CAI 700M User manual

700M HFID 6-2-15
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700M HFID 6-2-15
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Table of Contents
Introduction ...........................................................................................................................5
Analyzer Specifications.........................................................................................................9
Installation...........................................................................................................................11
Safety Information ..............................................................................................................11
Startup and Shutdown.......................................................................................................... 22
Using the Keypad..................................................................................................................24
Menu Flow Chart .................................................................................................................26
Main Menu........................................................................................................................... 34
Measure Screen.................................................................................................................35
Measure Mode ..................................................................................................................38
THC Mode...............................................................................................................................39
CH4Mode................................................................................................................................39
THC/CH4/NMHC Mode..........................................................................................................40
Analyzer Info.................................................................................................................... 41
Remote/Manual.................................................................................................................42
Standby ............................................................................................................................43
Ignition.............................................................................................................................44
Menus ..................................................................................................................................45
Calibration .......................................................................................................................46
Manual Calibration..................................................................................................................47
THC or CH4Mode................................................................................................................48
Zero....................................................................................................................................49
Span...................................................................................................................................52
THC/CH4/NMHC Mode.......................................................................................................54
Automated Calibration.............................................................................................................55
Initiate Sequenced Cal..........................................................................................................57
Initiate Sequenced Check .....................................................................................................59
Cal Gas Concentrations ...........................................................................................................60
Calibration Setup.....................................................................................................................61
Auto Calibration Schedule....................................................................................................62
Auto Calibration Parameters.................................................................................................64
Calibration Via Pump/Valves...............................................................................................66
Auto Calibration/Check........................................................................................................67
Auto Calibration Timing.......................................................................................................68
Deviation Limits...................................................................................................................70
Maximum Calibration Error..............................................................................................71
Maximum Verifying Error.................................................................................................72
Analog Hold on Cal..............................................................................................................73
Calibration Factors...................................................................................................................74
Manual Deviations................................................................................................................75
Zero Gas Deviations..........................................................................................................76
Span Gas Deviations..........................................................................................................77
Auto Cal Deviations .............................................................................................................78

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Verifying Zero Deviations.................................................................................................79
Verifying Span Deviations ................................................................................................80
Offset/Gain Factors...............................................................................................................81
Reset Factory Settings ..........................................................................................................82
Range Setup......................................................................................................................85
Range Limits............................................................................................................................86
AutoRange On/Off...................................................................................................................88
AutoRange Switch Points........................................................................................................89
Diagnostics........................................................................................................................90
Diagnostic Values....................................................................................................................91
Raw Values Display ................................................................................................................93
I/O Status.................................................................................................................................95
Analyzer Digital Outputs......................................................................................................96
Analyzer Digital Inputs.........................................................................................................97
Programmable Digital Outputs.............................................................................................98
Status Line...............................................................................................................................99
Setup Menu..................................................................................................................... 100
Measure Settings....................................................................................................................101
Averaging Time..................................................................................................................102
THC/CH4/NMHC Mode Times..........................................................................................103
CH4Correction Factors.......................................................................................................104
Output Settings......................................................................................................................106
Programmable Analogs ......................................................................................................107
Output Assignments.........................................................................................................108
Output Scaling.................................................................................................................110
Output Adjustments.........................................................................................................112
Programmable Digitals.......................................................................................................114
Output Assignments.........................................................................................................115
Output Hold/Clear ...........................................................................................................118
Output Test......................................................................................................................119
TCP/IP Parameters.................................................................................................................121
Data Logging Time................................................................................................................122
Auto Start Settings.................................................................................................................123
Clock Settings........................................................................................................................125
Alarms Menu..................................................................................................................126
Current Alarms ......................................................................................................................127
Alarm Log..............................................................................................................................128
Alarm Limits..........................................................................................................................130
Temperatures ......................................................................................................................131
Pressures.............................................................................................................................132
EPC Voltages......................................................................................................................133
Concentrations....................................................................................................................134
Alarm Display On/Off...........................................................................................................135
Service Menu..................................................................................................................136
Linear Coefficients ................................................................................................................137
Factory Service......................................................................................................................139
Security ..........................................................................................................................140
Operator Levels .....................................................................................................................141
Change Password...................................................................................................................142
Reset Password......................................................................................................................143

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Communication and Interface............................................................................................. 144
Analog and Digital Interface............................................................................................ 145
Serial Interface................................................................................................................149
AK Protocol....................................................................................................................150
Instruction Command ............................................................................................................152
Error Handling.......................................................................................................................154
General AK Requirements.....................................................................................................155
Scan Commands ....................................................................................................................157
Control Commands................................................................................................................168
Configuration Commands......................................................................................................172
Modbus Protocol............................................................................................................. 177
MBAP Description ................................................................................................................177
MBAP Header Description....................................................................................................178
Modbus Command Function Codes ......................................................................................179
Modbus Map..........................................................................................................................196
01H Single-Read Coil.........................................................................................................196
05H Write Single Coil........................................................................................................198
03H Read Floating Point ....................................................................................................199
16H Write Floating Point....................................................................................................202
Warranty Statement........................................................................................................... 204

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Introduction
Thank you for purchasing the CAI 700M HFID Analyzer. Before using the 700M HFID, 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 CAI 700M HFID analyzer is an exceptionally accurate Flame Ionization Detection (FID)
gas analyzer designed for measuring hydrocarbons concentrations in gas samples. The analyzer
utilizes a highly sensitive flame ionization detector for measuring volatile hydrocarbon
concentrations in industrial or vehicle emission applications.
The 700M HFID incorporates a non-methane hydrocarbon “cutter” that removes all
hydrocarbons except methane from the sample gas. This capability allows the operator to obtain
the methane, non-methane and total hydrocarbon concentrations of the sample.
The heated sample gas is maintained above its dew point by a self-contained, internally
adjustable oven. The oven temperature is factory-set to be controlled at 191ºC. The sample gas is
maintained at this elevated temperature until it exits the analyzer’s bypass outlet, preventing any
loss of hydrocarbon concentration in the sample due to condensation.

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Features
•Measures THC/CH4/NMHC from 1 to 30,000 ppmc full-scale.
•Heated version for maximum stability and “hot/wet” sampling.
•Temperature-stabilized detector.
•Electronic flow control.
•Selectable output options of current or 1, 5 or 10 VDC.
•Output options: voltage, current, Modbus, RS232 using AK Protocol, and TCP/IP.
•Automatic fuel and air shutoffs.
•Automatic calibration and ranging.
•Fast response time.
•CE Mark and ETL listed – conforms to UL STD 61010-1, certified to CAN/CSA
C22.2 STD 61010.1.
•1065-compliant configurations.
The analyzer offers four basic factory ranges (30/300/3000/30,000 ppmc or 10/100/1000/10,000
ppm C3) that can be scaled at the factory per customer specifications. These ranges can also be
re-scaled in the field at any time via the analyzer’s keypad. The analyzer’s analog output signals
(0-10 VDC, 4-20 mA or 0-20 mA) are scaled according to the selected range and can be rescaled
to specific concentrations. The operating range of the analyzer can be selected through the
keypad, by a contact closure, via the RS232 or TCP/IP interface, or automatically when the
analyzer is placed in the Auto Range.
The 700M HFID is available with an optional internal heated sample pump, and internal zero and
span solenoids. It includes a backlit 3 x 5 inch liquid-crystal display and a 20-key data/operation
input keypad.

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Operating Principle
The CAI 700M HFID methane/non-methane hydrocarbon analyzer uses the principle of Flame
Ionization Detection (FID) to determine the hydrocarbons within a gaseous sample.
For methane analysis, a solenoid valve diverts the sample through a cutter assembly that removes
all the hydrocarbons from the sample except methane. The removal efficiency is 98% for ethane
and heavier hydrocarbons, with less than a 10% loss of methane. The subtraction of the methane-
only concentration from the total hydrocarbon concentration provides the concentration of non-
methane hydrocarbons in the sample.
A heated oven (191°C) contains a burner and an optional heated pump. The small flame of the
burner is elevated and sustained by the regulated flows of air and either pure hydrogen or a 40/60
mixture of hydrogen and helium or nitrogen.
The split-ring detector contains two electrodes. One electrode is negatively polarized using a
precision power supply, and the other electrode (known as the collector) is connected to a high-
impedance, low-noise electronic amplifier. The two electrodes establish an electrostatic field.
When a gaseous sample is introduced to the burner, it is ionized in the flame, and the
electrostatic field causes the charged particles (ions) to migrate to their respective electrodes. The
ion migration creates a small current between the electrodes. This current is measured by the
precision electrometer amplifier and is directly proportional to the hydrocarbon concentration of
the sample.
Heated Oven
The heated sample gas is maintained above its dew point by a self-contained internal oven. The
oven temperature is adjusted at the factory to be controlled at 191°C. The sample gas is
maintained at this elevated temperature until it exits the analyzer’s bypass outlet, preventing any
loss of hydrocarbon concentration in the sample due to condensation.

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Flow System
Combustion air and fuel used by the instrument are controlled by an Electronic Proportional
Control (EPC) valve whose function is to maintain a constant pressure for combustion air at the
inlet to a capillary. The pressure is factory-set for optimum analyzer performance.
NOTE: The correct pressures are determined by the factory for optimal analyzer performance
and measured with NIST traceable standards. They are recorded on the analyzer’s Factory
Settings Screen.

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Analyzer Specifications
Specifications are subject to change without notice.
Detector: Flame Ionization Detection
Ranges: Four user definable ranges up to 0-30 to 30,000 ppm as methane or 0-10 to 10,000 ppm
as propane
Response Time: 90% Full Scale < 2.0 seconds
Resolution Detection Limit:10 ppb carbon
Accuracy:Better than 2% of reading at or above 3.0 ppm
Precision:Better than 1% of Full Scale
Linearity:Better than 1% of Full Scale
Noise:Less than 1% of Full Scale
Zero and Span Drift: Less than 1% of Full Scale per 24 hours
O2Effect:Less than 2%
CH4Effect:Less than 1.2 to propane
Flow Control: Electronic proportional pressure controller
Sample Flow Rate:Typically 2.0 to 2.5 LPM (consult CAI for other flow rates)
Fuel Requirements:40% H2/60% He (250cc/min). (Approx. flows)
Fuel Inlet Pressure:25 psig
Air Requirements:Less than 1 ppm carbon purified or synthetic air (approximate flow
450cc/min)
Air Inlet Pressure:25 psig
Fuel and Air Control:Electronic proportional pressure controller
Readout: As ppm CH4or C3H8
Outputs:Voltage or current, AK RS-232 and TCP/IP and Modbus TCP/IP
Diagnostics: Temperatures (Oven, Burner Temperature and Cutter), Pressures (Sample, Fuel and
Air), Flow Rates and EPC Control Voltages
Special Features: Calculated NMHC, Auto ranging
Ignition: Local, remote or automatic
Sample Temperature:Up to 191°C, non-condensing

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Oven Temperature:191°C
Ambient Temperature: 5 to 40°C
Ambient Humidity: Less than 90% RH (non-condensing)
Warm-up Time:1 hour (typical)
Fittings:¼-inch tube
Power Requirements: 115 VAC/60 Hz or 230 VAC/50 Hz ± 10%, 750 Watts max.
Dimensions:5¼” H x 19” W x 23” D
Weight: Approximately 50 lbs. depending on options.