CAI 600 Series User manual

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
6 0 0
S E R I E S
MHFID
Total Hydrocarbon Analyzer
USER’S MANUAL
Note: For Serial Numbers After
June 2007, Please See Addendum on
Page 113 of This Manual

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
Standards
The 600 series instruments meet or exceed the following directives and standards. (CE)
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)
(This analyzer was tested by ETL to confirm that it is in complete compliance to CE,CSA.
and the equivalent UL specifications, in accordance with the above directives and standards )

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
600 Series HFID Quick Start Guide
Note: DO NOT energize the sample pump or introduce any moisture-containing
sample until the oven has reached an operating temperature of at least 100°C.
1. Connect analyzer to AC power (115 VAC 60 Hz OR 230 VAC 50 Hz , ±10%) and turn
on main power switch that is located on the back panel.
2. Connect combustion air, combustion fuel, zero gas and span gas through the back
panel. Set supply pressures to 20-25 psig.
This analyzer uses a fuel that contains a FLAMMABLE LEVEL OF HYDROGEN.
Any leakage from this fuel can result in an explosion. Carefully check the fuel
supply system, to the analyzer for leaks upon installation, before initial start-up. The
operating technician should be properly trained for work with hazardous materials.
Note: The analyzer uses pure H2 OR a H2/He mixture as indicated on the back
panel and identified as combustion fuel. Serious damage may occur if the incorrect
fuel is used.
Note: Purge fuel line at the analyzer to remove any residual air in the line to aid
in flame ignition.
3. Press and release F8 IGNITE on the main menu to initiate the ignition sequence.
Note: If the Burner fails to ignite a Burner Temp Failure message displays at the
bottom of the screen.
4. Use at least an Extended User Operator Level-3 password for access to the screen
needed to define the value of the span gas that will be used for calibration (See
Section 5.)
5. From the Main Menu, press F5, Setup.
6. Press F1, Range Select.
7. Select the appropriate range for the span gas that is connected to the analyzer and
enter the concentration value of the gas.
Note: The four ranges are specified by the customers order. When not otherwise
defined, the factory default ranges are, 30, 300, 3,000, and 30,000 ppm.
8. Press BACK to return to the SETUP screen.
9. Press F2, Calibration Settings.
10. Press F3 if calibrating using the optional internal solenoids or F5 if calibrating with an
internal or system supplied sample pump.
11. Press Main to return to the Main Menu
12. Press F4, Calibrations, and then press F2, Manual Calibrations.
13. Press F1 to Flow Zero or F2 to Flow Span Gas and observe the displayed results.
14. Press F1 to save the appropriate zero and span calibration values.

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
QUICK MANUAL CALIBRATION
SETUP
1. Define span gas concentration for each range press, F5, F1.
2. Define Calibration path using SOLENOIDS F5, F2, F4, or PROBE (pump) F5, F2, F5.
CALIBRATION
1. Select range (MEASUREMENT screen)
2. Select ZERO GAS press F4, F1, F1.
3. Save Value press F1.
4. Select SPAN GAS press F4, F2, F2.
5. Save Value press F1.
QUICK AUTO CALIBRATION
SETUP
1. Single range
a) Define span gas concentration for each range press F5, F1.
b) Define Calibration path using SOLENOIDS press F5, F2, F4, or PROBE (pump)
press F5, F2, F5.
c) Define Gas flow windows TIMES press F5, F2, F2, (Purge, Calibrating, Verifying,
Purge After).
d) Define Measuring Deviation press F5, F2, F2.
e) Define Deviations press F5, F2, F3 (% Absolute ((CAI Ideal CAL Curve,
m=1.b=0)) (% Relative ((Last & New ABS Curve)).
2. All Ranges All Channels**
a) Define span gas concentration for each range press F5, F1.
b) Define Calibration path.
c) SOLENOIDS press F5, F2, F4.
d) PROBE (pump) press F5, F2, F5.
e) Define Gas flow windows: TIMES press F5, F2, F2, (Purge, Calibrating, Verifying,
Purge After).
f)Define Measuring Deviation press F5, F2, F2.
g) Define Deviations press F5, F2, F3: (% Absolute ((CAI Ideal CAL Curve,
m=1.b=0)) % Relative (Last Cal Curve).
h) Define Auto Cal Start Time press F5, F7, F1, F1 (Date, Hour, Frequency).
CALIBRATION
1. Single range
a) Select /range (MEASUREMENT screen)
b) AUTOMATIC CALIBRATION press F4, F1: (Instrument flows zero & span gas
and saves value if operator defined deviation requirements are realized)
2. All ranges.
a) AUTO CAL ENABLED press F5, F7, F1, F4.
b) Calibration per real-time clock F5, F7, F1, F3.

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
FILTER HOUSING MAINTENANCE
1) Whenever the Filter Element is replace ALWAYS apply a fairly liberal
coating of silicone lubricant to the threads of the Filter Housing before re-assembly to
prevent galling and seizing of the threads.
NOTE: Use a silicone lubricant that is free of Hydrocarbons to eliminate
measurement errors and contaminate the analyzer
2) ALWAYS, use a second wrench on the body of the Filter Housing when attempting to
Inspect or replace the filter.
3) NEVER attempt to disassemble the Filter Housing while it is hot. Always allow it to
cool to room temperature before attempting any maintenance.
4) NEVER attempt to re-assemble the Filter housing when it is hot. Re-assembly
must ONLY be performed when the analyzer is at room temperature.
5) DO NOT over-tighten. The sealing of the Filter Housing is
accomplished by the o-ring. Re-assembly should be made 'just past finger tight' and only when
the Filter Housing is at room temperature.

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
TABLE OF CONTENTS
1. Introduction................................................................................................................... 1
1.1. Overview.................................................................................................................. 1
1.2. Unpacking Instructions ............................................................................................ 1
1.3. Reporting Damage .................................................................................................. 1
1.4. Contact Information ................................................................................................. 1
1.5. Warranty Certificate................................................................................................. 2
1.6. Possible Explosion Hazard ...................................................................................... 4
1.7. Electrical Shock Hazard........................................................................................... 4
1.8. Fuel Requirements .................................................................................................. 4
1.9. Potential Sample Pump Damage............................................................................. 4
1.10. Removing Protective Caps ...................................................................................... 5
2. Features......................................................................................................................... 6
2.1. Description............................................................................................................... 6
2.2. Features-General .................................................................................................... 6
2.2.1. Ranges.......................................................................................................................7
2.2.2. Calibration ..................................................................................................................7
2.2.2.1 Manual Calibration......................................................................................................7
2.2.2.2 Auto Calibration..........................................................................................................8
2.3. Model 600 MHFID Specifications............................................................................. 9
3. Installation....................................................................................................................10
3.1. General...................................................................................................................10
3.2. Site and Mounting...................................................................................................10
3.3. Electrical.................................................................................................................11
3.4. Sampling System....................................................................................................13
3.5. Required Gases and Gas Handling Equipment ......................................................13
3.6. Gas Connections....................................................................................................13
3.7. Sampling Requirements .........................................................................................14
3.7.1. Filtration....................................................................................................................14
3.7.2. Condensation ...........................................................................................................14
3.7.3. Presence of Corrosive Gases ..................................................................................14
3.7.4. Gas Temperature.....................................................................................................14
3.7.5. Pressure and Flow Rates.........................................................................................14
3.7.6. Sample Gas Bypass Outlet Vent (1) and Exhaust Port (2) ...................................... 16

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
4. Basic Operation...........................................................................................................17
4.1. Applied AC Power...................................................................................................17
4.2. Menu Overview.......................................................................................................17
4.3. ALARMS.................................................................................................................18
4.4. DEVIATIONS..........................................................................................................19
4.5. CALIBRATION........................................................................................................19
4.6. Display (Measurement Screen)...............................................................................19
4.7. Keypad...................................................................................................................21
4.7.1. Operation with the Selector Bar and the Arrow Keys...............................................21
4.7.2. Operation with the Function Keys.............................................................................21
4.7.3. Enter Key.................................................................................................................21
5. Password and Operating Level Menu Structure........................................................22
5.1. Operating levels......................................................................................................22
5.1.1. Password Level Menu..............................................................................................22
5.2. User Functions (Level 1).........................................................................................23
5.3. Advanced User Functions (Level 2)........................................................................23
5.4. Maintenance Functions (Level 3)............................................................................23
5.5. System User Functions (Level 4)............................................................................23
5.6. Selection of an Operation Level and Entering a Password .....................................24
5.6.1. F1 Enter Password..................................................................................................25
5.6.2. F2 Change Password..............................................................................................26
5.6.3. F3 Reset Passwords...............................................................................................26
5.7. Available Menus with Access levels........................................................................27
5.7.1. Main Menu................................................................................................................27
5.7.2. F4 Calibrations ........................................................................................................28
5.7.3. F5 Setup Menu........................................................................................................ 30
6. Menus...........................................................................................................................32
6.1. Main Menu Tree......................................................................................................33
6.2. F1 Measurement Menu Tree ..................................................................................34
6.3. F4 Calibrations Menu Tree ....................................................................................36
6.4. F5 Setup Menu Tree..............................................................................................37
6.5. F5 Password Menu Tree (sub menu of F5 Setup) ..................................................39
7. Menu Function Descriptions.......................................................................................41

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
7.1. F1 Measurements Menu........................................................................................41
7.1.1. (Measurement) F3 Diagnostics...............................................................................42
7.1.2. (Measurement) F4 C1/C3 ....................................................................................... 43
7.1.3. (Measurement) F5 Toggle Zero..............................................................................43
7.1.4. (Measurement) F6 Toggle Span.............................................................................43
7.1.5. (Measurement) F7 Standby.....................................................................................44
7.1.6. (Measurement) Select Range .................................................................................. 44
7.2. F3 Diagnostics.......................................................................................................46
7.3. F4 Calibrations Set Up...........................................................................................46
7.3.1. Entering the Span Gas Concentration...................................................................... 46
7.3.2. Selecting the Path for Calibration Gas Introduction. ................................................47
7.3.3. Selecting the Range to be Calibrated....................................................................... 47
7.3.4. F2 Automatic Calibration.........................................................................................47
7.3.4.1 Setting the Analyzer’s Internal Clock and Calendar. ................................................47
7.3.4.2 Defining the Calibration Schedule............................................................................49
7.3.4.3 Defining the Ranges to be Calibrated. .....................................................................49
7.3.4.4 Enabling the Autocalibration Sequence....................................................................49
7.3.4.5 Entering the Automatic Calibration Span Gas Concentration. .................................50
7.3.4.6 Calibration Gas Introduction/Automatic Calibration Sequence. ...............................50
7.3.4.7 Setting of Automatic Calibration Times....................................................................51
7.3.4.8 Measuring Deviations...............................................................................................51
7.3.4.9 Deviations.................................................................................................................52
7.4. Manual Calibration..................................................................................................52
7.4.1. Zero Calibration........................................................................................................52
7.4.2. Span Calibration.......................................................................................................52
7.4.3. Calibration Verification (Manual Mode). ...................................................................52
7.4.4. (Calibrations) F4 Check Calibration ........................................................................53
7.4.5. (Calibrations) F5 Reset Calibration Values.............................................................54
7.4.6. (Calibrations) F6 Calibration Range Selection........................................................55
7.5. F3 Display Deviations............................................................................................57
7.5.1. Zero Gas Deviations.................................................................................................58
7.5.2. Span Gas Deviations................................................................................................59
7.5.3. Verifying Deviations Zero. ........................................................................................59
7.5.4. Verifying Deviations Span. .......................................................................................60
7.6. F5 Setup................................................................................................................61
7.6.1. Entering the Span Gas Concentration......................................................................61
7.6.2. F2 Calibration Settings............................................................................................62
7.6.2.1 F1 Times .................................................................................................................62

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
7.6.2.2 F2 Measuring Deviations.........................................................................................62
7.6.2.3 F3 Deviations ..........................................................................................................64
7.6.2.4 F4 Calibrations via Valves/Probe ............................................................................65
7.6.3. F3 Range Limits......................................................................................................66
7.6.3.1 Setting Full Scale Range Values..............................................................................66
7.6.3.2 Auto Range Switching Levels...................................................................................66
7.6.4. Alarms ...................................................................................................................... 67
7.6.4.1 F1 Temperatures and Concentration Alarms (T/C Alarms) ....................................67
7.6.4.2 F2 Pressure Alarms ................................................................................................67
7.6.4.3 F3 EPC Coil Alarms ................................................................................................69
7.6.5. F5 Password ...........................................................................................................69
7.6.6. F6 Linearization....................................................................................................... 70
7.6.6.1 Change Linearization Coefficients............................................................................70
7.6.6.2 Display Raw Value ...................................................................................................71
7.6.7. F7 System Settings .................................................................................................71
7.6.7.1 Real Time Clock.......................................................................................................72
7.6.7.2 System Setup F1 Real Time Clock .........................................................................72
7.6.7.3 F2 TCP/IP Settings..................................................................................................73
7.6.7.4 F3 Output Assignment.............................................................................................73
7.6.7.5 F4 Output Range.....................................................................................................74
7.6.7.6 F5 Status Line ON/OFF...........................................................................................74
7.6.7.7 F7 Autostart.............................................................................................................74
7.6.8. F8 Measure Settings...............................................................................................75
7.6.9. F10 Version.............................................................................................................76
7.6.10. F6 Remote / Manual Control...................................................................................77
7.6.11. F7 Standby..............................................................................................................77
7.6.12. F8 Ignition................................................................................................................78
8. Functional Description................................................................................................79
8.1. Operating Principle.................................................................................................79
8.2. Burner Assembly....................................................................................................79
8.3. Flow System...........................................................................................................79
8.4. Sample Supply .......................................................................................................80
9. Analyzer Components.................................................................................................81
9.1. Rear Panel..............................................................................................................81
9.2. Internal Component Locations................................................................................82
9.2.1. Model 600 MHFID Interior Layout ............................................................................82
9.2.2. Model 600 MHFID Electronics Section.....................................................................83
9.2.3. Model 600 MHFID Solenoid Layout.......................................................................... 84

Model 600 MHFID Analyzer
C-ETC-US/CE Manual Rev 1.0
9.2.4. Oven Compartment Layout......................................................................................86
10. Operation......................................................................................................................88
10.1. Startup....................................................................................................................88
10.2. Shutdown Procedure..............................................................................................89
11. Troubleshooting ..........................................................................................................90
11.1. Troubleshooting-Disassembly Procedures..............................................................90
11.1.1. Oven Burner Assembly Filter Unit/Filter Removal....................................................90
11.1.2. Flow System/Fuel and Burner Air Supply.................................................................90
11.2. Troubleshooting Guide ...........................................................................................91
11.3. Error Messages......................................................................................................92
12. GLOSSARY...................................................................................................................93
12.1. ABS DEVIATIONS..................................................................................................93
12.1.1. Calibration Via Probe................................................................................................93
12.1.2. Calibration Via Solenoid Valves ...............................................................................93
12.1.3. Change Linear Coefficients......................................................................................93
12.2. Linear Curve: Standard FACTORY.........................................................................93
12.3. Lin. Value ...............................................................................................................93
12.4. Measured Curve.....................................................................................................93
12.5. MEASURING DEVIATION......................................................................................93
12.6. Measured Value......................................................................................................93
12.7. Physical Range (AKA Linear Curve).......................................................................94
12.8. Purge / Calibration / Verifying Purge After..............................................................94
12.9. Purge: (MAIN MENU) .............................................................................................94
12.10. Real Time...............................................................................................................94
12.11. Raw Value..............................................................................................................94
12.12. RELATIVE DEVIATIONS........................................................................................94
12.13. Reset Calibration Values ........................................................................................94
12.14. Software Range (AKA Measurement Curve) ..........................................................94
12.15. Status Line .............................................................................................................94
13. AK Protocol Format.....................................................................................................95
13.1. Serial Interface and AK-Commands .......................................................................95
13.2. Interface Parameters..............................................................................................95
13.3. General AK Requirements......................................................................................96
13.4. Scans .....................................................................................................................96