CAI 600-NDIR User Manual Download Page 1

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Summary of Contents for 600-NDIR

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Page 2: ...formance A WARNING safety alert appears with information that is important for protecting you others and equipment from damage Pay very close attention to all warnings that apply to your application T...

Page 3: ...rical Safety Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Standard s to which Conformity is Declared Electrical Safety Standard for Electrical Equipment for M...

Page 4: ...A or voltage V as desired a The mA setting will give 4 20 mA or 2 10V if 500 ohm resisters are installed b The V setting will give 0 20mA or 0 10V if 500 ohm resistors are installed Disconnect power b...

Page 5: ...2 Features 17 2 1 Description 17 2 2 Features General 17 2 3 Features General 17 2 4 Infrared Gas Analyzers 18 2 5 Interference Gases 19 2 6 Electronics 20 2 7 Model 600 NDIR Specifications 21 2 8 Mod...

Page 6: ...2 32 6 3 Maintenance Functions Level 3 32 6 4 System User Functions Level 4 32 7 Main Menu Function Descriptions 33 7 1 F1 Measurements 33 7 1 1 F1 Measurement 33 7 1 2 Range Select 34 7 2 F2 Purge A...

Page 7: ...46 7 6 1 F1 Real Time Clock 46 7 6 2 System Setup F2 Displays TCP IP Address 48 7 6 3 Systems Setup F3 Displays Output Signal Assignments 48 7 6 4 System Setup F4 Displays Output Ranges 48 7 6 5 F5 T...

Page 8: ...ench Measuring Cell Infrared Analyzers Only 60 10 3 Optical Bench Configuration 60 10 4 Removal of Pipe Cell 62 10 5 Removal of Block Cell 64 10 6 Disassembly of Combination Pipe Block Type Cells 66 1...

Page 9: ...Data Description 75 12 3 4 Error Handing 75 12 4 Scan Commands 76 12 4 1 AKON Measured concentration value 76 12 4 2 AEMB Get measuring range 76 12 4 3 AMBE Measuring range limit 76 12 4 4 AKAK Calibr...

Page 10: ...ibration 81 12 5 6 SSPL Purge Analyzer with zero gas 81 12 5 7 SATK Start automatic calibration 81 12 5 8 SEMB Set measuring range 81 12 5 9 SARE Auto range on 82 12 5 10 SARA Auto range off 82 12 5 1...

Page 11: ...ET90 Set Lowpass Filter Time 84 12 6 10 EDAL Diagnostic alarm limits 84 12 6 11 ETCP Set TCP IP Parameters 84 12 6 12 EH2O Set H2O correction parameters 84 12 6 13 ECO2 Set CO2 correction parameters 8...

Page 12: ...35 Figure 7 6 Purge Screen 35 Figure 7 7 Diagnostics Screen I 35 Figure 7 8 Calibration Screen 36 Figure 7 9 Auto Calibration Screen 36 Figure 7 10 Manual calibration 37 Figure 7 11 Manual zero calib...

Page 13: ...ensation 50 Figure 7 46 P Compensation 50 Figure 7 47 Low pass filter time constant 51 Figure 7 48 Analyzer Information 51 Figure 7 49 Software Version 51 Figure 7 50 F6 Remote Manual 51 Figure 7 51 F...

Page 14: ...ping container and carefully remove the analyzer from the packing materials Inspect the instrument for any sign of damage Remove the Top Cover retaining screws Visually check for loose parts or connec...

Page 15: ...repaid and CAI will return the repaired or replaced product freight collect d if the product claimed to be defective requires on site repair such warranty labor will be provided at no charge however t...

Page 16: ...le Tampering or use of substitute components may cause a safety hazard Use only factory authorized replacement parts 1 8 Electrical Shock Hazard Disconnect power before removing cover Servicing requir...

Page 17: ...RS 232C communications After turning on the analyzer it needs at least 30 seconds for initialization During this time the screen is illuminated IMPORTANT TIP When the analyzer is powered up it default...

Page 18: ...ugh the measuring cell filled with a sample gas where the light energy is partially absorbed or attenuated before it reaches the front chamber of the detector Both the front and rear chambers of the d...

Page 19: ...ristic of Detector 2 5 Interference Gases Whenever a sample gas contains a gas component that has an absorption spectrum that overlaps the spectrum of the gas to be measured that gas is commonly refer...

Page 20: ...the sample cell This signal is amplified by successive AC amplifiers and then demodulated and filtered The resulting DC signal is further amplified and fed into two output buffer amplifiers The DC sig...

Page 21: ...magnetic O2 RANGES 0 1 up to 0 100 O2 Full Scale Four Definable Ranges O2 RESPONSE TIME 90 2 Seconds 2 8 Model 600 NDIR Features OUTPUTS AVAILABLE TCP IP RS232 Four Scalable Analog 0 10 V 4 20 mA Allo...

Page 22: ...instrument to corrosive or combustible gases The instrument must not be subject to severe vibration If severe vibration is present use isolation mounts The instrument is designed for rack mounting Opt...

Page 23: ...n and range selection are obtained via the rear panel connections When a range is selected the corresponding control line is pulled low to zero VDC Ranges not selected will remain at approximately 5 V...

Page 24: ...unction 3 8 Sampling Requirements 3 8 1 Filtration Dust must be eliminated completely Use filters as necessary The final filter must be capable of removing particles larger than 4 microns 3 8 2 Conden...

Page 25: ...1 THE TOP INFORMATION AREA CONTAINS 2 The AK Protocol Information This capability is for advanced uses and may be toggled on and off in the setup screen F5 Next to the symbol for the active operating...

Page 26: ...Alarms F5 Password F6 Linearization F7 System settings F8 Measure settings F10 Version Remote Manual Stand By Sets analyzer in purge mode F1 F2 F3 F4 F5 F6 F7 F1 Starts auto calibration on range in u...

Page 27: ...calibration Manual Calibration F1 Flow zero gas F2 Flow span gas Display Deviations F1 Zero gas deviations F2 Span gas deviations F3 Verifying devs zero F4 Verifying devs span Check Calibration Reset...

Page 28: ...ings F1 Times F2 Measuring deviations F3 Deviation F4 Calibration via values F5 Calibration via pump Range limits F1 Range 1 4 F2 Autorange Alarms I Password F1 Standard user F2 Extended user F3 Maine...

Page 29: ...cursor position is shown as a black horizontal bar TIP If you are not yet familiar with the screens and their fields just press any cursor key after a screen appears This moves the cursor from field t...

Page 30: ...Advanced user operating level 2 F3 Maintenance operating level 3 F4 System user operating level 4 A password can be assigned to each operating level Only the system user who normally has the highest o...

Page 31: ...n initial start up the analyzer reverts to ONLY Level 1 access See Section 7 5 5 for Password information All functions can be selected with the cursor keys and activated by pressing the Enter key or...

Page 32: ...ed User Functions Level 2 Main Menu Setup Menu Password Menu F1 Measurements F3 Range Limits F1 Enter password F2 Purge Analyzer F5 Password F3 Diagnostics F10 Version F4 Calibrations F5 Setup F7 Stan...

Page 33: ...CE Operators Manual Page 33 of 86 7 Main Menu Function Descriptions 7 1 F1 Measurements Figure 7 1 Main Menu Screen 7 1 1 F1 Measurement The measurements screen is activated by pressing F1 on the Main...

Page 34: ...an be selected and locked in which will disable the auto range capability Continue pressing the arrow keys will recycle the analyzer back to auto range The range and or auto range is displayed on the...

Page 35: ...5 Main Menu User Level 4 Figure 7 6 Purge Screen F2 from the Main Menu activates the Purge analyzer function if equipped 7 3 F3 Diagnostics F3 from the Main Menu activates the Diagnostics function F3...

Page 36: ...value was constant during calibration time it is checked to determine if this value deviates from the preceding value If the deviations are too large a warning Deviation error appears and the user ca...

Page 37: ...ibration From the Calibration screen F2 starts manual calibration If auto range is selected calibration is not possible and the appropriate range can be selected Figure 7 10 Manual calibration In the...

Page 38: ...f span gas during verifying F1 and F2 deviations are displayed in percent Figure 7 14 Zero gas deviations Figure 7 15 Span gas deviations During calibration there is verification for zero and span gas...

Page 39: ...ted range 7 4 8 F4 Check Calibration There is a default calibration Pressing F4 activates an automatic zero and span check for verification 7 4 9 F5 Reset Calibration Values There is a default calibra...

Page 40: ...put the concentration of the span gas in ppm For every range the span gas concentration can be changed After pressing F1 in the setup menu a screen appears in which changes can be made Select with the...

Page 41: ...nd saved as above 7 5 4 F2 Measuring Deviations During auto calibration the measured value is only saved if it is within a certain time within an upper and a lower limit These two limits format a work...

Page 42: ...ly adapted This means that if the upper range limit of range 1 for example has reached 90 of the upper range limit in the auto range mode it is switched automatically to the second range Figure 7 21 C...

Page 43: ...with alarm limits that can be defined The user can define the range limits and if exceeded will display an error message Figure 7 23 Alarm screen I Figure 7 24 Alarm screen II Set Temperature Alarms...

Page 44: ...ntered on the numeric keypad If the code word is incorrect you are asked to re enter the codeword IMPORTANT TIP When a new analyzer is powered up it defaults to access level 1 User To operate ALL para...

Page 45: ...ith 5 coefficients By pressing F1 these 5 coefficients can be changed for each range By pressing F2 the raw value can be displayed This is the value before linearization and offset span correction The...

Page 46: ...Time Clock This brings up the clock time set screen auto cal and auto cal enable screens Figure 7 32 Clock and Timing Setup Screen Figure 7 33 Clock set screen The current time may be set by using th...

Page 47: ...01P 602 602P 603 NDIR Analyzer California Analytical Model 600_NDIR_Series_v10 0 CE Operators Manual Page 47 of 86 Figure 7 34 Set Auto Cal Timing Figure 7 35 Set Auto Cal Ranges Figure 7 36 F4 Toggle...

Page 48: ...48 of 86 7 6 2 System Setup F2 Displays TCP IP Address Figure 7 37 TCP IP Address 7 6 3 Systems Setup F3 Displays Output Signal Assignments Used to Adjust Analog Output Channels Figure 7 38 Output Ass...

Page 49: ...urns Status Line On or Off The status line displays the AK Protocol action on the top line of the display Figure 7 40 Status line Figure 7 41Status line on off 7 6 6 F8 Measure Settings This screen al...

Page 50: ...ore continuing with a zero or span calibration Figure 7 44 Purge Time 7 6 9 F3 Set Temperature Compensation Figure 7 45 T compensation 7 6 10 F4 Pressure Compensation Figure 7 46 P Compensation 7 6 11...

Page 51: ...the factory recommended air and sample pressure settings Figure 7 48 Analyzer Information Figure 7 49 Software Version 7 7 F7 Remote Manual Control The analyzer can be remote controlled either by a m...

Page 52: ...fornia Analytical Model 600_NDIR_Series_v10 0 CE Operators Manual Page 52 of 86 7 8 F8 Standby Figure 7 51 F7 Standby Main Menu User Level 4 In Standby mode pump is turned off and the solenoids are cl...

Page 53: ...eds sample gas to the analyzer Inch Tube 2 Sample Gas Bypass Outlet Vent Exhaust for sample Inch Tube 3 TCP IP Connection Connect Network Connector 4 28 Pin output terminal strip main 1 standard 5 28...

Page 54: ...2 Conc 1 Alarm D Output 11 Sense Range 1 Sense Range 1 Sense Range 1 D Output 11 Ch 2 Conc 2 Alarm Hi True D Input 12 Set AutoRange 12 Set AutoRange 12 Set AutoRange D Output 12 Ch 3 Conc 1 Alarm D I...

Page 55: ...unction 1 DCD Carrier Detect 2 RxD Receive Data 3 TxD Transmit Data 4 DTR Data Terminal Ready 5 Ground 6 DSR Data Set Ready 7 RTS Ready to Send 8 CTS Clear to Send 9 RI Ring Indicator 8 3 2 TCP IP 8 P...

Page 56: ...alytical Model 600_NDIR_Series_v10 0 CE Operators Manual Page 56 of 86 8 4 Internal Component Locations 3 5 4 2 1 Figure 8 1 Internal components 1 Signal conditioning PCB 2 NDIR detector 3 Sample cell...

Page 57: ...rators Manual Page 57 of 86 8 5 Main Electronics Board Potentiometers Figure 8 2 Main Electronic Board Potentiometers 1 RP2 Detector voltage adjust 2 RP3 Fine zero adjust 3 RP4 Not used Fully CW 4 RP5...

Page 58: ...600_NDIR_Series_v10 0 CE Operators Manual Page 58 of 86 8 6 NDIR Detector Assembly Figure 8 3 NDIR detector assembly 1 Detector Assembly 2 Sample cell assembly 3 Light source and chopper motor assembl...

Page 59: ...referable but not essential that zero gas flow through the instrument at a rate of about 1 Liter minute LPM Note To achieve final stability the analyzer may require an additional warm up period of up...

Page 60: ...is present check the sampling system especially the filters to eliminate the source of contamination Periodic maintenance is generally not required Cleaning is accomplished by use of a cleaning agent...

Page 61: ...igure 10 1 Optical Bench with Pipe Sample Cell Item Description Item Description 1 3 Screw M4 12 Pipe sample cell 4 Base 13 O Ring 5 Infrared source unit 14 Window 6 7 Screw M4 15 Detector 8 Connector...

Page 62: ...in Figure 10 1 for signs of deterioration Replace if necessary 9 The CaF2 window is bonded to the window holder Inspect and clean the windows as necessary using cotton swabs and a suitable cleaning so...

Page 63: ...86 Figure 10 2 Optical Bench with Block Sample Cell Item Description Item Description 1 3 Screw M4 11 Block sample cell 4 Base 12 O Ring 5 Infrared source unit 13 Window 6 Screw M4 14 Detector 7 Scre...

Page 64: ...etector to the infrared light source assembly and remove the detector from the optical bench The cell is removed together with the detector as a unit 7 While holding the detector in the palm of your h...

Page 65: ...d Block Type Sample Cells Item Description Item Description 1 3 Screw M4 14 Window 4 Base 15 Detector 5 Infrared source unit 16 Bridge circuit board 6 Screw M4 17 Optical filter if installed 7 Screw 1...

Page 66: ...ing the detector in the palm of your hand remove the two flat head screws No 18 in figure 10 3 which fix the cell to the detector Note the cell window No 10 in figure 10 3 is loose and is only retaine...

Page 67: ...th sides of the liner and the inside of the pipe cell If the liner has been subjected to a corrosive substance it should be replaced In either case ensure that the small gas holes in the liner are ali...

Page 68: ...initial power up of a replacement detector or NDIR amplifier board 11 2 Coarse Zero Adjustment With zero gas still flowing connect a DC voltmeter to TP7 and TP9 common Switch JP8 to the on position a...

Page 69: ...amplifier board check terminals TPp common and TP3 When the NDIR amplifier board infrared light source unit and chopper are normal but ac waveform approximately 10 Hz is not observable at TP3 gas is l...

Page 70: ...he optical bench This would be normal and not necessarily indicative of a problem Purge the analyzer case with N2 gas 3 Replacement After disconnecting wires from the two terminal screws and motor con...

Page 71: ...ible 11 7 3 Check and or replace After removing the measuring cell check the cell and windows for contamination If contaminated remove contaminant with a soft cloth and alcohol Take care not to damage...

Page 72: ...nt it is recommended that a check for contamination in the cell and cell windows be done first as this can lead to a reduction in amplitude of the ac signal Note Check cell first for contamination and...

Page 73: ...ote control of the analyzer by a master computer It is implemented as an RS232 V24 interface and meets all requirements of the AK protocol A 9 pin male connector at the back of the unit is used to con...

Page 74: ...lank 8th Byte K 9th Byte 0 10th Byte Blank D A T A AK instruction parameters length is variable nth Byte ETX ASCII code 03 Table 12 1 Structure of an instruction command 12 3 2 Acknowledgement command...

Page 75: ...rrors disappear or are added If it had the value 10 it would be reset to 1 The error status byte does not indicate the real number of errors If the analyzer does not have errors the error status byte...

Page 76: ...range limit Command Response Description _AMBE_K0 _AMBE_s_M1_w w _M2_x x _M3_y y _M4_z z All existing measuring range limits of channel m are responded _AMBE_K0_Mn _AMBE_s_Mn_z z Range limit of Range...

Page 77: ...ded Errors 1 Channel 1 Flow Failure 8 Channel 1 not calibrated 2 Channel 2 Flow Failure 9 Channel 2 not calibrated 3 Channel 3 Flow Failure 10 Channel 3 not calibrated 4 External Analog 1 Failure 11 1...

Page 78: ...Description _AGRD_Km_Mn _AGRD_s_Mn_a0_a1_a2_a3_a4 Polynomial coefficients of channel m range Mn are responded 12 4 14 AANG Deviation from zero point after autocalibration Command Response Description...

Page 79: ...yymmdd year month day each 2 characters wide no spaces hhmmss hour minute second each 2 characters wide no spaces 12 4 20 AT90 Respond Lowpass filter time Command Response Description _AT90_K0_ _AT90...

Page 80: ...nt y y 1st order coefficient x x 2nd order coefficient 12 4 25 ACO2 Query CO2 correction parameter Command Response Description _ACO2_Km _ACO2_s_z z_y y_x x_w w z z Offset voltage of A in with no CO2...

Page 81: ...l measuring range _SNGA_Km_Mn _SNGA_s Open valve for zero gas calibration of range Mn 12 5 5 SEGA Open valve for end gas calibration Command Response Description _SEGA_K0 _SEGA_s Open all three end ga...

Page 82: ...and Response Description _SMGA_K0 _SMGA_s Start measuring Open all sample valves _SMGA_Km _SMGA_s Open sample valve of channel m 12 5 14 SNKA Saves measured value as new offset Command Response Descri...

Page 83: ...name _EKEN_s Set new device identification Maximum length of device name is 40 characters NOTE To change device identification you must first rename the device to RESET Now a name up to 40 characters...

Page 84: ...mits 1 Flow of channel 1 7 Temperature 2 Flow of channel 2 8 Sample concentration channel 1 3 Flow of channel 3 9 Sample concentration channel 2 4 External analog in 1 10 Sample concentration channel...

Page 85: ...ode optional UDP_IP Alternative IP address for open the UDP connection when it should not use the IP of connected TCP IP client optional 12 6 15 Format of the streaming Data via UDP ASCII Mode The mea...

Page 86: ...Section 12 Model 601 601P 602 602P 603 NDIR Analyzer California Analytical Model 600_NDIR_Series_v10 0 CE Operators Manual Page 86 of 86 13 Appendix Electrical Block Diagram...

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