California Analytical Instruments 300 HFID User manual

OPERATION AND MAINTENANCE
MANUAL FOR MODEL 300 HFID/MHFID ANALYZER
I nstruments, I nc.
C alifornia A nalytical
1312 West Grove Avenue, Orange, CA 92865 - 714 974-5560 - Fax [phone]
Website: www.gasanalyzers.com

Section 1 Model 300 HFID/MHFID Analyzer
Operations and Maintenance Manual 300HFID V7.0.doc 1-2
MODEL 300 HFID/MHFID
HEATED HYDROCARBON ANALYZER
INSTRUCTION MANUAL
This manual describes the installation, calibration and operation of California Analytical
Instruments, Inc. Model 300 HFID and Model 300M HFID Heated Total Hydrocarbon Gas
Analyzer.
To assure correct operation and accurate results, it is recommended that the user carefully
read this document.
June, 2003
Version B.031
P/N 970040
MODEL 300 HFID INSTRUCTION MANUAL
$25.00 EACH

Section 1 Model 300 HFID/MHFID Analyzer
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Table of Contents
1. INTRODUCTION................................................................................................................... 1-6
1.1. Overview......................................................................................................................... 1-6
1.2. Unpacking Instructions................................................................................................... 1-6
1.3. Reporting Damage ......................................................................................................... 1-6
1.4. Contact Information........................................................................................................ 1-6
1.5. Warranty Certificate........................................................................................................ 1-7
1.6. Possible Explosion Hazard............................................................................................. 1-8
1.7. Electrical Shock Hazard ................................................................................................. 1-8
1.8. Fuel Requirements......................................................................................................... 1-8
1.9. Potential Sample Pump Damage ................................................................................... 1-8
1.10. FACTORY QA CHECKOUT SHEET .......................................................................... 1-9
2. FEATURES AND PRINCIPLES OF OPERATION .............................................................. 2-10
2.1. Description.................................................................................................................... 2-10
2.2. Product Specifications Model 300 HFID/MHFID .......................................................... 2-11
2.3. FID OPTIONS............................................................................................................... 2-11
3. INSTALLATION................................................................................................................... 3-12
3.1. General.........................................................................................................................3-12
3.2. Site and Mounting......................................................................................................... 3-12
3.3. Electrical....................................................................................................................... 3-12
3.4. Remote Range Operation............................................................................................. 3-13
3.5. Sampling System.......................................................................................................... 3-14
3.6. Required Gases and Gas Handling Equipment............................................................ 3-14
3.7. Gas Connections.......................................................................................................... 3-14
3.8. Sampling Requirements............................................................................................... 3-15
3.9. Pressure and Flow Rate............................................................................................... 3-15
3.10. Sample Gas By-Pass Outlet (Vent) .......................................................................... 3-15
4. DESCRIPTION AND FUNCTION COMPONENTS............................................................. 4-16
4.1. Model 300 HFID/MHFID Analyzer Front Panel ............................................................ 4-16
4.2. Model 300 HFID/MHFID Analyzer Rear Panel............................................................. 4-17
5. Major Internal Components ................................................................................................. 5-19
5.1. Model 300 HFID/MHFID Interior Layout....................................................................... 5-19
5.2. MAIN CIRCUIT BOARD............................................................................................... 5-21
5.3. MAIN AMPLIFIER BOARD........................................................................................... 5-22
5.4. Burner Assembly.......................................................................................................... 5-23
5.5. Automatic Ignite Board................................................................................................. 5-24
5.6. Diagnostic Board.......................................................................................................... 5-25
5.7. EPC and Dual Temperature Control Board.................................................................. 5-26
5.8. EPC Hydrogen and Ch4 Cutter Control Board Components........................................ 5-27
5.9. Valve Driver Board ....................................................................................................... 5-28
6. Operation............................................................................................................................. 6-29
6.1. Start-Up Procedure....................................................................................................... 6-31
6.2. Shutdown Procedure.................................................................................................... 6-31
7. FUNCTIONAL DESCRIPTION............................................................................................ 7-32
7.1. Operating Principle....................................................................................................... 7-32
7.2. Burner Assembly.......................................................................................................... 7-32
7.3. Methane Cutter (Non-Methane Hydrocarbons)............................................................ 7-32
7.4. Flow System................................................................................................................. 7-33
8. ELECTRONICS................................................................................................................... 8-34

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8.1. Main Circuit Board........................................................................................................ 8-34
8.2. Main Amplifier Board.................................................................................................... 8-34
8.3. Automatic Ignite Board................................................................................................. 8-34
8.4. Diagnostic Board.......................................................................................................... 8-34
8.5. EPC/Dual Temperature Control Board......................................................................... 8-34
8.6. EPC Hydrogen/Cutter Temperature Control Board...................................................... 8-35
8.7. Valve Driver Control Board........................................................................................... 8-35
9. GENERAL INFORMATION-TROUBLESHOOTING-DISASSEMBLY PROCEDURES....... 9-36
9.1. Oven Burner Assembly Filter Unit/Filter Removal........................................................ 9-36
9.2. Electronic Boards/Removal.......................................................................................... 9-36
9.3. Electronics.................................................................................................................... 9-36
9.4. Flow System/Fuel and Burner Air Supply..................................................................... 9-37
9.5. Sample Supply ............................................................................................................. 9-37
10. TROUBLESHOOTING GUIDE....................................................................................... 10-38
11. FLOW DIAGRAMS AND SCHEMATICS ....................................................................... 11-39

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Table of Figures
Figure 3-1 AC Power Switch, Connector, and Fuse................................................................... 3-12
Figure 3-2 EMI Suppressor......................................................................................................... 3-13
Figure 4-1 Model 300 HFID/MHFID Analyzer Front Panel with CH4Cutter................................ 4-16
Figure 4-2 Model 300 HFID/MHFID Analyzer Rear Panel.......................................................... 4-17
Figure 5-1 Model 300 HFID/MHFID Interior Layout.................................................................... 5-19
Figure 5-2 Model 300 HFID/MHFID Main Circuit Board ............................................................. 5-21
Figure 5-3 Model 300 HFID/MHFID Amplifier Board .................................................................. 5-22
Figure 5-4 Model 300 HFID/MHFID Burner Assembly................................................................ 5-23
Figure 5-5 Model 300 HFID/MHFID Automatic Ignite Board....................................................... 5-24
Figure 5-6 Model 300 HFID/MHFID Output Diagnostic Circuit Board......................................... 5-25
Figure 5-7 Model 300 HFID/MHFID EPC and Dual Temperature Control Board ....................... 5-26
Figure 5-8 Model 300 HFID/MHFID EPC Hydrogen and CH4 Cutter Control Circuit Board....... 5-27
Figure 5-9 Model 300 Valve Driver Board................................................................................... 5-28
Tables
Table 4-1 Connector for External Wiring..................................................................................... 4-18
Table 4-2 Twenty Eight Conductor Cable Color Chart................................................................ 4-18

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1. INTRODUCTION
1.1. Overview
Thank you and congratulations! 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 retaining screws and lift off the
cover panel. Visually check for proper seating of parts and or connectors. If all internal
components appear to be normal replace the cover and secure it with the screws previously
removed.
1.3. Reporting Damage
Should there be any apparent damage either to the inside or outside of the instrument due to
shipping or handling, notify the shipper immediately. Retain the shipping container or packing
materials for inspection by the shipper.
1.4. Contact Information
California Analytical Instruments, Inc.
1312 West Grove Avenue
Orange, CA 92865
714 974-5560
Fax [phone]
Website: www.gasanalyzers.com

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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 that by their nature are not intended to or will not
function for one year are warranted only to give reasonable service for a reasonable time. What
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 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 produced in writing and approved by an expressly authorized officer of CAl.

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Danger
1.6. Possible Explosion Hazard
Do not apply power to the analyzer or attempt to ignite the burner until performing ALL leak
checks and until determining the analyzer environment to be non-hazardous.
Use this analyzer in a NON-HAZARDOUS environment.
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, both
inside and outside the analyzer for leaks upon installation, before initial start-up, during any
maintenance: or after the integrity of the system is broken.
This analyzer has not been designed for use with a hazardous sample.
Tampering or use of substitute components may cause a safety hazard. Use only factory
authorized replacement parts.
1.7. Electrical Shock Hazard
Do not operate without the cover secured. Servicing requires access to live electrical
components that can cause death or serious injury. Refer servicing to qualified service
personnel. For safety and proper performance, connect this instrument to a properly grounded
three-wire receptacle.
Caution
1.8. Fuel Requirements
The CAI factory configures the Model 300 HFID/MHFID for either 100% Hydrogen or 40%/60%
Hydrogen/Helium Fuel. Please make sure to use the CORRECT fuel.
Use of INCORRECT fuel will DAMAGE the instrument and could cause an EXPLOSION.
1.9. Potential Sample Pump Damage
For applications that require injection of calibration gas via the sample port of the analyzer, it is
MANDATORY that pressures do not exceed 2.0 PSIG pressure. Damage sustained by the
Plug Removal
Do not operate this analyzer UNTIL REMOVING the red plastic ¼ inch plugs from the
sample/zero/span/fuel fittings on the rear panel.

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1.10. FACTORY QA CHECKOUT SHEET
FID SERIAL NUMBER:
FACTORY AIR PRESSURE SETTING:
FACTORY FUEL PRESSURE SETTING:
FACTORY SAMPLE PRESSURE SETTING:

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2. FEATURES AND PRINCIPLES OF OPERATION
2.1. Description
The CAI Model 300 HFID Heated Total Hydrocarbon Analyzer utilizes a highly sensitive flame
ionization detector (FID) gas analyzer for measuring gas concentrations in industrial and
vehicle emission applications.
The CAI Model 300 MHFID Heated Total Hydrocarbon Analyzer is exactly the same
instrument as the Model 300 HFID, except that it contains a catalyst that may be switched in
and out of the sample stream, with the front panel switch or via a contact closure, to analyze
the methane content of the sample. This catalyst (Methane Cutter) removes all hydrocarbons
from the sample stream except methane.
The heated sample gas is maintained above the dew point by a self contained internal
adjustable temperature oven. The oven temperature may be adjusted between 60 and 200
degrees C. The sample gas is maintained at an elevated temperature until it exits the FID
burner assembly. This prevents any loss of hydrocarbon concentration in the sample due to
condensation.
The instrument contains a front panel, nine position, range switch which allows the selection of
eight full scale ranges or remote from 3 to 10,000 or 10 to 30,000 ppm Carbon. The
instrument has a 0 to 10 VDC and 4-20 MADC analog (recorder) output signal for each
selected range. The ranges may be remote selected externally.