CAI 700 Series User manual

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Table of Contents
Introduction ....................................................................................................................5
Operating Principle ........................................................................................................7
Analyzer Specifications ..................................................................................................8
Installation ......................................................................................................................9
Safety Information .........................................................................................................9
Startup and Shutdown ...................................................................................................19
Using the Keypad...........................................................................................................21
Menu Flow Chart...........................................................................................................23
Main Menu..................................................................................................................31
Measure Screen............................................................................................................33
Change Channel...........................................................................................................36
Analyzer Info ..............................................................................................................37
Remote/Manual ...........................................................................................................38
Standby.......................................................................................................................39
Menus ...........................................................................................................................40
Calibration ..................................................................................................................41
Manual Calibration..................................................................................................................... 42
Zero............................................................................................................................................ 43
Span............................................................................................................................................ 46
Automated Calibration............................................................................................................... 48
Initiate Sequenced Cal................................................................................................................ 50
Initiate Sequenced Check........................................................................................................... 52
Cal Gas Concentrations.............................................................................................................. 53
Calibration Setup........................................................................................................................ 54
Auto Calibration Schedule......................................................................................................... 54
Auto Calibration Parameters...................................................................................................... 57
Calibration Via Pump/Valves..................................................................................................... 59
Auto Calibration/Check ............................................................................................................. 60
Auto Calibration Timing............................................................................................................ 61
Deviation Limits......................................................................................................................... 63
Maximum Calibration Error....................................................................................................... 64
Maximum Verifying Error......................................................................................................... 65
Analog Hold on Cal ................................................................................................................... 66
Calibration Factors..................................................................................................................... 67
Manual Deviations..................................................................................................................... 68
Zero Gas Deviations................................................................................................................... 69
Span Gas Deviations.................................................................................................................. 70
Auto Cal Deviations................................................................................................................... 71
Zero Gas Deviations Verifying.................................................................................................. 72
Span Gas Deviations Verifying.................................................................................................. 73
Offset/Gain Factors.................................................................................................................... 74
Reset Factory Settings................................................................................................................ 75

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Range Setup ................................................................................................................80
Range Limits.............................................................................................................................. 81
Auto Range On/Off.................................................................................................................... 83
AutoRange Switch Points .......................................................................................................... 84
Diagnostics .................................................................................................................85
Diagnostic Values ...................................................................................................................... 86
Raw Values Display................................................................................................................... 89
I/O Status.................................................................................................................................... 91
Analyzer Digital Outputs ........................................................................................................... 92
Analyzer Digital Inputs.............................................................................................................. 93
Programmable Digital Outputs................................................................................................... 94
Status Line.................................................................................................................................. 95
Setup Menu.................................................................................................................96
Measure Settings........................................................................................................................ 97
Averaging Time ......................................................................................................................... 98
Comp Factors............................................................................................................................. 99
T & P Compensation................................................................................................................ 100
H2O Compensation.................................................................................................................. 100
Gas Compensation ................................................................................................................... 101
Output Settings......................................................................................................................... 102
Programmable Analogs............................................................................................................ 103
Output Assignments................................................................................................................. 104
Output Scaling.......................................................................................................................... 106
Output Adjustments ................................................................................................................. 108
Programmable Digitals............................................................................................................. 110
Output Assignments................................................................................................................. 111
Output Hold/Clear.................................................................................................................... 114
TCP/IP Parameters................................................................................................................... 117
Data Logging Time.................................................................................................................. 118
Auto Start Settings ................................................................................................................... 119
Clock Settings .......................................................................................................................... 121
Alarms Menu.............................................................................................................122
Current Alarms......................................................................................................................... 123
Alarm Log................................................................................................................................ 124
Alarm Limits............................................................................................................................ 126
Temperatures............................................................................................................................ 127
Pressures................................................................................................................................... 128
Voltages ................................................................................................................................... 129
Concentrations.......................................................................................................................... 130
Alarm Display On/Off.............................................................................................................. 131
Service Menu ............................................................................................................132
Linear Coefficients................................................................................................................... 133
Factory Service......................................................................................................................... 135
Security ....................................................................................................................136
Operator Levels........................................................................................................................ 137
Change Password..................................................................................................................... 138
Reset Password......................................................................................................................... 139
Communication and Interface ......................................................................................140
Analog and Digital Interface........................................................................................141
Serial Interface...........................................................................................................145

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AK Protocol ..............................................................................................................146
Instruction Command............................................................................................................... 148
Acknowledgement Command.................................................................................................. 149
Error Handling ......................................................................................................................... 150
General AK Requirements....................................................................................................... 151
Scan Commands....................................................................................................................... 153
Control Commands .................................................................................................................. 164
Configuration Commands........................................................................................................ 168
Modbus Protocol........................................................................................................174
MBAP Description................................................................................................................... 174
MBAP Header Description...................................................................................................... 175
Modbus Command Function Codes......................................................................................... 176
Modbus Map ............................................................................................................................ 193
01H Single-Read Coil .............................................................................................................. 193
03H Read Floating Point.......................................................................................................... 197
16H Write Floating Point......................................................................................................... 202
Warranty Statement ....................................................................................................204

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Introduction
PRELIMINARY
Thank you for purchasing the CAI 700 NDIR CO/CO2/O2 Analyzer. 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
Technical Support for assistance. We want you to be among our thousands of satisfied
customers.
Description
The 700 NDIR analyzer is based on the infrared absorption characteristics of gases. The
analyzer’s oxygen channel utilizes either the paramagnetic or electrochemical fuel-cell
method to determine the percent level of oxygen contained in the sample gas.
Features
Measures IR from low ppm up to 100% Full Scale and oxygen from 0-1% to 0-
100%

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Multiple channels –up to three NDIR channels or two NDIR channels plus
oxygen
Auto calibration and ranging
Fast response time
Temperature and pressure compensation
Comprehensive diagnostics
CE Mark and ETL listed –conforms to UL STD 61010-1, certified to CAN/CSA
C22.2 STD No. 610610.1
1065-compliant configurations
Options
Paramagnetic or electrochemical oxygen channel
Oxygen channel-only configuration
Internal sample pump
Sample flow control
Multiple sample inputs
19” rack-mount slides
Output options: Voltage, Current, RS-232 AK protocol, TCP/IP Modbus and AK
protocol

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Operating Principle
The CAI 700 NDIR/O2analyzer is based on the infrared absorption characteristics of
gases. Using a single infrared beam to measure gas concentrations, this analyzer delivers
highly stable and reliable results.
A single infrared light beam is modulated by a chopper system and passed through a
sample cell of predetermined length containing the gas sample to be analyzed. As the
beam passes through the cell, the sample gas absorbs some of its energy. The attenuated
beam (transmittance) emerges from the cell and is introduced into the front chamber of a
two-chamber infrared microflow detector. The detector is filled with the gas component
of interest, and consequently the beam experiences further energy absorption. This
absorption process increases the pressure in both chambers.
The differential pressure between the front and rear chambers of the detector causes a
slight gas flow between the two chambers. This flow is detected by a mass-flow sensor
and is converted into an output signal.
The 700 NDIR/O2analyzer’s oxygen channel utilizes either the paramagnetic or
electrochemical fuel-cell method to determine the percent level of oxygen contained in
the sample gas. The oxygen level is displayed on the LCD panel in percent concentration.

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Analyzer Specifications
Specifications are subject to change without notice.
IR Analysis Method: Non-dispersive infrared (NDIR)
NDIR Components: CO, CO2, CH4, SO2, NO
Detector Type: Microflow
NDIR Ranges*: From 0-50 ppm up to 0-100% *SO2, 0-1% up to 0-20%, and CH40-
1,000 ppm up to 0-100%
Range Ratio: 10:1
Response Time (IR): 90% of Full Scale in < 1 second, depending on cell length, flow
rate and time constant
IR Sample Cell: Stainless steel w/ replaceable gold cell liner
Resolution: Typically 0.1% of Full Scale
Repeatability: Better than 1.0% of Full Scale
Linearity: Better than 1.0% of Full Scale of factory-calibrated ranges
Noise: Less than 1% of Full Scale of factory-calibrated ranges
Zero and Span Drift: Less than 1% of Full Scale per 24 hours
Sample Flow Rate: 0.5 to 2.0 LPM
Oxygen Analysis Method: Paramagnetic or Electrochemical Fuel Cell
O2Ranges: 0-1% (paramagnetic only) up to 0-100% O2Full Scale; four definable ranges
O2Response Time: T90 - 2seconds paramagnetic; 16 seconds fuel cell
Outputs Available: Voltage, current, TCP/IP, RS-232, Modbus
Display: 3” x 5” backlit LCD
Sample Temperature: Up to 50°C, non-condensing
Ambient Temperature: 5 to 40°C
Ambient Humidity: Less than 90% RH (non-condensing)
Fittings: ¼-inch tube
Power Requirements: 115/230 (±10%) VAC; 50/60Hz; 300 Watts maximum
Dimensions: 5¼”H x 19”W x 23”D
Weight: 30-45 lbs., depending on configuration

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Installation
Safety Information
Safety Alert Temperature Hazard Electrical Shock Hazard
Caution or Warning Caution or Warning Caution or Warning
Note, Caution and Warning symbols appear on the instrument and in 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 its performance.
A “WARNING” safety alert appears with information that is important for protecting
you, other people and equipment from damage. Pay especially 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 underscore in a triangle) precedes an
elevated temperature hazard CAUTION or WARNING statement.

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The symbol (a lightning bolt in a triangle) precedes an electrical 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.