CAI 600 Series User manual

S E R I E S
6 0 0
6 0 0
6 0 0 CLD
CLD
CLD
USER’S MANUAL
Note: For Analyzers Sold After
June, 2007 Please See Addendum
Starting After Page 86 of This
Manual
1312 West Grove Avenue
Orange, CA 92865-4134
Phone: [phone] Fax: [phone]
www.gasanalyzers.com

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.

The 600 series CLD 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)

POSSIBLE EXPLOSION HAZARD
Do not apply power to the analyzer or attempt to energize the ozone supply or
converter until ALL leak checks have been performed and until the analyzer
environment has been determined to be non-hazardous.
This analyzer is designed for use in a NON-HAZARDOUS environment.
This analyzer is designed for use with a HAZARDOUS sample.
Tampering or use of substitute components may cause a safety hazard. Use only
factory authorized replacement parts.
Do not operate without the cover secured. Servicing
requires access to live electrical components which
can cause death or serious injury. Refer servicing to
qualified service personnel. For safety and proper
performance, this instrument must be connected to a
properly grounded three-wire receptacle.

TABLE OF CONTENTS
Section Title Page
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
2. FEATURES AND SPECIFICATIONS ------------------------------------------------------ 3
3.1. Descriptions--------------------------------------------------------------------------------------3
2.2. Features ------------------------------------------------------------------------------------------3
2.3. Specifications------------------------------------------------------------------------------------4
3. INSTALLATION --------------------------------------------------------------------------------- 5
3.1. General--------------------------------------------------------------------------------------------5
3.2. Site and Mounting ------------------------------------------------------------------------------5
3.3. Electrical --------------------------------------------------------------------------------------- 5-6
3.4. OutputConnections ----------------------------------------------------------------------------6
3.5. Required Gases---------------------------------------------------------------------------------7
3.6. Gas Handling Equipment---------------------------------------------------------------------7
3.7. Gas Connections -------------------------------------------------------------------------------5
3.8. Sampling Requirements ----------------------------------------------------------------------7
3.8.1. Filtration ----------------------------------------------------------------------------------------7
3.8.2. Condensation ---------------------------------------------------------------------------------7
3.8.3. Presence of Corrosive Gases-------------------------------------------------------------7
3.8.4. Gas Temperature ----------------------------------------------------------------------------7
3.8.5. Flow Rate ----------------------------------------------------------------------------------- 7-8
3.8.6. Sample Gas Outlet --------------------------------------------------------------------------8
4. BASIC OPERATION --------------------------------------------------------------------------- 9
4.1. Display --------------------------------------------------------------------------------------------9
4.2. Menu Tree-------------------------------------------------------------------------------------- 10
4.3. Keyboard --------------------------------------------------------------------------------------- 11
4.4. Operation with Cursor Keys --------------------------------------------------------------- 11
4.5. Operation with Function Keys ------------------------------------------------------------- 11
4.6. Read and Change Parameters ----------------------------------------------------------- 11
5. OPERATING STRUCTURE -----------------------------------------------------------------12
5.1. Main Menu ---------------------------------------------------------------------------------12-13
6. MENU STRUCTURE --------------------------------------------------------------------------13

6.1. User Functions (Level 1) ------------------------------------------------------------------- 13
6.2. Advanced User Functions (Level 2) ----------------------------------------------------- 13
6.3. Maintenance User Functions (Level 3) ------------------------------------------------- 13
6.4. System User Functions (Level 4)--------------------------------------------------------- 13
7. MAIN MENU -------------------------------------------------------------------------------------15
7.1. F1 Measurements ---------------------------------------------------------------------------- 15
7.1.1. F1 NO or NOx Measurement ----------------------------------------------------------- 16
7.1.2. F2 NO + NO2 Measurement --------------------------------------------------------15-16
7.1.3. F3 Diagnostics ------------------------------------------------------------------------------ 16
7.1.4. Arrow Keys to Cycle Ranges and Auto Range ------------------------------------- 17
7.2. F2 Purge Analyzer --------------------------------------------------------------------------- 18
7.3. F3 Diagnostics -------------------------------------------------------------------------------- 18
7.4. F4 Calibrations -------------------------------------------------------------------------------- 19
7.4.1. F1 Automatic Calibration-------------------------------------------------------------19-20
7.4.2. F2 Manual Calibration ----------------------------------------------------------------20-21
7.4.3. F3 Display Deviations-----------------------------------------------------------------21-22
7.4.4. F4 Check Calibration Values------------------------------------------------------------ 22
7.4.5. F5 Reset Calibration Values ------------------------------------------------------------ 22
7.4.6. F6 Range Select --------------------------------------------------------------------------- 22
7.5. F5 Setup ---------------------------------------------------------------------------------------- 23
7.5.1. F1 Span Gas Concentrations ----------------------------------------------------------- 24
7.5.2. F2 Calibration Settings ------------------------------------------------------------------- 24
7.5.2.1. F1 Times --------------------------------------------------------------------------- 24
7.5.2.2. F2 Measuring Deviations------------------------------------------------------- 25
7.5.2.3. F3 Deviations---------------------------------------------------------------------- 25
7.5.2.4. F4 Calibration via Valves------------------------------------------------------- 25
7.5.2.5. F5 Calibration via Probe-------------------------------------------------------- 25
7.5.3. F3 Range Limits ---------------------------------------------------------------------------- 25
7.5.3.1. F1 Change Upper Range Limits---------------------------------------------- 25
7.5.3.2. F2 Change Auto Range Limits------------------------------------------------ 26
7.5.4. F4 Change Alarms------------------------------------------------------------------------- 26
7.5.5. F5 Password -------------------------------------------------------------------------------- 27
7.5.5.1. F1 Enter Password -------------------------------------------------------------- 27
7.5.5.2. F2 Change Password ----------------------------------------------------------- 27
7.5.5.3. F3 Reset Passwords ------------------------------------------------------------ 28
7.5.6. F6 Linearization ---------------------------------------------------------------------------- 28
7.5.7. F7 System Settings------------------------------------------------------------------------ 29
7.5.7.1. F1 Clock Setup ---------------------------------------------------------------29-30
7.5.7.2. F2 TCP/IP Address -------------------------------------------------------------- 31
7.5.7.3. F3 Output Signal Assignments ----------------------------------------------- 31
7.5.5.4. F4 Output Ranges --------------------------------------------------------------- 31
7.5.7.5. F5 Protocol On/Off --------------------------------------------------------------- 32

7.5.7.6. F6 Set Langauge ----------------------------------------------------------------- 32
7.5.7.7. F7 Automatic Setup-------------------------------------------------------------- 32
7.5.8. F8 Measure Settings ---------------------------------------------------------------------- 33
7.5.8.1. F1 Set Purge Time Before Measure----------------------------------------- 33
7.5.8.2. F2 Set Converter Efficieny----------------------------------------------------- 33
7.5.8.3. F3 Set Time Constant----------------------------------------------------------- 34
7.5.8.4. F4 Set Purge Time Before Calibration-------------------------------------- 34
7.5.10. F10 Display Software Version ------------------------------------------------------34-35
7.6. F7 Remote/Manual Operation------------------------------------------------------------- 35
7.7. F8 Standby ------------------------------------------------------------------------------------- 35
8. ANALYZER COMPONENTS ----------------------------------------------------------------36
8.1. Rear Panel Connections-------------------------------------------------------------------- 36
8.1.1. Main Analog Connections---------------------------------------------------------------- 37
8.1.2. Auxiliary Analog Connections----------------------------------------------------------- 37
8.1.3. Digital (RS-232) Connections----------------------------------------------------------- 38
8.1.4. Digital (TCP/IP) Connections ----------------------------------------------------------- 38
8.2. Internal Components ------------------------------------------------------------------------ 39
8.3. Main Electronics Board (Potentiometers) ---------------------------------------------- 40
8.4. Main Electronics Board (Connections)-------------------------------------------------- 41
8.5. Reaction Chamber --------------------------------------------------------------------------- 42
8.6. Relay Board (Connections) ---------------------------------------------------------------- 43
9. OPERATION-------------------------------------------------------------------------------------44
9.1. Preparation------------------------------------------------------------------------------------- 44
9.2. Operation -----------------------------------------------------------------------------------44-45
9.3. Shut Down Procedure----------------------------------------------------------------------- 45
10. FUNCTIONAL DESCRIPTION--------------------------------------------------------------46
10.1. Operating Principle--------------------------------------------------------------------------- 46
10.2. Reaction Chamber Assembly ------------------------------------------------------------- 46
10.3. Flow System ----------------------------------------------------------------------------------- 46
10.4. Electronics-------------------------------------------------------------------------------------- 46
10.5. Main Electronics Board --------------------------------------------------------------------- 47
10.6. Relay Board------------------------------------------------------------------------------------ 47
11. REACTION CHAMBER-----------------------------------------------------------------------48
11.1. Reaction Chamber Disassembly --------------------------------------------------------- 48
11.2. Reaction Chamber Assembly ------------------------------------------------------------- 48
12. TROUBLESHOOTING ------------------------------------------------------------------------49
12.1. Ozone Air/O2 Supply ------------------------------------------------------------------------ 49
12.2. Sample Supply -------------------------------------------------------------------------------- 49
12.3. NO/NOx Converter --------------------------------------------------------------------------- 49
13. APPENDIX 1-------------------------------------------------------------------------------------50
13.1. AK Protocol --------------------------------------------------------------------------------51-62

13.2. I/O Lists ----------------------------------------------------------------------------------------- 63
13.3. Flow Diagrams ----------------------------------------------------------------------------64-67
13.4. Electrical Block Diagram-------------------------------------------------------------------- 68
13.5 Serial Number UO6081--------------------------------------------------------------------70

Section 1 INTRODUCTION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 1 of 81
1. Introduction
1.1. Overview
Congratulations and thank you! You have just purchased one of the most reliable gas
analyzers in the world. Before using the analyzer, please familiarize yourself with its
operation by reading this manual. If you have any questions, please do not hesitate to
call California Analytical Instruments for assistance. We want you to be a member of our
thousands of satisfied customers.
1.2. Unpacking Instructions
Open the shipping container and carefully remove the analyzer from the packing
materials. Inspect the instrument for any sign of damage. Remove the Top Cover
retaining screws. Visually check for loose parts or connectors that are not properly
seated. Verify all circuit boards and circuit board connections are secure. If all internal
components look normal, re-install the cover.
1.3. Reporting Damage
Should there be any apparent damage to either the inside or outside of the instrument
due to shipping or handling, immediately notify the shipper. The shipping container or
packing materials should be retained for inspection by the shipper.
1.4. Contact Information
California Analytical Instruments, Inc.
1312 West Grove Avenue
Orange, CA 92865
714974-5560
Fax [phone]
Website: www.gasanalyzers.com

Section 1 INTRODUCTION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 2 of 81
1.5. Warranty Certificate
Subject to the exceptions and upon the conditions stated below, California Analytical
Instruments (CAI) warrants that the products sold under this sales order shall be free
from defects in workmanship and materials for one year after delivery of the product to
the original Buyer by CAI and if any such product should prove to be defective within
such one year period, CAI agrees, at its option, either (i) to correct by repair or, at CAI’s
election, by replacement with equivalent product any such defective product, provided
that investigation and factory inspection discloses that such defect developed under
normal and proper uses, or (ii) to refund the purchase price. The exceptions and
conditions mentioned above are as follows:
a) components or accessories manufactured by CAI which by their nature are not intended to
and will not function for one year are warranted only to give reasonable service for a
reasonable time; which constitutes reasonable time and reasonable services shall be
determined solely by CAl. A complete list of such components and accessories is maintained
at the factory;
b) CAI makes no warranty with respect to components or accessories not manufactured by it; in
the event of defect in any such component or accessory CAI will give reasonable assistance
to Buyer in obtaining from the respective manufacturer whatever adjustment is authorized by
the manufacturer’s warranty;
c) any product claimed to be defective must be returned to the factory transportation charges
prepaid and CAI will return the repaired or replaced product freight collect;
d) if the product claimed to be defective requires on-site repair, such warranty labor will be
provided at no charge; however, transportation and living expenses will be charged to Buyer;
e) if the product is a consumable or the like, it is warranted only to conform to the quantity and
content and for the period (but not in excess of one year) stated on the label at the time of
delivery or 90 days;
f) CAI may from time to time provide a special printed warranty with respect to a certain product,
and where applicable, such warranty shall be deemed incorporated herein by reference;
g) CAI shall be released from all obligations under all warranties, either expressed or implied, if
any product covered hereby is repaired or modified by persons other than its own authorized
service personnel unless such repair by others is made with the written consent of CAl.
IT IS EXPRESSLY AGREED THAT THE ABOVE WARRANTY SHALL BE IN LIEU OF ALL
WARRANTIES OF FITNESS AND OF THE WARRANTY OF MERCHANTABILITY AND THAT
CAI SHALL HAVE NO LIABILITY FOR SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY
KIND OR FROM ANY CAUSE WHATSOEVER ARISING OUT OF THE MANUFACTURE USE,
SALE, HANDLING, REPAIR, MAINTENANCE OR REPLACEMENT OF ANY OF THE
PRODUCTS SOLD UNDER THIS SALES ORDER. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THAT
THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY. THIS WARRANTY GIVES
YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS, WHICH VARY
FROM STATE TO STATE.
Representations and warranties made by any person, including dealers and representatives of
CAI, which are inconsistent, or in conflict with the terms of this warranty, shall not be binding upon
CAI unless reduced to writing and approved by an expressly authorized officer of CAl.

Section 2 FEATURES AND SPECIFICATIONS
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 3 of 81
2. Features
2.1. Description
The CAI Model 600 CLD Analyzer is a highly sensitive chemiluminescent (CLD) gas
analyzer for measuring oxides of nitrogen gas concentrations in industrial and vehicle
emission applications.
2.2. Features-General
The Model 600 CLD analyzer has a 3 by 5 inch liquid crystal display and a 20 key
data/operation input keyboard. The 16 bit microprocessor control board consists of the
MSR-Card with 16 digital inputs, 16 digital outputs, 16 analog inputs and 4 analog
outputs. The analyzer can be manually operated from the keypad or remotely via TCP/IP
or RS-232C communications. After turning on the analyzer, it needs at least 30 seconds
for initialization. During this time, the screen is illuminated. The analyzer is available with
an optional internal heated sample pump and internal zero and span solenoids.
+IMPORTANT TIP: When the analyzer is powered up, it defaults to access
level 1 (User). To operate ALL parameters, check the access level. See
Section 5.5.5.
The contents of this operators manual include:
•Specifications
•Installation Requirements, Mechanical & Electrical
•Operation & Calibration Instructions
•Reaction Chamber Description with Procedures for Disassembly of its
Component Parts
•Function Explanation of the Electronic Circuitry
•Electrical Block Diagram
NOTE: A detailed service and factory setup instruction manual for
purchase will be available in April 2003 and will include full
schematics.

Section 4 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
March 2006 Page 4 of 68
Model 600 CLD Specifications
DETECTOR
Chemiluminescence (CLD) Photodiode (thermally stabilized with Peltier Cooler)
NO/NOx RANGES
0-1 to 3,000 ppm NO or NOX (Four user programmable ranges)
(Higher Ranges Available upon Request)
RESPONSE TIME
T90 < 2 Seconds to 60 Seconds Adjustable
RESOLUTION
10 ppb NO/NOX (Displays 5 significant digits)
REPEATABILITY
Better than 0.5% of Full Scale
LINEARITY
Better than 0.5% of Full Scale
NOISE
Less than 1% of Full Scale
ZERO & SPAN DRIFT
Less than 1% of Full Scale per 24 Hours
ZERO & SPAN ADJUSTMENT
Via front panel, TCP/IP or RS-232
NH3, HCN & SO2EFFECT
Not detectable with 100 ppm
CO2EFFECT
Less than 2.0 % with 10% CO2
FLOW CONTROL
Electronic Proportional Pressure Controller
SAMPLE FLOW RATE
Typically 2.0 LPM (0.6 LPM with Low Flow Option)
CONVERTER
Vitreous Carbon Material @ 205°C > 98% efficiency
OZONATOR
Ultraviolet Lamp
AIR OR O2REQUIREMENTS
Less than 0.01 ppm NOXat 350 cc/Min. @ 25 psig (Dew Point < -10ºC)
NO/NOXControl
Manual/Remote/Auto Cycle (Remote NOX mode by dry contact closure)
OUTPUTS AVAILABLE
TCP/IP, RS232, Four Scalable Analog 0-10 V / 4-20 mA Maximum
DISCRETE ALARMS
(Local & Remote Adjustable)
General Fault/ TTL Logic (Ground True)
Calibration Failure/ TTL Logic (Ground True)
High Concentration (2 each)/ TTL Logic (Ground True)
DIGITAL DIAGNOSTICS
Control Voltages
Temperatures
Pressures
Flow Parameters
KEYPAD DISPLAYS
Factory Settings
TCP/IP Address
Passwords (4)
Scalable Analog Output Voltages
Full Scale Range Select
Auto Cal Times
SPECIAL FEATURES
Calculated NO2 derived from NOX converter efficiency
Auto Ranging
Auto Calibration (adjustable through internal clock)
Less than 3 cc Gold Plated Reaction Chamber
DISPLAY
3” x 5” Back lit LCD
SAMPLE TEMPERATURE
Up to 50°C Noncondensing
AMBIENT TEMPERATURE
5 to 40°C
AMBIENT HUMIDITY
Less than 90% RH Noncondensing
WARM-UP TIME
1 Hour (Typical)
FITTINGS
1/4 Inch Tube
POWER REQUIREMENTS
115V 60Hz (Option: 230V 50 Hz) , Less than 3 amps
DIMENSIONS
5¼ H × 19 W × 23 D (Inches)
WEIGHT
45 Pounds
Note: .5 to 1.5 l/min flow rate options available upon request only
SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Section 3 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 5 of 81
3. Installation
3.1. General
The instrument is designed for industrial applications. These installation instructions are
for a typical site. Any questions regarding specific installation situations should be
directed to Technical Service of California Analytical Instruments, Inc.
3.2. Site and Mounting
NOTE: The following precautions must be carefully observed:
1. Select a site free from direct sunlight, radiation from a high temperature surface,
or abrupt temperature variations.
2. This analyzer is not suitable for installation outdoors.
3. Select a site where the air is clean. Avoid exposing the instrument to corrosive or
combustible gases.
4. The instrument must not be subject to severe vibration. If severe vibration is
present, use isolation mounts.
5. The instrument is designed for rack-mounting. Optional rack mount slides are
available.
6. Do not install near equipment emitting electromagnetic interference (EMI).
NOTE: A rear supporting brace or equivalent is required if the optional rack mount
slides were not purchased.
The power on/off switch is accessible from the rear of the instrument only. DO
NOT mount such that the power on/off switch is inaccessible.
3.3. Electrical
All wiring is connected at the rear of the instrument. The AC power is connected to the
power/fuse/switch as shown below:
0
I
AC Power Switch, Connector, and Fuse.

Section 3 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 6 of 81
NOTE: A defective ground may affect the operation of the instrument. The output
voltages are connected per Table 8.1.1. Shielded wiring is recommended for output
signals.
3.4. Analog Output Connections (Appendix)
See Appendix for connector pinouts located on the analyzer rear panel. Remote range
identification and range selection are obtained via the rear panel connections. When a
range is selected, the corresponding control line is pulled low to zero VDC. Ranges not
selected will remain at approximately 5 VDC. When remote range control is selected on
the front panel switch, a contact closure is provided at the rear panel connector. Remote
range selection is made by connection of the control line for the desired range to the
analyzers zero VDC line provided in the connector. Five VDC is also provided. Remote
NOx On is selected by connection to the common line. This contact closure turns on the
NOx function by flowing the sample first through the NO/NOx converter.
3.5. Gases
1. Air or O2 (Ozone Air, < 1 ppm C) in pressurized cylinder.
2. Nitrogen or (zero air) in pressurized cylinder.
3. Standard span gas(es) near full scale concentration with a nitrogen balance, in a
pressurized, certified cylinder.
3.6. Gas Handling Equipment
1. Pressure regulators for zero gas (Air or N2), ozone supply (air or O2) and span gas
cylinders.
2. Corrosive resistant gas tubing.
NOTE
High levels of Ammonia (greater than 10 PPM NH3) may reduce the NO2to NO Converter's
conversion efficiency to a level that is unacceptable. It is therefore recommended that the
customer purchase a commercially available NH3 scrubber and install it in the path of the sample
gas prior to its introduction into the analyzer.
3.7. Gas Connections
The tubing from the sampling system to the gas analyzer should be made from corrosive-
resistant material such as Teflon or stainless steel. Even when the gases being sampled
are corrosive themselves, rubber or soft vinyl tubing should not be used since readings
may be inaccurate due to gas absorption into the piping material. To obtain fast
response, the tube should be as short as possible. Optimum tube internal diameter is
0.16 inch (4 mm). Couplings to the instrument are ¼ Inch tube.
NOTE
Be sure tubing and joints are clean.
Dust entering the instrument may cause it to malfunction.

Section 3 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 7 of 81
3.8. Sampling Requirements
3.8.1. Filtration
Dust must be eliminated completely. Use filters as necessary. The final filter must be
capable of removing particles larger than 4 microns.
3.8.2. Condensation
Dew point of the sample gases must be lower than the instrument temperature to
prevent accidental condensation within the instrument. Pypass the sample through a
dehumidifier to reduce the dew point to about 2 to 4°C or less. If the sample contains
an acid mist, use an acid mist filter, cooler or similar device to remove all traces of the
mist.
3.8.3. Presence of Corrosive Gases
Useful service life of the instrument will be shortened if high concentrations of
corrosive gases such as Cl2, SO2, F2, HCl, etc., are present in the sampled gas.
3.8.4. Gas Temperature
When measuring high temperature gases, take care that the maximum rating of the
instrument 104 ºF (50 ºC) is not exceeded.
3.8.5 Pressure and Flow Rates
The air or oxygen supply entering the instrument is controlled by an electronically
controlled proportional flow (EPC) controller. The regulator is factory adjusted for
optimum analyzer performance. The ozone supply (Air or O2) air cylinder pressure
should be set at approximately 25 PSIG. The sample entering the instrument is
controlled by a factory set precision electronically controlled proportional flow (EPC)
controller. The EPC is factory set for optimum analyzer performance as indicated by
the sample pressure. If the analyzer does not contain the optional internal sample
pump, the sample gas entering the instrument should be at a pressure between 10
and 25 PSIG with a flow capacity at a minimum of 3 liters/min. If the analyzer
contains the optional sample pump, do not apply a pressurized sample. The optional
pump is capable of drawing a sample through a ¼ inch heated sample line of
approximately 75 feet. The calibration/span gas cylinder pressures should be set at
25 PSIG for delivery into the optional zero and span inlets located on the rear panel.
NOTE: If the analyzer contains an optional internal sample pump, the introduction of
a pressurized sample gas in excess of 1.5 PSIG will damage the pump.
3.8.6. Sample Gas Bypass Outlet (Vent)
A sample gas bypass outlet connector is located on the rear panel (¼ Inch Tube).
Pressure at this outlet should be kept at atmospheric level. ANY backpressure will
cause an error in reading. The vent outlet is located on the rear panel and may
contain high levels of ozone which should be vented away from the instrument.

Section 3 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 8 of 81
4. Basic Operation
The operation of the digital microprocessor conforms to the guidelines of the AK committee,
originally developed in the German automotive industry. Via the serial port of the MSR-Card,
the analyzer can be remote-controlled by a master computer. The serial communication fully
corresponds to the specifications of the AK protocol. TCP/IP communication is also
available.
4.1. Display
The analyzer's LCD display includes 16 lines with 30 characters each. The display also
has background lighting that can be switched on and off via the Display key on the
keyboard. The following example shows the measurement screen which is formatted into
4 information areas.
Measurement Screen
THE TOP INFORMATION AREA CONTAINS:
The AK Protocol Information. This capability is for advanced uses and may be toggled
on and off in the setup screen, F5. Next to the symbol for the active operating mode, the
device status is indicated. The status field is also displayed on all other screens.
SARE Autorange enabled
SMGA Measuring gas is flowing
SMAN Device is in manual operation status
The level of Password Entry is shown on the right with 1 to 4 horizontal lines.
THE LARGE INFORMATION AREA CONTAINS:
The Concentration of the gas sample and mode of operation.
THE THIRD INFORMATION AREA CONTAINS:
The help information for the parameter selected, ranges, etc.
THE LOWER INFORMATION AREA CONTAINS:
The time & date and any error condition.
The symbol in the bottom right corner indicates the keyboard mode. In the example
shown, the keyboard is in the function key mode. For input fields, the mode is usually
switched to numerical input. Then, an N appears in the lower right of the screen. This
symbol is displayed on all screens.

Section 3 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 9 of 81
4.2. Menu Tree
Main Menu (from “Main” Key) (p12)
F1 Toggles Between NO & NOx (p15)
F2 Toggles on NO +NO2 (p15)
F1 F3 Displays Diagnostics Screen (p16)
Arrow Keys Cycle Ranges 1-4 and Auto Range (p17)
F2 Sets Analyzer in Purge Mode (p18)
F3(p15)
F3
F1 Starts Auto Calibration on Range in Use (p19)
F2 (Zero Cal/Span Cal/Change Range) (p20)
F3DisplaysDeviations(p21)
F4 F4CalibrationCheck(p22)
F5ResettoFactoryDefault(p22)
F6 Range Change (p22)
F1SetsCalibrationGasValues(p24)
F2SetsAutoCalibrationTimes(p24)
F5 F3 Sets Upper Range Limits (p25)
F4 Set Range Concentration Limits (p26)
F5SetsUserPassword(p27)
F6EntersCurveFitPolynomials(p28)
F7DisplaysSystemSettings(p29)
F9DisplaysMeasureSettings(p33)
F10DisplaysConverterEfficiency(p34)
F6 Manual (Local) Control (p36)
F6
Toggles Pump ON/OFF (p36)
F7
F1 Measurement
F2 Purge Analyzer
F3 Diagnostics
F4 Calibration
F5 Setup
F6 Remote / Manual
F7 Standby
F1 NO/NOx
F2 Dual Mode
F3 Diagnostics
Up/Down Range
Purge Analyzer
F1 Auto Cal
F2 Manual Cal
F3 Display Deviations
F4 Check Calibration
F5 Reset Cal Values
F6 Range Select
F1 Span Gas Concentrations
F2 Calibrations Settings
F3 Range Limits
F4 Alarms
F5 Password
F6 Linearization
F7 System Settings
F8 Measure Settings
F10 Displays Version
Displays Diagnostics Screen
Activates Remote or Manual Control
In Standby, Sample Pump is OFF

Section 3 BASIC OPERATION
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 10 of 81
4.2. Keyboard
The keyboard looks as follows:
Del Main Back
67890
12345
F6 F7 F8 F9 F10
F1 F2 F3 F4 F5
Display lighting
on / off
Delete key
Switch-over of the keyboard
numeral / control keys
To the main menu
Cancel, back to
the last menu
End input,
open selected field for input
Arrow keys for selecting the functions and
editin
g
fields and for scrollin
g
possible input values
Combined control / numeral keys
Keyboard
4.3. Operation with the Cursor Keys and the Enter Key
When operating the unit with the cursor keys, you select the various functions with the
up/down cursor keys and start them with the Enter key. This method is particularly
suitable for less proficient users since the system displays a short on-line help for nearly
every function selected. The actual cursor position is shown as a black horizontal bar.
TIP: If you are not yet familiar with the screens and their fields, just press any cursor key
after a screen appears. This moves the cursor from field to field and displays the
corresponding online help.
4.4. Operation with the Function Keys
When using the function keys (Fl though F10), functions are directly accessed by
pressing their corresponding function keys. This method is suitable for the advanced user
since it is faster than the operation with the cursor keys.
4.5. Read/Change Parameters
To read and/or change parameters, you must switch to the parameter input mode by
pressing the Enter key after calling the corresponding parameter screen. The input
cursor (horizontal bar under the first character) then appears in the active edit field (black
background). The cursor can be positioned with the right and left cursor keys, and the
value displayed (number or letter) can be changed with the up and down cursor keys or
entered directly. Every input has to be concluded by pressing the Enter key again, which
causes the cursor to disappear.

Section 5 OPERATING STRUCTURE
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 11 of 81
5. Operating Structure
The analyzer’s operation can be divided into 4 operating levels. The current level is always
displayed as a stack of 1 to 4 horizontal bars in the top right corner of the screen. In the
access level menu, you can choose between the following operating levels:
F1 User (operating level 1)
F2 Advanced user (operating level 2)
F3 Maintenance (operating level 3)
F4 System user (operating level 4)
A password can be assigned to each operating level. Only the system user, who normally
has the highest operating priority, can assign the password. At the factory, the default
passwords for the CAI analyzers are set as follows:
User: 111
Advanced user: 222
Maintenance: 333
System: 444
The default setting can be changed only by the system user. This manual is written to
include all information for the advanced system user.
TIP: Because of the user settings, some of the parameters shown in this manual may not
appear on your analyzer. Check the access level.
5.1. The Main Menu
Upon power up,the CAI logo is first displayed and then the main menu appears as below:
Main Menu onPower Up Screen
NOTE: F6 is not available because, on initial start up, the analyzer reverts to ONLY
Level 1 access. See Section 7.5.5 for Password information.
All functions can be selected with the cursor keys and activated by pressing the Enter
NOTE:
Access
Level
Indication

Section 5 OPERATING STRUCTURE
California Analytical Model 600 CLD C_ETL_US/CE Operators Manual
Rev12 Page 12 of 81
key, or directly with the function keys F1 through F7. A ">" to the right of a function
means that one or more sub-menus are available. If this sign is missing, the function
starts immediately after the activation.
NOTE: Access level is 4.
Main User Menu (Level 4)
NOTE:
Access
Level
Indication