple functions depending on the current
screen that is displayed. For example, the functions of the F1, F2, and F3
buttons are defined by labels appearing above them on the LCD. The labels that
appear depend on the functions that can be performed in the particular screen
being displayed.
NOTE: A keypad backlight enables a user to read the keypad in
dimly-
lit areas. Turn the keypad backlight ON and OFF by briefly
pressing the I/O button.
NOTE: 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 instrument 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, though it is
not recommended.
2.3. Backlit Display
A large backlit color graphic display shows multiple combustion test values
simultaneously, and includes a zoom capability that provides extra large text.
Figure 2-2. Sample Display
2.4. Battery Compartment
The PCA®3 is powered by either its four internal batteries or by an optional AC
power adapter that operates from any convenient source of 100–240 VAC, 50/60
Hz power. Batteries may be either disposable alkaline or rechargeable NiMH.
2.5. AC Adapter Connector (POWER)
The AC power adapter P/N 0024-1254 can be used as an external power supply,
to run the analyzer on a continuous basis. It uses 100-240 VAC at 50/60 Hz.

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Figure 2-3. Battery Compartment
Figure 2-4. Bottom View Showing Connectors
2.6. Probe Connectors (Gas, Pressure, T-Stack)
The probe and hose assembly are connected to the analyzer by way of the
following connectors.
•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
prevents incorrect connection to their associated connectors on the analyzer.
See Figure 2-5.

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Figure 2-5. Probe Connectors GAS, +∆P, and T-STACK
2.7. Differential Pressure Connector (∆P)
Draft is measured by connecting the probe’s draft hose to the +∆P fitting, while
leaving the -∆P fitting open to the atmosphere. See Figure 2-5 on page 20.
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 0024-1103) 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.
2.8. Primary Air Thermocouple Connector (T-AIR)
If thermocouple P/N 0104-1797 (10 feet long) or Utility Wand P/N 0104-1799
(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. Refer to Figure 3-2 on page
23.
2.9. Computer Interface (USB)
Data stored in the analyzer’s memory can be downloaded to a personal
computer by connecting USB data cable P/N 0104-4032 between the USB ports
of the computer and analyzer. The PCA®3’s USB port is on its right side. See
Figure 2-1 on page 16.
2.10. Wireless Printer Port (IrDA)
Data that has been stored in the analyzer’s memory can be printed on a
compatible IrDA (Infrared data associated) wireless printer by aligning their IrDA
communication ports. The IrDA port of the PCA®3 is located at the top of the
device. See Figure 2-1 on page 16.
2.11. Options Connector (OPT)
The options connector is used for optional external measurement features. Refer
to Figure 3-2 on page 23.