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California Analytical Instruments 100 Operation And Maintenance Manual

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OPERATION AND MAINTENANCE
MANUAL FOR INFRARED ANALYZERS
MODELS 100, 200, 300
C
A
alifornia
nalytical
I
I
nstruments,
nc.
1312 West Grove Avenue, Orange, CA 92865 - 714 974-5560 - Fax 714 921-2531
Website: www.gasanalyzers.com

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  • Page 1 OPERATION AND MAINTENANCE MANUAL FOR INFRARED ANALYZERS MODELS 100, 200, 300 alifornia nalytical nstruments, 1312 West Grove Avenue, Orange, CA 92865 - 714 974-5560 - Fax 714 921-2531 Website: www.gasanalyzers.com...

  • Page 2: Table Of Contents

    Section 1 Models 100, 200, 300 Infrared Analyzers Table of Contents INTRODUCTION ........................6 1.1. Overview..........................6 1.2. Unpacking Instructions .......................6 1.3. Reporting Damage ......................6 1.4. Contact Information ......................6 1.5. Warranty Certificate......................7 FEATURES AND PRINCIPLES OF OPERATION ..............8 2.1. Description..........................8 2.2. Features-General .......................8 2.3.
  • Page 3 Section 1 Models 100, 200, 300 Infrared Analyzers 4.3.5. Start-Up and Routine Maintenance: ................39 4.4. Oxygen Analyzer Operation and Calibration ..............40 4.4.1. Power On: .........................40 4.4.2. Calibration: ........................40 MAINTENANCE........................41 5.1. Zero and Span Calibration....................41 5.2. Cleaning of the Optical Bench Measuring Cell (Infrared Analyzers Only) ......41 5.3.
  • Page 4 Figure 4-5 Model 300 Analyzer Front Panel ...................25 Figure 4-6 Model 300 Analyzer Rear Panel..................26 Figure 4-7 Model 100 Interior Layout – With Sample Gas Pump ...........27 Figure 4-8 Model 200 Interior Layout – Stacked Cell IR's – With Sample Gas Pump ....28 Figure 4-9 Model 200 Interior Layout –...
  • Page 5 Section 1 Models 100, 200, 300 Infrared Analyzers Figure 8-5 Resetting at Zero Too Slow ...................61 Figure 8-6 Excessive Drift.......................62 Figure 9-1 B-1 Analyzer Front Panel Outline & Mounting Dimensions ...........64 Figure 9-2 B-2 Analyzer Top View Outline & Mounting Dimensions..........65 Figure 9-3 B-3 NDIR Amplifier Schematic Diagram................66...

  • Page 6: Introduction

    Section 1 Models 100, 200, 300 Infrared Analyzers INTRODUCTION 1.1. Overview Thank you, and congratulations! You have just purchased one of the most reliable gas analyzers in the world. Before using the analyzer, please familiarize yourself with its operation by reading this manual. If you have any questions, please do not hesitate to call California Analytical Instruments for assistance.

  • Page 7: Warranty Certificate

    Section 1 Models 100, 200, 300 Infrared Analyzers 1.5. Warranty Certificate Subject to the exceptions and upon the conditions stated below, California Analytical Instruments (CAI) warrants that the products sold under this sales order shall be free from defects in workmanship and materials for one year after delivery of the product to the original Buyer by CAI and if any such product should prove to be defective within such one year period, CAI agrees, at its option, either (i) to correct by repair or, at CAI’s election, by...

  • Page 8: Features And Principles Of Operation

    2.1. Description The Model 100 single component, the Model 200 dual component, and the Model 300 three component infrared analyzers all incorporate a single-beam photometric system and a detector with a microflow sensor assuring high reliability, sensitivity, accuracy and stability. Depending upon the configuration, the analyzer may have one, two, or three optical benches within one case.

  • Page 9: Figure 2-1 Single Ndir Analyzer

    Section 2 Models 100, 200, 300 Infrared Analyzers 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.

  • Page 10: Interference Gases

    Section 2 Models 100, 200, 300 Infrared Analyzers 2.4. 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.

  • Page 11: Alarm Contacts (Optional)

    The operation of the analyzer is based upon the principle of the magneto-dynamic oxygen cell, the most accurate and reliable cell for determining the oxygen content of a gas mixture from 0-100 percent volume oxygen.

  • Page 12: Galvanic Fuel Cell Oxygen Option

    Section 2 Models 100, 200, 300 Infrared Analyzers 2.6.2. Galvanic Fuel Cell Oxygen Option This analyzer option utilizes a low cost fuel cell to determine the percent level of oxygen contained in the sample gas. The oxygen level is displayed on a digital panel meter.

  • Page 13: Installation

    Section 3 Models 100, 200, 300 Infrared Analyzers INSTALLATION 3.1. General The instrument is designed for industrial applications. These installation instructions are for a typical site. Any questions regarding specific installation situations should be directed to Technical Service of California Analytical Instruments, Inc.

  • Page 14: Electrical

    Section 3 Models 100, 200, 300 Infrared Analyzers 3.3. Electrical All wiring is connected at the rear of the instrument. The connect outputs, etc. are shown in Table 3-1 on the following page. The AC power is connected to the power/fuse/switch as shown below in Figure 3-1.

  • Page 15: Table 3-1 I/O Connections For S/N Xxh12100 And Lower

    Section 3 Models 100, 200, 300 Infrared Analyzers Table 3-1 I/O Connections for S/N xxH12100 and lower Model 100, 200, 300 with Texmate Pin # Outputs (Voltage or Current) Channel Positive Negative Positive Negative Positive Negative Controls for remote Range 2 Select (GND IN)

  • Page 16: Table 3-2 I/O Signal Connections For S/N Xxj01001 & Higher

    Section 3 Models 100, 200, 300 Infrared Analyzers Table 3-2 I/O Signal Connections for S/N xxJ01001 & higher Model 100, 200, 300 with Texmate Pin # Outputs (Voltage or Current) Channel Positive Negative Positive Negative Positive Negative Remote controls for bench # 1...

  • Page 17: Table 3-3 Optional Alarm Contact Connections

    Section 3 Models 100, 200, 300 Infrared Analyzers Table 3-3 Optional Alarm Contact Connections Model 100, 200, 300 — Alarm Contacts Note: All contacts are "DRY" High Alarms (1 Component) Pin # State Form Rating Set Point I.D. Factory Setting N.O.

  • Page 18: Table 3-4 Twenty Eight Conductor Cable Color Chart

    Section 3 Models 100, 200, 300 Infrared Analyzers Table 3-4 Twenty Eight Conductor Cable Color Chart Pin Number Wire Color Wire Color Abbreviation DARK BROWN DK BR ORANGE YELLOW GREEN LIGHT BLUE LT BL VIOLET GRAY WHITE BLACK LIGHT BROWN...

  • Page 19: Required Gases

    Section 3 Models 100, 200, 300 Infrared Analyzers 3.5. Required Gases • Nitrogen (zero gas) and/or instrument air in a pressurized cylinder. Note: Both must be free of organic carbon compounds (C) if CO, CO , CH , etc. are a measured component, as well as other contaminants such as moisture, hydrocarbons, etc.

  • Page 20: Gas Temperature

    Section 3 Models 100, 200, 300 Infrared Analyzers 3.8.4. Gas Temperature When measuring high temperature gases ensure that, the maximum temperature of the sample does not exceed 122 F (50 3.8.5. Flow Rate The gas entering the instrument should flow at a rate between 0.5 to 2 liters/min (LPM).

  • Page 21: Operation

    OPERATION 4.1. Description & Function of Components 4.1.1. Model 100 Analyzer Front Panel Figure 4-1 Model 100 Analyzer Front Panel Indicator Digital Display: Displays output from the infrared gas analyzer in direct engineering units Range Switch: Used for measuring range selection...

  • Page 22: Model 100 Analyzer Rear Panel

    4.1.2. Model 100 Analyzer Rear Panel ANALOG OUT ALARMS Purge Gas POWER Figure 4-2 Model 100 Analyzer Rear Panel Analog Output Connector: Control and Output Data Sample Gas Inlet: For introducing sample gas into the infrared gas analyzer. (¼” tube) Sample Gas Outlet: For exhausting sample gas.

  • Page 23: Model 200 Analyzer Front Panel

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.1.3. Model 200 Analyzer Front Panel Figure 4-3 Model 200 Analyzer Front Panel Indicator Digital Display: Displays output from the infrared gas analyzer in direct engineering units Range Switch: Used for measuring range selection...

  • Page 24: Model 200 Analyzer Rear Panel

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.1.4. Model 200 Analyzer Rear Panel ALARMS ANALOG OUT Purge Gas POWER Figure 4-4 Model 200 Analyzer Rear Panel Analog Output Connector: Control and Output Data Sample Gas Inlet: For introducing sample gas into the infrared gas analyzer (¼” tube) Sample Gas Outlet: For exhausting sample gas.

  • Page 25: Model 300 Analyzer Front Panel

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.1.5. Model 300 Analyzer Front Panel Figure 4-5 Model 300 Analyzer Front Panel Indicator Digital Display: Displays output from the infrared gas analyzer in direct engineering units Range Switch: Used for measuring range selection...

  • Page 26: Model 300 Analyzer Rear Panel

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.1.6. Model 300 Analyzer Rear Panel ALARMS ANALOG OUT Purge Gas POWER Figure 4-6 Model 300 Analyzer Rear Panel Analog Output Connector: Control and Output Data. Sample Gas Inlet: For introducing sample gas into the infrared gas analyzer (¼" tube).

  • Page 27: Figure 4-7 Model 100 Interior Layout - With Sample Gas Pump

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-7 Model 100 Interior Layout – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-27...

  • Page 28: Figure 4-8 Model 200 Interior Layout - Stacked Cell Ir's - With Sample Gas Pump

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-8 Model 200 Interior Layout – Stacked Cell IR's – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-28...

  • Page 29: Figure 4-9 Model 200 Interior Layout - Two (2) Independent Optical Benches - With Sample Gas Pump

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-9 Model 200 Interior Layout – Two (2) Independent Optical Benches – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-29...

  • Page 30: Figure 4-10 Model 200 - Single Ir, Fuel Cell O - With Sample Gas Pump

    Section 4 Models 100, 200, 300 Infrared Analyzers S W 1 S W 2 Figure 4-10 Model 200 – Single IR, Fuel Cell O – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-30...

  • Page 31: Figure 4-11 Model 200 Interior Layout - Single Ir, Paramagnetic O

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-11 Model 200 Interior Layout – Single IR, Paramagnetic O – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-31...

  • Page 32: Figure 4-12 Model 300 Interior Layout - Three (3) Ir's - With Sample Gas Pump

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-12 Model 300 Interior Layout – Three (3) IR's – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-32...

  • Page 33: Figure 4-13 Model 300 Interior Layout - Two (2) Stacked Cell Ir's, Fuel Cell O

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-13 Model 300 Interior Layout – Two (2) Stacked Cell IR's, Fuel Cell O – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-33...

  • Page 34: Figure 4-14 Model 300 Interior Layout - Two (2) Independent Ir's, Fuel Cell O

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-14 Model 300 Interior Layout – Two (2) Independent IR's, Fuel Cell O – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-34...

  • Page 35: Figure 4-15 Model 300 Interior Layout - Two (2) Stacked Cell Ir's, Paramagnetic O

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-15 Model 300 Interior Layout – Two (2) Stacked Cell IR's, Paramagnetic O – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-35...

  • Page 36: Figure 4-16 Model 300 Interior Layout - Two (2) Independent Ir's, Paramagnetic O

    Section 4 Models 100, 200, 300 Infrared Analyzers Figure 4-16 Model 300 Interior Layout – Two (2) Independent IR's, Paramagnetic O – With Sample Gas Pump OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 4-36...

  • Page 37: Interior Layout Component Identification

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.1.7. Interior Layout Component Identification Power Transformer: For supplying power to the main circuit board and optical bench Sample Pump: Optional Optical Bench for 1st Component: Measuring section of the infrared gas analyzer...

  • Page 38: Preparations For Operation

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.2. Preparations for Operation 4.2.1. External Wiring Make sure that the external wires have been connected as described in Section 3 Installation. 4.2.2. External Piping Review Section 3, 3-4 through 3-7. 4.3.

  • Page 39: Alarm Set Point And Control Programming Instructions

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.3.4. Alarm Set Point and Control Programming Instructions With power applied to the analyzer, locate the front-panel display meter and the three buttons on the faceplate. One will be marked “PROGRAM”, one will be a “DOWN ARROW”...

  • Page 40: Oxygen Analyzer Operation And Calibration

    Section 4 Models 100, 200, 300 Infrared Analyzers 4.4. Oxygen Analyzer Operation and Calibration Note: High-pressure oxygen is very dangerous. Virtually any material will burn in it, possibly explosively. It is essential that all persons using this analyzer are aware of the dangers of oxygen, and take all appropriate precautions.

  • Page 41: Maintenance

    Section 5 Models 100, 200, 300 Infrared Analyzers MAINTENANCE 5.1. Zero and Span Calibration The zero and span levels should be checked and/or calibrated daily or as often as required. (Refer to paragraphs 4.3.2 and 4.3.3). 5.2. Cleaning of the Optical Bench Measuring Cell (Infrared Analyzers Only) Dust or water droplets entering the measuring cell may cause drift due to contamination.

  • Page 42: Figure 5-1 Optical Bench With Pipe Sample Cell

    Section 5 Models 100, 200, 300 Infrared Analyzers Figure 5-1 Optical Bench with Pipe Sample Cell Item Description Item Description Screw (M4) Clamp Base Pipe sample cell Infrared source unit O-Ring Screw (M4) Window Connector Detector Sealed tubes Bridge circuit board...

  • Page 43: Removal Of Pipe Cell

    Section 5 Models 100, 200, 300 Infrared Analyzers 5.3.1. Removal of Pipe Cell (Figure 5-1) a) Discontinue the sample gas flow. When it contains harmful gas, purge the measuring cell sufficiently with zero gas. b) Turn the power switch to OFF.

  • Page 44: Figure 5-2 Optical Bench With Block Sample Cell

    Section 5 Models 100, 200, 300 Infrared Analyzers Figure 5-2 Optical Bench with Block Sample Cell Item Description Item Description Screw (M4) Screw (Flat Head) Base Block sample cell Infrared source unit O-Ring Screw (M4) Window Screw (Round or Pan Head)

  • Page 45: Removal Of Block Cell

    Section 5 Models 100, 200, 300 Infrared Analyzers 5.3.2. Removal of Block Cell (Figure 5-2) a) Discontinue the sample gas flow. When it contains harmful gas, purge the measuring cell sufficiently with zero gas. b) Turn the power switch to OFF.

  • Page 46: Figure 5-3 Optical Bench With Pipe And Block Type Sample Cells

    Section 5 Models 100, 200, 300 Infrared Analyzers Figure 5-3 Optical Bench with Pipe and Block Type Sample Cells Item Description Item Description Screw (M4) O-Ring Base Window Infrared source unit Detector Screw (M4) Bridge circuit board Screw Optical filter (if installed...

  • Page 47: Disassembly Of Combination Pipe & Block Type Cells

    Section 5 Models 100, 200, 300 Infrared Analyzers 5.3.3. Disassembly of Combination Pipe & Block Type Cells (Figure 5-3) a) Discontinue the sample gas flow. When it contains harmful gas, purge the measuring cell sufficiently with zero gas. b) Turn OFF the power switch.
  • Page 48 Section 5 Models 100, 200, 300 Infrared Analyzers r) The pipe cells contain a reflective metal foil liner (not shown in Figure 5-1) to enhance the light energy through put in the cell. Normally it is not necessary to remove the liner for cleaning;...

  • Page 49: Design And Function Of Electronic Circuitry

    Section 6 Models 100, 200, 300 Infrared Analyzers DESIGN AND FUNCTION OF ELECTRONIC CIRCUITRY 6.1. AC Signal Processing (NDIR’S only) The concentration of the measured gas component is converted into an AC electric signal by the microflow sensor contained inside the detector assembly (see Section 2 for details). This signal is amplified by AC amplifier U1 on the main circuit board.

  • Page 50: Adjustments Checks And Repairs

    Section 7 Models 100, 200, 300 Infrared Analyzers ADJUSTMENTS CHECKS AND REPAIRS 7.1. Adjustment of Detector Voltage (NDIR’S only) Note: Adjustment is required if detector or main PC board is replaced. The detector operating voltage is specified on the detector below the serialization number and type designation.

  • Page 51: Check And Repair Detector

    Section 7 Models 100, 200, 300 Infrared Analyzers 7.3. Check and Repair Detector (No. 15 in Figure 5-1) 7.3.1. Problem: Microflow sensor broken, bridge resistor defective or gas leak in detector. 7.3.2. Symptom: Zero adjustment impossible. 7.3.3. Check and/or replace: a) The microflow sensor and bridge resistors (No.

  • Page 52: Check And Repair Infrared Light Source Unit

    Section 7 Models 100, 200, 300 Infrared Analyzers 7.4. Check and Repair Infrared Light Source Unit (No. 5 in Figure 5-1) 7.4.1. Problem: A faulty infrared light source or a leaky gas seal. 7.4.2. Symptom: The unit reads off scale or the output is unstable.

  • Page 53: Check And Replace Chopper

    If the 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.

  • Page 54: Check And Repair Tubing Trouble

    Section 7 Models 100, 200, 300 Infrared Analyzers 7.7. Check and Repair Tubing Trouble 7.7.1. Problem: Tubing loosened, disconnected, contaminated, or restricted. 7.7.2. Symptom Indicator output unstable or response is too to slow. 7.7.3. Check and/or replace: a) When tubing is disconnected or loosened, firmly reconnect it.

  • Page 55: Check And Repair Main Circuit Board

    Section 7 Models 100, 200, 300 Infrared Analyzers 7.8. Check and Repair Main Circuit Board 7.8.1. Power Supply Circuit Checks: a) Check transformer secondary voltages: Transformer secondary voltages should be approximately 17 VAC and 100 VAC. b) Check positive power supply voltage: check positive power supply voltage across TP-5 (-) and TP-8 (+).

  • Page 56: Trouble Shooting Flow Charts

    Section 8 Models 100, 200, 300 Infrared Analyzers APPENDIX A 8.1. Trouble Shooting Flow Charts No Display or Change Of Indicated Value Zero Adjustment Impossible Indicator Reading Unstable (Display or Analog Output) Response Too Slow Resetting at Zero Too Slow Excessive Drift OPERATION AND MAINTENANCE MANUAL Version 7.0.doc...

  • Page 57: Figure 8-1 A 1 No Display Or Change Of Indicated Value

    Section 8 Models 100, 200, 300 Infrared Analyzers Figure 8-1 A 1 No Display or Change Of Indicated Value OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 8-57...

  • Page 58: Figure 8-2 A-2 Zero Adjustment Impossible

    Section 8 Models 100, 200, 300 Infrared Analyzers Figure 8-2 A-2 Zero Adjustment Impossible OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 8-58...

  • Page 59: Figure 8-3 Indictor Reading Unstable (Display Or Analog Output)

    Section 8 Models 100, 200, 300 Infrared Analyzers Figure 8-3 Indictor Reading Unstable (Display or Analog Output) OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 8-59...

  • Page 60: Figure 8-4 Response Too Slow

    Section 8 Models 100, 200, 300 Infrared Analyzers Figure 8-4 Response Too Slow OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 8-60...

  • Page 61: Figure 8-5 Resetting At Zero Too Slow

    Section 8 Models 100, 200, 300 Infrared Analyzers Figure 8-5 Resetting at Zero Too Slow OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 8-61...

  • Page 62: Figure 8-6 Excessive Drift

    Section 8 Models 100, 200, 300 Infrared Analyzers Figure 8-6 Excessive Drift OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 8-62...

  • Page 63: Mechanical & Electrical Drawings

    Section 9 Models 100, 200, 300 Infrared Analyzers APPENDIX B 9.1. Mechanical & Electrical Drawings B-1 Analyzer Front Panel Outline & Mounting Dimensions B-2 Analyzer Top View Outline & Mounting Dimensions B-3 NDIR Amplifier Schematic Diagram B-3 NDIR Component Layout Drawing OPERATION AND MAINTENANCE MANUAL Version 7.0.doc...

  • Page 64: Figure 9-1 B-1 Analyzer Front Panel Outline & Mounting Dimensions

    Section 9 Models 100, 200, 300 Infrared Analyzers Figure 9-1 B-1 Analyzer Front Panel Outline & Mounting Dimensions OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 9-64...

  • Page 65: Figure 9-2 B-2 Analyzer Top View Outline & Mounting Dimensions

    Section 9 Models 100, 200, 300 Infrared Analyzers 17.16 1.20 22.00 1.30 0.13 Figure 9-2 B-2 Analyzer Top View Outline & Mounting Dimensions OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 9-65...

  • Page 66: Figure 9-3 B-3 Ndir Amplifier Schematic Diagram

    Section 9 Models 100, 200, 300 Infrared Analyzers Figure 9-3 B-3 NDIR Amplifier Schematic Diagram OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 9-66...

  • Page 67: Figure 9-4 B-4 Ndir Component Layout Drawing

    Section 9 Models 100, 200, 300 Infrared Analyzers Figure 9-4 B-4 NDIR Component Layout Drawing OPERATION AND MAINTENANCE MANUAL Version 7.0.doc 9-67...

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