Home

Product Manual - California Analytical Instruments, Inc.

1. Wa Ee SOU L e2dtvs dl ee s dL NOH 009 SINSWNYLSNI TWWOLLATWNW WINNOSITVO vel e DE E Pe oz LN vz we BID J z p i 6 Bh aT oF L pO AST O ad aueuient EZE o mm at Wj eons SCH conse z Ana Fenn each INOA O Genen ovr SCH 6 e H JLYVHO di Bee Hera 9 Ino 0 siniogisan 2 onz oaa ws eH DW KE Lo E zeg TI E 20tel _ H ASS dl i IST dS dL d o CTY Nee Like BEG os p Pg EC elas Riko oo E CG ei E g zuer Mode 2108 Lg BE oe Ber See Owaz S Oe Lee Pes 3ONVe_S a EE 5 pa A See E ue Ce lt a Nene A See cs wav 29 Bry Arg BN e F CHGH Sot JJJWYS 5 Les RECH Tea zeg Ouaz ft TS aT cows Se Bie ee d ou gt aA E BATWAHSLU3ANOD LIMO KS CR EEN Su NEG gege o HE NY Ss GG Jee ANAT EM DEE H gt FE swoon Ee CS see TETTE gt d n 2 N B A nonoo ee CM Maesch Ee CS AOINE a O T Toas sonvuoLnv7o Ni SM ono EH Soe mo S ke sodas i a 3B m VE oe Ee Ee CSR Bee L SES gt ee E AA a CS EE KZ Dei F z ji F I y I ZS Appendix Electrical Block Diagram Section 12 13 Page 89 of 89 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual ADDENDUM TABLE OF CONTENTS ADDENDUM STARTING AFTER JUNE 2007 Section Title Page 1 0 Introduction eneen 2 0 Operation of Measurement Keys emmmer 2 1 Over Range
2. 2 7 le 3 0 New Functions EEN 3 1 Auto Start Up 3 2 Alarms On Off 3 3 Offset amp Gain 3 4 Calibrate The Analog Outputs 3 5 Save Data Archiving Time TABLE Aessen 3 6 User Digital Outputs TABLE Bessen TABLE C anne 4 0 Changes To Existing Functions 4 1 Saved or Outside Limits 4 2 Calibration Deviations 4 3 Flow Zero or Span Gas 4 4 Reset Calibration Values TABLE D HEEN California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 1 of 24 ADDENDU
3. 2 2 Diagnostics 2 3 Zero 2 4 Span 2 5 Range LimitS 2 6 Span Values 2 7 le 3 0 New Functions EEN 3 1 Auto Start Up 3 2 Alarms On Off 3 3 Offset amp Gain 3 4 Calibrate The Analog Outputs 3 5 Save Data Archiving Time TABLE Aessen 3 6 User Digital Outputs TABLE Bessen TABLE C 4 0 Changes To Existing Functions 4 1 Saved or Outside Limits 4 2 Calibration Dev
4. Figure 5 1 Main Menu on Power 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 key or directly with the function keys F1 through F7 A gt 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 NOTE Access Level Indication Figure 5 2 Main User Menu Level 4 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 32 of 89 Section 6 Model 601 601 P 602 602P 603 NDIR Analyzer 6 Menu Structure There are four operating levels based on the level of your password This section shows the access rights of the single levels 6 1 User Functions Level 1 Main Menu Setup Menu Password Menu F1 Measurements F5 Password F1 Enter password F2 Purge Analyzer F10 Version F3 Diagnostics F4 Calibrations F5 Setup F7 Standby 6 2 Advanced User Functions Level 2 Main Menu Setup Menu Password Menu F1 Measurements F3 Range Limits F1 Enter password F2 Purge Analyzer F5 Password F3 Diagnostics F10 Version F4 Calibrations F5 Setup F7 Standby 6 3 Maintenance Functions Level 3 Main Menu Setup Menu Password Menu System Settings Menu F1 Measurements Ei Span Gas F
5. A Use of this equipment in a manner not approved by California Analytical Instruments is not recommended and may cause harm to the equipment or operating personnel California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 17 of 89 Section 2 Model 601 601 P 602 602P 603 NDIR Analyzer 2 Features 2 1 Description The Model 600 series of NDIR analyzers incorporate a single beam photometric system and a detector with a microflow sensor assuring high reliability sensitivity accuracy and stability The microflow detector is a sealed unit filled with the same gas as the component of interest CO COz and CH4 The length of the sample cell determines the most sensitive range for each component 2 2 Features General The Model 600 series of NDIR analyzers have 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 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 2 3 Features General High s
6. California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 30 of 89 Section 5 Model 601 601 P 602 602P 603 NDIR Analyzer 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 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 31 of 89 Section 5 Model 601 601 P 602 602P 603 NDIR Analyzer 5 1 The Main Menu Upon power up the CAI logo is first displayed and then the main menu appears as below NOTE Access Level Indication
7. Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 6 14 EUDP Set UDP Data streaming parameters Command Response Description _EUDP_KO_ lt UDPPort gt _ lt DataFrequeny gt _ lt Mo _EUDP_s Configure an UDP channel for de gt lt UDP_IP gt 12 6 15 Format of the streaming Data via UDP ASCII Mode The measuring values will be sent with ASCII signs The format is lt Sequence number gt _x x_y y_z z data streaming of the measuring values via Ethernet UDP Port port for open the UDP connection DataFrequency Frequency for transmit the data in Hz Mode A ASCII Mode optional UDP_IP Alternative IP address for open the UDP connection when it should not use the IP of connected TCP IP client optional The sequence number will be incremented with every data packet which is sent The measuring values x x y y and z z will be sent like in AKON KO telegram 12 7 Abbreviations used Km K channel Number gt K1 K3 Mn Measuring range number M1 M4 Measuring Range 1 4 W W ZZ Numerical value W W Z Z Numerical value T Numeric integer value D Number a0 a4 Polynomial coefficients S Status California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 88 of 89 T BT EIN EEE Al J Lem R nqurnswewnsog ez Model 601 601 P 602 602P 603 NDIR Analyzer
8. California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 58 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 59 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer 8 5 Main Electronics Board Potentiometers jig TIR lt lt e ef naa AAA e DN 4 8 s Ce 283 EN i 5 Figure 8 2 Main Electronic Board Potentiometers 1 RP2 Detector voltage adjust 2 RP3 Fine zero adjust 3 RP4 Not used Fully CW 4 RP5 Coarse zero adjust 5 RP6 Span adjust NOTE Potentiometers are clearly labeled on both sides of the Wave PCB California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 60 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer 8 6 NDIR Detector Assembly Figure 8 3 NDIR detector assembly _ Detector Assembly 2 Sample cell assembly 3 Light source and chopper motor assembly 4 Sample inlet 5 Sample outlet 6 Temperature sensing element to J2 of Wave PCB California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 61 of 89 Section 9 Model 601 601 P 602 602P 603 NDIR Analyzer 9 Operation 9 1 External Wiring Make sure that the external wires have been connected as described in Section 3 Installation 9 2 Extern
9. SERIES Note For Analyzers Sold After June 2007 Please See Addendum Starting After Page 89 of This Manual CAH BI 1312 West Eae Avenue Orange CA 92865 4134 Phone 714 974 5560 Fax 714 921 2531 www gasanalyzers com Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 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 Ah symbol an exclamation point in a triangle precedes a general CAUTION or WARNING statement The AN symbol wavy vertical lines with an under score in a triangle precedes an elevated temperature hazard CAUTION or WARNING statement The AN 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
10. 7 4 3 Display Deviations from Calibration menu EZ 39 7 4 4 Absolute Zero Gas Deviaton ANEN 39 7 4 5 Relative Zero Gas Deviation en 39 7 4 6 Absolute Span Gas Deviaton 40 7 4 7 Relative Span Gas Deviation isc es tadteguugsh Eegeregie eebe 40 7 4 8 F4 Check Galbats Geet EEENSeeeCERE NEEN NEEN SEAN Ehe 40 7 4 9 F5 Reset Calibration Values sicxveoceaccy sans covvieerancicaageasvedsn cert cats ccsvessndertaenaante 40 7 4 10 ue E E 40 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 7 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer Toa Py OUP EE 41 7 5 1 F1 Span Gas Concentration sicss sccicccedscectvcahtees ted teaseseeteetsledeetees nue e Cen 41 7 5 2 Calibration Settings siecia a eE 42 7 5 3 Fi TIMES knna E E R GA Eed 42 7 5 4 F2 Measuring Deviations AAA 42 7 5 5 SREL 42 7 5 6 ko Range E 42 7 5 7 F1 Range 1 4 Change Upper Range Limits c cceceeeeeeeeeetteeeeeeeees 43 7 5 8 F2 Change Auto Range Limits enn 43 7 5 9 SE EE 44 7 5 10 Fo EIL EE 44 7 5 11 Fi Enter PASS WONG E 45 7 5 12 F2 Change te WEE 45 7 5 13 F3 Reset PaSSwOrds geep a i E EEEE EE NEE EEEE 45 7 5 14 PO LING all te EEN 46 76 F7 System Setting E 47 7 6 1 Fi Realtime Glockers nnna tied Aaeeea EN aeaa ARERR 47 7 6 2 System Setup F2 Displays TCP IP Address 49 7 6 3 Systems Setup F3 Displays Output Signal Aesigmments 49 7 6 4 System Setup F4 Displays Output Ha
11. 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 either to 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 714 974 5560 Fax 714 921 2531 Website www gasanalyzers com California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 15 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 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
12. Figure 4 2 Keyboard csscscs tc atein else a a alata ee 30 Figure 5 1 Main Menu on Power Up Screen EEN 32 Figure 5 2 Main User Menu Level Ai etugeester ENEE nade iarsseonte eevesdelieessiebundesbentiaedebadeedetinensiad 32 Figure 7 1 Main Menu Ee Eh A caren scents dee dee 34 Figure 7 2 Measurements SGreGn iivsasescccsenvcantens EREECHEN DEENEN EEN reams 34 Figure 7 3 Set to Auto Range 601 vicscccccseneciver vin eieheiasenyad shies eheanerehhndeinheta ead aaeeedehae eee 35 Figure 7 4 Analyzer set to Range 1 GO 35 Figure 7 5 Main Menu User Level ic c ccccdsetesiceadadieed ae Ae Aeon 36 Figure 7 6 Purge Scree seriei ENER EES ee ENAERE ETERRA REEERE EEEE 36 Figure 7 7 Diagnostics Screen NEE 36 Figure 7 8 ee En A O AE E A E eto A 37 Figure 7 9 Auto Calibration Gcreen ke 37 Figure 7 10 Manual eelere eege 38 Figure 7 11 Manual zero Calibrations x sicecsek cesaecahheediedeceahssae acest eketens sxe SEENREEE GAEREN 38 Figure 7 12 Manual span Calibration un 38 Figure 7 13 Display deviations ux Asie che tact cactine ebe adic bs th Reape eved eit seth Cyee dae 39 Figure 7 14 Zero gas EIDEN ANEREN eee ee 39 Figure 7 15 Span Gas deviations cases ee oes le Galt tere ge Raat EE oad 39 Figure 7 16 Setup menu screen l eegent eee eee ieee nade ege Eeer 41 Figure 7 17 setup menu screen 41 Figure 7 18 Change Span Gas Settings EEN 41 Figure 7 19 Change Auto Calibration Settings kee 42 Figure 7 20 Change Range Limits NENNEN 42 Figure 7 21 Change Up
13. Note The cell window No 10 in figure 10 2 is loose and is only retained by the clamping action between the detector and the block sample cell Take care not to drop the window when separating the block cell from the detector 8 9 Clean the cell interior and CaF windows using a soft cloth or tissue see Note on previous page Inspect the O Ring for flatness or deterioration and replace if necessary The block cell can be re assembled by following the reverse of the disassembly procedures Note the orientation of the loose window and 0 ring during disassembly California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 67 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer Figure 10 3 Optical Bench with Pipe and Block Type Sample Cells Item Description Item Description 1 3 Screw M4 14 Window 4 Base 15 Detector 5 Infrared source unit 16 Bridge circuit board 6 Screw M4 17 Optical filter if installed 7 Screw 18 Screw Flat Head 8 Connector 19 Screw Round or Flat Head 9 Sealed tubes 20 Block Sample Cell 10 Support 21 0 Ring 11 Clamp 22 Window 12 Pipe sample cell 23 Wave PCB 13 O Ring California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 68 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer 10 6 10 Disassembly of Combination Pipe
14. Q 0 00 Ranged 0 00 o NOT Exceed Max Range Maximum Range Limits i 000 Fi Saveitneuw sutorange Up Down a change channe sera SETT CAI Tel 800 959 0959 Hed May 14 16 48 50 2008 F 2 Versions The Channels and Ranges are factory defined and application specific Consult California Analytical if any changes are required Use the keys to observe the other Channels 2 6 Span Values F9 From the MEASUREMENT screen Span gas conc range limits Range e change channe Thu Jun 28 09 23 18 2007 Use the keys to select the desired Channel and the to select the Range Note The span gas value used for this channel and range is highlighted and can be changed if necessary Use the Enter key and the NUMERIC keys as required California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 5 of 24 ADDENDUM 2 7 Outputs F10 From the MEASUREMENT screen assignment IS Output Thu Jun 28 09 25 18 2007 Use this screen to define the signals and their location that will be monitored by a remote reordering device Use the to select the desired Output Press Enter to select Use the to select the desired Signal Press Enter to select Use this screen to define the signals and their location that will be monitored by a remote reordering device SEE TABLE D California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 6 of 24 ADDENDUM 3 0
15. amp Block Type Cells Figure 10 3 Discontinue the sample gas flow When it contains harmful gas purge the measuring cell sufficiently with zero gas Turn OFF the power switch After loosening the retaining screws on the sides of the top cover lift off top cover and locate the block cell Disconnect the inlet and outlet tube from both measuring cells Disconnect the wires from the two terminal screws of the infrared source unit and unplug the 2 pin connector No 8 in figure 10 3 from the chopper motor Disconnect the block cell s detector output cable connector from the main circuit board Remove the two screws No 1 in figure 10 3 that secure the infrared source unit to the base Remove the sub assembly consisting of the source unit block cell and detector Remove the two screws No 19 in figure 10 3 that secure the detector to the infrared source then separate the detector and block cell from the infrared source unit While holding the detector in the palm of your hand remove the two flat head screws No 18 in figure 10 3 which fix the cell to the detector Note the cell window No 10 in figure 10 3 is loose and is only retained by the clamping action between the detector and the block ample cell Take care not to drop the window when separating the block cell from the detector 11 12 Clean the cell interior and CaF windows using a soft cloth or tissue see Note on previous page Inspect the O Rin
16. 10 Model 601 601 P 602 602P 603 NDIR Analyzer Figure 10 1 Optical Bench with Pipe Sample Cell Item Description Item Description 1 3 Screw M4 12 Pipe sample cell 4 Base 13 O Ring 5 Infrared source unit 14 Window 6 7 Screw M4 15 Detector 8 Connector 16 Bridge circuit board 9 Sealed tubes 17 Optical filter if installed 10 Support 18 Wave PCB 11 Clamp Note Pipe cell foil liner not shown California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 64 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer 10 4 Removal of Pipe Cell Figure 10 1 Discontinue the sample gas flow When it contains harmful gas purge the measuring cell sufficiently with zero gas Turn the power switch to OFF After loosening the retaining screws on the sides of the top cover lift off top cover and locate the pipe cell Disconnect the sample gas inlet and outlet tubes from the measuring cell After loosening do not remove the two screws No 1 in Figure 10 1 which are used for securing the infrared light source unit No 5 in Figure 10 1 to the base plate shift the infrared light source away from the pipe cell No 12 in Figure 10 1 to form a gap After removing the pipe cell retainer screws No 7 in Figure 10 1 remove the retaining clamps No 11 in Figure 10 1 Carefully remove the cell from the optical bench and remove both
17. 2 D Output 11 User Defined NO Relay 3 D Output 12 User Defined NO Relay 4 D Output 13 User Defined NO Relay 5 D Output 14 User Defined NO Relay 6 NI IO O1 amp Oo Po ICH D Output 15 User Defined NO Relay 7 D Output 16 User Defined NO Relay 8 D Output 17 User Defined NO Relay 9 D Output 18 User Defined NO Relay 10 D Output 19 User Defined NO Relay 11 D Output 20 User Defined NO Relay 12 D Output 21 User Defined NO Relay 13 D Output 22 Reserved Do Not Connect D Input 23 Spare D Input 24 Spare D Input 25 Spare D Input 26 Set Remote D Output 27 User Defined NO Relay 14 D Output 28 User Defined NO Relay 15 California Analytical Instruments Model 600 NDIR Operators Manual May 27 2008 Page 24 of 24 ADDENDUM TABLE OF CONTENTS ADDENDUM STARTING WITH SERIAL U06081 Section Title Page 1 0 Introduction eneen 2 0 Operation of Measurement Keys emmmer 2 1 Over Range 2 2 Diagnostics 6 a 2 4 Span 2 5 Range LimitS 2 6 Span Values
18. 24vdc if internal SV OC 24vdc if internal SV D Output D Output D Output D Output Local Remote Read Cal Mode Reserved Reserved Local Remote Read Cal Mode Reserved Reserved Local Remote Read Cal Mode Reserved Reserved TTL low true TTL low true California Analytical Instruments Model 600 NDIR Operators Manual May 27 2008 Page 23 of 24 SECTION 13 ADDENDUM TABLE D 600 NDIR SERIES UO CHART 28 PIN AUXILLARY CONNECTOR ASSIGNMENTS opto Signal 601 602 603 Type Analog LEVELS Spare pin A Input 1 GND analog A Input 2 External Analog 1 0 10V A Input 3 External Analog 2 0 10V A Output 4 GND Isolated analog D Output 5 Relay RTN 1 9 10 11 12 use RTN 1 Alarms go OPEN when present Alarms Digital Status go CLOSED when active COM D Output 6 Relay RTN 2 13 14 15 16 use RTN 2 D Output 7 Relay RTN 3 17 17 19 20 use RTN 3 D Output 8 Relay RTN A 21 2728 use RTN 4 D Output 9 User Defined NO Relay 1 D Output 10 User Defined NO Relay 2 D Output 11 User Defined NO Relay 3 D Output 12 User Defined NO Relay 4 D Output 13 User Defined NO Relay 5 D Output 14 User Defined NO Relay 6 NI IO O1 amp Oo Po ICH D Output 15 User Defined NO Relay 7 D Output 16 User Defined NO Relay 8 D Output 17 User Defined NO Relay 9 D Output 18 User Defined NO Relay 10 D Ou
19. 4 3R4 61 3 In Calibrate 3C 62 3 In Zero 3z 63 3 In Span 3S 64 3 In Sample 3Sa Typical Relay Digital Out 600 SERIES Common These contacts 3 4 will drive continuously up to 500 MA using a customer voltage supply that does not to exceed 60 VDC California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 18 of 24 ADDENDUM e Operation Use Main F5 F9 to select the first eight outputs Use the to select the desired output Press ENTER and use to select desired item Press ENTER to save selection NOTE The 600 NDIR has 14 user selectable isolated digital outputs from the list of 64 in TABLE B amp C User DO I E2 S5TEY HI i EE E EE E E EE E E Set Unused Channels Of f SEEKS EERKR SEEKS Clear Hold z A A 5 2 1 A Press F1 to observe the remaining seven outputs Program as desired per the above User DO II E2 Gen IS pa Gel q i off ii off EE E E E EE E E EE E iz off S5et Unused LS Dff Channels Of f i4 off ee E r5 Off Fi i to 7 DO s MAIH BACK to SAVE Check Chi Temp EI California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 19 of 24 ADDENDUM 4 0 CHANGES TO EXISTING FUNCTIONS 4 1 Saved or Outside Limits During Manual Calibration the following screens will be displayed to indicate the instruments response to the value of the zero or span gas using the amount that the operator def
20. 4 7 ASTF Error status Command Response Description _ASTF_KO ASTF_s f1 f2 f3_ _f10 Current error numbers of all are responded Errors 1 Channel 1 Flow Failure 8 Channel 1 not calibrated 2 Channel 2 Flow Failure 9 Channel 2 not calibrated 3 Channel 3 Flow Failure 10 Channel 3 not calibrated 4 External Analog 1 Failure 11 13 Ch1 3 Low concentration warning 5 External Analog 2 Failure 14 16 Ch1 3 High concentration warning 6 Pressure Failure 17 19 Ch1 3 Temperature failure 7 Temperature Failure 20 22 Ch1 3 EPC Voltage failure 12 4 8 AKEN Device identification Command Response Description _AKEN_KO _AKEN_s_devicename Device identification is responded _AKEN_K1 _AKEN_s_ model Device model _AKEN_K2 _AKEN_s serialno Device serial number _AKEN_K3 _AKEN_s_samplepressure Suggested input sample pressure 12 4 9 ARMU Raw value Command Response Description _ARMU_KO ARMU_s_z z_y y_x x_t Raw value before linearization and offset span correction is responded for all channels t Timestamp 1 10 sec Raw value before linearization and offset span correction is responded for channel m t Timestamp 1 10 sec California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 80 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 4 10 ATEM Temperatures Command Response Description _ATEM_KO _ATEM_s zz Device temperature
21. 8 Model 600 NDIR Features EENEG TCP IP RS232 Four Scalable Analog 0 10 V 4 20 mA OUTPUTS AVAILABLE Allows Offset and Expandable Range DC Analog Outputs DISCRETE CONTROL Remote Local Control Range Change Range Sense Mode Al TTL Logic General Fault TTL Logic 0 5 VDC Ground True Calibration Failure TTL Logic 0 5 VDC Ground True High Concentration 2 each TTL 0 5 VDC Logic Ground True Factory Settings Scalable Analog Output Voltages KEYPAD DISPLAYS TCP IP Address Full Scale Range Select Passwords 4 Auto Cal Times Auto Ranging SPECIAL FEATURES Auto Calibration adjustable through internal clock 3 x 5 Back lit LCD Less than 90 RH Non condensing 115 V 60Hz Option 230V 50Hz 10 600W DIMENSIONS 5 4Hx19W x23D Inches gt S y O SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 22 of 89 Section 3 Model 601 601 P 602 602P 603 NDIR Analyzer 3 Installation 3 1 General The design of this instrument is for industrial applications These installation instructions are for a typical site Direct any questions regarding specific installation situations to Technical Service of California Analytical Instruments Inc 3 2 Site and Mounting NOTE The carefully observe the following precautions Select a site free from direct sunlight radiation from a high temperature surface or abrupt temper
22. ASCII character Generally a blank or an underscore _ is used for readability reasons The four function bytes represent the AK command A blank comes next followed by K and the channel number The analyzer is a single channel device and because of that the channel number is usually 0 For delimiting the command parameters from the channel number another blank follows This may be followed by command parameters with a variable length Every command ends with the ETX End of Text character The error status byte in the acknowledgment command signals if internal errors in the analyzer occurred It is zero when no error appeared and it is unequal zero when One or more errors occurred Every time a change in the errors happens the error status byte is incremented by one no matter if one or several errors disappear or are added If it had the value 10 it would be reset to 1 The error status byte does not indicate the real number of errors If the analyzer does not have errors the error status byte contains the value 0 In general AK commands are subdivided into three classes e Control commands Sxxx e Inquiry commands Axxx e Configuration commands Exxx 12 3 4 Error Handing It might happen that an unknown instruction is sent that the analyzer is busy with a function which is not the desired one or that an error occurred in the command parameters Table 1 4 summarizes all errors that can appear upon any master instruction Analyzer
23. Cal ON of OFF California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 48 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 6 2 System Setup F2 Displays TCP IP Address Figure 7 37 TCP IP Address 7 6 3 Systems Setup F3 Displays Output Signal Assignments Used to Adjust Analog Output Channels zg 05 11 PHS Figure 7 38 Output Assignments 7 6 4 System Setup F4 Displays Output Ranges Used to Adjust Scale of Analog Output Channels Figure 7 39 Output Ranges California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 49 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 6 5 F5 Turns Status Line On or Off The status line displays the AK Protocol action on the top line of the display Figure 7 40 Status line Figure 7 41Status line on off 7 6 6 F8 Measure Settings This screen allows several of the system settings to be displayed and modified Figure 7 42 Measure setup 7 6 7 F1 Set Lowpass filter Figure 7 43 Lowpass filter California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 50 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 6 8 F2 Purge Time F2 on the Menu Settings screen the sets the purge time before continuing with a zero or span calibration Figure 7 44 Purge Time 7 6 9 F3 Set Temperature Compensation Figure 7 45 T
24. Change Auto Calibration Settings In the calibration settings menu times and deviations can be changed 7 5 3 F1 Times There are four times in seconds for auto calibration that can be changed Purge measuring calibration and verifying time Changes are made and saved as above 7 5 4 F2 Measuring Deviations During auto calibration the measured value is only saved if it is within a certain time within an upper and a lower limit These two limits format a working window In the setup menu the deviation is in percent 7 5 5 F3 Deviations Here you can change absolute and relative deviation in percent After auto calibration it is checked to assure the deviations are within this limit If the deviations are not in this limit a warning Deviation error appears 7 5 6 F3 Range Limits There are 4 different ranges The user can define the upper range limits in ppm Kit SARA IS Figure 7 20 Change Range Limits California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 42 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 5 7 F1 Range 1 4 Change Upper Range Limits In this menu the upper range limits can be changed The new settings are saved by pressing MAIN or BACK The auto range limits are automatically adapted This means that if the upper range limit of range 1 for example has reached 90 of the upper range limit in the auto range mode it is switched automatic
25. F6 Range Limits F8 Span Values F9 Outputs F10 Note The operator can use these Short Cut Keys or continue to use existing procedures e NEW FUNCTIONS Auto Startup F5 F7 F7 ALARMS F5 F7 Use F6 to toggle ON OFF Offsets amp Gains F4 F3 F5 D A Calibration F5 F7 F8 Save Data Archiving Time F5 F7 F1 F5 ENTER to change record time User Digital Outputs F5 F9 e Modifications Saved Not good F4 F2 F1 or F2 To flow Zero or Span Gas Re Set Calibration Values F4 F5 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 2 of 24 ADDENDUM 2 0 OPERATION OF MEASUREMENT KEYS Note USE the F1 amp F2 Keys to view the complete list of menu items from the MEASUREMENT screen 2 1 Over Range 888888 In the MEASUREMENT mode only any value that exceeds the range by more than10 will be displayed as 888888 2 2 Diagnostics Use F3 to toggle between MEASUREMENT and DIAGNOSTIC 2 3 Zero From the MEASUREMENT screen select the required channel and range then press F5 Note For instruments with Zero Solenoid s select Calibration by Valves Main F5 F2 F4 Manual Zero izl Manual Zero K3 SMGA EJ Zero gas Use F3 To Toggle Reenter EE Toggle IIIS GEE eile tee Current Temp amp Press Channel Channel Q Range 8 Range D an al enu an ail enu CAI Tel 800 959 0959 CAI Tel 800 959 0959 Ia 2 Versions Zero Gas will be enabled and the observed results can
26. NEW FUNCTIONS 3 1 Auto Start Up Main F5 F7 F7 Auto Startup 1 Manual Chi Ch2 Ch3 1 1 il 1 1 1 All key analyzer parameters are stored in a secure memory location and retained when power is removed In the event of an unexpected power failure it may be desirable to change some parameters until an operator can resume control This screen may be used to establish several desirable special instrument start up parameters that define how the analyzer recovers from loss of AC power When enabled this screen will define the following Wait The time delay in minutes before proceeding If zero is selected the instrument will not start until all temperature warnings are cleared Calibrations The number of attempts to complete a successful calibration as required in the operator defined Deviation Tables If calibration is not successful the instrument will continue reporting results using the last completed calibration The analyzer can be configured use the previous calibration by selecting zero Calibrations Starting Range When all defined actions are completed the analyzer will return to the Measurement Screen and to the range specified Access Level The user level at Start Up Remote Manual Put the analyzer in either Remote or Manual at Start Up California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 7 of 24 ADDENDUM 3 2 Alarms On Off Main F5 F7 All key analy
27. Response Description _AUDP_KO _AUDP_s lt UDPPort gt _ Port port for open the UDP lt DataFrequeny gt _ lt Mode gt connection _ lt UDP_IP gt DataFrequency Frequency for transmit the data in Hz Mode A ASCII Mode UDP_IP Alternative IP address for open the UDP connection when it should not use the IP of connected TCP IP client California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 83 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 5 Control commands 12 5 1 SRES Reset Command Response Description _SRES_KO _SRES s Reset 12 5 2 SPAU Pause Command Response Description _SPAU_KO _SPAU_s Pause mode 12 5 3 STBY Standby Command Response Description _STBY_KO _STBY_s Standby mode for all channels _STBY_Km _STBY_s Standby mode for channel m 12 5 4 SNGA Open valve for zero gas calibration Command Response Description _SNGA_KO _SNGA_s Open all three zero gas valves _SNGA_Km _SNGA_s Open valve for zero gas calibration of actual measuring range SNGA_Km_Mn SNGA_s Open valve for zero gas calibration of range Mn 12 5 5 SEGA Open valve for end gas calibration Command Response Description _SEGA_KO _SEGA_s Open all three end gas valves _SEGA_Km _SEGA_s Open valve for end gas calibration of actual measuring range SEGA_Km_Mn SEGA_s Open valve for end gas calibration of range Mn 12 5 6 SSPL Purge Analyzer with zero gas Command Response Description _
28. The following screen appears Access Levels KLE STBY Figure 7 26 Access Level Screen F1 to F4 selects an access level Move the cursor to the access level to be modified You must enter the correct password for the access level desired The passwords for the various operation levels consist of three numbers that must to be entered on the numeric keypad If the code word is incorrect you are asked to re enter the codeword IMPORTANT TIP When a new analyzer is powered up it defaults to access level 1 User To operate ALL parameters and gain complete access select F4 Press the Enter key twice and enter 444 7 5 12 F2 Change Password The passwords can only be changed if you are in access level 4 After F2 enter your new 3 digit passwords IMPORTANT TIP You MUST remember and record this new password If this is lost you will need to consult the factory for the default password 7 5 13 F3 Reset Passwords The passwords can only be changed if you are in access level 4 Reset passwords will revert to the factory defaults California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 45 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 5 14 F6 Linearization Pressing F6 on the Setup screen brings up the Linearization screen The analyzer can be linearized by a polynomial with 5 coefficients By pressing F1 these 5 coefficients can be changed for each range By pressing F2 t
29. and or calibrated daily or as often as required 10 2 Cleaning of the Optical Bench Measuring Cell Infrared Analyzers Only Dust or water droplets entering the measuring cell may cause drift due to contamination When it is impossible to adjust the zero level with the zero control mounted on the front panel check the measuring cell for contamination If contamination is present check the sampling system especially the filters to eliminate the source of contamination Periodic maintenance is generally not required Cleaning is accomplished by use of a cleaning agent such as isopropyl alcohol or household glass cleaner and a non abrasive lint free cloth or tissue 10 3 Optical Bench Configuration Infrared analyzers may be configured with three types of optical benches with a pipe cell with a block cell or with both a pipe cell and a block cell see Table 10 1 Table 10 1 Optical Bench Configuration Optical Bench Type Illustration Paragraph Pipe Cell Figure 10 1 10 3 1 describes the Cell length 64 mm 125mm This figure illustrates the pipe EEN Cleaning ane or 250 mm cell y Block Cell Figure 10 2 10 3 2 describes the Cell length 4 mm 8 mm 16 This figure illustrates the block ao GE mm or 32 mm cell y Combination Figure 10 3 10 3 3 describes the This illustrates the combination GE reassembly assembly California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 63 of 89 Section
30. compensation 7 6 10 F4 Pressure Compensation Figure 7 46 P Compensation 7 6 11 F3 Low Pass Filter Time Constant F3 on the Menu Settings screen allows the software time constant to be set between 1 and 60 seconds This is very useful in eliminating noise when measuring low level concentrations California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 51 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer Figure 7 47 Low pass filter time constant 7 6 12 F10 Displays the Current Analyzer and Software Versions This displays the analyzers information including the factory recommended air and sample pressure settings Figure 7 48 Analyzer Information Figure 7 49 Software Version 7 7 F7 Remote Manual Control The analyzer can be remote controlled either by a master computer or via contact closures The TCP IP and serial communication fully corresponds to the specifications of the AK protocol To change remote manual control press F6 in the main menu This toggles between remote and manual control Figure 7 50 F6 Remote Manual Main Menu User Level 4 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 52 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 8 F8 Standby Figure 7 51 F7 Standby Main Menu User Level 4 In Standby mode pump is turned off and the solenoids are closed The CAI logo is disp
31. in degrees Celsius is responded _ATEM Km _ATEM_s zz Detector temperature of channel m is returned in z z 12 4 11 ADRU Pressures Valve voltage Command Response Description _ADRU_KO _ADRU_s zz Pressure in is responded _ADRU_Km _ADRU_s zz EPC voltage of channel m is returned in Z Z 12 4 12 ADUF Flows Command Response Description _ADUF_KO ADUF_s_2 z_y y_x x Sample gas flow of all channels is responded _ADUF_Km _ADUF_s zz Sample gas flow of channel m is responded 12 4 13 AGRD Polynom coefficients Command Response Description AGRD_Km_Mn _AGRD s Mn_a0_al_a2_a3 a4 Polynomial coefficients of channel m range Mn are responded 12 4 14 AANG Deviation from zero point after autocalibration Command Response Description _AANG_Km AANG_s_M1_z z_da_dr Verifying deviations from zero point _M2_z z da dr after auto calibration _M3 z z da_dr Values measured value z 2 _M4 z z da dr absolute dev da relative dev dr 12 4 15 AAEG Deviation from end point after autocalibration Command Response Description _AAEG_Km AANG_s_M1_z z_da_dr Verifying deviation from end point after _M2 z z da_dr auto calibration _M3 z z da_dr Values measured value z z absolute _M4 z z da dr dev da relative dev dr 12 4 16 AFDA Purge and Autocalibration times Command Response Description _AFDA Km_SATK _AFDAszyxw Auto calibration times of channel m z Purge time y Calibration time x Total calibration time w V
32. not observable at TP3 gas is leaking in the detector and the detector should be replaced 3 When check in item 1 above indicates abnormal voltage turn the power switch to OFF and disassemble the NDIR amplifier board from the top of the detector to access the bridge circuit board mounted on the detector 4 Check the microflow sensor for its resistance Measure resistance values between terminals 1 3 and between terminals 2 3 respectively on the bridge circuit board When the resistance values are about 25 to 50 ohms the microflow sensor is normal but the bridge resistor is defective If the resistance is infinite the microflow sensor is faulty 5 Replacement Replace the detector with a new one refer to 10 1 If the instrument is using the pipe cell the detector is attached to the optical bench from below Remove the four screws No 3 of Figures 10 1and 10 3 that secure the base No 4 of Figures 10 1and 10 3 to access the detectors retaining screws No 2 of figures 10 1and 10 3 6 After the detector has been replaced adjust the detector voltage to the specified value refer to section 11 1 of this manual 7 Adjust zero and span California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 72 of 89 Section 11 Model 601 601 P 602 602P 603 NDIR Analyzer 11 5 Check and Repair Infrared Light Source Unit No 5 in Figure 10 1 11 5 1 Problem A faulty infrared light sou
33. 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 CAIs 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 CAI A complete list of such components and accessories is maintained at the factory 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 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 if the product claimed to be defective requ
34. outputs the Offset and Gain values are independent and do not interact With the 4 20 ma output the Offset zero and Gain span values interact and may require a few more trials The following is a table of typical values OUTPUT OFFSET GAIN 0 20 ma 0 000 0 927 4 20 ma 1 820 0 740 0 1 V 1 300 0 820 0 5 V 1 100 0 820 0 10 V 1 050 0 820 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 10 of 24 ADDENDUM e Procedure 3 4 1 From the Main Menu press F5 F7 F3 to obtain following screen assignment K2 SARE zl Output Signal mA S Z ITET A Channels 4 Flowl Main F5 F7 F3 3 4 2 Use the to highlight the outputs that require calibration 3 4 3 Press enter to provide access to all the menu of signals that are available Real Time Channel 1 Channel 2 Calibration Sample pressure etc 3 4 4 Select Calibration and press ENTER to complete the selection assignment IS Output Signal WaT 3 Channel3 4 Flowl CAI Tel 800 959 0959 Note Any or all of the four outputs can be selected for calibration This screen will not be used again until calibration has been completed California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 11 of 24 ADDENDUM 3 4 5 Press BACK to return to the SYSTEM SETUP screen F5 F7 from the main menu 3 4 6 Press F8 to obtain the following screen MAIN F5 F7
35. the process or F2 to return to the Manual Calibration screen California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 4 of 24 ADDENDUM 2 5 Range Limits F8 From the MEASUREMENT screen Setup K2 SMAH IS Z U er range limits xe mJ Ped a TiS ANEN SCEN DCT aa ae eee HUST be ASCENDING 5 5 Rangel Rangez a OE Ranges D Q 0 00 Ranged 0 00 o NOT Exceed Max Range Maximum Range Limits i 000 Fi Saveitneuw sutorange Up Down a change channe sera SETT CAI Tel 800 959 0959 Hed May 14 16 48 50 2008 F 2 Versions The Channels and Ranges are factory defined and application specific Consult California Analytical if any changes are required Use the keys to observe the other Channels 2 6 Span Values F9 From the MEASUREMENT screen Span gas conc range limits Range e change channe Thu Jun 28 09 23 18 2007 Use the keys to select the desired Channel and the to select the Range Note The span gas value used for this channel and range is highlighted and can be changed if necessary Use the Enter key and the NUMERIC keys as required California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 5 of 24 ADDENDUM 2 7 Outputs F10 From the MEASUREMENT screen assignment IS Output Thu Jun 28 09 25 18 2007 Use this screen to define the signals and their location that will be monitored by a remote reord
36. windows right hand threaded No 14 in Figure 5 1 At this time inspect the O Ring No 13 in Figure 10 1 for signs of deterioration Replace if necessary The CaF window is bonded to the window holder Inspect and clean the windows as necessary using cotton swabs and a suitable cleaning solution Alcohol or an alcohol based glass cleaner is a suitable cleaning solution A soft cloth or tissue that will not deposit lint should be used to clean the liner amp windows 10 11 The pipe cells contain a reflective metal foil liner not shown in Figure 10 1 to enhance the light energy through put in the cell Normally it is not necessary to remove the liner for cleaning however the liner should be removed if the cell is subjected to grossly excessive moisture If necessary clean both sides of the liner and the inside of the pipe cell If the liner has been subjected to a corrosive substance it should be replaced In either case ensure that the small gas holes in the liner are aligned with the gas fittings at both ends of the pipe cell before reassembling the windows The pipe cell can be re assembled by following the reverse of the disassembly procedures In re assembly reserve gaps of approximately 0 5 mm between the infrared light source unit and cell and between the cell and detector respectively Larger gaps are undesirable California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page
37. 1 Problem eee ebe EERE AE EEE aktei 73 11 6 2 DY MPIO iea ei eaae i aaa ee eege A ege AE 73 11 6 3 Check and or replace sc xccccscactataelcnnc ee E 73 11 7 Check and Repair Measuring Cell ke 74 11 7 1 POL E 74 11 7 2 Oy MPIO en se ra eae tes Sic take Vales ech eds Was ease eek bss ea ae Se Ea 74 11 7 3 Ri ane OF PEDIACS E 74 11 8 Check and Repair Tubing Trouble kee 74 11 8 1 PRODI GI genee teas baler arctan EE a EES 74 11 8 2 DY UPTON sc cee ted ccc e E Geelen 74 11 8 3 Check ee 74 11 9 Check and Repair Amplifier Circuit ke 75 12 Communication Master Computer Analyzer AK Protocol cccccessesesseeeeteeees 76 12 1 Serial Interface and AK CommandsS ccccecceeeeeseeneeeeeeeeeeeeeeeeeseeeeeseseeeeneneeeees 76 12 2 e uge Ee Le e EE 76 12 3 Genie NR E 77 12 3 1 Instruction GOMMaANCh ee ee ean 77 12 3 2 Acknowledgement Command uk 77 12 3 3 Data El lle E 78 12 3 4 Eror FAN GIAG EE 78 12 4 Scan Commands EE 79 12 4 1 AKON Measured concentration value eeceeeeeeeeeee tree eeeeetneeeeeeeeeeeteeee 79 12 4 2 AEMB Get measuring range EEN 79 12 4 3 AMBE Measuring range limit EEN 79 12 4 4 AKAK Calibration gas concentrations 0 0 2 2 cece eeeeeeeeeee eee eeeeetneeeeeeeee teens 79 12 4 5 AMBU Upper and lower range switchover values for auto range 79 12 4 6 ASTZ Normal device Status si ccchcscesiocidesccg encevesvcdesnotcadetvae ene weedebeceer need 80 12 4 7 AST Erreeche a E a E
38. 1 Enter F1 Real Time Concentration password Clock F2 Purge F3 Range limits F2 Reset F5 Status Line Analyzer password on off F3 Diagnostics F5 Password F7 Auto Startup F4 Calibrations F7 System Settings F5 Setup F8 Measure Settings F7 Standby F10 Version 6 4 System User Functions Level 4 All Function described in this manual may be accessed from Level 4 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 33 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 Main Menu Function Descriptions 7 1 F1 Measurements Figure 7 1 Main Menu Screen 7 1 1 F1 Measurement The measurements screen is activated by pressing F1 on the Main Menu screen The concentration is displayed in actual engineering units Figure 7 2 Measurements Screen California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 34 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 1 2 Range Select With the arrow keys the ranges 1 to 4 can be selected and locked in which will disable the auto range capability Continue pressing the arrow keys will recycle the analyzer back to auto range The range and or auto range is displayed on the measurement screen If the limits are exceeded while not in the auto range mode a warning Over Range appears on the screen Measurements Kl STBY 0 00 Ch SIE Figure 7 3 Set to Auto Range 601 Measure
39. 12 13 14 15 16 h 3 Conc 1 Alarm h 3 Conc 2 Alarm D Output D Output D Output D eserved D Output ND Alarm D Output alibration Alarm 1 17 18 19 20 21 D Output alibration Alarm 2 Q D x lt D Output D Output alibration Alarm 2 Reserved w bi D Output D Output are pare D Output 22 Spare Spare Spare ke Cc Di x lt Page 56 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer D Output spare 8 3 Digital Outputs 8 3 1 RS 232 Standard 9 Pin DIN Connector Pin Function DCD Carrier Detect RxD Receive Data TxD Transmit Data DTR Data Terminal Ready Ground DSR Data Set Ready RTS Ready to Send CTS Clear to Send RI Ring Indicator TCP IP 8 Pin RJ 47 Connector Function TDX TDX RXD Open Open RXD LNLED LNLED o ooiAenlolbito ib l zl l ca lelono A oo ro 3 IMPORTANT TIP For direct connect to a PC a crossover cable is required Connection to a hub requires a straight cable California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 57 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer 8 4 Internal Component Locations Figure 8 1 Internal components Signal conditioning PCB 2 NDIR detector 3 Sample cell 4 IR source and chopper motor assembly 5 DC power supply module
40. 3 Display deviations F4 Check calibration F5 Reset calibration values to factory default F1 Change span gas concentration for every range F2 Sets auto calibration times Mesuring deviations Deviations F3 Sets upper range limits F4 Sets concentration flow Preesure temperture ext alarms F5 Set user password F6 Linearization F7 System setup screen F9 Displays measure settings F10 Displays version Model S N Air press Sample press Software version Device info Toggles remote Manual local control Stand By Toggles pump OFF Page 27 of 89 Section 4 Main Menu All access F1 Measurement F2 Purge Analyzer F3 Diagnostics F4 Calibration F5 Setup F6 Remote Manual F7 Stand by F4 Calibration F1 Auto calibration F2 Manual calibration F3 Display deviations F4 Check calibration F5 Reset calibration values gt Model 601 601 P 602 602P 603 NDIR Analyzer Auto calibration Flow zero gas F1 Save value Manual Calibration F2 Close zero gas value F1 Flow zero gas F2 Flow span gas Flow span gas F1 Save value F2 Close span gas value Display Deviations F1 Zero gas deviations F2 Span gas deviations F3 Verifying devs zero F4 Verifying devs span Check Calibration Reset calibration values California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 28 of 89 Section 4 Main Menu All access F1 Measurement F2 Purge Analyzer F3 Diagnosti
41. 65 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer 6 Figure 10 2 Optical Bench with Block Sample Cell Item Description Item Description 1 3 Screw M4 11 Block sample cell 4 Base 12 O Ring 5 Infrared source unit 13 Window 6 Screw M4 14 Detector 7 Screw Round or Pan Head 15 Bridge circuit board 8 Connector 16 Optical filter if installed 9 Sealed tubes 17 Wave PCB 10 Screw Flat Head California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 66 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer 10 5 Figure 10 2 Removal of Block Cell Discontinue the sample gas flow When it contains harmful gas purge the measuring cell sufficiently with zero gas Turn the power switch to OFF After loosening the retaining screws on the sides of the top cover lift off the top cover and locate the block cell Disconnect the sample gas inlet and outlet tubes from the measuring cell Disconnect the detector output cable connector from the main circuit board Remove the two screws No 7 in Figure 10 2 attaching the detector to the infrared light source assembly and remove the detector from the optical bench The cell is removed together with the detector as a unit While holding the detector in the palm of your hand remove the two flat head screws No 10 in figure 10 2 which fix the cell to the detector
42. 9 Section 4 Model 601 601 P 602 602P 603 NDIR Analyzer 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 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 that is formatted into 4 information areas TE Se 11 Heasurements K2 SMAN El Lu COU3 Us Ri io008 Ri i6 Ke Mon Nou 17 16 45 55 2003 Figure 4 1 LCD Display 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 Auto range enabled SMGA Measuring gas is flowing SMAN Device is in manual operation status SWET Device Shown on the right is the Password Entry level with 1 to 4 horizontal lines THE LARGE INFORMATION AREA CONTAINS the data portion of the screen THE THIRD INFORMATION AREA CONTAINS the
43. A BAS 80 12 4 8 AKEN Device identification ANEN 80 12 4 9 ARMU Raw Value E 80 12 4 10 ATEM Temperatures i ccsciesecccess ces eviosecencie baie NS ENEE teenies ottawa 81 12 4 11 ADRU Pressures Valve Voltage ANNE 81 12 4 12 ADUF FlOWS irie a dened haan EEE EEE TR 81 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 10 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 12 4 13 AGRD Polynom coefficients esssnneneeeeseeesnrrrntrrssrrrrrrnrresrrrrnnrnnnnnsseennnn 81 12 4 14 AANG Deviation from zero point after autocalbraion 81 12 4 15 AAEG Deviation from end point after autocalibration cceeeeeeee 81 12 4 16 AFDA Purge and Autocalibration mes 81 12 4 17 APAR Request Autocalibration tolerance values 82 12 4 18 AKAL Deviations from calibration kee 82 12 4 19 ASYZ Respond System Tune EE 82 12 4 20 AT90 Respond Lowpass filter time ee 82 12 4 21 ADAL Diagnostic alarin WnitS 2c 0 2c A ioe teehee ae ot ee Reed 82 12 4 22 ATCP Query TCP IP settings EE 82 12 4 23 AVER Query Software version EEN 83 12 4 24 AH20 QueryH 0 correction Darameier un 83 12 4 25 ACO2 Query CO correction parameter s ssessssssserrrereserrrrrrrnerrsserrnne 83 12 4 26 AUPD Query UDP data streaming parameter ccceeeeeeeeeeeeeeeeeeeeeee 83 12 5 ene E enn En E 84 12 5 1 SRES ROS E 84 12 5 2 GE 84 12 5 3 HEEN E 84 12 5 4 SNGA Open valv
44. AVE Check Chi Temp EI California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 19 of 24 ADDENDUM 4 0 CHANGES TO EXISTING FUNCTIONS 4 1 Saved or Outside Limits During Manual Calibration the following screens will be displayed to indicate the instruments response to the value of the zero or span gas using the amount that the operator defined in the deviation table Manual Zero Ei SMAW IS Manual Span K2 SARE lI Zero gas Use F3 To Toggle Span gas Use F3 To Toggle Diagnostics Cal His Diagnostics Cal Via Using Current Temp amp Press Using Current Temp amp Press BEA oo Qutside Deviation Limits Channel Channel Conc MEA Range Range ia Fil Save value an al enu F2 Man Cal Menu Hed Max 14 16 47 09 2008 lal CAI Tel 85001 93259 09539 lai The Above is shown using Zero and Span Cal From Measurement use F5 zero or F6 span From Main Menu use F4 F2 F1 zero or F2 span California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 20 of 24 ADDENDUM 4 2 Calibration Deviations MAIN F5 F2 F2 Deviations F3 Measuring Deviations Setup Ki SMGA E Measuring deviationl ad Deviations z 1 J absolute relati Rangel io oo 10 Paved Al 8 Ba 28 Ranged BS 16 60 10 ee ae Enter deviations for channel i1 800 959 0959 Sum Jan G1 00 11 48 2003 lal Note These screens ar
45. California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 76 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 3 Protocol Description 12 3 1 Instruction command Character Explanation 1 Byte STX ASCII code 02 27 Byte Don t Care Any ASCII code 37 Byte Function Code 1 AT Byte Function Code 2 AK instruction 5 Byte Function Code 3 e g ASTF 6 Byte Function Code 4 7 Byte Blank 8 Byte K 9 Byte 0 10 Byte Blank D A AK instruction parameters T length is variable A nth Byte ETX ASCII code 03 Table 12 1 Structure of an instruction command 12 3 2 Acknowledgement command Character Explanation 1 Byte STX ASCII code 02 27 Byte Don t Care Any ASCII code 3 Byte Function Code 1 4 Byte Function Code 2 Echo of the AK instruction 5 Byte Function Code 3 command 6 Byte Function Code 4 7 Byte Blank 8 Byte K 9 Byte 0 10 Byte Blank D A AK acknowledgement T parameters length is variable A nth Byte ETX ASCII code 03 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 77 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer Table 12 2 Structure of an acknowledgement command 12 3 3 Data Description Each command begins with STX Start of Text in the fist byte The don t care byte can be any
46. E PC PrP oir Eero eee tenet a Ee pers ee 62 9 3 2 Zer Sam e EE 62 9 3 3 Start Up and Routine Maintenance cccceeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeneaaees 62 AP MAINTENANCE eet ee eege 63 10 1 Zero and Span Calibration 22 Soest ege heeded eel ee ENEE BEE 63 10 2 Cleaning of the Optical Bench Measuring Cell Infrared Analyzers Onlly 63 10 3 Optical Bench Configuration seht caacives caeseedecdeetwesedessvacatenteee SNE ER SENEgE NA 63 10 4 Removal OF Pipe TEE 65 10 5 Removal of Block Coelliscncccscesesveviesitaspesauaryhocescneed ees eebedaiennad es DESEN ieee 67 10 6 Disassembly of Combination Pipe amp Block Type Cell 69 11 ADJUSTMENTS CHECKS AND REPAIRS 0 ce ccceeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeneees 71 11 1 Adjustment of Detector Voltage NDIR S oniv eee teeeeenneeeeeeeeeeteee 71 11 2 Coarse E E EE 71 11 3 Span Gain Eer EE 71 11 4 Check and Repair RE EE 72 11 4 1 PROD OM EE E EE 72 11 4 2 SOUEEN ee eege eege e eege S 72 11 4 3 Check and or replace 4 6 adn sheen ened deren ies ase eege 72 11 5 Check and Repair Infrared Light Source Unit ee 73 11 5 1 Eet ee E EE EE 73 11 5 2 SEITEN ee eege E ee EA EN 73 11 5 3 Check ee EE 73 11 6 Check and Replace Chopper sts seater rhe aula aaa ete eal 73 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 9 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 11 6
47. F8 3 4 7 Use the to select the desired output press ENTER 3 4 8 Press F1 to select a ZERO signal and observe the results on the remote device 3 4 9 Change the offset value press BACK to save the new value 3 4 10 Press F8 to return to the D A Calibration screen and note the results on the remote device 3 4 11 Repeat steps 3 4 8 thru 3 4 10 until a satisfactory ZERO calibration is achieved 3 4 12 Complete steps 3 4 8 thru 3 4 10 for each of the remaining outputs that require calibration 3 4 13 Press F5 to produce a full scale 100 signal 3 4 14 Use the arrow keys to position the curser at the require GAIN value 3 4 15 Observe the results on the remote device and make a correction to the GAIN value for the output of interest Press BACK to save this new value 3 4 16 Press F8 to return to the D A calibration screen 3 4 17 Observe the results on the remote device and repeat steps change the GAIN value by repeating steps 3 4 14 thru 3 4 16 as needed for each output 3 4 18 Return to the OUTPUT Assignment screen F5 F7 F3 from the main menu and change the output signals from CALIBRATE to their original values as defined in step 3 4 1 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 12 of 24 ADDENDUM 3 5 Save Data Archiving Time F5 F7 F1 F5 Archive Time is the Time in seconds between each set of data points If zero no data is stored in the SEC data files The SEC data fil
48. M 13 5 Starting With Serial Number U06081 1 0 INTRODUCTION The Model 600 NDIR Series of instruments starting with Serial Number U06081 have several new Hardware and Software features The Hardware includes the use of a new memory system isolation of the analog output signals and 15 relays that are used to buffer the many new digital output signals that are now available SEE TABLE D The available digital signals consist of a SERVICE group which can be used to externally monitor a number of conditions for preventative maintenance and diagnostics A second STATUS group is provided to define the operation of the instrument such as Spanning Zeroing Calibrating and the current Range 1 2 3 4 AUTO Many of the various signals are duplicated because an NDIR instrument can consist of up to three different channels The Software includes modifications to existing functions changes to the Measurement screen additional Short Cut Keys and several New Functions that are listed as follows e MEASUREMENT Over Range 888888 Diagnostics F3 Zero F5 Span F6 Range Limits F8 Span Values F9 Outputs F10 Note The operator can use these Short Cut Keys or continue to use existing procedures e NEW FUNCTIONS Auto Startup F5 F7 F7 ALARMS F5 F7 Use F6 to toggle ON OFF Offsets amp Gains F4 F3 F5 D A Calibration F5 F7 F8 Save Data Archiving Time F5 F7 F1 F5 ENTER to change record time User Digital Outputs F5 F9
49. MS ee eg enee 25 3 8 Sampling Requirements xe sees aeas a Sea Seag a ws a daSss e ence ee ee 25 3 8 1 PI AU gene de EE ie eene 25 3 8 2 CONOSNSALON oauchen wacaut anianmute ui Oacok an eetate aeoet 25 3 8 3 Presence of Corrosive Gases jcacvicciivsieeedte cote neater de eee eae 25 3 8 4 Gas Temperature cc dees ege Eege eege 25 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 6 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 3 8 5 Sample Gas Bypass Outlet Vente EEN 25 4 Basle ele E EE 26 e GE 26 4 2 NIGH NN 27 Bde UR CY DONO WEE 30 4 3 1 Operation with the Cursor Keys and the Enter Key ssssssssssseeeeesssrrrreeee 30 4 3 2 Operation with the Function Keys 30 4 3 3 Read Change Parameters ANEN 30 5 Operating EE TTT e eo cee as a a ae ea td ea 31 Sali TheMain E E 32 6 EU TT 33 6 1 User Functions Level EE 33 6 2 Advanced User Functions Level EE 33 6 3 Maintenance Functions Level 3 33 6 4 System User Functions Level A ENEE 33 7 Main Menu Function DeSCriptions cccccccccsseeeeseeeeeeeeeeeseeeeeneneeeeeeeeeeeeeeeneeeeeeeeeeeneeees 34 Pele PAP MGASUrOMOIS EE 34 7 1 1 Fl Measurement iesen gue ee EES 34 7 1 2 Range Selecties E 35 T2 F2 Purga Analyzer EE 36 Tlr le el Lee 36 EC NR ed 37 7 4 1 F1 Automatic Calibration E 37 7 4 2 F2 Manual Calibration ic csctcecesitecteebecentvcaQeestetetenersandeectehedeerveestustededeetcade 38
50. SSPL_KO _SSPL_s Open zero gas valve and purge all channels 12 5 7 SATK Start automatic calibration Command Response Description _SATK_Km _SATK_s Start automatic calibration with selected range of channel m SATK_Km_Mn SATK_s Start automatic calibration for channel m Range n 12 5 8 SEMB Set measuring range Command Response Description SEMB_Km_Mn SEMB_s Set measuring range Auto range will be disabled California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 84 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 5 9 SARE Auto range on Command Response Description _SARE_KO _SARE_s Set auto range on for all channels _SARE_Km _SARE_s Set auto range on for channel m 12 5 10 SARA Auto range off Command Response Description _SARA_KO _SARA s Set auto range off for all channels _SARA_Km _SARE_s Set auto range off 12 5 11 SREM Remote mode for Ak commande Command Response Description _SREM_KO _SREM e Set device in remote mode 12 5 12 SMAN Manual control to control device manually Command Response Description _SMAN_KO _SMAN e Set device in manual mode 12 5 13 SMGA Start measuring Command Response Description _SMGA_KO _SMGA_s Start measuring Open all sample valves _SMGA_Km _SMGA_s Open sample valve of channel m 12 5 14 _SNKA Saves measured value as new offset Command Response Description _SNKA_KO _SNKA_s Saves measured value of actual range for
51. al Piping Review Section 3 3 7 and 3 8 9 3 Operation amp Calibration 9 3 1 Power On Turn on the power switch located on the rear panel The LCD display should illuminate Allow the instrument to warm up for approximately one hour It is preferable but not essential that zero gas flow through the instrument at a rate of about 1 Liter minute LPM Note To achieve final stability the analyzer may require an additional warm up period of up to four hours depending on variables in the analyzer s environment 9 3 2 Zero San Adjustment Follow the Quick Start Guide at the front of this manual Note Span gas concentration should not be less than 80 of the range to be spanned 9 3 3 Start Up and Routine Maintenance Prepare and check the sample system Adjust the flow of sample gas to about 1 L min The instrument should show a meter indication The infrared gas analyzer is designed for extended operation and may be left switched on continuously California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 62 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer 10 MAINTENANCE Warning All replacement parts must be as supplied and or specified by California Analytical Instruments Failure to used specified parts may reduce the safety features of the instrument or create a hazardous condition 10 1 Zero and Span Calibration The zero and span levels should be checked
52. ally to the second range Figure 7 21 Change Upper Range Limits 7 5 8 F2 Change Auto Range Limits Although the auto range limits are adapted automatically it is possible to define them manually Up means the value when the next higher range is selected in auto range mode down the value when the next lower range is selected Figure 7 22 Change Auto Range Limits California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 43 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 5 9 F4 Alarms Error reports are always displayed in the lowest line of the screen There are two pressures three temperatures one concentration and two voltages with alarm limits that can be defined The user can define the range limits and if exceeded will display an error message Figure 7 23 Alarm screen Figure 7 24 Alarm screen Il Set Temperature Alarms Set Concentration Pressure and Voltage Alarms 7 5 10 F5 Password After turning on the analyzer you are in access level 1 To change the access level or to change the passwords press F5 Setup in the main menu and Press F5 Password again The following screen appears Figure 7 25 Enter Change Password California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 44 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 5 11 F1 Enter Password To change access level press F1
53. alytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 3 of 24 ADDENDUM 2 4 Span From the MEASUREMENT screen select the required Channel and Range then press F6 Note For instruments with Span Solenoid s select Calibration by Valves Main F5 F2 and F4 anual Span izl Manual Span K3 SMAH B a Span gas Use FS qe Toggle Diagnostics Cal Wi Using Current Tem HE amp Press Channel Conc ny Ranges D Fi Save value F2 Man Cal Menu Wed Mayr 14 16 43 27 2008 lal 2 Versions Span Gas for Channel1 and Range 1 will be enabled and the observed results can be used to evaluate instrument performance Press F3 to toggle to the Diagnostic screen for additional information Press F1 to save the new value and complete the SPAN calibration for this Channel and Range Note The span gas value used for this channel and range is highlighted and can be changed if necessary Use the Enter key and the numeric keys as required Press MAIN F1 to return to the MEASUREMENT screen to select other Channels and Ranges and repeat the process or F2 to return to the Manual Calibration screen California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 4 of 24 ADDENDUM 2 5 Range Limits F8 From the MEASUREMENT screen Setup K2 SMAH IS Z U er range limits xe mJ Ped a TiS ANEN SCEN DCT aa ae eee HUST be ASCENDING 5 5 Rangel Rangez a OE Ranges D
54. aminated remove contaminant with a soft cloth and alcohol Take care not to damage the windows since they are fragile For details refer to section 10 of this manual 11 8 Check and Repair Tubing Trouble 11 8 1 Problem Tubing loosened disconnected contaminated or restricted 11 8 2 Symptom Indicator output unstable or response is too to slow 11 8 3 Check and or replace 1 When tubing is disconnected or loosened firmly reconnect it 2 When tubing is contaminated or restricted disconnect it and blow out contaminants with high pressure air or replace the tubing Caution Cracked broken or frayed tubing may cause a hazardous condition Replacement tubing must be as specified by California Analytical Instruments to prevent possible damage to operating personnel or equipment California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 74 of 89 Section 11 Model 601 601 P 602 602P 603 NDIR Analyzer 11 9 Check and Repair Amplifier Circuit 1 Connect an oscilloscope across check terminals TP3 signal and TP9 common and observe the ac waveform While zero gas is flowing the amplitude of the waveform should be between 2 48Vpp and 2 8Vpp as shown below This can be adjusted by following the procedure described under section 12 2 before making this adjustment it is recommended that a check for contamination in the cell and cell windows be done first as this can lead to a redu
55. annel 1 A Input A Output Channel 2 Channel 2 A Input External Analog 2 A Output Channel 3 Channel 3 A Input Spare analog A Output A Input 5 K i ES D aa AutoRange D Output e Sense Range 4 Retr ma Sense Range 4 D Output lo Sense Range 3 it SenseRanges al Sense Range 3 D Ki KS ited aa ai Bai Era Bi Signal Type Pi 5 tt H 5 Spare analog GND Digital D Output GND Alarm Sense AutoRange Sense D Output e GND Digital D Output 7 D Output 7 General Alarm AutoRange Ch 1 Conc 1 Alarm Ch 1 Conc 2 Alarm Ch 2 Conc 1 Alarm Ch 2 Conc 2 Alarm D Output D Output D Output 10 D Output Sense Range 1 tHi tue D Input Set AutoRange 12 12 Set AutoRange D Input Control Range 1 Control Range 1 D Input Control Range 2 Control Range 2 D Input Control Range 3 Control Range 3 D Input Control Range 4 Control Range 4 NEE D Input Auto Cal Auto Cal D Input alibrate Calibrate D Input ero ero D Input Sp D Input ump ump D Output Zero Gas Flow Zero Gas Flow Zero Gas Flow D Output Span Gas Flow Span Gas Flow Span Gas Flow Sample Gas Sample Gas Sample Gas eet Flow Flow D Output Local Remote Local Remote Local Remote Spare D Output Read Cal Mode Read Cal Mode Read Cal Mode FT Spare D Output LI Spare i O California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual 10 11 Sense Range 2 Sense Range 2 D Output Sense Range 1 D Output
56. ature variations This analyzer is not suitable for installation outdoors Select a site where the air is clean Avoid exposing the instrument to corrosive or combustible gases The instrument must not be subject to severe vibration If severe vibration is present use isolation mounts The instrument is designed for rack mounting Optional rack mount slides are available 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 Ji Figure 3 1 AC Power Switch Connector and Fuse California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 23 of 89 Section 3 Model 601 601 P 602 602P 603 NDIR Analyzer 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 Replace fuses with recommended fuse size indicated on rear panel of instrument Replacement with any other size fuse may cause damage to the instrument and possible injury to operating personnel 3 4 Analog Outpu
57. be used to evaluate instrument performance Press F3 to toggle to the Diagnostic screen for additional information Press F1 to save the value and complete a ZERO calibration for this channel and range Press MAIN F1 to return to the MEASUREMENT screen to select other channels and ranges and repeat the process or press F2 to return to the Manual Calibration screen California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 3 of 24 ADDENDUM 2 4 Span From the MEASUREMENT screen select the required Channel and Range then press F6 Note For instruments with Span Solenoid s select Calibration by Valves Main F5 F2 and F4 anual Span izl Manual Span K3 SMAH B a Span gas Use FS qe Toggle Diagnostics Cal Wi Using Current Tem HE amp Press Channel Conc ny Ranges D Fi Save value F2 Man Cal Menu Wed Mayr 14 16 43 27 2008 lal 2 Versions Span Gas for Channel1 and Range 1 will be enabled and the observed results can be used to evaluate instrument performance Press F3 to toggle to the Diagnostic screen for additional information Press F1 to save the new value and complete the SPAN calibration for this Channel and Range Note The span gas value used for this channel and range is highlighted and can be changed if necessary Use the Enter key and the numeric keys as required Press MAIN F1 to return to the MEASUREMENT screen to select other Channels and Ranges and repeat
58. bration deviations Use lt keys to change channel The OFFSET is the value stored during zero calibration The GAIN is the value stored during span gas calibration using the operator defined calibration gas An increasing or decreasing change to the OFFSET or GAIN when used in conjunction with Deviations will provide insight to both short and long term changes to system performance 3 4 Calibrate The Analog Outputs Main F5 F7 F8 D A Calibration Main F5 F7 F3 Output Assignment e Overview The 600 NDIR Series of instruments are designed to provide analog outputs that can be configured as 0 1 VDC 0 5 VDC 0 10 VDC 4 20 mA or 0 20 mA With this version the outputs can also be configured to include an additional 1 0 volt and 5 0 volt output and a calibration capability The outputs can be calibrated to exactly match the results obtained on a PLC Recorder Data Logger or other remote recording device that may be connected to the analyzer The operator will first select the OUTPUT ASSIGNMENT Main F5 F7 F3 screen and choose the output that is to be calibrated By selecting calibrate as the output all outputs of interest may be selected When calibration is competed the operator will return the outputs to their original assignment California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 9 of 24 ADDENDUM The D A CALIBRATION screen will then be used to complete the ca
59. calibration and purge times sssesssessnernneeeserrrrrrrreesee 86 12 6 7 EPAR Set autocalibration tolerance values sssssessesereneeeseerrrerrnreesne 86 12 6 8 ESYZ Set System DE 87 12 6 9 ET90 Set Lowpass Filter Time ENNEN 87 12 6 10 EDAL Diagnostic alarm IIMS E 87 12 6 11 ETCP Set TCP IP e la 87 12 6 12 EH20 Set H20 correction parameters ANEN 87 12 6 13 ECO2 Set CO Correction parameters ENNEN 87 12 6 14 EUDP Set UDP Data streaming Darameterg 88 12 6 15 Format of the streaming Data via UD 88 12 7 Abbreviations USE ere cece eege cede eens ss NENNEN SEENEN 88 13 APpendiX gege eared ceed ane eneeier an aata naa ea eaaa ataa ea aenak Epaia arae EEan e sotacenets agencsotsdeauens 89 13 1 Electrical BIOCK RT re TA EE 89 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 12 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer Table of Figures Figure 2 1 Single NDIR Analyzer scsi 2icces cas ccees nc deccustebeceatessesces ted etvaresdeneisisdeceeneetevsesel EE eege 19 Figure 2 2 Detector Output Signal 20 Figure 2 3 Absorption Characteristic of Detector ke 20 Figure 2 4 Block Diagram ergeet eaaa ane aE REER EE A TER EE ERER 21 Figure 3 1 AC Power Switch Connector and FUSE ccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 23 Figure 3 2 EMI Suppressor ENNEN Error Bookmark not defined Figure 4 1 KEEN ee Ga eect noes geen Deen egenen 26
60. cs F4 Calibration F5 Setup F6 Remote Manual F7 Stand by Setup All access 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 a Xe XE lt P Ap XT OG Model 601 601 P 602 602P 603 NDIR Analyzer Span gas concentrations Calibration settings F1 Times F2 Measuring deviations F3 Deviation F4 Calibration via values F5 Calibration via pump Range limits F1 Range 1 4 F2 Autorange Password F1 Standard user F2 Extended user F3 Mainenance F4 System operator Linearization Systems settings Measure settings Displays version Factory default vallues F1 Standard user 111 F2 Extended user 222 F3 Mainenance 333 F4 System operator 444 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 29 of 89 Section 4 Model 601 601 P 602 602P 603 NDIR Analyzer 4 2 Keyboard p Combined control numeral keys 1 2 3 4 5 SS F6 F7 F8 F9 Q Display lighting 6 H 8 ail 0 S 4 _ Cancel back to on off SC x SS Jh i DI Mam Back the last menu Delete key a End input Numfof Fx 4q eg F Enter open selected field for input Switch over of the keyboard numeral control keys _To the main menu Arrow keys for selecting the functions and editing fields and for scrolling possible input values Figure 4 2 Keyboar
61. ction in amplitude of the ac signal Note Check cell first for contamination and clean if necessary 2 48 2 8V peak to peak Lal 10Hz _ ia Figure 11 1 Amplifier circuit ac wave form If an ac waveform cannot be observed in step a above observe the ac waveform across terminals TP4 signal and TP9 common If an ac waveform of 10 Hz and peak to peak amplitude of 147mV to 164mV is observed ac amplifier U1 is normal and AC amplifier U7 is not functioning If an AC Waveform is not observed across terminals TP4 signal and TP9 common check the detector per section 12 4 of this manual California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 75 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 Communication Master Computer Analyzer AK Protocol 12 1 Serial Interface and AK Commands The serial interface enables remote control of the analyzer by a master computer It is implemented as an RS232 V24 interface and meets all requirements of the AK protocol A 9 pin male connector at the back of the unit is used to connect a master computer with the following pin assignment Pin 2 Rxd receive O O O Cy Pin 3 Txd transmit Pin 5 Gnd ground Cc Cy Pi ER Figure 12 1 Serial Interface 12 2 Interface Specifications Speed 9600 bps Character Length 1 start bit 8 data bits 1 stop bit Parity none Handshake no
62. d 4 2 1 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 2 2 Operation with the Function Keys When using the function keys FI 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 2 3 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
63. e 1 With the power switch turned ON listen for a frictional noise from the chopper blade If noise can be heard it is necessary to adjust the chopper blade so that no contact is made with other parts Remove the infrared light source assembly and detach the protective cover for access to the chopper blade Take care not to damage the blade as it is made of thin material No adjustment is required as long as the output is normal California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 73 of 89 Section 11 Model 601 601 P 602 602P 603 NDIR Analyzer 2 Ifthe motor shaft does not rotate after energizing the instrument disconnect the power supply connector from the motor and check to see if AC 100 Volts is supplied to the connector on the power supply side When power is supplied but the motor shaft does not rotate check the shaft and blade sector for an obstruction When the motor does not rotate and there is no abnormal contact on the shaft or sector blade the motor itself is defective 3 Replacement When the motor is defective the infrared light source assembly must be replaced 11 7 Check and Repair Measuring Cell Detector Window and Infrared Light Source Window 11 7 1 Problem Cell and window badly contaminated 11 7 2 Symptom Zero adjustment impossible 11 7 3 Check and or replace After removing the measuring cell check the cell and windows for contamination If cont
64. e Modifications Saved Not good F4 F2 F1 or F2 To flow Zero or Span Gas Re Set Calibration Values F4 F5 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 2 of 24 ADDENDUM 2 0 OPERATION OF MEASUREMENT KEYS Note USE the F1 amp F2 Keys to view the complete list of menu items from the MEASUREMENT screen 2 1 Over Range 888888 In the MEASUREMENT mode only any value that exceeds the range by more than10 will be displayed as 888888 2 2 Diagnostics Use F3 to toggle between MEASUREMENT and DIAGNOSTIC 2 3 Zero From the MEASUREMENT screen select the required channel and range then press F5 Note For instruments with Zero Solenoid s select Calibration by Valves Main F5 F2 F4 Manual Zero izl Manual Zero K3 SMGA EJ Zero gas Use F3 To Toggle Reenter EE Toggle IIIS GEE eile tee Current Temp amp Press Channel Channel Q Range 8 Range D an al enu an ail enu CAI Tel 800 959 0959 CAI Tel 800 959 0959 Ia 2 Versions Zero Gas will be enabled and the observed results can be used to evaluate instrument performance Press F3 to toggle to the Diagnostic screen for additional information Press F1 to save the value and complete a ZERO calibration for this channel and range Press MAIN F1 to return to the MEASUREMENT screen to select other channels and ranges and repeat the process or press F2 to return to the Manual Calibration screen California An
65. e for Zero gas CGalbration 84 12 5 5 SEGA Open valve for end gas Calibration c cccccceeeeeeeeeeteeeeeeeeeeeteee 84 12 5 6 SSPL Purge Analyzer with zero gaS ecceeeeeeeeeeeeeeeeeeenneeeeeeeeeeeeeeesaaees 84 12 5 7 SATK Start automatic Calibration cee cece eee eee eeeeeneeeeeeeeeeteeeeaaees 84 12 5 8 SEMB Set measuring range ENEE 84 12 5 9 SARE Auto Wee E EE 85 12 5 10 SARA Auto range off dino ea eee eae eee gia eee te nase 85 12 5 11 SREM Remote mode for Ak Commande 85 12 5 12 SMAN Manual control to control device manually ccceeeeeteeeeeeees 85 12 5 13 SMGA Start measuring EEN 85 12 5 14 SNKA Saves measured value as new offset sssssereerssserrrrrrnrrrssrrrene 85 12 5 15 SEKA Saves measured value as new span value 85 12 5 16 SUDP Start Stop UDP data sireamimg teeta 85 A ED een eet Melee E ege tee 86 12 6 1 EKAK The four span gas concentration values are set 86 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 11 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 12 6 2 EMBE The four measuring range end values are set 86 12 6 3 EMBU The upper and the lower range switchover for auto range are set 86 12 6 4 EKEN Set new device identification and information sesssessssereeeeese 86 12 6 5 EGRD Set polynom COGTICIONIS 2a cesrcesnetscetnrciinnteiian Aces ar dee 86 12 6 6 EFDA Set auto
66. e used by the operator to define the maximum acceptable limits of the Zero and Span gas for both Manual and Automatic Calibrating 4 3 Flow Zero or Span Some analyzers have the above and the ability to flow Zero and Span Gas Manual calib Ki SHGA IS Manual calib Ki SARA IS Cuz CO Ri i6b 00 ARIL 100 0 Hed May 14 16 45 58 2008 l Wed Hax 14 16 47 28 2008 The above is shown using Zero SPAN Gas From Cal Screen use F2 or Main or Back From Main Menu use F4 F2 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 21 of 24 SECTION 13 ADDENDUM 4 4 Reset Calibration Values When the re set calibrations value function is used all recorded deviations will be set to zero Def cal value Span gas devs izl Span gas devs Span gas devs verifying Span gas deviations XZ measured deviatio abs rel angel pn e ae 9 op 9 og ange2 a J F 5 S ee Ei CN E 3 80 CS ange4 S D Z 2 Gebeier SC select EE CAI Tel 800 959 0959 i CAI Tel 800 959 0959 F Main F4 F3 F4 Main F4 F3 F2 Used to observe Auto Cal Results Used to observe Manual Cal results The above are the new deviations after the operator elects to re set the calibration values California Analytical Instruments Model 600 NDIR Operators Manual May 27 2008 Page 22 of 24 SECTION 13 ADDENDUM TABLE D 600 NDIR SERIES UO CHART 28 PIN MAIN CONNECTOR ASSIGNMENTS AO Analog Output OC Open Collect
67. each channel as new offset if zero valve is opened _SNKA_Km _SNKA_s Saves measured value of actual range as new Offset if zero valve is opened 12 5 15 SEKA Saves measured value as new span value Command Response Description _SEKA_KO _SEKA s Saves new span values for each channel if span valve is opened _SEKA Km _SEKA s Saves measured value of actual range as new span value if span valve is opened 12 5 16 SUDP Start Stop UDP data streaming Command Response Description _SUDP_KO_ON _SUDP_s Start Data streaming via the UDP channel You need to configure the channel before with EUDP command _SUDP_KO_OFF _SUDP s Stop streaming via the UDP channel California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 85 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 6 Settings 12 6 1 EKAK The four span gas concentration values are set Command Response Description _ EKAK_Km_M1_w w_M2_x x_M3_y y_M4_zz _EKAK_s__ Set end gas values for channel m 12 6 2 EMBE The four measuring range end values are set Command Response Description EMBE_Km_ M1_w w_M2_x x_M3_y y_M4 z z EMBE_s_ Set range limits 12 6 3 EMBU The upper and the lower range switchover for auto range are set Command Response Description EMBU_Km_M1_w w_W W_M2_x x_X X_M3_y EMBU_s_ Set lower and upper range y_Y Y_M4 zz Z Z switchover limits 12 6 4 EKEN Set new device identification and information Comma
68. efault calibration Pressing F5 a new screen appears and asks if the user is sure to reset calibration values to the default calibration values F1 confirms and the calibration values are reset to default calibration values F2 leaves this menu without resetting to default values This function will overwrite all calibrations with factory values In addition the linearization polynomial will be overwritten with the factory values 7 4 10 F6 Range Select This allows a range change to be activated from the calibration menu California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 40 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 5 F5 Setup From the Main Menu F5 brings up the setup menu Span gas concentrations calibration settings range limits alarms password linearization system and measure settings can be changed The Setup menu begins as shown below A description of each parameter is shown in the information box NOTE Use the down arrow key to obtain the additional setup parameters K2 SARA IS Setu K3 SMAH ZI i Ka gt or P E R A P L S M Show version Mon Nov 17 10 52 29 2003 F Mon How 17 10 53 10 2003 z Figure 7 16 Setup menu screen Figure 7 17 setup menu screen II 7 5 1 F1 Span Gas Concentration Note If you do not have a specific gas for a specific range the calibration will use the previous ranges calibration You must have a least one span ga
69. erator can select from the following the desired SERVICE or STATUS groups that are to be digitally monitored Index ON OOK Go M O Re 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 34 TABLE B Service Group Flow 1 Failure Flow 2 Failure Flow 3 Failure Extern Analog 1 Failure Extern Analog 2 Failure Pressure Failure Temperature Failure Channel 1 is not calibrated Channel 2 is not calibrated Channel 3 is not calibrated Ch1 Low conc Warning Ch2 Low conc Warning Ch3 Low conc Warning Ch1 High conc Warning Ch2 High conc Warning Ch3 High conc Warning Ch1 Temperature Ch2 Temperature Ch3 Temperature Ch1 EPC failure Ch2 EPC failure Ch3 EPC failure Ch1 Range overflow Ch2 Range overflow Ch3 Range overflow Ch1 ADC Range Overflow Ch2 ADC Range Overflow Ch3 ADC Range Overflow Ch1 ADC Range Underflow Ch2 ADC Range Underflow Ch3 ADC Range Underflow dummy text for RTC General Alarm 1 Cal Alarm 2 Cal Alarm 3 Cal Alarm In Remote California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 User DO Screen Display F1 F2 F3 E1 E2 P T 1NC 2NC 3NC 1LoC 2LoC 3LoC 1HIC 2HIC 3HIC 1DT 2DT 3DT 1EV 2EV 3EV 10R 2OR 3OR 1AU 2AU 3AU 1AO 2AO 3AO Off 1CA 2CA 3CA Page 17 of 24 ADDENDUM TABLE C STATUS GROUP Ee Index Display 38 1 AutoRange 1AR 39 1 Ra
70. erify time z y X w in seconds _AFDA KO_SSPL _AFDA_s z Purge time will be responded California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 81 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 4 17 APAR Request Autocalibration tolerance values Command Response Description _APAR_Km_SATK APAR_S 2 Z_y y_X X_W W Autocalibration tolerance value z z Range 1 y y Range 2 x x Range 3 w w Range 4 12 4 18 AKAL Deviations from calibration Command Response Description _AKAL Km_ AKAL_s_ M1_z z_y y_x x_w w Deviation M2_z z_y y_X X_W W z z Zero gas relative last calibration M3_z z_y y_X X_W W y y Zero gas factory calibration M4_z z_y y_X X_W W x x Span gas relative last calibration w w Span gas factory calibration 12 4 19 ASYZ Respond System Time Command Response Description _ASYZ_KO_ _ASYZ_s_yymmdd_hhmmss System time yymmdd year month day each 2 characters wide no spaces hhmmss hour minute second each 2 characters wide no spaces 12 4 20 AT90 Respond Lowpass filter time Command Response Description _AT90_KO_ _AT90 s t Respond low pass filter time t filter time in seconds 12 4 21 ADAL Diagnostic alarm limits Command Response Description _ADAL_KO ADAL es ai mm al max All alarms limits are responded _al6 min_a16 max ADAL_KO_x ADAL_s_x min_x max Alarm limits of x Ala
71. ering device Use the to select the desired Output Press Enter to select Use the to select the desired Signal Press Enter to select Use this screen to define the signals and their location that will be monitored by a remote reordering device SEE TABLE D California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 6 of 24 ADDENDUM 3 0 NEW FUNCTIONS 3 1 Auto Start Up Main F5 F7 F7 Auto Startup 1 Manual Chi Ch2 Ch3 1 1 il 1 1 1 All key analyzer parameters are stored in a secure memory location and retained when power is removed In the event of an unexpected power failure it may be desirable to change some parameters until an operator can resume control This screen may be used to establish several desirable special instrument start up parameters that define how the analyzer recovers from loss of AC power When enabled this screen will define the following Wait The time delay in minutes before proceeding If zero is selected the instrument will not start until all temperature warnings are cleared Calibrations The number of attempts to complete a successful calibration as required in the operator defined Deviation Tables If calibration is not successful the instrument will continue reporting results using the last completed calibration The analyzer can be configured use the previous calibration by selecting zero Calibrations Starting Range When all defined action
72. es are in CSV format for direct import into Excel CAI can provide the tools necessary to download these files Use ENTER to change recording time SEE TABLE A California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 13 of 24 ADDENDUM TABLE A 600 SERIES NDIR DATA ARCHIVE FILES Time Date Month Year Error Index TimeStamp Pressure Temperature Name Concentration Detector Volts Range Auto Manual Span Value Offset Gain Sample Pressure Sample Flow Sample EPC Volts Detector Temperature Meas Mode Local Remote If 2 Channel this data is added Name Concentration Detector Volts Range Auto Manual Span Value Offset Gain Sample Pressure Sample Flow Sample EPC Volts Detector Temperature Meas Mode Local Remote California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 14 of 24 ADDENDUM TABLE A cont 600 SERIES NDIR DATA ARCHIVE FILES If 3 channel this data is added Name Concentration Detector Volts Range Auto Manual Span Value Offset Gain Sample Pressure Sample Flow Sample EPC Volts Detector Temperature Meas Mode Local Remote California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 15 of 24 ADDENDUM 3 6 User Digital Outputs e Overview The 600 NDIR Series of instruments have 15 solid state opticall
73. ess d er e oe Span gas value 0 0 Time Q Channel W Range H Mon Nou 17 10 47 71 2003 Figure 7 9 Auto Calibration Screen California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 37 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 4 2 F2 Manual Calibration From the Calibration screen F2 starts manual calibration If auto range is selected calibration is not possible and the appropriate range can be selected Figure 7 10 Manual calibration In the manual calibrations menu two options are possible F1 Flow zero gas F2 Flow span gas Figure 7 11 Manual zero calibration Figure 7 12 Manual span calibration California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 38 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer When zero or span gas is flowing the measured value can be saved by pressing F1 If the screen is left by pressing the buttons Main or Back the measured value is not saved Solenoids are closed by pressing F2 7 4 3 Display Deviations from Calibration menu F3 Figure 7 13 Display deviations After every calibration the deviations are calculated for zero and for span gas F1 Zero gas deviations F2 Span gas deviations F3 Deviations of zero gas during verifying F4 Deviations of span gas during verifying F1 and F2 deviations are displayed in percent Figure 7 14 Zero gas dev
74. essure Failure Temperature Failure Channel 1 is not calibrated Channel 2 is not calibrated Channel 3 is not calibrated Ch1 Low conc Warning Ch2 Low conc Warning Ch3 Low conc Warning Ch1 High conc Warning Ch2 High conc Warning Ch3 High conc Warning Ch1 Temperature Ch2 Temperature Ch3 Temperature Ch1 EPC failure Ch2 EPC failure Ch3 EPC failure Ch1 Range overflow Ch2 Range overflow Ch3 Range overflow Ch1 ADC Range Overflow Ch2 ADC Range Overflow Ch3 ADC Range Overflow Ch1 ADC Range Underflow Ch2 ADC Range Underflow Ch3 ADC Range Underflow dummy text for RTC General Alarm 1 Cal Alarm 2 Cal Alarm 3 Cal Alarm In Remote California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 User DO Screen Display F1 F2 F3 E1 E2 P T 1NC 2NC 3NC 1LoC 2LoC 3LoC 1HIC 2HIC 3HIC 1DT 2DT 3DT 1EV 2EV 3EV 10R 2OR 3OR 1AU 2AU 3AU 1AO 2AO 3AO Off 1CA 2CA 3CA Page 17 of 24 ADDENDUM TABLE C STATUS GROUP Ee Index Display 38 1 AutoRange 1AR 39 1 Range 1 1R1 40 1 Range 2 1R2 41 1 Range 3 1R3 42 1 Range 4 1R4 43 1 In Calibrate 1C 44 1 In Zero 1Z 45 1 In Span 1S 46 1 In Sample 1Sa 47 2 Auto Range 2AR 48 2 Range 1 2R1 49 2 Range 2 2R2 50 2 Range 3 2R3 51 2 Range 4 2R4 52 2 In Calibrate 2C 53 2 In Zero Ke 54 2 In Span 2S 55 2 In Sample 2Sa 56 3 Auto Range 3AR 57 3 Range 1 3R1 58 3 Range 2 3R2 59 3 Range 3 3R3 60 3 Range
75. f the detector below the Serialization Number and Type designation On the NDIR amplifier board the voltage supplied to the detector can be measured between TP 1 and TP 9 common Adjust RP2 to achieve the voltage specified on the detector to within 0 001 VDC WARNING The detector may be damaged if the applied voltage is excessive For this reason it is recommended to adjust RP2 to its maximum counter clockwise position before initial power up of a replacement detector or NDIR amplifier board 11 2 Coarse Zero Adjustment With zero gas still flowing connect a DC voltmeter to TP7 and TP9 common Switch JP8 to the on position and leave JP6 and JP7 in the off position The target DC voltage for TP7 is OmV Adjust RP5 first and use RP3 for the final adjustment 11 3 Span Gain Adjustment With a full scale span gas flowing connect a DC voltmeter to TP8 and TP9 common The target voltage for TP8 with a full scale span gas flowing is 8 0OVDC Turn RP4 fully clockwise 12 turns To achieve this voltage select a resistor value or combination of values to install into R30 R35 R36 and or R37 Set the corresponding Jumper JP9 JP12 to the on position for each resistor used to set the gain The value needed may range between 1K and 100K ohms A smaller resistor value increases the gain and achieves a larger DC voltage at TP8 when span gas is flowing RP6 can be used to make a small gain adjustment when the target voltage is close W
76. g for flatness or deterioration and replace if necessary The block cell can be re assembled by following the reverse of the disassembly procedures Note the orientation of the loose window and 0 ring during disassembly Note Before re installing the infrared source unit block cell and detector sub assembly you should first remove and clean the pipe cell 13 14 15 16 17 Remove the pipe cell retaining screws No 7 in figure 10 3 Remove the retaining clamps No 11 in figure 10 3 Lift the pipe cell out of its two supports No 10 in figure 10 3 and remove both windows right hand threaded No 14 in figure 10 3 At this time inspect the O Ring No 13 in Figure 10 3 for signs of deterioration Replace if necessary The CaF window is bonded to the window holder Inspect and clean the windows as necessary using cotton swabs and a suitable cleaning solution California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 69 of 89 Section 10 Model 601 601 P 602 602P 603 NDIR Analyzer Alcohol or an alcohol based glass cleaner is a suitable cleaning solution A soft cloth or tissue that will not deposit lint should be used to clean the liner amp windows 18 19 The pipe cells contain a reflective metal foil liner not shown in Figure 10 3 to enhance the light energy through put in the cell Normally it is not necessary to remove the liner for cleaning however the l
77. he raw value can be displayed This is the value before linearization and offset span correction There are two values on the screen The value at the top is the linearized offset span corrected value and the other value is the raw value Figure 7 27 Linearization Screen Figure 7 28 Coefficients Range Select Figure 7 29 Change Coefficients Figure 7 30 Linearized and raw data California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 46 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 6 F7 System Settings This screen allows all the system settings to be displayed and modified Figure 7 31 System Setup Screen 7 6 1 F1 Real Time Clock This brings up the clock time set screen auto cal and auto cal enable screens Figure 7 32 Clock and Timing Setup Screen Figure 7 33 Clock set screen The current time may be set by using the cursor to highlight the entry and using the numeric keys to change the values F2 brings up the auto cal time set As above the date and times can be set by using the cursor to highlight the entry and using the numeric keys to change the values F3 Sets autocalibration ranges California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 47 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer Figure 7 34 Set Auto Cal Timing Figure 7 35 Set Auto Cal Ranges Figure 7 36 F4 Toggles Auto
78. help information for the parameter selected ranges etc THE LOWER INFORMATION AREA CONTAINS The time and 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 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 26 of 89 Section 4 Model 601 601 P 602 602P 603 NDIR Analyzer 4 1 Menu Trees Main Menu All access F1 Measurement F2 Purge Analyzer F3 Diagnostics F4 Calibration F5 Setup F6 Remote Manual F7 Stand by California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual VN NEY SS Ss Model 601 Menu Tree Measurement Purge Analyzer Diagnostics Flow 1 Temperature Barometric pressure External 1 External 2 Calibration F1 Auto calibration F2 Manual calibration F3 Display deviations F4 Check calibration F5 Reset calibration values Setup F1 Span gas concentrations F2 Calibrations settings F3 Range limits F4 Alarms F5 Password F6 Linearization F7 System settings F8 Measure settings F10 Version Remote Manual Toggles pump on Sets analyzer in purge mode F1 Starts auto calibration on range in use F2 Zero span calibration change range F
79. hen finished setting the gain adjustment flow zero gas again and repeat the previous to step to achieve a good zero at TP8 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 71 of 89 Section 11 Model 601 601 P 602 602P 603 NDIR Analyzer 11 4 Check and Repair Detector No 15 in Figure 10 1 and Figure 10 3 No 14 in Figure 10 2 11 4 1 Problem Microflow sensor broken bridge resistor defective or gas leak in detector 11 4 2 Symptom Zero adjustment impossible 11 4 3 Check and or replace 1 The microflow sensor and bridge resistors No 16 in Figure 10 1 are normal when DC voltages of about 1 5 to 2V are measured between bridge circuit board terminals numbered 1 3 and between terminals numbered 2 3 respectively and the difference between these voltages is a few tenths of a volt These two voltage readings can be measured from the top of the NDIR amplifier board between ground TP9 and pin 1 of J3 and pin 3 of J3 respectively when R7 is removed J3 is not labeled on the top of the circuit board as it is mounted on the bottom side of the circuit board The pins are accessible on the top of the board between U3 and JP1 Pin 1 is designated with a square pad 2 Connect an oscilloscope between the NDIR amplifier board check terminals TPp common and TP3 When the NDIR amplifier board infrared light source unit and chopper are normal but ac waveform approximately 10 Hz is
80. iations 4 3 Flow Zero or Span Gas 4 4 Reset Calibration Values TABLE D HEEN California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 1 of 24 ADDENDUM 13 5 Starting With Serial Number U06081 1 0 INTRODUCTION The Model 600 NDIR Series of instruments starting with Serial Number U06081 have several new Hardware and Software features The Hardware includes the use of a new memory system isolation of the analog output signals and 15 relays that are used to buffer the many new digital output signals that are now available SEE TABLE D The available digital signals consist of a SERVICE group which can be used to externally monitor a number of conditions for preventative maintenance and diagnostics A second STATUS group is provided to define the operation of the instrument such as Spanning Zeroing Calibrating and the current Range 1 2 3 4 AUTO Many of the various signals are duplicated because an NDIR instrument can consist of up to three different channels The Software includes modifications to existing functions changes to the Measurement screen additional Short Cut Keys and several New Functions that are listed as follows e MEASUREMENT Over Range 888888 Diagnostics F3 Zero F5 Span
81. iations Figure 7 15 Span gas deviations During calibration there is verification for zero and span gas With option F3 and F4 you can view the deviations during the verification time Absolute deviation is the absolute average difference from the saved value in ppm Relative deviation is the absolute average difference in percent related to the range limit 7 4 4 Absolute Zero Gas Deviation Absolute zero gas deviation is zero gas content calculated by the factory polynomial related to the range limit of the calibrated range 7 4 5 Relative Zero Gas Deviation Relative zero gas deviation is the actual deviation minus the deviation of the previous calibration related to the range limit of the calibrated range California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 39 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 4 6 Absolute Span Gas Deviation Absolute span gas deviation is span gas bottle value minus span gas value calculated by the factory polynomial related to the range limit of the calibrated range 7 4 7 Relative Span Gas Deviation Relative span gas deviation is the actual deviation minus the deviation of the previous calibration related to the range limit of the calibrated range 7 4 8 F4 Check Calibration There is a default calibration Pressing F4 activates an automatic zero and span check for verification 7 4 9 F5 Reset Calibration Values There is a d
82. ined AO 2 User Defined AO 3 User Defined AO 4 User Defined AO 1 User Defined AO 2 User Defined AO 3 User Defined AO 4 1v 5v 10v mA 1v 5v 10v mA 1v 5v 10v mA 1v 5v 10v mA Digital Digital Digital D Output D Output D Output D Output D Output D Output GND Digital Sense Auto Range Sense Range 1 Sense Range 2 Sense Range 3 Sense Range 4 6 7 8 9 10 11 GND Digital Sense Auto Range Sense Range 1 Sense Range 2 Sense Range 3 Sense Range 4 6 7 8 9 10 11 GND Digital Sense Auto Range Sense Range 1 Sense Range 2 Sense Range 3 Sense Range 4 TTL low true TTL low true TTL low true TTL low true TTL low true D Input D Input D Input D Input D Input Set Auto Range Control Range 1 Control Range 2 Control Range 3 Control Range 4 12 13 14 15 16 Set Auto Range Control Range 1 Control Range 2 Control Range 3 Control Range 4 12 13 14 15 16 Set Auto Range Control Range 1 Control Range 2 Control Range 3 Control Range 4 D Input D Input D Input D Input D Input SPARE Auto Cal Calibrate Zero Span Sample 17 18 19 20 21 Auto Cal Calibrate Zero Span Sample 17 18 19 20 21 Auto Cal Calibrate Zero Span Sample D Output D Output D Output Zero Gas Flow Span Gas Flow Sample Gas Flow Zero Gas Flow Span Gas Flow Sample Gas Flow Zero Gas Flow Span Gas Flow Sample Gas Flow OC 24vdc if internal SV OC
83. ined in the deviation table Manual Zero Ei SMAW IS Manual Span K2 SARE lI Zero gas Use F3 To Toggle Span gas Use F3 To Toggle Diagnostics Cal His Diagnostics Cal Via Using Current Temp amp Press Using Current Temp amp Press BEA oo Qutside Deviation Limits Channel Channel Conc MEA Range Range ia Fil Save value an al enu F2 Man Cal Menu Hed Max 14 16 47 09 2008 lal CAI Tel 85001 93259 09539 lai The Above is shown using Zero and Span Cal From Measurement use F5 zero or F6 span From Main Menu use F4 F2 F1 zero or F2 span California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 20 of 24 ADDENDUM 4 2 Calibration Deviations MAIN F5 F2 F2 Deviations F3 Measuring Deviations Setup Ki SMGA E Measuring deviationl ad Deviations z 1 J absolute relati Rangel io oo 10 Paved Al 8 Ba 28 Ranged BS 16 60 10 ee ae Enter deviations for channel i1 800 959 0959 Sum Jan G1 00 11 48 2003 lal Note These screens are used by the operator to define the maximum acceptable limits of the Zero and Span gas for both Manual and Automatic Calibrating 4 3 Flow Zero or Span Some analyzers have the above and the ability to flow Zero and Span Gas Manual calib Ki SHGA IS Manual calib Ki SARA IS Cuz CO Ri i6b 00 ARIL 100 0 Hed May 14 16 45 58 2008 l Wed Hax 14 16 47 28 2008 The above is sh
84. iner should be removed if the cell is subjected to grossly excessive moisture If necessary clean both sides of the liner and the inside of the pipe cell If the liner has been subjected to a corrosive substance it should be replaced In either case ensure that the small gas holes in the liner are aligned with the gas fittings at both ends of the pipe cell before reassembling the windows The pipe cell can be re assembled and installed by placing it in its supports and securing with its retaining brackets Note Before tightening the retaining brackets be certain that a gap of approximately 0 5 1 0 mm exists between the pipe cell and the pipe cell detector 20 Reinstall the infrared source unit block cell and detector sub assembly by performing steps e f g h and in reverse being sure to leave a slight gap of approximately 0 5 1 0 mm between the back of the block cell and the front pipe cell window California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 70 of 89 Section 11 Model 601 601 P 602 602P 603 NDIR Analyzer 11 ADJUSTMENTS CHECKS AND REPAIRS 11 1 Adjustment of Detector Voltage NDIR S only Note Adjustment is required if detector or NDIR amplifier board is replaced Important Turn RP2 to its maximum counter clockwise position before initial power up of a replacement detector or NDIR The detector operating voltage is specified on the label attached to the side o
85. ires on site repair such warranty labor will be provided at no charge however transportation and living expenses will be charged to Buyer 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 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 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 CAI 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 Representa
86. its of _M2 x x channel m are responded _M3_y y _M4 zz AMBE_KO_Mn AMBE_s_ Mm zz Range limit of Range Mn is responded 12 4 4 AKAK Calibration gas concentrations Command Response Description _AKAK_Km _AKAK_s_ MI ww All existing calibration gas values are _M2_x x responded for selected channel m _M3_y y _M4 zz _AKAK_Km_Mn AKAK s Mn zz For selected channel m calibration gas value of Range Mn is responded 12 4 5 AMBU Upper and lower range switchover values for auto range _AMBU_Km AMBU_s_ MI ww WW Lower and upper range switchover M xx SS value of auto range are responded for _M3_y y_Y Y channel m _M4 z z Z Z AMBU_Km_Mn _AMBU_s Mn ww W W Lower and upper range switchover value of auto range are responded for channel m range n California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 79 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 4 6 ASTZ Normal device status Command Response Description _ASTZ_KO ASTZ_s K1_State1_State2_State3 Respond device status for all K2 State1 State2_State3 channels K3_State1 State2_State3 _ASTZ_Km ASTZ_s_State1_State2_State3 Respond device status only for channel m Possible states State 1 State 2 State 3 SREM remote STBY standby SARE auto range on SMAN manual SPAU pause SARA auto range off SMGA measuring gas SNGA zero gas SEGA end gas SATK SNGA zero gas during auto cal SATK SEGA end gas during auto cal 12
87. layed Figure 7 52 Standby Mode California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 53 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer 8 Analyzer Components 8 1 Rear Panel The following details the rear panel connections Figure 32 Rear Panel Sample Gas Inlet Feeds sample gas to the analyzer 1 4 Inch Tube 2 Sample Gas Bypass Outlet Vent Exhaust for sample 1 4 Inch Tube 3 TCP IP Connection Connect Network Connector 4 28 Pin output terminal strip main 1 standard 5 28 Pin output terminal strip main 2 optional 6 28 Pin output terminal strip main 3 optional 7 Power Entry Module Power connection power switch fuse compartment 2 Amp With Rear Panel Power ON OFF Switch Turns ON OFF line power to instrument California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 54 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer 8 Serial Connector Connect Serial Connector California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 55 of 89 Section 8 Model 601 601 P 602 602P 603 NDIR Analyzer 8 2 Rear Panel Connectors 28 Pin Main Connector Assignments 28 Pin Auxiliary Connector Assignments Main 1 Main 2 Main 3 601 602 603 Optional Optional Analog Analog Analog Analog A Output 1 GND analog GND analog A Output Channel 1 Ch
88. libration procedure D onj o Z Le che et CC obs ct DHH Dt i tooo m l gt I TZ wo ok cr I room h O OF 2000D wi P i P 1 2 A A e H E r Oo Sp o bd cns TW go el Ro This screen provides a section that is used to record the zero signal corrections zero offset and a second area to record the 100 signal corrections Gain for each of the four output signals that may be defined to develop a voltage or current signal Since this is a Digital to Analog conversion the calibration will require the completion of a simple trial and error procedure The operator will observe the results of a zero or span Gain signal generated by the analyzer to the remote recording device and select a correction factor The operator will save this value and then observe the results on attached the remote recording device The process of selection and saving for zero and span will be repeated until a satisfactory calibration is achieved For 0 1VDC 0 5VDC 0 10VDC and a 0 20 mA outputs the Offset and Gain values are independent and do not interact With the 4 20 ma output the Offset zero and Gain span values interact and may require a few more trials The following is a table of typical values OUTPUT OFFSET GAIN 0 20 ma 0 000 0 927 4 20 ma 1 820 0 740 0 1 V 1 300 0 820 0 5 V 1 100 0 820 0 10 V 1 050 0 820 California Analytical Instrume
89. ment such as Spanning Zeroing Calibrating and the current Range 1 2 3 4 AUTO etc SEE TABLE C amp D The individual output signals can be operator selected and set to a HOLD or CLEAR mode In the HOLD mode an activated signal is retained until the operator returns to the Digital Output Screen and selects the appropriate output signal and performs a manual CLEAR After performing a Clear Operation the operator must press F2 again to put the outputs back onto HOLD mode User DO I E2 SsTBY E i SERS E EE EE EE E Set Unused Channels Off EE EE E EE ERE ES Hold E A A D 6 S z 1 A In the Clear Mode the signal will automatically change when the microprocessor detects that the noted condition no longer exists User DO II E2 SHAH IS Ei Hm J 16 off ii of SESE EE EE E EE iz Off S5et Unused 13 Off Channels Off 14 Off EE E EE EE EE 15 off Fi ito r DO s MHAIN BACK to SAVE Check Chi Temp la California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 16 of 24 ADDENDUM The operator can select from the following the desired SERVICE or STATUS groups that are to be digitally monitored Index ON OOK Go M O Re 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 34 TABLE B Service Group Flow 1 Failure Flow 2 Failure Flow 3 Failure Extern Analog 1 Failure Extern Analog 2 Failure Pr
90. ments K2 SMAN zl 12 50 PPM J F8 z Peo e a eoa Lu LUZ KAS R1 1000 R1i 16 Ri 2000 E ee eee ea Mon How 17 12 10 26 2003 Figure 7 4 Analyzer set to Range 1 603 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 35 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 2 F2 Purge Analyzer Figure 7 5 Main Menu User Level 4 Figure 7 6 Purge Screen F2 from the Main Menu activates the Purge analyzer function if equipped 7 3 F3 Diagnostics F3 from the Main Menu activates the Diagnostics function F3 brings up the two diagnostics screens The Diagnostics screens may be brought up from EITHER the Main Menu or the Measurements screen Figure 7 7 Diagnostics Screen California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 36 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 4 F4 Calibrations F4 from the Main Menu activates the Calibrations screen Calibrations may be automatic or manual Deviations can also be displayed Calibration values can be reset to default values and the range to be calibrated can be changed Calibrations K3 STBY E An a Ri inod d d 25 Automatic calibration Mon How 17 10 46 51 2003 Figure 7 8 Calibration Screen 7 4 1 F1 Automatic Calibration From the Calibrations screen F1 starts automatic calibration If auto range is selected the actual range in u
91. mple gas If the concentration is incorrect the analyzer will need to be calibrated using zero and span calibration gases Please reference the appropriate section of the manual for a description on how to zero and span the analyzer California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 5 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer TABLE OF CONTENTS 1 Introduction EE 15 EN UN o 15 1 23 Unpacking HASTEN SOR CC tise taa set aca as ba a Saeed ca ee via Rat eer aeene eee 15 1 3 Reporting Damage E 15 1 4 lt Gontack EENEG een eneen e tetany 15 1 5 Warranty Certificate EE 16 1 6 Possible Explosion Hazard EE 17 1 7 Electrical Shock Hazard sde egcgeNet ER oSedihee ddan oS aches EENS EEN d Ncdadeseddaaades 17 1 85 Plig Removal EE 17 P PE OTT 18 2d Description EE 18 22 EE EE 18 23 Features Gonetal E 18 2 4 Infrared Gas Analyzers guden ts Shiges edie tuwasechtved stake qeustdaueeladeeteensseeueediede 19 e lee 20 26 edel e 21 2 7 Model 600 NDIR Specifications un 22 2 8 Model 600 NDIR E antreg iezetets iedteee eege eelere dee ege E 22 3 rps telat e EE 23 Ot COME Al EE 23 2 SMe le We e e EE 23 O07 Eed 23 3 4 Analog Output Connections Appendix ccccceeeeeeeeeeeeeeeeeeeeeeeenneeeeeeeeeeteneeaaees 24 Bie MASS caches ei scwh tad Sa leclag acta E E E E E E ES 24 3 6 Gas Handling Equipment dc 10 c cean DEER AER EE Eege 25 37e MAAS GO MME CH O
92. ncy is related to the rate of the beam interrupting chopper blade The signal amplitude is related to the measured gas concentrations in the sample cell This signal is amplified by successive AC amplifiers and then demodulated and filtered The resulting DC signal is further amplified and fed into two output buffer amplifiers The DC signal output of the printed circuit board is the input to a microprocessor Here it is digitized and linearized for digital display The digitized information is then fed to a D A Converter so it can be isolated and converted to a 0 10 VDC or 4 20 mA output This output along with optional alarm contacts is sent to the 28 pin output connector located on the rear panel of the analyzer for customer connection Printed Circuit Board D Rectifier amp AC Smoothing DC Amplifiers Circuit Amplifier Detector ep Infrared os Chopper Motor Infrared Source Unit Figure 2 4 Block Diagram California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 21 of 89 Section 2 Model 601 601 P 602 602P 603 NDIR Analyzer 2 7 Model 600 NDIR Specifications IR ANALYSIS METHOD Non Dispersive Infrared NDIR NDIR COMPONENTS CO CO 2 CH4 C3Hs SO2 NOISE Less than 1 of Full Scale of Factory Calibrated Ranges 0 25 to 2 0 Liters minute LPM Consult Factory for other flow rates O2 RANGES 0 1 up to 0 100 O Full Scale Four Definable Ranges 2
93. nd Response Description _EKEN_KO_new device name _EKEN_s Set new device identification Maximum length of device name is 40 characters NOTE To change device identification you must first rename the device to RESET Now a name up to 40 characters can be given NOTE The device name must not have any blanks between characters e g CAl CLD is not allowed You can use underscores e g CAl_CLD 12 6 5 EGRD Set polynom coefficients Command Response Description EGRD_Km_Mn_a0_al_a2_ a3 ad _EGRD_s Set polynomial coefficients of range Mn on channel m 12 6 6 EFDA Set autocalibration and purge times Command Response Description EFDA_Km_SATK_z_y_x_w _EFDA s Set auto cal times for channel m z Purge time y Calibration time x Total calibration time w Verify time z y X w in seconds EFDA_KO_SSPL_z _EFDA_s Set analyzer purge time to z seconds 12 6 7 EPAR Set autocalibration tolerance values Command Response Description EPAR_Km_SATK_z z_y y_x x_w w _EPAR_s Autocalibration tolerance value z z Range 1 y y Range 2 x x Range 3 w w Range 4 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 86 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 6 8 ESYZ Set System Time Command Response Description _ESYZ_KO_yymmdd_hhmmss _ESYA_s_ Set system time yymmadd year month day each 2 characters wide no spaces hhmmss hou
94. nge 1 1R1 40 1 Range 2 1R2 41 1 Range 3 1R3 42 1 Range 4 1R4 43 1 In Calibrate 1C 44 1 In Zero 1Z 45 1 In Span 1S 46 1 In Sample 1Sa 47 2 Auto Range 2AR 48 2 Range 1 2R1 49 2 Range 2 2R2 50 2 Range 3 2R3 51 2 Range 4 2R4 52 2 In Calibrate 2C 53 2 In Zero Ke 54 2 In Span 2S 55 2 In Sample 2Sa 56 3 Auto Range 3AR 57 3 Range 1 3R1 58 3 Range 2 3R2 59 3 Range 3 3R3 60 3 Range 4 3R4 61 3 In Calibrate 3C 62 3 In Zero 3z 63 3 In Span 3S 64 3 In Sample 3Sa Typical Relay Digital Out 600 SERIES Common These contacts 3 4 will drive continuously up to 500 MA using a customer voltage supply that does not to exceed 60 VDC California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 18 of 24 ADDENDUM e Operation Use Main F5 F9 to select the first eight outputs Use the to select the desired output Press ENTER and use to select desired item Press ENTER to save selection NOTE The 600 NDIR has 14 user selectable isolated digital outputs from the list of 64 in TABLE B amp C User DO I E2 S5TEY HI i EE E EE E E EE E E Set Unused Channels Of f SEEKS EERKR SEEKS Clear Hold z A A 5 2 1 A Press F1 to observe the remaining seven outputs Program as desired per the above User DO II E2 Gen IS pa Gel q i off ii off EE E E E EE E E EE E iz off S5et Unused LS Dff Channels Of f i4 off ee E r5 Off Fi i to 7 DO s MAIH BACK to S
95. nges 49 7 6 5 F5 Turns Status Line On or Off eege geben encore 50 7 6 6 F8 Measure Settings ex ca sessgs atch ccs en NEE Ee ace eek taal tees beta ees E 50 7 6 7 Ft SetLowpass filter Acti cr ale cad ace enact ek cas heen ed 50 7 6 8 E2 Purge TIME raina e e AT E E REER aaah 51 7 6 9 F3 Set Temperature Compensaton ENNEN 51 7 6 10 F4 Pressure Compensaton EEN 51 7 6 11 F3 Low Pass Filter Time Constant c2eccscucecscsieveesceaie nce Ee Ze ge 51 7 6 12 F10 Displays the Current Analyzer and Software Versions s1eeenee 52 7 7 F7 Remote Manual Me en e EE 52 7 8 el EE 53 8 Analyzer COMPONGIUS assisi cacecccecsccecscacnexsaccbaneenccdeuesscaaanesscacutasiceiaseenseceenteeaensaehs 54 Bilis Rear EEN 54 8 2 Rear Panel EDERT E EEeEe 56 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 8 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer GE DER Riet CH helt 57 8 3 1 RS 232 Standard 9 Pin DIN CGonnechor AA 57 8 3 2 TCP IP 8 Pin RJ 47 Connector i xcseccsctesnelenciiateteenl ood titel 57 8 4 Internal Component Locations s c 5 22 ced insasdotivenesteasedonienpl e SEENEN 58 8 5 Main Electronics Board Potentometers 60 8 6 NDIR Detector Assembly 2 veogeh EZKENAESENEEER SEENEN EEN ieee heen al eneteede 61 9 OOK AU OM EE 62 E External Wiring E 62 9 2 External Piping eege ge Deele 62 9 3 Operation amp e e EE 62 9 3 1 POwWSTOMS monre ae er REN RE PA
96. nteetseeckvabidelcudetsvteeqehteas Qeakseakteesteakiiessteheeasreseteeases 51 Figure 7 46 P Compensation BEEN 51 Figure 7 47 Low pass filter time constant oc sicdise secs cerstavsd loco beeveeeeecivees SEENEN degen d 52 Figure 7 48 Analyzer Information 52 Figure 7 49 S ftware Versio ecicee ssetatcelvrectiendee bean reas tuedat N E E R 52 Figure 7 50 F6 Remote Manuall sees se shccececs eceaavcahivnd tebecvahssaeuces ENEE EEEEE AEN EE 52 Figure EE 53 Figure 7 52 Standby E 53 Figure 8 1 Internal Gnichtel NEES ENEE NEES 58 Figure 8 2 Main Electronic Board Potentiometers AAA 60 Figure 8 3 elle el e TEE 61 Figure 10 1 Optical Bench with Pipe Sample Cell 64 Figure 10 2 Optical Bench with Block Sample Cell ccccecceeeeeeeeeeeeeeeeeeeeee eee eeeeeneeeeeeeeeeeeeeea 66 Figure 10 3 Optical Bench with Pipe and Block Type Sample Cell 68 Figure 11 1 Amplifier circuit ac wave form EEN 75 Figure 12 1 Serial WMO ACE eelere eenegen 76 Tables Table 10 1 Optical Eeer ne UE e LEE 63 Table 12 1 Structure of an instruction Commande ENNEN 77 Table 12 2 Structure of an acknowledgement commande 78 Table 12 3 Acknowledgment response in case Of emt 78 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 14 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 1 Introduction 1 1 Overview Congratulations and thank you You have just purchased one of the most reliable gas analyzers in the world
97. nts Model 600 NDIR Operators Manual January 10 2011 Page 10 of 24 ADDENDUM e Procedure 3 4 1 From the Main Menu press F5 F7 F3 to obtain following screen assignment K2 SARE zl Output Signal mA S Z ITET A Channels 4 Flowl Main F5 F7 F3 3 4 2 Use the to highlight the outputs that require calibration 3 4 3 Press enter to provide access to all the menu of signals that are available Real Time Channel 1 Channel 2 Calibration Sample pressure etc 3 4 4 Select Calibration and press ENTER to complete the selection assignment IS Output Signal WaT 3 Channel3 4 Flowl CAI Tel 800 959 0959 Note Any or all of the four outputs can be selected for calibration This screen will not be used again until calibration has been completed California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 11 of 24 ADDENDUM 3 4 5 Press BACK to return to the SYSTEM SETUP screen F5 F7 from the main menu 3 4 6 Press F8 to obtain the following screen MAIN F5 F7 F8 3 4 7 Use the to select the desired output press ENTER 3 4 8 Press F1 to select a ZERO signal and observe the results on the remote device 3 4 9 Change the offset value press BACK to save the new value 3 4 10 Press F8 to return to the D A Calibration screen and note the results on the remote device 3 4 11 Repeat steps 3 4 8 thru 3 4 10 until a satisfactory ZERO calibration i
98. om the Main Menu press F5 Setup then F7 System Settings ii Press F3 output assignments to setup the output channels 1 Set to real time 2 AUX 1 3 AUX 2 4 AUX 3 5 Press back to return to the system settings menu iii Press F4 output range to setup the output ranges 1 Set the Min and Max to zero 0 This will cause the outputs to default to the current ranges 2 Set the outputs for milliamps mA or voltage V as desired a The mA setting will give 4 20 mA or 2 10V if 500 ohm resisters are installed b The V setting will give 0 20mA or 0 10V if 500 ohm resistors are installed AN Disconnect power before proceeding 5 Connect all appropriate analog outputs a Pin 1 is the output common ground b Pins 2 3 4 and 5 are output channels 1 2 3 and 4 as setup in step 4 a ii c If the output is set for voltages but there is no voltage output you will need to install a 500 ohm resistor between pin 1 and the channel you are trying to measure You will have to measure the voltage drop across this resistor 6 Reconnect the power and turn on the analyzer Press F1 from the analyzer s main Menu to get to the measurement screen 7 Supply sample gas to the analyzer California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 4 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 8 The measurement screen should indicate the concentration of the sa
99. or SV Solenoid Valve TTL Transistor Logic 601 Analog Signal Type 602 Analog 603 Analog Levels pin GND Isolated analog pin GND Isolated analog pin GND Isolated analog A Output Isolated Al A Output A Output A Output A Output 5 User Defined AO 1 User Defined AO 2 User Defined AO 3 User Defined AO 4 User Defined AO 1 User Defined AO 2 User Defined AO 3 User Defined AO 4 User Defined AO 1 User Defined AO 2 User Defined AO 3 User Defined AO 4 1v 5v 10v mA 1v 5v 10v mA 1v 5v 10v mA 1v 5v 10v mA Digital Digital Digital D Output D Output D Output D Output D Output D Output GND Digital Sense Auto Range Sense Range 1 Sense Range 2 Sense Range 3 Sense Range 4 6 7 8 9 10 11 GND Digital Sense Auto Range Sense Range 1 Sense Range 2 Sense Range 3 Sense Range 4 6 7 8 9 10 11 GND Digital Sense Auto Range Sense Range 1 Sense Range 2 Sense Range 3 Sense Range 4 TTL low true TTL low true TTL low true TTL low true TTL low true D Input D Input D Input D Input D Input Set Auto Range Control Range 1 Control Range 2 Control Range 3 Control Range 4 12 13 14 15 16 Set Auto Range Control Range 1 Control Range 2 Control Range 3 Control Range 4 12 13 14 15 16 Set Auto Range Control Range 1 Control Range 2 Control Range 3 Control Range 4 D Input D Input D Input D Input D Input SPARE A
100. own using Zero SPAN Gas From Cal Screen use F2 or Main or Back From Main Menu use F4 F2 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 21 of 24 SECTION 13 ADDENDUM 4 4 Reset Calibration Values When the re set calibrations value function is used all recorded deviations will be set to zero Def cal value Span gas devs izl Span gas devs Span gas devs verifying Span gas deviations XZ measured deviatio abs rel angel pn e ae 9 op 9 og ange2 a J F 5 S ee Ei CN E 3 80 CS ange4 S D Z 2 Gebeier SC select EE CAI Tel 800 959 0959 i CAI Tel 800 959 0959 F Main F4 F3 F4 Main F4 F3 F2 Used to observe Auto Cal Results Used to observe Manual Cal results The above are the new deviations after the operator elects to re set the calibration values California Analytical Instruments Model 600 NDIR Operators Manual May 27 2008 Page 22 of 24 SECTION 13 ADDENDUM TABLE D 600 NDIR SERIES UO CHART 28 PIN MAIN CONNECTOR ASSIGNMENTS AO Analog Output OC Open Collector SV Solenoid Valve TTL Transistor Logic 601 Analog Signal Type 602 Analog 603 Analog Levels pin GND Isolated analog pin GND Isolated analog pin GND Isolated analog A Output Isolated Al A Output A Output A Output A Output 5 User Defined AO 1 User Defined AO 2 User Defined AO 3 User Defined AO 4 User Defined AO 1 User Def
101. p Pressure Temperature Name Concentration Detector Volts Range Auto Manual Span Value Offset Gain Sample Pressure Sample Flow Sample EPC Volts Detector Temperature Meas Mode Local Remote If 2 Channel this data is added Name Concentration Detector Volts Range Auto Manual Span Value Offset Gain Sample Pressure Sample Flow Sample EPC Volts Detector Temperature Meas Mode Local Remote California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 14 of 24 ADDENDUM TABLE A cont 600 SERIES NDIR DATA ARCHIVE FILES If 3 channel this data is added Name Concentration Detector Volts Range Auto Manual Span Value Offset Gain Sample Pressure Sample Flow Sample EPC Volts Detector Temperature Meas Mode Local Remote California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 15 of 24 ADDENDUM 3 6 User Digital Outputs e Overview The 600 NDIR Series of instruments have 15 solid state optically coupled isolated relays that can be programmed by the operator to indicate the status of numerous signals The available digital signals consist of a SERVICE Group that can be used to externally monitor a number of conditions to aid in preventative maintenance and diagnostics SEE TABLE B amp D A second STATUS group is provided and is used to define the operation pf the instru
102. per Range Seege reegelen ieee eee 43 Figure 7 22 Change Auto Range Limits EEN 43 Figure 7 23 EN WEE 44 Figure 7 24 EE 44 Figure 7 25 Enter Change Password EE 44 Figure 7 26 Access Level Screen cis ccaeicads cated pete tetera cies ends chee al tia ad cael ead 45 Figure 7 27 Linearization Screen eeh EEkuggeued ee EE SEENEN ARENS qouescakages thee sbiauehnees ites cena 46 Figure 7 28 Coefficients Range Select AEN 46 Figure 7 29 Change Coefficients ees SC eege hae 46 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 13 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer Figure 7 30 Linearized and raw Cala ME 46 Figure 7 31 System Setup Screen DEE 47 Figure 7 32 Clock and Timing Setup Screen ANNE EEN 47 Figure 7 33 COCK Set Sereen rs ncetaticoe cat recat E hots ca ook tote amen does aed aad 47 Figure 7 34 Set Auto Cal Timi scsicessesctees Seed ENER nederwessdaeseussechages thas sueasnchteastteeteeasds 48 Figure 7 35 Set Auto Cal Ranges RRE 48 Figure 7 36 F4 Toggles Auto Cal ON Of OF Fisissccaticee ggesgreeeg ees ieee ene teeta Ries 48 Figure 7 37 TOPAP gege eis otek cpedekuee a a E E 49 Figure 7 38 Output Assignments EE 49 Figure 7 39 Oulput Ranges EE 49 Figure 7 40 Status e E 50 Figure 7 41Status line e EE 50 Figure 7 42 Measure Setup a e Ean e aa add E EEEE SEENEN EE 50 Figure 7 43 Lowpass EE Eeer ee 50 Figure 7 44 Purge TEE 51 Figure 7 45 Trend ics cc ceivessdekecnteteecendtda
103. r minutes seconds each 2 characters no spaces 12 6 9 ET90 Set Lowpass Filter Time Command Response Description _ET90 KO t _ET90_s Set lowpass filter time t filter time in seconds 12 6 10 EDAL Diagnostic alarm limits Command Response Description EDAL_KO_a1 min_a1 mas_ _a12max _EDAL s Get al alarm limits EDAL_KO_x_x min_xmax _EDAL s Set alarm limits of x Alarm Limits 1 Flow of channel 1 7 Temperature 2 Flow of channel 2 8 Sample concentration channel 1 3 Flow of channel 3 9 Sample concentration channel 2 4 External analog in 1 10 Sample concentration channel 3 5 External analog in 2 11 13 Temperature alarm limits channel 1 3 6 Pressure 14 16 EPC voltage alarm limits channel 1 3 12 6 11 ETCP Set TCP IP Parameters Command Response Description _ETCP_KO_222Z 22z 22zz zzz _EDAL_s zzz TCP IP address VW NNN NNN NNN yyy TCP IP subnet mask _XXXX xxxx TCP IP port All changes take effect after next power on cycle 12 6 12 EH2 Set H2O correction parameters Command Response Description EH2O_Km_z z_y y_x x _EH2O s z z dry y y 1st order coefficient X X 2nd order coefficient 12 6 13 ECO2 Set CO correction parameters Command Response _ Description EH20_Km_z z_y y_x x _EH2O s z z dry y y 1st order coefficient X X 2nd order coefficient California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 87 of 89
104. rce or a leaky gas seal 11 5 2 Symptom The unit reads off scale or the output is unstable 11 5 3 Check and or replace 1 After turning the power switch to OFF and disconnecting the lead wires from the two terminal screws measure the resistance between the two terminals The resistance should normally be about 38 ohms If the resistance is infinite the infrared light source is faulty Output drifts in the negative direction as resistance decreases 2 When indicator output drifts due to influence from atmosphere in spite of normal operations of the detector and main circuit board gas may be leaking into the infrared light source unit Note In the case of a low concentration CO analyzer the indicator output may fluctuate due to atmospheric CO penetrating the gaps in the optical bench This would be normal and not necessarily indicative of a problem Purge the analyzer case with N2 gas 3 Replacement After disconnecting wires from the two terminal screws and motor connector remove the two screws that are used to attach the infrared light source unit to the optical bench The light source assembly can be replaced referring to Figure 10 1 or Figure 10 2 4 After replacement of the infrared light source unit adjust the zero level and span 11 6 Check and Replace Chopper See Figure 2 1 11 6 1 Problem Rotation abnormal 11 6 2 Symptom Indicator output unstable or unresponsive 11 6 3 Check and or replac
105. rm Limits 1 Sample gas flow channel 1 7 Temperature 2 Sample gas flow channel 2 8 Sample concentration channel 1 3 Sample gas flow channel 3 9 Sample concentration channel 2 4 External input 1 10 Sample concentration channel 3 5 External input 2 11 13 Temperature channel 1 3 6 Barometric Pressure 14 16 EPC voltage channel 1 3 12 4 22 ATCP Query TCP IP settings Command Response Description _ATCP_KO _ADAL_S _22Z 22Z 2Zz zzz zzz TCP IP Address VW NNN NNN VV yyy TCP IP subnet mask _XXXX xxxx TCP IP port California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 82 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 4 23 AVER Query Software version Command Response Description _AVER_KO AVER_s_ 3MAIN_z 3USER_y_OS z Main version x xxx b_dd mm yyyy MSR_x y User version x xxx b_dd mm yyyy x OSMSR version X Xxx_dd mm yyyy 12 4 24 AH20 QueryH 0 correction parameter Command Response Description _AH20O_Km AH2O_s_z z_y y_x x z z Dry voltage of A in with no water present y y 1st order coefficient x x 2nd order coefficient 12 4 25 ACO2 Query CO correction parameter Command Response Description _ACO2_Km ACO2 Ss zz vN XX WA z z Offset voltage of A in with no CO present y y Min A in if A in is below this value no CO correction will be done x x 1st order coefficient w w 2nd order coefficient 12 4 26 AUPD Query UDP data streaming parameter Command
106. s For calibration it is necessary to input the concentration of the span gas in ppm For every range the span gas concentration can be changed After pressing F1 in the setup menu a screen appears in which changes can be made Select with the cursor buttons the range to change The selected field turns black To change parameters switch to parameter input mode by pressing the Enter key 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 Then the input cursor disappears and a new range can be selected The changes are saved by leaving the screen by pressing Main or Back At the right side of the screen the range limits of the 4 ranges are displayed They cannot be changed in this screen K3 SMAN Z range limits UEZ LI d Mon Hoy 17 10 53 37 20035 F Figure 7 18 Change Span Gas Settings California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 41 of 89 Section 7 Model 601 601 P 602 602P 603 NDIR Analyzer 7 5 2 Calibration Settings K3 SMAM Izl LU LUZ Le a change channe Change purge measuring s yverifvina scalibratian time Mon Hoy 17 10 53 46 2003 F Figure 7 19
107. s Acknowledgement Explanation 222 f1 Analyzer does not know the instruction sent wax f BS Analyzer is busy with another function xxxx f SE Syntax error within command parameters or incomplete command xxxx f NA Requested function or data are not available xxxx f DF Data error The kind or number of given parameters are not valid xxxx f OF Offline Analyzer is offline i e analyzer is in local Mode Only inquiry commands and SREM set analyzer in remote mode are allowed Table 12 3 Acknowledgment response in case of error 1 f stands for the error status byte 2 xxxx stands for the function code of the sent master command California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 78 of 89 Section 12 Model 601 601 P 602 602P 603 NDIR Analyzer 12 4 Scan Commands 12 4 1 AKON Measured concentration value Command Response Description _AKON_KO AKON S zz vy XX WW Measured concentration value of all channels is responded t Timestamp 1 10 sec _AKON_Km _AKON s z z t Measured concentration value of channel m is responded t Timestamp 1 10 sec 12 4 2 AEMB Get measuring range Command Response Description _AEMB_KO AEMB_s Mn_Mn_Mn Current measuring range of all channels is responded _AEMB_Km _AKON_s Mn Current measuring range of channel m is responded 12 4 3 AMBE Measuring range limit Command Response Description _AMBE_KO _AMBE_s MI ww All existing measuring range lim
108. s Manual January 10 2011 Page 8 of 24 ADDENDUM 3 3 Offset amp Gain Main F4 F3 F5 Offset and Gain bel Zero Span applied correction Offset Gain Rangel 0 00 i 00 Range2 0 00 1 600 Range3 0 00 1 600 Range4 0 00 1 600 Neila 0 02 to select channel CAI Tel 800 9359 0959 iF This screen can be used to provide an additional means to display calibration deviations Use lt keys to change channel The OFFSET is the value stored during zero calibration The GAIN is the value stored during span gas calibration using the operator defined calibration gas An increasing or decreasing change to the OFFSET or GAIN when used in conjunction with Deviations will provide insight to both short and long term changes to system performance 3 4 Calibrate The Analog Outputs Main F5 F7 F8 D A Calibration Main F5 F7 F3 Output Assignment e Overview The 600 NDIR Series of instruments are designed to provide analog outputs that can be configured as 0 1 VDC 0 5 VDC 0 10 VDC 4 20 mA or 0 20 mA With this version the outputs can also be configured to include an additional 1 0 volt and 5 0 volt output and a calibration capability The outputs can be calibrated to exactly match the results obtained on a PLC Recorder Data Logger or other remote recording device that may be connected to the analyzer The operator will first select the OUTPUT ASSIGNMENT Main F5 F7 F3 screen and choose the ou
109. s achieved 3 4 12 Complete steps 3 4 8 thru 3 4 10 for each of the remaining outputs that require calibration 3 4 13 Press F5 to produce a full scale 100 signal 3 4 14 Use the arrow keys to position the curser at the require GAIN value 3 4 15 Observe the results on the remote device and make a correction to the GAIN value for the output of interest Press BACK to save this new value 3 4 16 Press F8 to return to the D A calibration screen 3 4 17 Observe the results on the remote device and repeat steps change the GAIN value by repeating steps 3 4 14 thru 3 4 16 as needed for each output 3 4 18 Return to the OUTPUT Assignment screen F5 F7 F3 from the main menu and change the output signals from CALIBRATE to their original values as defined in step 3 4 1 California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 12 of 24 ADDENDUM 3 5 Save Data Archiving Time F5 F7 F1 F5 Archive Time is the Time in seconds between each set of data points If zero no data is stored in the SEC data files The SEC data files are in CSV format for direct import into Excel CAI can provide the tools necessary to download these files Use ENTER to change recording time SEE TABLE A California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 13 of 24 ADDENDUM TABLE A 600 SERIES NDIR DATA ARCHIVE FILES Time Date Month Year Error Index TimeStam
110. s are completed the analyzer will return to the Measurement Screen and to the range specified Access Level The user level at Start Up Remote Manual Put the analyzer in either Remote or Manual at Start Up California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 7 of 24 ADDENDUM 3 2 Alarms On Off Main F5 F7 All key analyzer parameters are stored in a secure memory location and retained when power is removed In the event of an unexpected power failure it may be desirable to change some parameters until an operator can resume control This screen may be used to establish several desirable special instrument start up parameters that define how the analyzer recovers from loss of AC power When enabled this screen will define the following System setup IS Bea Jire Clock settings Bu utput assignment F Late ange FS status line on off off os analyser Alarms ON 7 OFF CAI Tel 800 959 0959 Use F6 to toggle ON OFF The instrument has an extensive library of error messages that will aid in the identification of various anomalous events and are displayed at the bottom of the screen These messages will assist in Diagnostics and indicating the need for preventative maintenance This screen provides an option to disable these messages during initial start up or as may be desired for a particular application California Analytical Instruments Model 600 NDIR Operator
111. s the concentration of measured gas component increases Figure 2 3 Infrared Source Unit Sample In Exhaust Front Chamber Infrared Source l t Rear Chamber Detector ee l ba or Chopper Motor Sample Cell Micro Flow Sensor Chopper Blade Figure 2 1 Single NDIR Analyzer California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 19 of 89 Section 2 Model 601 601 P 602 602P 603 NDIR Analyzer Output Zero gas Span gas bei Vs Span gas K Constant Vo Concentration Figure 2 2 Detector Output Signal Figure 2 3 Absorption Characteristic of Detector 2 5 Interference Gases Whenever a sample gas contains a gas component that has an absorption spectrum that overlaps the spectrum of the gas to be measured that gas is commonly referred to as an interference gas The Microflow Detector was specifically designed to minimize the effect of interference gases When these gases are present the pressure rises in the front and rear chamber of the detector cancel each other minimizing any response to the interference gases California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 20 of 89 Section 2 Model 601 601 P 602 602P 603 NDIR Analyzer 2 6 Electronics The sinusoidal output signal of the detectors microflow sensor is transmitted to the AC amplifiers on the main circuit board The signal freque
112. se will be calibrated Auto calibration works as follows First zero gas is purged a certain time called purge time Then the measurement begins The measured value must be a minimum time called measuring time and within an upper and a lower limit to be saved as new offset value The maximum length of measuring time is 9 seconds If the measured value was constant during calibration time it is checked to determine if this value deviates from the preceding value If the deviations are too large a warning Deviation error appears and the user can choose if the new value is saved or not At last the zero gas is flowed a further time verifying time so it can be checked if the signal is still constant All of these times can be changed After zero gas calibration the same happens with span gas During auto calibration Calibration in progress is displayed It also shows which gas is flowing and which time runs When auto calibration has finished it is displayed If the span value of the selected range is 0 see section 5 6 1 then it will not be calibrated If one range is calibrated and the span value for the lower ranges is zero calibration parameters will be copied to this range To calibrate all ranges with the same span gas you must enter the gas concentration in the Span Gas Calibration screen for ALL RANGES You must also calibrate each range Offsets and scalors are NOT copied to other ranges Auto calib KLiSTBY Calibration in progr
113. t 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 3 5 Gases 1 Nitrogen or zero air in pressurized cylinder 2 Standard span gas es near full scale concentration with a nitrogen balance in a pressurized certified cylinder California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 24 of 89 Section 3 Model 601 601 P 602 602P 603 NDIR Analyzer 3 6 Gas Handling Equipment 1 Pressure regulators for zero gas Air or N2 and span gas cylinders 2 Corrosive resistant gas tubing 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 ob
114. t source emits infrared light in all directions The light emitted forward is transmitted and reflected into the detectors The infrared light emitted backward is reflected by a reflecting surface and is added to the infrared light emitted forward Arranged between the infrared light source and measuring cell is a chopper blade which rotates to modulate the infrared light beam at regular frequency The modulated infrared light beam thus formed passes through the measuring cell filled with a sample gas where the light energy is partially absorbed or attenuated before it reaches the front chamber of the detector Both the front and rear chambers of the detector are filled with the gas component to be measured The infrared light energy is partially absorbed in the front chamber and residual light is absorbed in the rear chamber thereby increasing pressure in both chambers Since the detector is designed to produce a pressure difference between the front and rear chambers a slight gas flow is produced through a path connecting these chambers with each other This slight flow is converted into an AC electrical signal by a microflow sensor arranged in the path connecting the chambers with each other The AC signal is amplified and rectified to a DC voltage supplied to the output terminals and indicator Figure 2 4 Figure 2 2 shows the detector output signal with the greatest amplitude when zero gas is flowing in the measuring cell Amplitude is reduced a
115. tability is provided by an improved photometric system which assures less influence due to contamination of the measuring cell and higher long term stability than conventional dual beam analyzers e A dual chamber type detector effectively minimizes influence due to concomitant gas components e A microflow sensor within the detector features high reliability long service life very low noise and excellent resistance to vibration e The easily serviced single beam photometric system does not require delicate adjustment of the optical balance e Simple construction assures reliable performance e Modular component design simplifies maintenance Independent elements are easily removed for maintenance e Low Power Consumption The instruments are of energy saving design with power consumption as low as 30 VA California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 18 of 89 Section 2 Model 601 601 P 602 602P 603 NDIR Analyzer 2 4 Infrared Gas Analyzers The infrared gas analyzer measures gas concentration based on the principle that each type of gas component shows a unique absorption line spectrum in the infrared region The instrument consists of an infrared light source a chopper a measuring cell and a detector filed with a gas mixture containing the gas component to be measured The operating principle of the instrument is described with reference to Figure 2 1 The infrared ligh
116. tain 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 1 4 Inch tube Note Be sure tubing and joints are clean Dust entering the instrument may cause it to malfunction 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 Bypass 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 High concentrations of corrosive gases such as Cla SOs F HCI in the sample gas shorten the useful service life of the instrument 3 8 4 Gas Temperature Do not exceed the maximum rating of the instrument 104 F 50 C when measuring high temperature gases 3 8 5 Sample Gas Bypass Outlet Vent A sample gas bypass outlet connector is located on the rear panel o Inch Tube Pressure at this outlet should be kept at atmospheric level ANY backpressure will cause an error in reading California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 25 of 8
117. tions 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 CAI California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 16 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 1 6 Proper Operation Personnel should be trained in the proper operation of this equipment before attempting to operate the equipment 1 7 Possible Explosion Hazard Do not apply power to the analyzer or attempt to energize the analyzer until determining the analyzer environment to be non hazardous Use this analyzer in a NON HAZARDOUS environment 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 8 Electrical Shock Hazard Disconnect power before removing cover 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 9 Plug Removal Do not operate this analyzer UNTIL REMOVING the red plastic 14inch plugs from the sample inlet and exhaust fittings on the rear panel
118. tput 19 User Defined NO Relay 11 D Output 20 User Defined NO Relay 12 D Output 21 User Defined NO Relay 13 D Output 22 Reserved Do Not Connect D Input 23 Spare D Input 24 Spare D Input 25 Spare D Input 26 Set Remote D Output 27 User Defined NO Relay 14 D Output 28 User Defined NO Relay 15 California Analytical Instruments Model 600 NDIR Operators Manual May 27 2008 Page 24 of 24
119. tput that is to be calibrated By selecting calibrate as the output all outputs of interest may be selected When calibration is competed the operator will return the outputs to their original assignment California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 9 of 24 ADDENDUM The D A CALIBRATION screen will then be used to complete the calibration procedure D onj o Z Le che et CC obs ct DHH Dt i tooo m l gt I TZ wo ok cr I room h O OF 2000D wi P i P 1 2 A A e H E r Oo Sp o bd cns TW go el Ro This screen provides a section that is used to record the zero signal corrections zero offset and a second area to record the 100 signal corrections Gain for each of the four output signals that may be defined to develop a voltage or current signal Since this is a Digital to Analog conversion the calibration will require the completion of a simple trial and error procedure The operator will observe the results of a zero or span Gain signal generated by the analyzer to the remote recording device and select a correction factor The operator will save this value and then observe the results on attached the remote recording device The process of selection and saving for zero and span will be repeated until a satisfactory calibration is achieved For 0 1VDC 0 5VDC 0 10VDC and a 0 20 mA
120. uto Cal Calibrate Zero Span Sample 17 18 19 20 21 Auto Cal Calibrate Zero Span Sample 17 18 19 20 21 Auto Cal Calibrate Zero Span Sample D Output D Output D Output Zero Gas Flow Span Gas Flow Sample Gas Flow Zero Gas Flow Span Gas Flow Sample Gas Flow Zero Gas Flow Span Gas Flow Sample Gas Flow OC 24vdc if internal SV OC 24vdc if internal SV OC 24vdc if internal SV D Output D Output D Output D Output Local Remote Read Cal Mode Reserved Reserved Local Remote Read Cal Mode Reserved Reserved Local Remote Read Cal Mode Reserved Reserved TTL low true TTL low true California Analytical Instruments Model 600 NDIR Operators Manual May 27 2008 Page 23 of 24 SECTION 13 ADDENDUM TABLE D 600 NDIR SERIES UO CHART 28 PIN AUXILLARY CONNECTOR ASSIGNMENTS opto Signal 601 602 603 Type Analog LEVELS Spare pin A Input 1 GND analog A Input 2 External Analog 1 0 10V A Input 3 External Analog 2 0 10V A Output 4 GND Isolated analog D Output 5 Relay RTN 1 9 10 11 12 use RTN 1 Alarms go OPEN when present Alarms Digital Status go CLOSED when active COM D Output 6 Relay RTN 2 13 14 15 16 use RTN 2 D Output 7 Relay RTN 3 17 17 19 20 use RTN 3 D Output 8 Relay RTN A 21 2728 use RTN 4 D Output 9 User Defined NO Relay 1 D Output 10 User Defined NO Relay
121. whenever one of these symbols is encountered on the equipment ALWAYS REMOVE POWER BEFORE CONNECTING OR DISCONNECTING SIGNAL CABLES OR WHEN SERVICING THE EQUIPMENT California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 2 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer The 600 series NDIR 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 California Analytical Model 600 SERIES NDIR OPERATORS MANUAL REV 111 docOperators Manual Page 3 of 89 Section 1 Model 601 601 P 602 602P 603 NDIR Analyzer 600 NDIR Quick Start Guide Plug in the analyzer and turn the power on 2 Connect the appropriate gas lines and vents to the analyzer 3 Allow the analyzer to stabilize for at least one 1 hour 4 During the analyzer s stabilization period setup the analyzer to the desired configuration a Set the analyzer s output as desired i Fr
122. y coupled isolated relays that can be programmed by the operator to indicate the status of numerous signals The available digital signals consist of a SERVICE Group that can be used to externally monitor a number of conditions to aid in preventative maintenance and diagnostics SEE TABLE B amp D A second STATUS group is provided and is used to define the operation pf the instrument such as Spanning Zeroing Calibrating and the current Range 1 2 3 4 AUTO etc SEE TABLE C amp D The individual output signals can be operator selected and set to a HOLD or CLEAR mode In the HOLD mode an activated signal is retained until the operator returns to the Digital Output Screen and selects the appropriate output signal and performs a manual CLEAR After performing a Clear Operation the operator must press F2 again to put the outputs back onto HOLD mode User DO I E2 SsTBY E i SERS E EE EE EE E Set Unused Channels Off EE EE E EE ERE ES Hold E A A D 6 S z 1 A In the Clear Mode the signal will automatically change when the microprocessor detects that the noted condition no longer exists User DO II E2 SHAH IS Ei Hm J 16 off ii of SESE EE EE E EE iz Off S5et Unused 13 Off Channels Off 14 Off EE E EE EE EE 15 off Fi ito r DO s MHAIN BACK to SAVE Check Chi Temp la California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 16 of 24 ADDENDUM The op
123. zer parameters are stored in a secure memory location and retained when power is removed In the event of an unexpected power failure it may be desirable to change some parameters until an operator can resume control This screen may be used to establish several desirable special instrument start up parameters that define how the analyzer recovers from loss of AC power When enabled this screen will define the following System setup IS Bea Jire Clock settings Bu utput assignment F Late ange FS status line on off off os analyser Alarms ON 7 OFF CAI Tel 800 959 0959 Use F6 to toggle ON OFF The instrument has an extensive library of error messages that will aid in the identification of various anomalous events and are displayed at the bottom of the screen These messages will assist in Diagnostics and indicating the need for preventative maintenance This screen provides an option to disable these messages during initial start up or as may be desired for a particular application California Analytical Instruments Model 600 NDIR Operators Manual January 10 2011 Page 8 of 24 ADDENDUM 3 3 Offset amp Gain Main F4 F3 F5 Offset and Gain bel Zero Span applied correction Offset Gain Rangel 0 00 i 00 Range2 0 00 1 600 Range3 0 00 1 600 Range4 0 00 1 600 Neila 0 02 to select channel CAI Tel 800 9359 0959 iF This screen can be used to provide an additional means to display cali

Product Manual - California Analytical Instruments, Inc.

Contents

Download Pdf Manuals

Related Search

Related Contents