Andros 6900 User manual

Incorporated
Model 6900 Product Manual
Reorder Number 891166-001
Models 6900/6500/6510
Compact
Automotive Gas
Subsystem and Components
Andros Incorporated
870 Harbour Way South vRichmond, CA 94804
Voice [phone] vFAX [phone]

Preface
Table of Contents
Table of Contents ................................................................................................iii
Preface...................................................................................................................7
About This Manual....................................................................................................................................................................... 7
Andros Notation........................................................................................................................................................................... 8
Manual History.............................................................................................................................................................................. 8
Chapter 1 —Introduction ....................................................................................9
Key Features and Configurations............................................................................................................................................... 9
Pneumatics Configurations .......................................................................................................................................................10
Government Programs Supported...........................................................................................................................................12
End-User Maintenance ..............................................................................................................................................................12
Options and Accessories ...........................................................................................................................................................12
Chapter 2 —Specifications...............................................................................13
Environmental Specifications ...................................................................................................................................................13
Mechanical Specifications..........................................................................................................................................................13
Power Specifications ..................................................................................................................................................................13
Gas Measurement Accuracy, Repeatability, Noise, and Resolution...................................................................................14
Propane Equivalency Factor (PEF).........................................................................................................................................15
Cross-Gas Interference..............................................................................................................................................................15
System Transport Time..............................................................................................................................................................16
System Response Time ..............................................................................................................................................................16
Model 6500/6510 Analyzer/Sensor Response Time............................................................................................................16
Host Communications Interface..............................................................................................................................................17
Auxiliary I/O Interfaces ............................................................................................................................................................17
Chapter 3 —Operation ......................................................................................19
Gas Concentration Measurement.............................................................................................................................................19
HC, CO, and CO2Measurement ..............................................................................................................................................19
Simple NDIR Gas Analyzer Model..........................................................................................................................................19
The Infrared Transmission Spectra .............................................................................................................................................20
Air-Fuel Ratio and the Stoichiometric Point ...............................................................................................................................21
Lambda ( l ) and Catalytic Converter Efficiency ..........................................................................................................................22
O2and NOXMeasurement........................................................................................................................................................22
Functional Description ..............................................................................................................................................................23
Pneumatic System.......................................................................................................................................................................23
Infrared Source ...........................................................................................................................................................................24
Optical Block .............................................................................................................................................................................24
System Board Assembly..............................................................................................................................................................24
O2and NOXSensors.................................................................................................................................................................24

Preface
Configuration Modes .................................................................................................................................................................25
Model 6900 / 6500 / 6510 Operating Modes........................................................................................................................25
Start-up Operating Mode............................................................................................................................................................25
Normal Operating Mode ............................................................................................................................................................25
Standby Operating Mode............................................................................................................................................................25
System Fault Operating Mode ....................................................................................................................................................26
6500 Process Flow .....................................................................................................................................................................27
Model 6500 / 6510 Temperature Measurements ..................................................................................................................28
Pressure Measurements..............................................................................................................................................................28
Chapter 4 —Calibration.....................................................................................29
Factory Characterization............................................................................................................................................................29
Field Calibration..........................................................................................................................................................................29
Zero Calibration.........................................................................................................................................................................29
$02 Zero/O2Span Calibration Procedure..................................................................................................................................30
Additional ISO 3930/OIML R 99, and BAR-97 Zero Calibration Requirements.................................................................32
Span Calibration........................................................................................................................................................................32
$03 Span Calibration Procedure.................................................................................................................................................32
Additional ISO 3930/OIML R 99, and BAR-97 Span Calibration Requirements................................................................34
$09 Reset Span..........................................................................................................................................................................34
Chapter 5 —Hardware Interfaces.....................................................................35
Configuration Jumpers...............................................................................................................................................................38
Jumper............................................................................................................................................................................................38
Configuration Function.....................................................................................................................................................................38
Power and Interface ...................................................................................................................................................................39
Model 6500/6510 Circuit Board Connector Locations........................................................................................................39
Outline and Mounting Dimensions Model 6500/6510........................................................................................................40
Outline and Mounting Dimensions Model 6900...................................................................................................................41
Chapter 6 —Sample Delivery............................................................................43
Pneumatics Ports ........................................................................................................................................................................43
Hose and Probe Sample Gas Port.......................................................................................................................................43
Room Air Port........................................................................................................................................................................43
Calibration Gas Port..............................................................................................................................................................43
Zero Gas Port.........................................................................................................................................................................43
Calibration Check Gas Port .................................................................................................................................................43
Exhaust Gas Port......................................................................................................................................................................44
Water Drain Port....................................................................................................................................................................44
Pump.............................................................................................................................................................................................44
Room Air Filtration....................................................................................................................................................................44
Water Trap / Filter Assembly...................................................................................................................................................44
Sample Delivery Configurations...............................................................................................................................................45
OIML 6900 Pneumatics Configuration (standard) ....................................................................................................................45
BAR-97 6900 Pneumatics Configuration (customer option).......................................................................................................46

Preface
Chapter 7 —Host Communications.................................................................49
Communications Protocol ........................................................................................................................................................49
Host Command Format ............................................................................................................................................................50
ACK Response Format..............................................................................................................................................................50
NAK Response Format.............................................................................................................................................................51
NAK Error Codes ......................................................................................................................................................................51
Command Set ..............................................................................................................................................................................52
Command Set Summary.............................................................................................................................................................52
$01 —Data/Status .................................................................................................................................................................53
$02 —Zero/O2Span Calibration...........................................................................................................................................59
$03 —Span Calibration...........................................................................................................................................................60
$04 —System ID.....................................................................................................................................................................62
$05 —Miscellaneous Data .......................................................................................................................................................63
$06 —Extended Data/Status ..................................................................................................................................................64
$07 —Pump On/Off...............................................................................................................................................................65
$08 —Device Control...............................................................................................................................................................66
$09 —Reset Span ....................................................................................................................................................................70
$0A —New NOXSensor........................................................................................................................................................71
$0B —Leak Test.....................................................................................................................................................................72
$F0 —Reset.............................................................................................................................................................................73
$F1 —Configuration Mode Control..........................................................................................................................................74
$11 —1 Point Pressure Span/Reset Span Calibration..............................................................................................................76
$12 —Raw NOx and O2 Data...............................................................................................................................................77
$13 —Channel Switch ON/OFF command.............................................................................................................................78
$14 —Read User Memory .......................................................................................................................................................79
$15 —Write User Memory ......................................................................................................................................................80
$16 —Pressure Data.................................................................................................................................................................81
$17 —Standby Enable / Disable command.............................................................................................................................82
$18 —SW Checksum..............................................................................................................................................................83
Chapter 8 —Service Procedures......................................................................84
Maintenance and Service ...........................................................................................................................................................84
General Maintenance Considerations ..........................................................................................................................................84
Water Trap / Filter Element Replacement.................................................................................................................................85
6900 Subassembly Maintenance Items........................................................................................................................................86
Model 6500/6510 Analyzer Maintenance Items.......................................................................................................................87
Sample Cell Cleaning .................................................................................................................................................................89
Bench Upgrade Download Procedure...........................................................................................................................................90
Troubleshooting Error Status...................................................................................................................................................90
System Fault Error ..............................................................................................................................................................91
CO2, CO, and HC Channel Errors .................................................................................................................................91
Zero Calibration Errors .....................................................................................................................................................91
Span Calibration Errors .....................................................................................................................................................92
Sample Delivery Errors ......................................................................................................................................................92
New NOXor O2Sensor Required ..................................................................................................................................92
IR Signal Lost Error ...........................................................................................................................................................93
Ambient Temperature Error ............................................................................................................................................93

Preface
Chapter 9 —Product Support...........................................................................94
Technical Support and Training...............................................................................................................................................94
How To Return Products For Service ....................................................................................................................................94
To Andros USA Service Depot From The USA.......................................................................................................................95
To Andros USA Service Depot From International Locations...................................................................................................96
To Andros Europe Service Center...............................................................................................................................................97
Appendix A —Supplemental Documentation.................................................98
$01 Data/Status Reference Chart ............................................................................................................................................98
Appendix B —Supplemental Documentation.................................................99

Preface 7
Preface
About This Manual
Important Note : This manual contains preliminary technical information and all features, specifications, procedures, and
descriptions are subject to change prior to final product release. If you have any questions, please contact your Andros sales or
technical representative.
Chapter 1
Introduction
Key features, applications, and configurations of the Model 6900 compact
automotive emissions gas subsystem are described. Supported government
mandated emissions programs are listed. Options and Accessories for the
6900 are listed.
Chapter 2
Specifications
Model 6900/6500/65106900 / 6500 / 6500 product performance
specifications are defined.
Chapter 3
Operation
The Model 6900 subsystem and Model 6500/6510 analyzer’s gas
concentration measurement techniques are discussed. Functional
descriptions are proved for the primary components and subassemblies. The
start-up, warm-up, normal, standby and boot program operating modes are
defined. The 6900 configuration mode control is reviewed.
Chapter 4
Calibration
Zero and span calibration is covered in detail.
Chapter 5
Hardware Interfaces
Model 6900/6500/6510 power, communications, and auxiliary I/O interfaces
are described in detail.
Chapter 6
Sample Delivery
The 6900 pneumatic components and configurations are discussed. The
6900 leak test procedure is detailed.
Chapter 7
Host Communications
The Model 6900/6500/6510’s communications protocol and command set are
defined.
Chapter 8
Service Procedures
The 6900 maintenance and service guidelines, replacement procedures, and
troubleshooting are covered in detail.
Chapter 9
Product Support
Depot service, technical support, and training programs are identified.
Appendices Additional reference information for the 6900 is provided.

Preface 8
Andros Notation
The Model 6500/6510 always refers to the Andros bench analyzer. The Model 6500 contains all the associated driver
circuitry and connections necessary to support the operation of a 12 VDC pump and solenoids, and is used in the
Model 6900. The Model 6510 does not support the operation of a pump and solenoids. Users of the Model 6510 are
required to supply all pump and solenoid controls separately.
The Model 6900 is the product number for a family of subsystems that are built around the Model 6500/6510
analyzer. When the term“6900”is used without reference to the term “Model”in this manual it may be referring to
the bench analyzer, or one of the analyzer’s functions, within a general subsystem context.
Hexadecimal numbers are preceded by a $ (dollar sign). The $F0 Reset command requires transmission of the
hexadecimal command code $F0, which is equivalent to 240 decimal or 11110000 binary.
Analog-to-digital converters and their output values are abbreviated as both A–D and ADC.
Both NO and NOx are used to refer to nitric oxide (NO) and nitrogen dioxide (NO2) collectively.
Individual bytes or bits in host system commands and ACK/NAK responses are specified in the following format:
Command_Code—Byte_Name—Bit_Number.
Bit numbers are not referred to when the entire byte is defined.
Example #1: $01–STAT1–5 refers to the $01 Data/Status command, STAT1 (System Status) byte, bit 5 (Zero
Request).
Example #2: $03–TVM refers to the $03 Span Calibration command, TVM (Tag Value Mask) byte.
Example #3: $01-STAT2-7,6 = 11 refers to the $01 Data/Status command, STAT2 (Data Status 1) byte, CO2
Data status field (bits 7 and 6). In this example the CO2 Data status is reported as CO2 Zero Fail
(11). Bits are always shown with the most significant bit listed first (on left).
Manual History
Revision Date Description
1 8/11/05 First preliminary release
2 16-MAY-06 Added new commands, updated drawings, added Model 6510 data
3 17-AUG-06 Various, changes reflect validation and B-Test issues, added new commands
4 19-OCT-06 Chapter 7: revised command descriptions; Chapter 5: revised connector locations and pinouts;
Chapter 8: revised service procedures
5 15-MAR-07 Chapter 7: Added $18, SW Checksum command; revised Zero request conditions; Removed Flash
Read/Write commands and support documentation; Chapter 5: Corrected connector tables J8 and J9;
Chapter 3: revised Standby/Warm up specifications

Introduction 9
Chapter 1 —Introduction
Key Features and Configurations
· Standard 6900 subsystems can be ordered as either 4-gas or 5-gas subsystems.
· Standard 6900 subsystems are shipped with a single-solenoid valve. The multi-solenoid valve version can
be configured for BAR-97 gas delivery (e.g., zero calibration uses bottled zero gas). It requires an
additional sample pump and solenoid valves which are to be supplied by customer.
· Custom 6900 subsystems can be designed for the high-volume OEM. Additional sample delivery
options and accessories are available. Custom sheet metal to meet the OEMs system requirements can
be provided.
· All Model 6900s include a Model 6500 Miniature Automotive Gas Analyzer.
· All 6900s exceed BAR-97 and OIML Class 0 gas measurement accuracy.
· All 6900s are ready for integration into OIML Class 0/1 systems.
· Single +12 VDC input power requirement (+9 to +16 VDC). Can be powered by +12 VDC power
supply or automotive battery.
· Small-volume gas analysis subsystem package.
· Lightweight (2.0 to 2.4 kg, depending on configuration).
· Low power consumption: 13.5 watts nominal.
· Rugged design and construction.
· Fast warm-up time (within 35 seconds). Defined as the time from Power On Reset (POR) until Start-Up
Status bit clears.
· Easy-to-use host system command set and RS-232C, USB 1, or TTL (3.3VDC) communications
interface.
· End-user maintainable particulate filtration, O2sensor and NOxsensor. These assemblies are mounted
on the outside of the 6900 for easy end-user access. Optionally, the O2 and NOxsensors can be mounted
behind a panel or cover when mandated by a government program.
· 10,000 hours MTBF (excluding O2 sensor, NOxsensor, pump and end-user replaceable filters).
· End-user or service-depot cleanable or replaceable sample cell and source.

Introduction 10
Pneumatics Configurations
The 6900 subsystems are available in the following pneumatics configurations. Custom pneumatics configurations
can be delivered.
Standard
(Single-Solenoid
Valve)
6900
Pneumatics
Configuration:
Designed to support the lowest cost subsystem requirements, a Basic 6900 subsystem includes the following:
§ High-capacity, fast-response sample delivery design.
§ Wet- and dry-side pneumatic pump.
§ Water trap/filter assembly: User-replaceable particulate filter. Automatic water bowl drain. Float check valve
positively protects the Model 6500/6510 analyzer if the water trap bowl ever fills.
§ Sample gas/room air solenoid valve.
§ Calibration gas port.
§ Designed to support diagnostic/repair applications and Inspection/Maintenance (I/M) programs (e.g., OIML
Class 0 and Class 1).
Gas Measurement Configurations
All 6900 subsystem configurations can be ordered with an Andros NOx sensor included (5-gas) or without (4-gas).
Note: All 4-gas 6900s can be field upgraded to a 5-gas operation by installing a NOxsensor and performing a gas
span calibration.
Caution: Any procedures involving bottled NO and/or NO2should be performed with
adequate active venting to prevent lung damage due to exposure to toxic gases.