Alpha Omega Instruments 9600 Operating Manual

SERIES 9600

OXYGEN AND CARBON DIOXIDE ANALYZER

USER MANUAL

CAUTION
Please read this manual before starting to use the Series 9600 Oxygen and Carbon Dioxide Analyzer. Instructions
within the manual are essential for the proper operation of the product.

Alpha Omega Instruments Corp.
40 Albion Road, Suite 100
Lincoln, RI 02865
Phone: [phone]
Fax: [phone]
Website: www.aoi-corp.com
Email: [e-mail]

Rev 1.4.1, October 2011

ALPHA OMEGA INSTRUMENTS CORP. ALL
RIGHTS RESERVED INCLUDING THE RIGHT TO
REPRODUCE THIS MANUAL, OR ANY PORTION
THEREOF, IN ANY FORM.

USER MANUAL ALPHA OMEGA INSTRUMENTS CORP

© COPYRIGHT 2011. Alpha Omega Instruments Corp. All rights reserved including the right to
reproduce manual or any portion thereof in any form.

WARRANTY

Alpha Omega Instruments Corp. (Seller) warrants the products delivered to be free from defects in
material and workmanship at the time of delivery to the FOB. point specified in the purchase order, its
liability under this warranty being limited to repairing or replacing, at Alpha Omega Instruments option,
items which are returned to it prepaid within two (2) years from the date of shipment and found to
Seller’s satisfaction to be defective.

Alpha Omega Instruments offers a two (2) year warranty on both the oxygen and carbon dioxide
sensors. This warranty period commences on the date of shipment from Alpha Omega Instruments
manufacturing facility. The oxygen sensor, should it fail under normal use, must be returned to Seller
prepaid and, if such sensor is determined by Seller to be defective, Seller shall provide Buyer a
replacement sensor at no charge. If the carbon dioxide sensor should fail, please contact the factory
before removing the carbon dioxide sensor. Buyer must provide the serial number of the analyzer
from which the sensor(s) have been removed. If a sensor is found to be defective and a new one
issued, the warranty of the replacement sensor (s) is for a period of one year from the date of
shipment. At times, it may be necessary to ship a replacement sensor in advance of receiving one
returned for warranty claim. In such cases, if the returned sensor has been tested and not found to be
defective, it will not be covered under warranty, and the user will be charged the full price of a
replacement sensor. Note: replacement of the carbon dioxide sensor must be done at the factory. In
no event shall Alpha Omega Instruments Corp. be liable for consequential damages.

NO PRODUCT IS WARRANTED AS BEING FIT FOR A PARTICULAR

PURPOSE AND THERE IS NO WARRANTY OF MERCHANTABILITY.

This warranty applies only if:

(i) the items are used solely under the operating conditions and manner recommended in this

manual, product specifications, or other product specific literature;

(ii) the items have not been misused or abused in any manner or unauthorized repairs were

attempted thereon;

(iii) written notice of the failure within the warranty period is forwarded to Alpha Omega

Instruments Corp. and, the directions received for properly identifying items returned under
warranty are followed;

(iv) the return notice authorizes Alpha Omega Instruments Corp. to examine and disassemble

returned products to the extent the Company deems necessary to ascertain the cause of
failure.

The warranties stated herein are exclusive. THERE ARE NO OTHER WARRANTIES, EITHER
EXPRESSED OR IMPLIED, BEYOND THOSE SET FORTH HEREIN, and Alpha Omega Instruments
Corp. does not assume any other obligation or liability in connection with the sale or use of said
products.

Disclaimer of Warranty

Alpha Omega Instruments Corp. makes no representation or warranties, either expressed or implied, by or with
respect to anything in this manual, including, but not limited to, implied warranties of merchantability or fitness for
a particular purpose. In no event will Alpha Omega Instruments Corp. be liable for any damages, whether direct or
indirect, special, consequential, or incidental arising from the use of this manual. Some states in the USA do not
allow the exclusion of incidental or consequential damages. Alpha Omega Instruments Corp. also reserves the right
to make any changes to improve the performance of its products at any time and without notice.

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ALPHA OMEGA INSTRUMENTS CORP USER MANUAL

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Explanation of graphic symbols

The information listed below is essential to the proper operation of the analyzer. Please review the
following safety precautions prior to using the analyzer. Cautionary notes are included throughout this
manual.

THIS SYMBOL IS INTENDED TO ALERT THE USER TO THE PRESENCE OF IMPORTANT
OPERATING AND MAINTENANCE INSTRUCTIONS

THIS SYMBOL IS INTENDED TO ALERT THE USER TO POTENTIALLY DANGEROUS
SITUATIONS OR ITEMS THAT SHOULD BE AVOIDED

Important Safety Information

POTENTIALLY HAZARDOUS AC VOLTAGES EXIST WITHIN THE

DANGER

RISK OF

SHOCK

ANALYZER, IF NOT AVOIDED, COULD POTENTIALLY RESULT IN
SERIOUS INJURY OR DEATH. DISCONNECT ALL SOURCES OF
POWER AND EXTERNAL CONNECTIONS BEFORE REMOVING
THE COVER TO THE ANALYZER

TO AVOID THE RISK OF FIRE OR ELECTRIC SHOCK, DO NOT
EXPOSE THE SERIES 9600 OXYGEN AND CARBON DIOXIDE
ANALYZER TO RAIN, WATER SPRAY, OR ANY OTHER LIQUIDS.

RF Disclaimer

This instrument generates and uses small amounts of radio frequency energy, and there is no
guarantee that interference will not occur in a particular installation. If this equipment does cause
interference to radio or television reception, try to correct the interference by one or more of the
following steps:

1. Reorient the receiving antenna.

2. Relocate the instrument with respect to the receiver.

3. Change the AC outlet of the instrument so the instrument and receiver are on different
branch circuits.

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ALPHA OMEGA INSTRUMENTS CORP USER MANUAL

1 Table of Contents

PAGE

Copyright, Warranty, and Disclaimer-------------------i

Explanation of Graphic Symbols, Important Safety
Information, and RF Disclaimer-------------------------iii

Table of Contents-------------------------------------------iv

Tables and Figures-----------------------------------------vii

1 Overview--------------------------------------------------------1

1.1 Instrument Description-----------------------------------------------------------------1

1.1.1 Oxygen Sensor-----------------------------------------------------------------------------1

1.1.2 CO2 Sensor----------------------------------------------------------------------------------1

1.1.3 Water Vapor---------------------------------------------------------------------------------1

1.2 Optional Equipment Descriptions--------------------------------------------------2

1.2.1 Low Pressure Regulator-----------------------------------------------------------------2

1.2.2 High Pressure Regulator-----------------------------------------------------------------2

1.2.3 Sample Pump Option---------------------------------------------------------------------2

1.2.4 Particulate Filter----------------------------------------------------------------------------2

1.2.5 Needle Valve--------------------------------------------------------------------------------2

1.2.6 Isolated RS-232C Serial Communications------------------------------------------2

1.2.7 Isolated RS-485C Serial Communications------------------------------------------2

1.2.8 Coalescing Filter---------------------------------------------------------------------------2

1.2.9 Data Logger---------------------------------------------------------------------------------3

1.2.10 Flow Meter-----------------------------------------------------------------------------------3

1.2.11 Flow Meter with Integral Valve---------------------------------------------------------3

1.2.12 Bypass Plumbing Assembly-------------------------------------------------------------3

1.2.13 Analog Output Isolation------------------------------------------------------------------3

1.2.14 Rack / Panel Mounting Kit---------------------------------------------------------------3

1.3 Standard Features-----------------------------------------------------------------------4

1.4 General Specifications-----------------------------------------------------------------5

Oxygen Sensor-----------------------------------------------------------------------------5

Carbon Dioxide Sensor------------------------------------------------------------------6

2 Installation Procedures------------------------------------7

2.1 Unpacking the Instrument------------------------------------------------------------7

2.2 Electrical Installation-------------------------------------------------------------------7

2.3 Mechanical Configuration-------------------------------------------------------------8

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2.4 Wiring Alarm Relays--------------------------------------------------------------------8

2.5 Wiring the mA Outputs-----------------------------------------------------------------9

3 Operation------------------------------------------------------10

3.1 Preparation for Operation-----------------------------------------------------------10

3.1.1 Mounting Configurations---------------------------------------------------------------10

3.1.2 Initial Check--------------------------------------------------------------------------------10

3.2 Operating Procedures----------------------------------------------------------------10

3.2.1 Power ON----------------------------------------------------------------------------------10

3.2.2 Front Panel Controls and Indicators------------------------------------------------10

3.3 Navigating the Front Panel and Menu System-------------------------------11

3.3.1 General Navigation----------------------------------------------------------------------11

3.3.2 Pass codes--------------------------------------------------------------------------------11

3.4 Miscellaneous Settings---------------------------------------------------------------12

3.4.1 Setting the Baud Rate------------------------------------------------------------------12

3.4.2 Enabling and Setting Instrument Addresses in Optional RS485------------12

3.4.3 Enabling and Setting the System Software Clock-------------------------------12

3.5 Analog Outputs of the Analyzer---------------------------------------------------13

3.5.1 Setting the Analog Output Sensor Association-----------------------------------13

3.5.2 Setting the Analog Output Range----------------------------------------------------13

3.5.3 Setting the Analog Output Offset----------------------------------------------------14

3.5.4 Analog Output Options Overview----------------------------------------------------14

3.6 Alarm System----------------------------------------------------------------------------14

3.6.1 Setting the Alarm Sensor Type Association--------------------------------------15

3.6.2 Setting the Alarm Set point------------------------------------------------------------15

3.6.3 Setting the Alarm Hi or Lo-------------------------------------------------------------15

3.6.4 Setting the Alarm Latch-----------------------------------------------------------------15

3.6.5 Setting the Alarm Failsafe-------------------------------------------------------------16

3.6.6 Setting the Alarm Audible--------------------------------------------------------------16

3.6.7 Alarm Options Overview---------------------------------------------------------------16

3.7 Timing Out--------------------------------------------------------------------------------17

4 Sample Gas Handling-------------------------------------18

4.1 Positive Pressure Sampling-------------------------------------------------------19

4.2 Negative Pressure Sampling------------------------------------------------------20

4.3 Gas System Pressure and Flow Limits ----------------------------------------21

4.4 Corrosive Gases------------------------------------------------------------------------22

4.5 Orientation--------------------------------------------------------------------------------22

4.6 Condensible Gas Constituents----------------------------------------------------22

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4.7 Sample Filtration-----------------------------------------------------------------------22

5 Calibration Procedures-----------------------------------23

5.1 Routine Calibration Check----------------------------------------------------------23

5.2 Oxygen Calibration--------------------------------------------------------------------23

5.2.1 Procedure for Checking Oxygen Calibration--------------------------------------23

5.2.2 Zero Adjustment for Oxygen----------------------------------------------------------24

5.2.3 Change Oxygen Sensor Notice------------------------------------------------------24

5.3 Carbon Dioxide Calibration---------------------------------------------------------24

5.3.1 Procedure for Checking Carbon Dioxide Calibration---------------------------25

5.3.2 Zero Check of the Carbon Dioxide Channel--------------------------------------25

6 Menu System-------------------------------------------------26

6.1 Main Menu--------------------------------------------------------------------------------26

7 Maintenance and Troubleshooting-------------------28

7.1 User Maintenance----------------------------------------------------------------------28

7.2 Serviceable Items----------------------------------------------------------------------28

7.3 Troubleshooting------------------------------------------------------------------------28

8 Optional RS-232/RS-485 Serial Communications.29

8.1 Baud Rates-------------------------------------------------------------------------------29

8.1.1 To set the RS-232/485 baud rate----------------------------------------------------29

8.1.2 RS485 Commands----------------------------------------------------------------------29

8.2 Standard Commands------------------------------------------------------------------29

8.3 Detailed RS Command Descriptions--------------------------------------------31

8.4 RS232/485 Connections--------------------------------------------------------------36

Appendix A - Bench Top Configuration Drawings

Part Number BTP------------------------------------------------------------------------37

Appendix B - Oxygen Sensor Material Safety Data Sheet

Part Numbers: 1SEN and 2SEN ----------------------------------------------------38

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Tables and Figures

Tables

Table 2.1 Relay Configurations----------------------------------------8

Table 2.2 Customer Wiring---------------------------------------------9

Table 3.5.1 Analog Output Factory Default Settings--------------13

Table 3.5.2 Overview of Analog Output Settings------------------14

Table 3.6.7 Overview of Alarm Settings------------------------------17

Table 6.1 Main Menu Settings, Values, and Descriptions-- - -26

Table 8.1 Standard RS Commands--------------------------------30

Table 8.2 RS232/485 Wiring------------------------------------------36

Figures

Figure 2.1 Mechanical Dimensions------------------------------------7

Figure 2.2 Rear View------------------------------------------------------8

Figure 4.1 Simple Positive Pressure Sampling ------------------18

Figure 4.2 Simple Negative Pressure Sampling with

Internal PUMP---------------------------------------------19

Figure 4.3 Positive Pressure Sampling System------------------20

Figure 4.4 Negative Pressure Sampling System-----------------21

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1 Overview

1.1 Instrument Description

The Series 9600 Oxygen and Carbon Dioxide Analyzer provides an accurate and repeatable
measurement of both oxygen and carbon dioxide in a variety of gas streams. The instrument is
powered from a universal power supply equipped to accept 90-264 VAC, 47-63Hz. Optional
equipment includes pressure regulators, particulate and coalescing filters, and a vacuum pump for
conditions when the sample gas lacks sufficient pressure to move the sample through the instrument's
plumbing.

The analyzer is housed in a NEMA 1 equivalent enclosure rated for general purpose indoor use.
Oxygen and carbon dioxide values are displayed on a 4 line by 20 character liquid crystal display
(LCD) with a total height of 0.81" (20.8 mm). The front panel also includes a membrane panel with
seven buttons that provide access to the analyzer's settings. The instrument is equipped with two
alarm relays (see specifications) which are user configurable and can optionally be set for fail-safe
operation. In addition to the alarm relays, the Series 9600 Oxygen and Carbon Dioxide Analyzer has a
built-in audible alarm and two front panel light emitting diodes (LEDs) for visual indication of an alarm
condition. The audible alarm can be canceled by the user, however the alarm event will still be in
effect and indications of the alarm condition will still be available through the front panel LEDs and
relay contact(s). A flow meter is mounted on the front panel of the instrument and is standard
equipment for the Series 9600 Oxygen and Carbon Dioxide Analyzer. A flow meter with integrated
flow control needle valve is available as optional equipment. The standard Series 9600 Oxygen and
Carbon Dioxide Analyzer comes equipped with two direct current (DC) analog outputs. These analog
outputs can be independently configured for 0-20 mA or 4-20 mA. Both are scalable over the
operating range of the instrument's sensors. Using a terminating resistor on either of these outputs
can also provide any analog voltage in the range of 0-10 volts (see general specifications on page 4
for maximum resistance).

1.1.1 Oxygen Sensor

The Series 9600 Oxygen and Carbon Dioxide Analyzer features an ambient temperature
electrochemical sensor with an Enhanced Electrolyte System (EES). One of the features of the EES is
the use of a weak acid electrolyte in place of potassium hydroxide. This produces a sensor with a
greatly extended useful life and excellent measurment stability.

1.1.2 CO2 Sensor

The Series 9600 Oxygen and Carbon Dioxide Analyzer uses a non-dispersive infrared (NDIR) sensor
to determine the carbon dioxide concentrations in gases. Infrared gas sensors, which are comprised of
solid state devices, do not chemically react with the gas.

1.1.3 Water Vapor

The Series 9600 Oxygen and Carbon Dioxide Analyzer incorporates a CO2 sensor that uses a high
precision optical system. Therefore, in order to provide accurate and repeatable data, it is essential
that the CO2 sensor not be exposed to condensed water or liquids of any type. The dew point
temperature of the sample gas should always be lower than the temperature of the NDIR sensor, thus
helping to prevent the condensation of water vapor on the sensor’s optics. If it is anticipated that the
sample gas may be saturated with water vapor, provisions should be made to remove the water by

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USER MANUAL ALPHA OMEGA INSTRUMENTS CORP

filtration/coalescing, refrigeration, vortex cooling, etc. Consult Alpha Omega Instruments Corp. for
more information on this subject.

1.2 Optional Equipment Descriptions

The Series 9600 Oxygen and Carbon Dioxide Analyzer incorporates standard features that make it
immediately suitable for many applications. However, for certain requirements, the user may desire to
augment the capabilities of the instrument by equipping it with one or more of the available options, as
described below.

1.2.1 Low Pressure Regulator P/N 96-LPR

Aluminum body with a maximum input pressure of 145 PSIG.

1.2.2 High Pressure Regulator P/N 96-PRR

High capacity stainless steel pressure regulator with 3000 PSIG inlet capacity and an adjustable
output pressure range of 0-5 PSIG. Note: Typically used with the optional needle valve (P/N 9NV).

1.2.3 Sample Pump Option P/N 96-PMP

Sample pump designed for applications where the sample pressure is insufficient to transport the
sample gas through the instrument's plumbing.

1.2.4 Particulate Filter P/N 96-95S

Miniature T-type 316 stainless steel filter with 1/4” compression fittings. Recommended when particle
sizes are greater than 5 microns.

1.2.5 Needle Valve P/N 96-NV

Stainless steel needle valve for high pressure sample source (greater than 1 PSIG). Also used in
bypass style plumbing arrangements for applications where the instrument will be used to measure
both positive and negative pressure sources using a sample pump.

1.2.6 Isolated RS-232C Serial Communications P/N 96-RS2

The RS-232C Serial Communications option is installed at the factory and is designed for applications
where enhanced serial communications is required between the Series 9600 Oxygen and Carbon
Dioxide Analyzer and a host system. The maximum distance from the host system is 50 feet.

1.2.7 Isolated RS-485C Serial Communications P/N 96-RS4

The RS-485 Serial Communications option is installed at the factory and is designed for applications
where enhanced serial communications is required between the Series 9600 Oxygen and Carbon
Dioxide Analyzer and a host system over a distance greater than 50 feet. The maximum distance from
the host system is 4000 feet.

1.2.8 Coalescing Filter P/N 96-CF

Filter with aluminum housing. Rated for nominal 0.3 microns (95%).

Spare filter elements for P/N 96-CF. P/N 96-CFE

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1.2 Optional Equipment Descriptions (continued)

1.2.9 Data Logger P/N 9DL

Internally mounted four channel data logger (no display). The data logger can be used to record the O
and CO2 concentrations and operates in a wrap-around mode so that when the memory is full, the
oldest data will be replaced with the newest. Recording frequency is adjustable from once every 0.5
seconds to once every 9 hours (user selectable). Memory is non-volatile EEPROM with 32,000
readings kept in storage. Software will be provided that allows downloading of the data to a PC via
serial port.

1.2.10 Flow Meter P/N 9FLMA

Durable one-piece acrylic flow meter without flow control adjustment. Standard equipment.

1.2.11 Flow Meter with Integral Valve P/N 9FLMC

Durable one-piece acrylic flow meter with flow control adjustment. Optional equipment.

1.2.12 Bypass Plumbing Assembly P/N 9BYPASS

Plumbing arrangement used when the instrument will be used for both positive and negative pressure
source applications. Includes a needle valve and a bypass “tee” on the inlet of the instrument. This is
typically used in conjunction with 9PMP Sample Pump Option. Some high pressure applications will
also make use of such a plumbing arrangement. Details are discussed later in the manual.

2

1.2.13 Analog Output Isolation. P/N 9AOISO

Installed at the factory, galvanic isolation of both analog outputs.

1.2.14 Rack / Panel Mounting Kit P/N 96-RMK

Used for mounting the instrument in either a Rack configuration or inside a panel cutout.

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1.3 Standard Features

1

Analog Outputs: Two 0/4-20 mA, configurable for voltage or direct current

Individually configurable for either O2 or CO2 monitoring

Maximum load: less than 950 ohms @ 25C

Alarm Relays: Two (2) SPDT Form C contacts rated 10 A (250 VAC) / 5A (100 VDC).

Alarms may be cleared manually or automatically, by user selection.

Individually configurable to be set as high or low alarms for either O2 or
CO2 levels.

Input Power: Universal 90-264 VAC, 47-63 Hz

Audible Alarms: Internal audible alarm (user configurable per alarm)

Audible Alarm Canceling: Individual front panel buttons

Operating Temperature: 50° to 104°F (10° to 40°C) / 99% max humidity (non-condensing)

Enclosure: Aluminum, equivalent to NEMA 1

Enclosure Dimensions: 13 inches (330 mm) – length

11 Inches (280 mm) – width

7 Inches (178 mm ) - height

Sample Delivery: Pressure or optional pump

Display: 4 Line by 20 character LCD

1

All specifications are based on a temperature of 77°F (25°C) at standard pressure of 29.9 inches of mercury

(1 atmosphere).

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1.4 General Specifications

Oxygen Sensor

Measurement Range: Percent: 0-100

Resolution: Greater than 10% = 0.1%

Less than 10% = 0.01%

Accuracy: ±1% for full scale ranges >10% .

±5% for full scale ranges <10%

Sensor Type: Long-life electrochemical sensor

Recommended Sample

<1.0 PSIG

1

Pressure:

Response Time: 90% of full scale response

in < 20 seconds.

Warm Up Time: Instantaneous

Sample Flow Rate: 0.1-0.5 liters per minute (LPM) optimum

Operating Humidity Range: 0-99% RH (non-condensing)

Calibration: Ambient air or calibration gas

1

The actual pressure of the sample can be much higher, however higher pressure sampling requires different

plumbing arrangements that are described later in the manual.

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General Specifications (continued)

Carbon Dioxide Sensor

Measurement Range1: Percent: 0-20

Trace: 0-5,000 PPM

(determined at order placement)

Resolution: Greater than 10% = 0.1%

Less than 10% = 0.01%
Less than 10,000ppm = 1 ppm

Accuracy: Percent: ±0.5% full scale or ±5% of reading,

whichever is greater
Trace: ±30ppm or ±2% of reading, whichever
is greater.

Sensor Type: Non Dispersive Infrared (NDIR)

Recommended Sample

<1.0 PSIG (see footnote 1 opposite page)

Pressure :

Response Time: < 35 seconds to 63% step change at a sample

flow of 0.5 liters per minute

Warm Up Time: < 90 seconds

Sample Flow Rate: 0.1-0.5 liters per minute (SLPM) optimum

Operating Humidity Range: 5-95% RH (non-condensing)

Calibration: Calibration gas

1

Other ranges for CO2 covering ppm and percent to 100% are available. Please contact the factory for details.

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2 Installation Procedures

Figure 2.1 Mechanical Dimensions

2.1 Unpacking the Instrument

Upon opening the shipping container, carefully unpack the instrument to check if the outer surfaces
have been damaged. If so, report the findings immediately to Alpha Omega Instruments who will, in
turn, provide further instructions.

NOTE: IF DAMAGE HAS BEEN FOUND, DO NOT PROCEED
FURTHER, BUT INSTEAD, CONTACT THE FACTORY.

If there is no apparent damage, check the contents to ensure all items were shipped. In some cases,
items may be back ordered. All damage and shortage claims must be made known to Alpha
Omega Instruments within 10 days after receipt of shipment. Carefully rotate the analyzer and
check to make sure no components have been loosened or dislodged. If there are loose or
dislodged components (rattling of any kind), contact the factory for further instructions. If there
is no evidence of loose or dislodged components, the installation procedure can begin.

2.2 Electrical Installation

ELECTRICAL INSTALLATION SHOULD BE PERFORMED BY A

WARNING

The Series 9600 Oxygen and Carbon Dioxide Analyzer is shipped with a standard North American
power cord NEMA style 5-15P. The mating receptacle on the rear panel of the analyzer is an IEC style
60320 C13/C14. The analyzer accepts a power input of 90 VAC to 264 VAC @ 50/60 Hz. There is an
On/Off switch located on the rear of the instrument.

QUALIFIED PERSON AND SHOULD COMPLY WITH
APPLICABLE FEDERAL, STATE, OR LOCAL ELECTRICAL
SAFETY CODES.

SERIES 9600 Oxygen and Carbon Dioxide Analyzer PAGE 7