Alpha Omega Instruments 9510 Series User manual

40 Albion Rd, Suite 100
Lincoln, RI 02865
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VER 1.3 11/06
SERIES 9510
CARBON DIOXIDE ANALYZER
INSTRUCTION MANUAL
ALPHA OMEGA
INSTRUMENTS
[email protected]

WARRANTY
Alpha Omega Instruments Corp. warrants the products delivered to be free from defects in material and
workmanship at the time of delivery to the FOB point specified in the purchase order, its liability under this
warranty being limited to repairing or replacing, at Alpha Omega Instruments' option, items which are
returned to it prepaid within 2 years from the date of shipment and found to Seller’s satisfaction to have
been so defective.
Alpha Omega Instrument's 2 year sensor warranty offers protection for 2 years from the date of shipment
of the Series 9510 Carbon Dioxide Analyzer. Any sensor from a Series 9510 Carbon Dioxide Analyzer
that fails under normal use must be returned to Seller prepaid and, if such sensor is determined by Seller
to be defective, Seller shall provide Buyer a replacement sensor. Buyer must provide the serial number of
the analyzer from which the sensor has been removed. If a sensor is found to be defective and a new one
issued, the warranty of the replacement sensor(s) is for a period of one year from the date of shipment. In
no event shall Alpha Omega Instruments Corp. be liable for consequential damages.
NO PRODUCT IS WARRANTED AS BEING FIT FOR A PARTICULAR
PURPOSE AND THERE IS NO WARRANTY OF MERCHANTABILITY.
This warranty applies only if:
(i) the items are used solely under the operating conditions and manner recommended
in this manual, specifications, or other literature;
(ii) the items have not been misused or abused in any manner or repairs attempted
thereon;
(iii) written notice of the failure within the warranty period is forwarded to Alpha Omega
Instruments Corp. and the directions received for properly identifying items returned
under warranty are followed;
(iv) the return notice authorizes Alpha Omega Instruments Corp. to examine and
disassemble returned products to the extent the Company deems necessary to
ascertain the cause of failure.
The warranties stated herein are exclusive. THERE ARE NO OTHER WARRANTIES, EITHER
EXPRESSED OR IMPLIED, BEYOND THOSE SET FORTH HEREIN, and Alpha Omega Instruments
Corp. does not assume any other obligation or liability in connection with the sale or use of said products.
Disclaimer of Warranty
Alpha Omega Instruments makes no representation or warranties, either expressed or implied, by or with respect to anything in this
manual, including, but not limited to, implied warranties of merchantability or fitness for a particular purpose. In no event will Alpha
Omega Instruments Corp. be liable for any damages, whether direct or indirect, special, consequential, or incidental arising from the use
of this manual. Some states in the USA do not allow the exclusion of incidental or consequential damages. Alpha Omega Instruments
Corp. also reserves the right to make any changes to improve the performance of its products at any time and without notice.
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ALPHA OMEGA INSTRUMENTS CORP.
SERIES 9510 CARBON DIOXIDE ANALYZER INSTRUCTION MANUAL

WARNINGS
Explanation of graphic symbols
THIS SYMBOL IS INTENDED TO ALERT THE USER TO THE
PRESENCE OF IMPORTANT OPERATING AND MAINTENANCE
INSTRUCTIONS.
To avoid the risk of fire or electric shock, do not expose the Series 9510 Carbon Dioxide Analyzer to rain
or water spray.
WHEN POWERED, THE PRESENCE OF DANGEROUS VOLTAGES WITHIN THE INSTRUMENT MAY
BE OF SUFFICIENT MAGNITUDE TO CONSTITUTE A RISK OF ELECTRICAL SHOCK RESULTING IN
INJURY OR DEATH. LEAVE ALL SERVICING TO QUALIFIED PERSONNEL.
REMOVE ALL POWER SOURCES WHEN INSTALLING OR REMOVING AC POWER OR DATA
SIGNAL CONNECTIONS AND WHEN PERFORMING ANY WORK INSIDE THE INSTRUMENT
ENCLOSURE.
RF Disclaimer
This instrument generates and uses small amounts of radio frequency energy, and there is no guarantee
that interference will not occur in a particular installation. If this equipment does cause interference to
radio or television reception, try to correct the interference by one of more of the following steps:
1. Reorient the receiving antenna.
2. Relocate the instrument with respect to the receiver.
3. Change the AC outlet of the instrument so the instrument and receiver are on different branch
circuits.
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SERIES 9510 CARBON DIOXIDE ANALYZER INSTRUCTION MANUAL

TABLE OF CONTENTS
PAGE
WARRANTY ii
WARNINGS iii
SECTION 1.0 INTRODUCTION 1
1.1 General Description 1
1.2 Optional Equipment Descriptions 1
1.2.1 Open Diffuser Configuration 1
1.2.2 Battery Operation 2
1.2.3 Serial Communications / RS232C 2
1.2.4 Serial Communications / RS485 2
1.2.5 Particulate Sample Filter 2
1.2.6 Low Pressure Regulator 2
1.2.7 Sample Pump 2
1.2.8 Coalescing Filter 2
1.2.9 Horn & Strobe 2
1.3 Non-Dispersive Infrared Sensor for Carbon Dioxide 3
1.4 General Specifications 5
SECTION 2.0 INSTALLATION PROCEDURES 6
2.1 Unpacking the Instrument 6
2.2 Electrical Installation 6
2.2.1 Wiring the AC/DC Power in Place of the Existing Power Cord 6
2.2.2 CO
2
Sensor 8
2.2.3 Wiring Alarm Relays 8
2.2.4 Wiring 4-20 mADC and 0-2 VDC Outputs 10
2.2.5 Wiring to the Optional RS-232C or RS-485 Outputs 10
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SECTION 3.0 OPERATION 11
3.1 Preparation for Operation 11
3.1.1 AC Input Voltage Selection 11
3.1.2 Mounting Configurations 12
3.1.3 Initial Check 12
3.2 Operating Procedures 13
3.2.1 Power ON 13
3.2.2 Front Panel Controls and Indicators 13
3.2.3 Scaling of the outputs 14
3.3 3.3 Alarm System 15
3.3.1 General Description of Alarm Processing 15
3.3.2 User Settings and Alarm Defaults 15
3.3.3 Fail Safe 16
3.3.4 Manual Clear / Auto Clear 16
3.3.4.1 Manual Clear Operation 16
3.3.4.2 Auto Clear Operation 16
3.3.5 Setting the Alarm Levels 16
3.3.6 Timing out During Setting 17
3.4 Sample Gas Handling 17
3.4.1 Sample Connections 17
3.4.2 Gas System Pressure and Flow Limits 17
3.4.3 Corrosive Gases 17
3.4.4 Radioactive Sample Gases 17
3.4.5 Condensable Gas Constituents 17
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SECTION 4.0 CALIBRATION PROCEDURES 18
4.1 Routine Calibration Check 18
4.2 Calibration Gas 18
4.3 No Zero Check Required 18
4.4 Procedure for Checking Calibration with a Flow Through System 19
4.5 Procedure for Checking Calibration with an Open Diffuser System 19
4.6 Timing Out during Calibration Checks 20
4.7 When Adjustments Exceed Factory Preset Limits 20
SECTION 5.0 MAINTENANCE 21
5.1 Calibration Check 21
5.2 Optional Battery Pack Replacement 21
SECTION 6.0 BASIC SERIAL COMMUNICATIONS 22
6.1 Baud Rates 22
6.2 Standard Commands 22
6.3 RS232/485 Connections 27
SECTION 7.0 ENHANCED REMOTE CONTROL COMMANDS WITH RS-485 28
7.1 General 28
7.2 Special Commands for RS-485 29
7.3 Added RS-485 Commands 30
7.4 RS-485 Enhanced Commands 32
APPENDICES Appendix A Bench Top/Portable Configuration 33
Part Number BTP
Appendix B Panel Mounting Configuration 34
Part Number PNL, PNR, & PTX
Appendix C Explosion Proof Configuration (EXX Type) 38
Appendix D Wiring Instructions for Explosion Proof System (EXX Type) 41
Appendix E Wall Mounted Electronics with Remote Sensor Enclosure 42
Appendix F Wiring Diagram for Remote Explosion Proof 43
Sensor Enclosure
Appendix G Explosion Proof Sensor Enclosure (Remote Sensor Type) 44
Appendix H Explosion Proof Remote Sensor Enclosure Showing 45
Internally Mounted Electrical Terminal Block
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SERIES 9510 CARBON DIOXIDE ANALYZER INSTRUCTION MANUAL

SECTION 1.0
INTRODUCTION
1.1 General Description
The Series 9510 Carbon Dioxide (CO2) Analyzer is a microprocessor based instrument providing accurate
and repeatable trace or percent carbon dioxide measurements. The sensor used in the Series 9510 is a
non-dispersive infrared type, which does not react chemically with the sample gas. Due to its robust
design, a comparatively low frequency of re-calibration is required.
The standard analyzer is housed in a NEMA 1 enclosure rated for general purpose use. The front panel
contains five switches that provide access to the analyzer's settings. Carbon dioxide values are displayed
on a 10.2 mm (0.4") high 4-1/2 digit liquid crystal display (LCD). The instrument is equipped with three
CO2alarm relays and one instrument status alarm relay. All four relays are Form C (SPDT) types rated at
10 amps at 115/230 VAC / 30 VDC. The relays are user configurable for fail-safe operation. In addition to
the four alarm relays, the Series 9510 Carbon Dioxide Analyzer has a built-in audible alarm and three red
LEDs for audible and visual indication of a CO2alarm condition. The audible alarm may be manually
canceled at any time. If the audible alarm is canceled and the alarm event continues, indications of this
condition will still be available through the front panel LEDs and relay contact(s).
The Series 9510 Carbon Dioxide Analyzer comes equipped with two standard analog outputs, 4-20 mADC
and 0-2 VDC, which are scalable by the user. For communications capability, the Series 9510 Carbon
Dioxide Analyzer can be equipped with optional RS-232C serial communications. RS-485 is also
available as an option. The analyzer can be powered from either 115/230 VAC @ 50-60Hz or 18-32 VDC
input, with battery operation an option for the AC powered versions (not available in explosion proof
configurations).
The Series 9510 Carbon Dioxide Analyzer offers users a choice of PPM or PERCENT measurement
ranges.Consult the factory for the appropriate range designations prior to ordering.
1.2 Optional Equipment Descriptions *
The Series 9510 Carbon Dioxide Analyzer incorporates standard features that make it immediately
suitable for many applications. However, for certain requirements, the user may desire to augment the
capabilities of the instrument by equipping it with one or more of the available options, as described below.
Please note that some of these options are not available with the open diffuser sensor configuration
1.2.1 Optional Open Diffuser Configuration
The Series 9510 Carbon Dioxide Analyzer comes in two sample gas configurations, depending upon
customer requirements. It is normally configured for process applications as a flow through system with
sample input and sample output fittings. It can also be supplied with an optional open diffuser
configuration for measurement of carbon dioxide in the air and/or gas surrounding the instrument.
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1.2.2 Optional Battery Operation P/N 95BAT
The Series 9510 can be equipped so that it may be powered from a normal AC/DC source as well as an
optional built-in battery pack.The batteries are installed at the factory and are designed for applications
where the user desires to power the analyzer for short periods using the batteries. With this option, the
Series 9510 Carbon Dioxide Analyzer will operate for a period of at least 8 hours. If equipped with a
sample pump, operating time will be reduced to less than four hours of continuous use. The Series 9510
Carbon Dioxide Analyzer is equipped with a “smart charging” capability for the Nickel Metal Hydride
(NiMH) battery pack. Smart charging eliminates the risk of the battery pack being over-charged (not
available with explosion proof systems). To acheive a full-charge after the batteries have been discharged,
allow for approximately 16 hours of charging time. See cautionary note on page 12.
1.2.3 Optional Serial Communications / RS232C P/N 9RS2
The RS-232C serial communications option is installed at the factory and is designed for applications
where enhanced serial communications is required between the analyzer and a host system. The
maximum distance between the analyzer and host system is 50 feet
1.2.4 Optional Serial Communications / RS485 P/N 9RS4
The RS-485 serial communications option is installed at the factory and is designed for applications where
enhanced serial communications is required between one or several analyzers and a host system over the
same communications channel. The RS-485 format allows both sending and receiving of signals over
greater distances than RS-232C, making it ideal for installations where the analyzer(s) are located at
distances greater than 50 feet from the host. The maximum distance recommended between devices is
4,000 feet
The following options are only available with the flow through system configuration only:
1.2.5 Optional Particulate Sample Filter P/N 995S
Miniature T-type 316 stainless steel filter with 1/8" NPT in-line ports. Recommended when particle loading
exceeds 3 mg/ft3and hydrocarbon mist exceeds 0.7 mg/ft3. Installed at the factory unless otherwise
specified by the customer.
1.2.6 Optional Low Capacity Pressure Regulator P/N 9LPR
Pressure Regulator with aluminum body recommended for use when sample pressure is
below 100 PSIG. The regulator does not include a gauge (can be ordered separately).
1.2.7 Optional Sample Pump P/N 9PMP
Addition of a sample pump is designed for those applications where the sample pressure or flow is
insufficient to transport the sample through the sensor housing.
1.2.8 Optional Coalescing Filter P/N 9CF
Coalescing filter recommended when the sample may contain a light mist together with particles.
1.2.9 Optional Horn & Strobe P/N Spec-HnSt
The Series 9510 can be equipped with an optional 24 VDC or 115 VAC Horn & Strobe for remote alarm
indication (separate from the Series 9510 Electronics that has its own audible and visual alarm indicators).
* Please contact the factory for other options and accessories.
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1.3 Non-Dispersive Infrared Sensor for Carbon Dioxide
Alpha Omega Instruments uses a non-dispersive infrared (NDIR) sensor to determine carbon dioxide
concentrations in gases. Infrared gas sensors, which are comprised of solid state devices, do not
chemically react with the gas.
Infrared radiation is a part of the electromagnetic radiation spectrum which also contains visible and
ultraviolet radiation. Since electromagnetic radiation is wavelike, infrared radiation has wavelengths
ranging from 0.8 to 100 microns. Gas molecules are made up of atoms which are bonded together.
These bonds constantly undergo vibrations and rotations. The frequencies of these vibrational and
rotational motions are a strong function of the size of the atoms and bond strengths. By nature, these
frequencies match with the frequency of the middle portion of the infrared spectrum (called mid IR). When
exposed to a beam of infrared radiation, most gas molecules will absorb IR radiation at their
vibration/rotation frequencies. The unique structure of each compound means that it will have a unique IR
fingerprint which can often be used to identify it with an IR instrument.
The ability of certain gases to absorb infrared radiation has been successfully utilized in developing
instruments for gas sensing. An infrared gas sensor consists of an infrared source (emitting broad band
radiation including the wavelength absorbed by the target gas) and an infrared detector that are separated
by a gas cell. In non-dispersive IR (NDIR) sensors, an IR source and an IR detector are separated by a
gas sample cell. An optical “band pass” filter is placed either in front of the source or the detector to
screen out all radiation except for the wavelength that is absorbed by the target gas.
The characteristic output of the sensor element is called “absorption” and is the percentage loss between
the IR radiation that reaches the detector with and without the target gas in the gas cell. The absorption is
calculated for the infrared signals measured under zero gas (gas that does not have infrared absorption,
i.e. Nitrogen) lo, and under the gas of interest lG using the relationship:
A=
l
O
−l
G
L
O
Absorption increases with increasing gas concentration and increasing optical path length between the
detector and the source. Knowing the dependence of absorption on the gas concentration for a given path
length, a sensor will measure an unknown gas concentration based on the measured absorption.
A simple, single channel sensor interprets that any loss in infrared signal is due to increasing absorption
by the target gas. Therefore, the sensor design should ensure that the signal loss is not due to any other
means such as infrared source or detector deterioration, changes in the optical assembly, or temperature
variations. In practice, a reference channel is added to the sensor to correct for these potential problems.
A reference channel is employed to optically measure change in infrared radiation that are not caused by
the gas being analyzed.
Alpha Omega Instrument’s infrared gas sensor design utilizes a “virtual reference” channel at the
absorbing wavelength that eliminates the need for locating a non absorbing infrared region for the
reference channel. The optical design and the absorption theory are described in detail as follows.
The sensor is comprised of two infrared sources (Lamp 1 and Lamp 2), one infrared detector, and a
narrow band optical filter that passes infrared radiation only at the wavelength absorbed by the gas of
interest. For example, carbon dioxide (CO2) is absorbed at a wavelength of 4.2 microns. Lamps 1 and 2
are placed in the gas cell at distances L1and L2 respectively from the detector. When a gas concentration
C is present in the cell, it will absorb the infrared radiation emitted by both the sources according to Beer’s
Law.
.
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Sensing lamp signal S1=l1e(-KCL1)
Reference lamp signal S2=l2e(-KCL2)
K= absorption constant
C= gas concentration
I= IR intensity emitted by the source
The ratio “R” (S1/S2) = (l1/l2)e{-KC(L1-L2)}
Since the radiation from Lamp 2 travels a much shorter path through the gas, it will be absorbed less than
the radiation from Lamp 1. The ratio of these signals shows the same absorption characteristics with an
equivalent cell length of (L1-L2). However, the signal from Lamp 2 will be equally effected by
environmental factors, system aging, and other unwanted factors. The absorption calculated from this ratio
for the differential path system can be used to sense the gas concentration while referencing out
non-signal impacts. Lamp 2 acts as a “virtual reference” to the system at the absorption wave length.
A key factor in traditional IR sensors is the temperature dependence of the detector/filter pair. The use of a
single detector and single optical filter in calculating the absorption ratio in Alpha Omega Instrument’s
sensor provides excellent temperature immunity. Movements in output due to temperature dependence of
the detector/filter pair are effectively referenced out. Furthermore, this design is considered to be optically
efficient. IR radiation is provided by incandescent lamps that are operated at a fraction of their
recommended power. This provides the sensor with a long mean time between failure (MTBF). It also
adds stability since the heated elements age at an insignificant rate. Utilizing signal ratios with proprietary
signal processing schemes adds higher resolution and provides more stable output from the sensor.
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DET
Lamp 1
Sensing Lamp 2 Reference 4.2um Optical Filter
Pathlength L
2
Pathlength L
1

1.4 General Specifications
Measurement Ranges Trace: 0-5,000 Parts Per Million
Percent: 0-20%, 0-10%, and 0-5%.
Accuracy Trace: ± 100 PPM CO2or ± 5% of reading., whichever
is greater.
Percent: ± 5% of reading or 0.15% CO2, whichever is
greater.
Sensor Type Non-Dispersive Infrared
Response Time < 35 seconds to 63% of step change
Display 10.2 mm (0.4") high 4-1/2 digit liquid crystal display
Input Power 115/230 VAC, 50-60Hz, or 18-32 VDC
(Battery Operation is optional with AC Power Sources)
Standard Outputs 4-20 mADC and 0-2 VDC.
Optional Digital Interfaces RS-232 or RS-485
Audible Alarm Internal audible alarm
Audible Alarm Cancel Front panel switch
CO2Alarm Relays Three (3) SPDT Form C contacts rated 10 A @ 30V DC
/ 115/230 VAC. Alarms may be cleared manually or
automatically, by user selection.
Instrument Status Alarm Relay 1 SPDT Form C contact rated 10 A @ 30V DC /
115/230 VAC.
4-20 mA Open Loop Status Alarm Open collector (drain) output at terminal #10
Operating Temperature 0° to 50°C (32° to 122°F)
Enclosure Enclosure is a light gray polycarbonate with a hinged
clear front cover rated NEMA 1.
Dimensions for the Standard 9.35 inches (237.5 mm) length
Polycarbonate Electronics 6.29 inches (159.8 mm) width
Enclosure. 3.54 inches (89.9 mm) height
Weight (BTP Configuration) 5 pounds (2.26 kg.)
Alpha Omega Instruments Corp. reserves the right to change or modify its product specifications without notice
ALPHA OMEGA INSTRUMENTS CORP.
SERIES 9510 CARBON DIOXIDE ANALYZER INSTRUCTION MANUAL
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SECTION 2.0
INSTALLATION PROCEDURES
2.1 Unpacking the Analyzer
Upon receiving the shipping container, carefully examine the packaging to check if the outer surfaces
have been damaged. If so, report the findings immediately to Alpha Omega Instruments who will, in turn,
provide further instructions.
NOTE: IF DAMAGE TO THE SHIPPING CONTAINER HAS
BEEN FOUND, DO NOT PROCEED FURTHER.
CONTACT THE FACTORY IMMEDIATELY.
If there is no apparent damage, check the contents to ensure all items were shipped. In some cases,
items may be back-ordered. Retain the shipping material in the event that the unit has to be returned to
the factory for repair or calibration. All damage and shortage claims must be made known to Alpha
Omega Instruments within 10 days after receipt of shipment.
There are six screws on the standard Series 9510 Carbon Dioxide Analyzer that fasten the clear cover to
the polycarbonate enclosure. Loosen these screws to disengage them from the enclosure, and open the
cover exposing the front panel membrane switches. The membrane panel is installed on a metal backing
plate that is hinged and swings out in the same direction as the cover. Swing out the membrane panel
and check inside the control unit to make sure no components have been loosened or dislodged. If there
are loose or dislodged components, contact the factory for further instructions. If all is found to be
satisfactory, the installation procedure can begin.
2.2 Electrical Installation
ELECTRICAL INSTALLATION SHOULD BE PERFORMED BY A
LICENSED ELECTRICIAN AND SHOULD COMPLY WITH
APPLICABLE FEDERAL, STATE, OR LOCAL ELECTRICAL
SAFETY CODES.
NOTE: For Explosion Proof Systems please refer to Appendix D in the back of this manual.
The Series 9510 Carbon Dioxide Analyzer is shipped with a power cord. Some installations may require
wiring through conduit into an electrical hub on the rear panel (where the existing power cord is installed).
For such installations, removal of the existing power cord can be easily accomplished as described in
section 2.2.1. The position of jumpers S02, located at the lower left quadrant of the printed circuit board
determines the line voltage setting. The default setting is 115 VAC, 50-60Hz. If the AC input voltage is
changed in the field, please refer to Section 3.1.1 for instructions.
2.2.1 Wiring the AC/DC Power in Place of the Existing Power Cord
Referring to the printed circuit board diagram (FIGURE 1.0) on page 5, locate the AC power terminals
31,32, and 33. Each connector is equipped with a screw terminal wire holder to facilitate insertion or
removal of the wire from the connector. Strip approximately 6.0 mm (1/4 inch) of insulation from each of
the three conductors and then connect AC line, AC neutral, and chassis ground to each connector.
Tighten down on each screw turning clockwise to securely fasten each conductor. If the primary power to
the instrument is direct current (18-32 VDC), wire to terminals 29 (BAT+) and 30 (BAT-). For safe
connections, make sure that there is no un-insulated wire extending outside of the connectors.
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MAIN PRINTED CIRCUIT BOARD
FIGURE 1.0
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SW-6
Fuse

2.2.2 CO2Sensor
Wiring of the CO2sensor has been done at the factory.
2.2.3 Wiring Alarm Relays
Access to the control signals generated from the Series 9510 Carbon Dioxide Analyzer is accomplished
using customer-supplied signal cable. This cable is installed through an output cable strain relief on the
rear of the electronics enclosure. The number of conductors needed is determined by the number of
signals to be interfaced.
The Series 9510 Carbon Dioxide Analyzer is equipped with four single pole double throw (SPDT) relays
with Form C contacts rated at 10 amperes @ 30 VDC and 115/230 VAC. All alarm relays are user
configurable with the three CO2alarms defaulting to factory setting of low CO2alarms. To configure any of
the three CO2alarm relays to act as low alarms, please refer to Section 3.3. Alarm 4 is the instrument
status alarm, which is not displayed as a discrete alarm on the front panel,.
The technique for wiring to the connectors is identical to that discussed in Section 2.2.1. The wiring
configuration is as follows:
Terminal CO2Alarm 1 Relay
26 Common Contact
27 Normally Open Contact
28 Normally Closed Contact
CO2Alarm 2 Relay
23 Common Contact
24 Normally Open Contact
25 Normally Closed Contact
CO2Alarm 3 Relay
20 Common Contact
21 Normally Open Contact
22 Normally Closed Contact
Instrument Status Alarm
(Alarm 4 Relay)
17 Common Contact
18 Normally Open Contact
19 Normally Closed Contact
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TABLE 1.0 illustrates the various wiring configurations for the four alarms in the analyzer based on
whether the alarms are going to be configured for fail-safe or non fail-safe operation.
TABLE 1.0
18(NO) to
17(COM)
19(NC) to
17(COM)
Low Battery or
Instrument
Status/ Relay 4
21(NO) to
20(COM)
22(NC) to
20(COM)
High or Low
CO
2
Alarm3 /
Relay 3
24(NO) to
23(COM)
25(NC) to
23(COM)
High or Low
CO
2
Alarm2 /
Relay 2
27(NO) to
26(COM)
28(NC) to
26(COM)
High or Low
CO
2
Alarm1 /
Relay 1
Fail-safe OFFFail-safe ON
Alarm ONContacts
shorted for
each Alarm
Relay
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2.2.4 Wiring 4-20 mADC and 0-2 VDC Outputs
The Series 9510 Carbon Dioxide Analyzer has two linear outputs, 4-20 mADC and 0-2 VDC over the
instrument's range. These outputs can be measured simultaneously. To wire to the 4-20 mADC output,
wire to terminals 12 (4-20) and 13 (AGND). To wire to the 0-2 VDC output, use terminals 8 (positive,
labeled DAC) and 9 (negative, labeled AGND). The terminals can be found on the right side of the printed
circuit board (refer to FIGURE 1.0) Note: If a jumper wire is in place between terminals 12 and 13, it
must be removed prior to using the 4-20 mADC output..
NOTE: IF THE 4-20MA DC OUTPUT IS NOT GOING TO BE USED,
IT SHOULD BE SHORTED TO AVOID AN OPEN LOOP WARNING
VIA TERMINAL 10 (B-LO)
2.2.5 Wiring to the Optional RS-232C or RS-485 Outputs.
The Series 9510 Carbon Dioxide Analyzer can be equipped with either RS-232C or RS-485 digital
communications. To wire for either the RS-232 or RS-485, use terminal 14 (TXD) for transmit and 15
(RXD) for receive. You must connect the GND terminal for RS-232C for the instrument to work properly.
Further details on these communication channels are contained in Section 6.0.
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SECTION 3.0
OPERATION
3.1 Preparation for Operation
3.1.1 AC Input Voltage Selection
The Series 9510 Carbon Dioxide Analyzer has an ON/OFF power switch on the side of the instrument.
The instrument is shipped to operate on the line voltage specified in the purchase order. If the line voltage
is not specified, the instrument will be configured for operation at 115 VAC, 50-60Hz. If the instrument is
going to be powered from an external DC power source, please refer to section 2.2.1. Please note that if
an option such as a sample pump has been ordered, the power to instrument must be in accordance with
the power requirements of the option in question. For instance, you cannot power the Series 9510 with
115 VAC if it has been equipped with a 24 VDC sample pump. Please check the original purchase order.
The input voltage can be changed in the field by changing the S02 jumpers located on the lower left
quadrant of the printed circuit board (refer to FIGURE 1.0). The Series 9510 Carbon Dioxide Analyzer is
configured for operation with a .5 ampere slo-blow fuse. The Fuse type is Wickman WK4041BK.
Changing the AC input voltage can be done as follows:
1. Turn Power off and disconnect the Series 9510 Carbon Dioxide Analyzer from all AC power.
2. Swing out the front panel to gain access to the main printed circuit board
(refer to Section 2.1 for instructions).
3. Remove the cover on the lower left of the main circuit board, and examine the jumpers on the main
circuit board. Shown below are the two ways of installing the AC input selection jumpers at S02.
230 115
S02 S02
4. To change the AC configuration, remove the jumpers and place them according to the above
diagram. Be sure to replace the cover.
5. Reassemble the instrument and proceed to the next section.
3.1.2 Mounting Configurations
Bench Top / Portable (BTP Configuration) The BTP is the basic configuration for the Series 9510
Carbon Dioxide Analyzer, designed for either bench top or portable applications. All gas and electrical
connections are located on the instrument's rear panel for ease of access.
Panel Mounting (PNL)- In the PNL configuration, a panel mounting frame is supplied. Make the
appropriate panel modifications as indicated in the drawing in Appendix B.
Explosion Proof Enclosure (EXX). Please refer to the Appendix C
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Wall Mounted Electronics with Remote Sensor Enclosure. Please refer to Appendix D
3.1.3 Initial Check
The Series 9510 Carbon Dioxide Analyzer is ready to use out of the shipping container. The analyzer has
been calibrated at the factory and, under normal conditions, re-calibration is not required at initial start-up.
In the case of explosion proof systems, some wiring to meet local electrical codes will be required Please
refer to Section 4.0 for details regarding routine calibration checks.
Optional Battery Operation
NOTE FOR BATTERY OPERATION
If the Series 9510 has been equipped with optional NiMH batteries, it is designed to provide up to eight
hours of operation on a fully charged set of batteries (without pump). With a pump, one may expect to
obtain up to 3-4 hours of continuous operation before charging of the batteries will be necessary. The
batteries should be fully charged upon receipt of the analyzer. If not, the user should recharge the batteries
upon initial startup by powering the analyzer from AC power. Allow at least 16 hours of recharging time.
NOTE: THE POWER ON SWITCH MUST BE KEPT IN THE “ON” POSITION DURING CHARGING.
The battery option should never be used when the analyzer is powered from a separate DC source. This will
cause the batteries to overcharge which may cause the batteries to explode. Be certain all wiring (alarms,
remote sensor, RS-232C, etc.) has been done before applying AC power to the instrument
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3.2 Operating Procedures
3.2.1 Power ON
Power to the instrument is applied when the power cord is plugged into an AC outlet and the power switch
on the left side of the instrument is switched ON. The Series 9510 Carbon Dioxide Analyzer is equipped
with battery backed RAM so when the instrument is initialized, all values set by the user via the front panel
or optional RS-232C or RS-485 inputs will be maintained if switch #8 of SW6 is set to the "ON" position.
This power on initialization gives the user the opportunity to make sure the microprocessor, internal
memory, front panel LEDs, and the audible alarm are functioning normally. During an initialization
sequence, the instrument's front panel liquid crystal display (LCD) will display a series of dashes in series
like [¯ ¯ ¯ ¯][----][_ _ _ _], each of the three front panel LED's will blink simultaneously for approximately 5
seconds, and the audible alarm will sound intermittently for as long as the LEDs are blinking. After this,
the display will briefly show the onboard switch settings such as [| | | | | | | |]. In this example, switch #8 of
SW6 is ON and switches # 1-7 are in the OFF positions.
To read the on-board switch settings, set SW6 - switch # 8 to "OFF" and push the front panel UP, DOWN,
and Alarm 3 buttons simultaneously. This causes an initialization without the power cycling (referred to in
the industry as a “warm boot”). Do not hold the buttons down very long after the display shows the
dashes described above. You will see the same sequence as above, with switch #8 indicating low.
Powering on with switch #8 in the "OFF" position will cause the Series 9510 Carbon Dioxide analyzer to
configure system alarm operation by the settings of SW6. In this case, all CO2alarms will default to low,
and non fail-safe operation will be selected.
3.2.2 Front Panel Controls and Indicators
The front panel of the Series 9510 Carbon Dioxide Analyzer contains a 4-1/2 digit liquid crystal display
(LCD), three (3) alarm set membrane switches, three (3) alarm LEDs, and up and down membrane
switches. An Audible Alert Indicator is located behind the front panel of the instrument.
Liquid Crystal Display: The 4-1/2 digit LCD display shows the concentration of CO2in the sample being
measured by volume, and displays messages or alerts from the microprocessor. Within 90 seconds after
the analyzer is powered on, the analyzer will measure and display the CO2concentration of the sample
gas being exposed to the sensor.
When the Series 9510 Carbon Dioxide Analyzer is equipped with the Battery Option, the LCD will display
[LOBAT ] when battery power has reached the point when normal instrument operation is in jeopardy.
To protect important information stored in the analyzer’s memory [monitor’s memory], the
analyzer [monitor] suspends operation of the microprocessor when further operation could
corrupt that memory. The microprocessor displays the word HALT on the LCD, then suspends
further operation. The microprocessor does not resume operation until power is reapplied and
the battery voltage is verified to be high enough to safely take over operation for a short time in
the event of a recurring power failure.
When calibrating the Series 9510 Carbon Dioxide Analyzer, the liquid crystal display momentarily reads [
CAL] and then the value of the CO2concentration of the gas being measured. For further information on
calibrating the analyzer, please refer to Section 4.0.
The Series 9510 Carbon Dioxide Analyzer alarms are set at the factory as low alarms. Anyone of these
alarms can be set by the user for operation as low alarms also. Please refer to Section 3.3, Alarm
System, for instructions on how to set Alarms for either high or low operation and how to adjust the levels
of the alarms.
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3.2.3 Scaling Analog Outputs of the Analyzer
For certain applications, it may be desirable to change the analog output of the Series 9510 Carbon
Dioxide Analyzer over a narrower range of measurement. Users wishing to do so can make this change
quite easily using the instrument’s front panel adjustment. As stated previously, the analyzer is equipped
with two analog outputs, 0-2 VDC and 4-20 mADC. It is shipped from the factory with the 0 PPM / % CO2
equivalent to 0 VDC and 4 ma respectively, and the maximum scale value PPM / % CO2equivalent to 2
VDC and 20 mADC.
In order to adjust the zero points of the two analog outputs of the 9510, the instrument must be placed in
the scaling mode. To do so, press the “A2 & A3” buttons simultaneously and the front panel display will
respond by alternating the display [outL] or [outH] followed by the display of the existing CO2concentration
that is equivalent to 0 VDC. Adjust this value up or down by using the front panel up and down arrow
keys until the desired value is achieved. To adjust the span points of the two analog outputs of the Series
9510, press the UP and DN buttons simultaneously, and the instrument will toggle to the “span”
adjustment mode. The instrument will respond by alternating the display [outH] followed by the display of
the existing CO2concentration that is equivalent to 2 VDC and 20 mADC. Adjust this value up or down by
using the up and down arrow keys until the high value desired is displayed.
There are a few shortcuts for entering new values:
Pressing the [A1] key sets the value to 0;
Pressing the [A2] key sets the value to mid-scale for the range selected;
Pressing the [A1] and [A2] keys simultaneously sets the value to the maximum value for the range
of the analyzer.
Pressing the [A3] key will exit and display [CANCELLED]; the old values will not be changed.
The scaling software in the Series 9510 has built-in safeguards that will not allow the analyzer to be
adjusted so that the “outL” value is set above that of the current “outH” value, or have the “outH” value set
below that of the current “outL” value. To toggle from one mode to the other, depress the UP and DN
buttons simultaneously and make the required change. When the desired scaling values have been set,
press “A2 & A3” buttons simultaneously to leave the scaling mode. If you wish to exit the scaling mode
without any changes to the values currently entered, just press [A3]. If the analyzer is left in a “change
pending” state for over two minutes, the analyzer will automatically revert to the previous settings, and exit
the scaling mode.
NOTE: Regardless of how the analog outputs are scaled, the analyzer will always be capable of
displaying CO2concentrations up to the instrument’s maximum range. Scaling the outputs does not
scale the front panel digital display. Furthermore, CO2alarm relays, if not adjusted for the scaled range
of interest, will change state if the CO2values they are set at are met or exceeded.
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