CAI 600-NDIR User manual

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
Page 2 of 86
Safety Alert Temperature Hazard Electrical Shock Hazard
Caution or Warning Caution or Warning Caution or Warning
Safety Information in this Manual
Note, caution and warning symbols appear on the instrument and throughout this manual to draw
your attention to important operational and safety information.
A “NOTE” marks a short message to alert you to an important detail.
A “CAUTION” safety alert appears with information that is important for protecting your equipment
and performance.
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.
The symbol (an exclamation point in a triangle) precedes a general CAUTION or
WARNING statement.
The symbol (wavy vertical lines with an under score in a triangle) precedes an elevated
temperature hazard CAUTION or WARNING statement.
The symbol (a lightning bolt in a triangle) precedes an electric shock hazard CAUTION or
WARNING statement.
Some or all of the above symbols may appear in this manual or on the equipment. This manual
should be consulted whenever one of these symbols is encountered on the equipment.
ALWAYS REMOVE POWER BEFORE CONNECTING OR DISCONNECTING SIGNAL
CABLES OR WHEN SERVICING THE EQUIPMENT.

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
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The 600 series NDIR instruments meet or exceed the following
directives and standards.
Application of Council Directive(s):
Electrical 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 Measurement, Control, and Laboratory Use [EN
61010-1:2001 (2nd Edition)
Electromagnetic Compatibility:
EN 61326:1997 Electrical equipment for measurement, control and laboratory use
- EMC requirements (Amendment A1: 1998 to EN 61326:1997; Amendment
A2:2001 to EN 61326:1997)

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
Page 4 of 86
600 NDIR Quick Start Guide
1) Plug in the analyzer and turn the power on.
2) Connect the appropriate gas lines and vents to the analyzer.
3) Allow the analyzer to stabilize for at least one (1) hour.
4) During the analyzer’s stabilization period, setup the analyzer to the desired
configuration.
a) Set the analyzer’s output as desired.
i) From the Main Menu press F5 (Setup) then F7 (System Settings.)
ii) Press F3 (output assignments) to setup the output channels.
(1) Set to real time.
(2) AUX 1
(3) AUX 2
(4) AUX 3
(5) Press back to return to the system settings menu.
iii) Press F4 (output range) to setup the output ranges
(1) Set the Min and Max to zero (0). This will cause the outputs to
default to the current ranges.
(2) Set the outputs for milliamps (mA) 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 before proceeding
5) Connect all appropriate analog outputs.
a) Pin 1 is the output common (ground).
b) Pins 2, 3, 4, and 5 are output channels 1, 2, 3, and 4 as setup in step 4.a.ii.
c) If the output is set for voltages but there is no voltage output, you will need to
install a 500 ohm resistor between pin 1 and the channel you are trying to
measure. You will have to measure the voltage drop across this resistor.
6) Reconnect the power and turn on the analyzer. Press F1 from the analyzer’s
main Menu to get to the measurement screen.
7) Supply sample gas to the analyzer.
8) The measurement screen should indicate the concentration of the sample gas. If
the concentration is incorrect, the analyzer will need to be calibrated using zero
and span calibration gases. Please reference the appropriate section of the
manual for a description on how to zero and span the analyzer.

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
Page 5 of 86
TABLE OF CONTENTS
1. Introduction....................................................................................................................14
1.1. Overview...................................................................................................................14
1.2. Unpacking Instructions.............................................................................................14
1.3. Reporting Damage ...................................................................................................14
1.4. Contact Information..................................................................................................14
1.5. Warranty Certificate..................................................................................................15
1.6. Possible Explosion Hazard.......................................................................................16
1.7. Electrical Shock Hazard ...........................................................................................16
1.8. Plug Removal...........................................................................................................16
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. Model 600 NDIR Features........................................................................................21
3. Installation......................................................................................................................22
3.1. General.....................................................................................................................22
3.2. Site and Mounting.....................................................................................................22
3.3. Electrical...................................................................................................................22
3.4. Analog Output Connections (Appendix)...................................................................23
3.5. Gases.......................................................................................................................23
3.6. Gas Handling Equipment..........................................................................................24
3.7. Gas Connections......................................................................................................24
3.8. Sampling Requirements...........................................................................................24
3.8.1. Filtration.......................................................................................................24
3.8.2. Condensation...............................................................................................24
3.8.3. Presence of Corrosive Gases......................................................................24
3.8.4. Gas Temperature.........................................................................................24
3.8.5. Sample Gas Bypass Outlet (Vent)...............................................................24

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
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4. Basic Operation.............................................................................................................25
4.1. Display......................................................................................................................25
4.2. Menu Trees ..............................................................................................................26
4.3. Keyboard..................................................................................................................29
4.3.1. Operation with the Cursor Keys and the Enter Key.....................................29
4.3.2. Operation with the Function Keys................................................................29
4.3.3. Read/Change Parameters...........................................................................29
5. Operating Structure.......................................................................................................30
5.1. The Main Menu.........................................................................................................31
6. Menu Structure ..............................................................................................................32
6.1. User Functions (Level 1) ..........................................................................................32
6.2. Advanced User Functions (Level 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 Analyzer....................................................................................................35
7.3. F3 Diagnostics..........................................................................................................35
7.4. F4 Calibrations .........................................................................................................36
7.4.1. F1 Automatic Calibration .............................................................................36
7.4.2. F2 Manual Calibration..................................................................................37
7.4.3. Display Deviations – from Calibration menu F3...........................................38
7.4.4. Absolute Zero Gas Deviation.......................................................................38
7.4.5. Relative Zero Gas Deviation........................................................................38
7.4.6. Absolute Span Gas Deviation......................................................................39
7.4.7. Relative Span Gas Deviation.......................................................................39
7.4.8. F4 Check Calibration...................................................................................39
7.4.9. F5 Reset Calibration Values........................................................................39
7.4.10. F6 Range Select..........................................................................................39
7.5. F5 Setup...................................................................................................................40
7.5.1. F1 Span Gas Concentration........................................................................40

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
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7.5.2. Calibration Settings......................................................................................41
7.5.3. F1 Times......................................................................................................41
7.5.4. F2 Measuring Deviations.............................................................................41
7.5.5. F3 Deviations...............................................................................................41
7.5.6. F3 Range Limits...........................................................................................41
7.5.7. F1 Range 1-4 (Change Upper Range Limits)..............................................42
7.5.8. F2 Change Auto Range Limits.....................................................................42
7.5.9. F4 Alarms ....................................................................................................43
7.5.10. F5 Password................................................................................................43
7.5.11. F1 Enter Password......................................................................................44
7.5.12. F2 Change Password..................................................................................44
7.5.13. F3 Reset Passwords....................................................................................44
7.5.14. F6 Linearization...........................................................................................45
7.6. F7 System Settings ..................................................................................................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 Turns Status Line On or Off....................................................................49
7.6.6. F8 Measure Settings....................................................................................49
7.6.7. F1 Set Lowpass filter...................................................................................49
7.6.8. F2 Purge Time.............................................................................................50
7.6.9. F3 Set Temperature Compensation ............................................................50
7.6.10. F4 Pressure Compensation.........................................................................50
7.6.11. F3 Low Pass Filter Time Constant...............................................................50
7.6.12. F10 Displays the Current Analyzer and Software Versions.........................51
7.7. F7 Remote / Manual Control ....................................................................................51
7.8. F8 Standby...............................................................................................................52
8. Analyzer Components...................................................................................................53
8.1. Rear Panel................................................................................................................53
8.2. Rear Panel Connectors............................................................................................54
8.3. Digital Outputs..........................................................................................................55
8.3.1. RS-232 (Standard 9 Pin DIN Connector).....................................................55
8.3.2. TCP/IP (8 Pin RJ-47 Connector) .................................................................55

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
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8.4. Internal Component Locations..................................................................................56
8.5. Main Electronics Board (Potentiometers).................................................................57
8.6. NDIR Detector Assembly..........................................................................................58
9. Operation........................................................................................................................59
9.1. External Wiring.........................................................................................................59
9.2. External Piping .........................................................................................................59
9.3. Operation & Calibration............................................................................................59
9.3.1. Power On:....................................................................................................59
9.3.2. Zero/San Adjustment:..................................................................................59
9.3.3. Start-Up and Routine Maintenance: ............................................................59
10. MAINTENANCE..............................................................................................................60
10.1. Zero and Span Calibration........................................................................................60
10.2. Cleaning of the Optical Bench 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
11. ADJUSTMENTS CHECKS AND REPAIRS....................................................................68
11.1. Adjustment of Detector Voltage (NDIR’S only).........................................................68
11.2. Coarse Zero Adjustment...........................................................................................68
11.3. Span Gain Adjustment..............................................................................................68
11.4. Check and Repair Detector......................................................................................69
11.4.1. Problem: ......................................................................................................69
11.4.2. Symptom:.....................................................................................................69
11.4.3. Check and/or replace:..................................................................................69
11.5. Check and Repair Infrared Light Source Unit...........................................................70
11.5.1. Problem: ......................................................................................................70
11.5.2. Symptom:.....................................................................................................70
11.5.3. Check and/or replace:..................................................................................70
11.6. Check and Replace Chopper ...................................................................................70
11.6.1. Problem: ......................................................................................................70
11.6.2. Symptom:.....................................................................................................70
11.6.3. Check and/or replace:..................................................................................70
11.7. Check and Repair Measuring Cell............................................................................71

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
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11.7.1. Problem: ......................................................................................................71
11.7.2. Symptom:.....................................................................................................71
11.7.3. Check and or replace:..................................................................................71
11.8. Check and Repair Tubing Trouble............................................................................71
11.8.1. Problem: ......................................................................................................71
11.8.2. Symptom......................................................................................................71
11.8.3. Check and/or replace:..................................................................................71
11.9. Check and Repair Amplifier Circuit...........................................................................72
12. Communication Master Computer / Analyzer (AK Protocol).....................................73
12.1. Serial Interface and AK-Commands.........................................................................73
12.2. Interface Specifications ............................................................................................73
12.3. Protocol Description .................................................................................................74
12.3.1. Instruction command ...................................................................................74
12.3.2. Acknowledgement command.......................................................................74
12.3.3. 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: Calibration gas concentrations........................................................76
12.4.5. AMBU: Upper and lower range switchover values for auto range...............76
12.4.6. ASTZ: Normal device status........................................................................77
12.4.7. ASTF: Error status.......................................................................................77
12.4.8. AKEN: Device identification ........................................................................77
12.4.9. ARMU: Raw value.......................................................................................77
12.4.10. ATEM: Temperatures..................................................................................78
12.4.11. ADRU: Pressures/ Valve voltage ................................................................78
12.4.12. ADUF: Flows...............................................................................................78
12.4.13. AGRD: Polynom coefficients.......................................................................78
12.4.14. AANG: Deviation from zero point after autocalibration ...............................78
12.4.15. AAEG: Deviation from end point after autocalibration.................................78
12.4.16. AFDA: Purge and Autocalibration times......................................................78
12.4.17. APAR: Request Autocalibration tolerance values.......................................79

Section 1 Model 601/601P/602/602P/603 NDIR Analyzer
California Analytical Model 600_NDIR_Series_v10.0 CE Operators Manual
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12.4.18. AKAL: Deviations from calibration ..............................................................79
12.4.19. ASYZ: Respond System Time.....................................................................79
12.4.20. AT90: Respond Lowpass filter time.............................................................79
12.4.21. ADAL: Diagnostic alarm limits.....................................................................79
12.4.22. ATCP: Query TCP/IP settings.....................................................................79
12.4.23. AVER: Query Software version...................................................................80
12.4.24. AH2O: QueryH2O correction parameter......................................................80
12.4.25. ACO2: Query CO2correction parameter.....................................................80
12.4.26. AUPD: Query UDP data streaming parameter............................................80
12.5. Control commands ...................................................................................................81
12.5.1. SRES: Reset ...............................................................................................81
12.5.2. SPAU: Pause ..............................................................................................81
12.5.3. STBY: Standby............................................................................................81
12.5.4. SNGA: Open valve for zero gas calibration.................................................81
12.5.5. SEGA: Open valve for end gas calibration..................................................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
12.5.11. SREM: Remote mode for AK-commands....................................................82
12.5.12. SMAN: Manual control to control device manually......................................82
12.5.13. SMGA: Start measuring ..............................................................................82
12.5.14. SNKA: Saves measured value as new offset..............................................82
12.5.15. SEKA: Saves measured value as new span value .....................................82
12.5.16. SUDP: Start /Stop UDP data streaming ......................................................82
12.6. Settings ....................................................................................................................83
12.6.1. EKAK: The four span gas concentration values are set .............................83
12.6.2. EMBE: The four measuring range end values are set ................................83
12.6.3. EMBU: The upper and the lower range switchover for auto range are set..83
12.6.4. EKEN: Set new device identification and information .................................83
12.6.5. EGRD: Set polynom coefficients .................................................................83
12.6.6. EFDA: Set autocalibration and purge times................................................83
12.6.7. EPAR: Set autocalibration tolerance values................................................83