Environmental Combustion Analyzer Model 450 Instruction 0024-9400 Operation & Maintenance Rev.
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.
ECA 450 Contents Table of Contents 1 Introduction .................................................................................................................... 1 1.1 1.2 1.3 1.4 1.5 1.6 2 General Description ...................................................................................................................................1 Features .....................................................................................................................................................
Contents ECA 450 2.17.11 2.17.12 2.17.13 2.17.14 2.17.15 2.17.16 2.17.17 2.17.18 2.17.10.2 Resetting Display Format Back to Factory Default .............................................44 Primary Air ...............................................................................................................................45 Data Logging ............................................................................................................................45 Statistics ............................
ECA 450 Introduction 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.
Introduction ECA 450 • 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.
ECA 450 Introduction 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.
Introduction ECA 450 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.
ECA 450 1.4 Introduction 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 setup procedures, signaling the appropriate action, and waiting until the correct steps are taken.
Introduction 1.5 ECA 450 Front Panel Connections and Controls Figure 1-1.
ECA 450 1.5.2 Introduction T-AIR (Primary Air Thermocouple) If thermocouple 0104-1797 (10 feet long) or Utility Wand 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 thermocouple to the analyzer’s T-AIR connector. Refer to Section 2.14 Primary Air Temperature Measurement for alternate methods of measuring the burner’s primary air temperature. 1.5.
Introduction 1.6 ECA 450 Front Panel Keypad Controls Descriptions of the front panel keypad controls are given below. Note that a control may perform multiple functions as determined by what screen is being displayed at the time. I/O RUN Starts and stops a combustion efficiency test when the Combustion Test RUN/HOLD screen is displayed. Pressing this key from any of the menu screens returns the analyzer to the Combustion Test HOLD screen.
ECA 450 Introduction CALIBRATE ENTER ESC Shortcut key to the Calibration List menu screen, where operators can choose the sensor to be calibrated. Note that a 4-place alphanumerical password must first be entered to begin calibration. Selects a menu item that has been chosen by the position of the cursor. In screens that require the ∧ and ∨ keys to be used to make a numerical or alphabetical selection (i.e., Date, Time, O2 Reference.
Introduction ECA 450 Notes: 10 Instruction 0024-9400
ECA 450 Operation 2 Operation 2.1 Turning On the Analyzer Important! Prior to initially operating the analyzer, be sure to first charge the battery per Section 4.1. Before turning on the analyzer, connect the probe’s gas hose, pressure hose, and thermocouple to the analyzer’s GAS, PRESSURE, and T-STACK connectors, respectively (refer to Section 1.5.1). Turn on the analyzer by pressing the I/O key. Observe that all display segments are briefly turned on to verify their operation.
Operation 2.3 ECA 450 Fuel Selection The fuel currently being used for combustion analysis is displayed in the top line of the Combustion Test RUN/HOLD screen. «HOLD««««««««««NGAS« In the above example, the current fuel is NGAS (natural gas). Fuel Codes: NGAS = Natural Gas OIL2 = Oil #2 OIL4 = Oil #4 OIL5 = Oil #5 OIL6 = Oil #6 PROP = Propane COAL = Coal WOOD = Wood KERO = Kerosene BGAS = Bagasse To select a different fuel: 1. Press FUEL key to display the Fuel menu screen.
ECA 450 2.4 Operation Performing a Combustion Test Important! When measuring nitrogen dioxide (NO2) and sulfur dioxide (SO2), it is recommended that a Sampler Conditioner (Bacharach P/N 0024-7224) be used to assure accurate readings. 1. If not already done, turn on analyzer (Section 2.1) and select a fuel (Section 2.3). 2. See Figure 2-1. Make a ½-inch sampling hole in stack to accommodate probe stop.
Operation ECA 450 7. Tip: Use < > keys to quickly advance to the top and bottom of screen. Also note that if “– – – –”, “x x x x”, or “* * * *” appear in a data field, then data cannot be displayed for that measurement. Refer to Section 5.3 Error Symbols for an explanation of these symbols and why data is not being displayed.
ECA 450 2.5 Operation Ending a Combustion Test 1. After performing a combustion test per Section 2.4, press RUN key to end the test. You should hear the pump stop running. WARNING: Burn hazard! Take all necessary precautions when handling a hot probe and probe stop. CAUTION: Allow a hot probe and probe stop to cool before storing them inside the analyzer’s carrying case. 2. Loosen thumbscrew on probe stop; then remove probe and probe stop from stack.
Operation 2.7 ECA 450 Saving Test Data By pressing the SAVE key, data that is currently being displayed in either the Combustion Test or Pressure screen is stored in one of the analyzer’s over 1000 internal memory locations. Observe that the following message appears when the SAVE key is pressed. Saving Memory Location nnnn Where: nnnn = memory location number At a later time, the stored data can be recalled for either viewing or downloading as described in Section 2.
ECA 450 2.9 Operation Recalling Test Data Stored in Memory To recall the contents of a particular memory location containing either combustion test data or a pressure measurement, do the following: 1. Press MEMORY key to display the Memory menu screen. 2. Use ∧∨ keys to place cursor next to “Memory Directory”; then press ENTER to show the directory of all stored test data. «««««««MEMORY««««««« ª Memory Directory Transmit Memory Clear Memory 3.
Operation ECA 450 4. Press ENTER key to display the contents of chosen memory location. Observe that “MEM:nnnn ” (where nnnn denotes the memory location number) appears in the top line, signifying that the data being displayed was recalled from memory. Also note that if any Test ID information was associated with the test data, this information is displayed at the bottom of the screen. Refer to Section 2.17.8 for additional information on Test ID. «MEM:nnnn««««««NGAS« O2 4.5 % CO 12 ppm EFF 82.2 % CO2 9.
ECA 450 Operation 2.10 Printing Data By pressing the PRINT key, the data which is currently being displayed in either the Combustion Test or Pressure screen is printed on the analyzer’s internal printer. Note that the contents of no other screen can be printed. Data which has been stored in memory can also be printed by first displaying the contents of the desired memory location as described in Section 2.9 Recalling Test Data Stored in Memory.
Operation ECA 450 2.11 Downloading Data to a Personal Computer Test data that was stored in memory can be downloaded to a personal computer in ASCII text, comma-delimited format, which can then be imported into most spreadsheet programs for analysis. The following describes how to download data to a computer that is running Windows®95/98, using HyperTerminal as the communications program.
ECA 450 Operation 3. After HyperTerminal is running: click Transfer, click Capture Text, then click Start to accept the default drive\directory\filename to which all received data will be stored as an ASCII text file. Note: By default, the captured text file will be stored on the hard drive at C:\Program Files\Accessories\HyperTerminal\CAPTURE.TXT. If desired, click Browse to select a different drive, directory and filename.
Operation ECA 450 7. Observe that HyperTerminal displays the data as it’s being received. After all data has been transmitted, the analyzer re-displays the Memory menu screen. Tip: The download process can be stopped by pressing the ESC key. 8. To stop capturing data and save it, click Transfer, click Capture Text, click Stop. 9. HyperTerminal and the connection to the ECA 450 can now be closed. 2.
ECA 450 Operation 4. Use ∧∨ keys to place cursor next to one of the following three methods of storing test data: Logging ª Internal PC Both • Internal: Stores test data in the analyzer’s internal memory (over 1000 data sets can be saved). • PC: Sends test data out the analyzer’s RS232 port to a personal computer. Before using this method, however, a personal computer must be connected to the analyzer and configured to store received data on its hard drive (refer to Section 2.
Operation ECA 450 8. With the analyzer set up per Section 2.4 Performing a Combustion Test, press ENTER key to begin testing and logging. «LOG«««(0025)««NGAS« This display shows that the analyzer is logging and currently saving data to internal memory location 25. Observe that the memory location number will increment as data is being saved.
ECA 450 Operation 2.13 Importing Saved Data Into a Spreadsheet A text file that was created as described in either Section 2.11 Downloading Data to a Personal Computer, or Section 2.12 Data Logging can be imported into spreadsheet programs that are capable of importing comma-delimited files. Note that each data record consists of 31 fields, some of which may be blank for different tests and analyzer configurations. TABLE 1.
Operation ECA 450 TABLE 2. TYPICAL SPREADSHEET FOR THE ECA 450* TESTID1 Customer Name Customer Name POLL UNIT ppm TAIR 68 NOX(O2R) 3 TESTID2 Address Address DATE 01/14/00 EA 21 TIME 2:45:30 PM NO 18 NO(O2) 19 NO2(O2) 6 TESTID3 Burner Number Burner Number O2 4 NO2 6 NOX(O2) 25 CO 12 FUEL Natural Gas EFF 82.2 NOX 24 SO2(O2R) 3 CO2 9.5 SO2 1 SO2(O2) 1 TEMP UNIT °F TSTACK 374 HC 0.01 PRESS UNIT inwc inwc TAIR SOURCE (T) CO(O2R) 3 CO(O2) 13 PRESSURE –0.25 –0.
ECA 450 Operation 2.14 Primary Air Temperature Measurement To properly calculate net stack temperature, the analyzer must know the burner’s primary air temperature. The following sections describe four methods of measuring and supplying this temperature value to the analyzer. 2.14.1 Thermocouple Method A thermocouple that is plugged into the T-AIR connector (see Figure 1-1) provides the analyzer with the most up-to-date primary air temperature information for combustion efficiency calculation purposes.
Operation ECA 450 2. Use ∧∨ keys to place cursor next to “Primary Air”; then press ENTER to display the Primary Air screen. Note: The message “Primary Air is measured by TC” will appear if a thermocouple is plugged into the T-AIR socket. This thermocouple must be removed to continue this procedure.
ECA 450 Operation 5. Wait until temperature display stabilizes; then press ENTER to save the displayed temperature value in the analyzer’s temperature memory buffer and return to the Setup List screen. Note: The temperature memory buffer is cleared when the analyzer is turned off, or when the T-AIR thermocouple is installed after the measured number is saved. 2.14.
Operation ECA 450 4. Use ∧∨ keys to place cursor next to “Enter”; then press ENTER to display the Primary Air Temperature screen. Primary Air Measure ª Enter 5. Press ENTER to move the cursor into the temperature data field; then use the ∧, ∨ , <, and > keys as necessary to enter the temperature value that was measured in Step 1. Note that leading zeros should be entered as either a numerical 0 or a blank space. For example: a primary air temperature of 35.5 °F should be entered as 035.5 in the display.
ECA 450 Operation 2.15 Differential Pressure Measurement To measure the differential pressure between two confined areas, do the following: 1. Press PRESSURE key to display the Pressure screen. ««««««PRESSURE«««««« n.nn xxxx Where: n.nn = current pressure reading xxxx = pressure units (refer to Section 2.17.2) 2. If desired, the pressure sensor can be zeroed as described below. To skip the zeroing procedure, proceed to Step 3.
Operation ECA 450 2.16 Statistics Mode The Statistics mode configures the ECA 450 to perform a statistical analysis of measured emissions data taken over a preset interval and duration. At the end of the prescribed duration, the average and standard deviation are calculated for each gas measured and shown on the front panel display. Turn ON the Statistics mode and begin the statistical analysis process as follows: 1. Press the SETUP key to display the Setup List screen.
ECA 450 Operation 5. The statistics duration is the length of time allocated to collecting data. Use ∧∨ keys to select desired duration; then press ENTER to make the selection and display the Statistics Summary screen. Note: The minimum and maximum duration values are dependent on the interval. The duration can never be less than the interval, and cannot record more than 120 readings. Statistics Duration 5 min 6.
Operation ECA 450 8. At the conclusion of the data collection process, the ECA 450 calculates the average and standard deviation values of the emissions data just recorded. A Final Statistics screen then appears that shows the average and one standard deviation of each gas measured; the number of readings taken; and the duration of the test. Use the ∧∨ keys to scroll through the readings on the display. If a sensor goes into over range or the calculated standard deviation exceeds 999.
ECA 450 Operation 2.17 Setting Up the Analyzer The analyzer has been set up at the factory for the following defaults: Temperature Units ....................°F Pressure Units ...........................Inches of Water Column (inwc) Pollution Units ............................ppm Language .....................................English Date .............................................Current date Time .............................................Current Eastern Standard Time O2 Reference ....................
Operation 2.17.1 ECA 450 Temperature Units Select to display the temperature in either degrees centigrade (C) or Fahrenheit (F) as follows: 1. Press SETUP key to display the Setup List screen. 2. Use ∧∨ keys to place cursor next to “Temperature Units”; then press ENTER to display the Temperature Units screen. Temperature Units °C ª °F 3. Place cursor next to either “°C” or “°F”; then press ENTER to make the selection and return to Setup List screen. 2.17.
ECA 450 Operation 5. Use ∧∨ keys to place cursor next to “Pollution Units”; then press ENTER to display the Pollution Units screen. Pollution Units ª ppm #/Mbtu mg/m3 g/GJ 6. Use ∧∨ keys to place cursor next to either “ppm”, “#/Mbtu”, “mg/m3”, or “g/GJ”; then press ENTER to make the selection and return to Setup List screen. 2.17.4 Language Information on the display screen can be shown in either English, Spanish, or French. Select the desired language as follows: 1.
Operation ECA 450 4. Press > key to place cursor on the month, day, or year digit to be changed; then, use ∧∨ keys to set that digit to desired number. Repeat this step until all digits are set correctly. 5. Press ENTER to save selections and start clock. Then press ESC to return to Setup List screen. 2.17.6 Time Time is stored in the format HH:MM:SS am/pm. Set the analyzer’s internal clock to the current time as follows: 1. Press SETUP key to display the Setup List screen. 2.
ECA 450 Operation 3. Use ∧∨ keys to place cursor next to the desired gas whose Oxygen reference is to be set; then press ENTER to display the O2 Reference screen for that gas. CO Ref to O2 n % Where: n = Oxygen reference 4. Use ∧∨ keys to choose desired Oxygen reference value from 0 to 15%. 5. Press ENTER to make the selection and return to O2 Reference gas menu screen. 6. Repeat Steps 3 thru 5 for remaining gases. 7.
Operation ECA 450 3. Use ∧∨ keys to place cursor next to “Edit Test ID”; then press ENTER to display the Edit Test ID menu, which shows the first line of each Test ID record. ª Edit Test ID 0 Customer1 1 ..... 2 ..... 31 ..... Note: Five periods (. . . . .) are used to identify empty lines. 4. Use ∧∨ keys to choose which Test ID record to edit; then press ENTER to display all three lines of that record. ª Edit Test ID Customer1 Address Burner Location 5.
ECA 450 Operation 3. Use ∧∨ keys to place cursor next to “Select Test ID”; then press ENTER to display the Select Test ID menu, which shows the first line of each Test ID record. ª Select Test ID 0 Customer1 1 ..... 2 ..... 31 ..... NO Test ID Note: Five periods (. . . . .) are used to identify empty records. 4. Use ∧∨ keys to choose a pre-entered Test ID, or choose “NO Test ID” to deselect a previously chosen record; then press ENTER to make the selection and return to the Test ID menu.
Operation ECA 450 5. The computer’s communication program and the connection to the ECA 450 can now be closed. 6. Press ESC to end this procedure and return to Setup List screen. 2.17.8.4 Clearing Test ID Information Clear all or individual pre-entered Test ID information from memory as follows: 1. Press SETUP key to display the Setup List screen. 2. Use ∧∨ keys to place cursor next to “Test ID”; then press ENTER to display the Test ID menu.
ECA 450 2.17.9 Operation Display Timeout To conserve battery life, the vacuum fluorescent display panel can be configured to turn itself off after 5 to 60 minutes of keyboard inactivity. Select the display’s time-delay off period as follows: 1. Press SETUP key to display the Setup List screen. 2. Use ∧∨ keys to place cursor next to “Display Timeout”; then press ENTER to show the Display Timeout screen. Display Timeout n Where: n = current timeout period 3.
Operation 2.17.10.1 ECA 450 Changing Display Format Change the order in which the data is displayed in the Combustion Test HOLD/RUN screen as follows: Note: Changing the order of the Combustion Test Data as displayed on the analyzer’s front panel does not change the order in which the data is printed or downloaded. 1. Press SETUP key to display the Setup List screen. 2. Use ∧∨ keys to place cursor next to “Display Format”; then press ENTER to show Display Format screen.
ECA 450 Operation 4. Use ∧∨ keys to choose “Yes”; then press ENTER to reset the display and return to the Display Format screen. Reset Display Format No ª Yes 5. When finished, press ESC to return to the Setup List screen. 2.17.11 Primary Air Refer to Section 2.14 Primary Air Temperature Measurement. 2.17.12 Data Logging Refer to Section 2.12 Data Logging. 2.17.13 Statistics Refer to Section 2.16 Statistics Mode. 2.17.14 User Name The name of the user or owner of the analyzer (e.g.
Operation ECA 450 4. Use ∧∨ keys to choose which User Name line to edit; then press ENTER to begin editing that line. 5. Use ∧∨ keys to display the first desired character. Then use the > key to move cursor to the next character’s position. Repeat this step until the line is complete (maximum of 20 characters). 6. When finished, press ENTER key to save the information just entered and redisplay the User Name menu. 7.
ECA 450 Operation 2.17.16 High Resolution NOx Enable When High Resolution NOx Enable is turned ON the ECA 450 will display the values of NO, NO2 and NOx at a resolution of 0.1 ppm when the values of these gases are <100 ppm. When a gas value becomes ≥100 ppm, the resolution for that gas switches to 1 ppm. When High Resolution NOx Enable is turned OFF, the display resolution for NO, NO2 and NOx is always 1 ppm. Turn High Resolution NOx Enable ON or OFF as follows: 1.
Operation ECA 450 5. When High Resolution NOx Enable is turned ON, and when viewing the Combustion Test RUN screen, observe in the example screens below that if the value of NO, NO2, or NOx is <100 ppm, then the resolution is 0.1 ppm, but when a gas value is ≥100 ppm the resolution becomes 1 ppm. «RUN«««««««««««NGAS« NO 18.3 ppm NO2 6.7 ppm NOX 25.0 ppm «RUN«««««««««««NGAS« NO 131 ppm NO2 73.0 ppm NOX 204 ppm 2.17.
ECA 450 Calibration 3 Calibration Bacharach recommends that the ECA 450 be calibrated by your nearest Bacharach Service Center (refer to Section 6.3). The analyzer, however, can be calibrated in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in this section. Important! To prevent the loss of data during calibration, perform the following procedures with a fully charged battery pack, or with the AC adapter connected to the analyzer. 3.
Calibration 3.2 ECA 450 Calibration Fixtures A gas and pressure fixture will be required to perform the various calibration procedures described in the sections that follow. Parts Required: • Calibration Kit (refer to Section 6.2) • Calibration Gas (refer to Section 6.2) • Bellows • Micro manometer Procedure: Assemble the appropriate fixture as required by the calibration procedure being performed. See Figure 3-1. Figure 3-1.
ECA 450 3.3 Calibration Starting and Ending a Calibration Procedure Start any calibration procedure by first pressing the CALIBRATE shortcut key. Before calibration can begin, however, a 4-place alphanumerical password must be entered. Enter the password by first pressing the ENTER key, and then using the ∧ ∨ and < > keys until the correct password is displayed. Note: The calibration password is provided on a separate card supplied with the analyzer.
Calibration ECA 450 2. With the Calibrate Pressure screen displayed, and with the hose from the calibration fixture connected to the analyzer’s PRESSURE port, adjust the bellows for a micro manometer reading of −4 in. H2O column (−10 mb). 3. Wait until the Measured reading on the screen stabilizes. Then use the ∧∨ and < > keys to enter an Applied value that equals the micro manometer reading. The calibration range is from –6 to –2 in. H2O column (−15 to −5 mb).
ECA 450 Calibration 4. Wait until Measured reading on screen stabilizes. Then use the ∧∨ and < > keys to enter an Applied value of 32 °F (0 °C). Typical Calibrate TS-Zero Screen During Calibration: «CALIBRATE TS-ZERO«« Measured 31°F Applied 032°F 5. Press ENTER to calibrate the analyzer’s Measured value to that of the Applied value; after which the message “Good Calibration” should appear followed by the CALIBRATE TS-SPAN screen. TS-Span Procedure: 6. Adjust simulator to 572 °F (300 °C).
Calibration ECA 450 2. Plug simulator’s K-type connector into analyzer’s T-AIR jack (see Figure 1-1). 3. Enter Calibration List screen; then choose T-Air per Section 3.3 to display the CALIBRATE TA-ZERO screen. 4. Wait until Measured reading on screen stabilizes. Then use the ∧∨ and < > keys to enter an Applied value of 32 °F (0 °C). Typical Calibrate TA-Zero Screen During Calibration: «CALIBRATE TA-ZERO«« Measured 31.2°F Applied 032.0°F 5.
ECA 450 Calibration Procedure: 1. Enter Calibration List screen; then choose HC per Section 3.3 to display the CALIBRATE HC screen. At the conclusion of this step the pump should be running. 2. Using the Gas Fixture shown in Figure 3-1, attach a CH4 calibration gas cylinder to the analyzer’s GAS inlet port. 3. Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH. 4. Wait until Measured reading on screen stabilizes (approximately 3 minutes).
Calibration ECA 450 3. Adjust regulator of calibration fixture for a flow meter indication of approximately 2 SCFH. 4. Wait until Measured reading on screen stabilizes (approximately 3 minutes). Then use the ∧∨ and < > keys to enter an Applied value that equals the concentration stamped on the CO gas cylinder. The calibration range is from 10 to 1500 ppm. An applied value that is outside this range will cause the message “Bad Calibration Entry” to appear.
ECA 450 Calibration 11. Press ENTER to calibrate the analyzer’s Measured value to that of the Applied value; after which the message “Good Calibration” should appear along with the Calibration List screen being redisplayed. If the message “Sensor Output Low” or “Sensor Not Calibrated” appears, refer Section “5.4 Troubleshooting Guide.” 12. Turn off regulator; then remove gas cylinder from calibration fixture. 3.
Calibration ECA 450 3.10 Calibrate NO Sensor The following procedure spans the optional Nitric Oxide sensor to a known gas level. Material Required: • Calibration Gas Fixture (Section 3.2) • Gas Cylinder: 250 ppm NO in Nitrogen (refer to Section 6.2) Procedure: 1. Enter Calibration List screen; then choose NO per Section 3.3 to display the CALIBRATE NO screen. At the conclusion of this step the pump should be running. 2.
ECA 450 Calibration 3.11 Calibrate NO2 Sensor This screen is used to span the optional Nitrogen Dioxide sensor to a known gas level. Material Required: • Calibration Gas Fixture (Section 3.2) • Gas Cylinder: 100 ppm NO2 (refer to Section 6.2) Procedure: 1. Enter Calibration List screen; then choose NO2 per Section 3.3 to display the CALIBRATE NO2 screen. At the conclusion of this step the pump should be running. 2.
Calibration ECA 450 3.12 Calibrate CO-HI Sensor This procedure spans the optional Carbon Monoxide High sensor (4,000 – 80,000 ppm CO) to a known gas level. Material Required: • Calibration Gas Fixture (Section 3.2) • Gas Cylinder: 4,000 ppm CO in air (refer to Section 6.2) Procedure: 1. Enter Calibration List screen; then choose CO-HI per Section 3.3 to display the CALIBRATE CO-HI screen. At the conclusion of this step the pump should be running. 2.
ECA 450 Maintenance 4 Maintenance Field maintenance of the ECA 450 is limited to the following: • • • • • • • Battery charging Water Trap Filter replacement Printer Paper replacement Sensor replacement Cleaning the probe Resetting the microprocessor Replacing the internal particulate filter All other maintenance should be performed by an authorized Bacharach Service Center (Section 6.3). 4.1 Battery Charging A fully charged battery pack will power the analyzer for a minimum of 8 hours.
Maintenance 4.2 ECA 450 Water-Trap / Filter Assembly The Water-Trap / Filter Assembly removes water condensate from the gas sample, and also prevents soot from contaminating the internal components of the analyzer. Figure 4-1. Water Trap / Filter Assembly End-Cap Filter Element Riser Tube End-Cap Inlet End Outlet End Drain the water condensate after every use. Procedure: 1. Pull off end-cap from inlet end of the Water-Trap / Filter Assembly. 2.
ECA 450 4.3 Maintenance Printer Paper Replacement Parts Required: • Replacement Paper Roll (refer to Section 6.1) Procedure: 1. Open printer by pressing the printer’s front-panel latch. See Figure 4-2. 2. The paper-roll carrier is mounted on the rear of the printer’s front panel and will swing out when the printer is opened. 3. Pinch in the two paper-roll clips at end of paper carrier; then remove paper-retainer disk and empty roller from carrier. 4.
Maintenance 4.4 ECA 450 Sensor Replacement The following sections described in detail how to replace the various sensors located in the analyzer’s sensor compartment. Refer to Figure 4-3 for the location and positioning of those sensors. Note: When a sensor-error message appears at the bottom of the screen (refer to Section “5.2 Problem Messages Displayed After Warm-Up”), it does not necessarily mean that the sensor has become depleted or is defective. Before replacing a sensor, refer to Section “5.
ECA 450 4.4.1 Maintenance O2, CO, NO, NO2, & SO2 Sensor Replacement All sensors, with the exception of the HC sensor, are replaced in a similar manner. Do the following to replace either the O2, CO-LO, CO-HI, NO, NO2, or SO2 sensor. Material Required: • Medium Phillips screwdriver • Replacement sensor (refer to Section 6.1) Procedure: 1. Remove two screws from sensor-cover plate, and then remove plate to gain access to sensor compartment. See Figure 4-3. 2.
Maintenance 4.4.2 ECA 450 Nitric Oxide Sensor Battery Replacement A single lithium battery, located on top of the Nitric Oxide printed circuit board, applies a bias voltage to the NO sensor to prevent the sensor from destabilizing when the analyzer is turned off. This battery has a life expectancy of at least 2 years. Replace the Nitric Oxide bias battery toward the end of its life expectancy, or when its voltage drops below 2 volts. Tip: Replace the bias battery whenever the NO sensor is replaced.
ECA 450 4.4.3 Maintenance HC Sensor Replacement Unlike the other sensors that are held in place by their associated bayonet holders, the HC sensor is plugged into its printed circuit board which, in turn, is secured inside the sensor compartment with four screws. Remove this board and replace the sensor as follows: Material Required: • Medium Phillips screwdriver • Small flat blade screwdriver • Replacement HC sensor (refer to Section 6.1) Procedure: 1.
Maintenance 4.5 ECA 450 Replacing Internal Particulate Filter An internal particulate filter is located at the inlet of the pump to protect the pump in the event dirt is drawn into the analyzer’s GAS inlet. Under normal operating conditions, the probe’s water trap / filter assembly should catch all dirt particles large enough to damage the pump. But if the probe’s filter fails or is disconnected, the internal particulate filter will provide backup protection.
ECA 450 4.6 Maintenance Cleaning the Probe and Sampling Hoses If the combustion analyzer is used on either coal or oil fired burners, particulates can accumulate within the probe and sampling hoses. These particulates may, in time, build up and restrict the flow of gas into the analyzer. Note that the probe’s water trap’s filter element should prevent soot from reaching the analyzer’s internal components.
Maintenance ECA 450 3. Clean probe assembly by generously spraying carburetor cleaner through each of the barbed fittings of the probe handle, while allowing the cleaner to flow out of the probe tip. 4. After spraying with carburetor cleaner, remove all the residual cleaner by repeatedly flushing the probe assembly with alcohol. 5. Clean sampling hoses by first squirting a few drops of detergent into one end of each sampling hose.
ECA 450 Maintenance Notes: Instruction 0024-9400 71
Parts & Service ECA 450 5 Troubleshooting 5.1 Analyzer Repair It is recommended that field repair of the ECA 450 be limited to: • • • • Simple checks of printed circuit board connectors Replacing the Probe Assembly Replacing the filter element in the Water Trap / Filter Assembly Replacing Sensors All other repairs should be performed by an authorized Bacharach Service Center. Any repairs performed by an unauthorized service organization will void the analyzer’s warranty and release Bacharach, Inc.
ECA 450 Parts & Service CO-HI Sensor Error – CO-HI sensor was exposed to flue gas during warm-up. CO-LO Sensor Error – CO sensor was exposed to flue gas during warm-up. Pressure Sens. Error – Pressure sensor is measuring a pressure that is outside the of range of ±3 inches of water column during warm-up. SO2 Sensor Error – SO2 sensor was exposed to flue gas during warm-up. Low Battery – Battery voltage is low. Only several minutes of operating time remain. 5.
Parts & Service 5.4 ECA 450 Troubleshooting Guide The following table lists the causes and remedies for most of the problems that may arise with the analyzer. If the information in Table 5-1 does not solve the problem, or for help with any problem that is not listed, then please contact one of the Bacharach Service Centers listed in Section 6.3. TABLE 5-1. TROUBLESHOOTING GUIDE Symptom Analyzer completely nonfunctional; won’t turn on when the I/O key is pressed. Probable Cause & Remedy a.
ECA 450 Parts & Service Symptom Probable Cause & Remedy “Low Battery” message appears at bottom of display, accompanied by a beeping alert tone. Battery close to being discharged. Analyzer will run for only several minutes after this message first appears before turning itself off. Recharge battery per Section 4.1. “O2 Sensor Error” message appears at bottom of display. a. Analyzer was turned on with probe sampling flue gas. Remove probe from stack and restart. b. O2 sensor depleted.
Parts & Service ECA 450 Symptom “NOXIDE Sensor Error” message appears at bottom of display. Probable Cause & Remedy a. Analyzer was turned on with probe sampling flue gas. Remove probe from stack and restart. b. NO sensor not zeroed at start up. Turn analyzer off and then on to rezero all sensors. If error persists, replace sensor. “CO-LO Sensor Error” message appears at bottom of display. a. Analyzer was turned on with probe sampling flue gas. Remove probe from stack and restart. b.
ECA 450 Parts & Service Symptom Probable Cause & Remedy “Sensor Output Low” message appears during calibration. Sensor is nearing the end of its useful life. Calibration is still good, but the sensor should be replaced soon. “Sensor Not Calibrated” message appears during calibration. Sensor’s output is too low to be calibrated. Replace sensor per Section 4.4. “– – – –” appears in one or more of the data fields in the Combustion Test RUN screen.
Parts & Service ECA 450 Symptom Erratic combustion test screen data. Probable Cause & Remedy a. Faulty sensor(s): - Check that all sensors are properly installed and their wiring harnesses are correctly connected to the analyzer. Refer to Section 4.4. - Check sensor calibration per Section 3. - Replace any sensor that does not calibrate, and then recalibrate. b. Leak in gas path. Check tightness of all hose connections on probe, and tightness of all hose connections internal to the analyzer.
ECA 450 6 6.1 Parts & Service Parts & Service Replacement Parts Complete ECA 450 Basic Configuration (O2, CO, Stack Temp., Ambient Temp, and Pressure measurement), with sampling probe (12 in. tube) and hose assembly .......................................... 0024-7221 AC Adapter: Charger Unit ............................................................................. 0024-0985 Power Cord ................................................................................. 4998-8986 Battery Pack ...........
Parts & Service 6.2 ECA 450 Accessories Calibration Kit (gas not supplied) ................................................. 0024-7059 Flue Gas Sample Conditioning Unit: Compact System. Includes Peltier chiller/probe assembly, built-in filter, condensate pump, and 15 ft hose assembly. .... 0024-7224 Gas Cylinders: CO, 500 ppm in air ................................................................... 0024-0492 CO/H2, 1000 ppm CO & 1000 ppm H2 in Nitrogen .................. 0024-0794 CO, 4000 ppm in air ..
ECA 450 6.3 Parts & Service Service Centers Service and replacement parts can be obtained by contacting a Bacharach Service Center at the following locations: United States Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Email: help@mybacharach.com Canada Bacharach of Canada, Inc. 20 Amber St. Unit #7 Markham, Ontario L3R SP4 Canada Phone: 905-470-8985 FAX: 905-470-8963 E-mail: bachcan@idirect.
Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 1-800-736-4666 Website: www.mybacharach.com • E-mail: help@mybacharach.
