Software version :V2.

00

126, rue Emile Baudot - Le Millénaire

34 000 MONTPELLIER France

Tél : (33) 04-67-156-156

Fax : (33) 04-67-224-224
e-mail :capelec.sarl@capelec.fr
www.capelec.fr
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Version Date Modifications

V1.52 A 08/10/2004 First edition
Calibrate Command, Most common procedures, Switch on and switch
V1.52 B 10/12/2004
off auxiliary communication port
V1.52 C 11/02/2005 Internal calibration: Install new IR emitter
V1.52 D 16/03/05 Supply input voltage correction
V1.53 A 09/11/05 Precision on status bit "Initial Zero in progress"
V1.53 B 21/11/05 Additional information on low flow detection (parag II 3.2)
V1.53 C 28/11/05 Additional information on real time PEF (parag II 3.3)
V2.00 A 09/05/06 First edition
V2.00 B 03/10/06 Add of heater configuration command
V2.00 C 08/11/06 Power supply modification
V2.00 D 08/12/06 Checksum calculation correction
V2.00 E 03/01/07 Additional information on leak detection
V2.00 F 22/09/08 CO measurement range modification
V2.00 G 24/02/09 Correction on command ‘I’ Data 1 + correction on pressure sensor name
V2.00 H 07/05/09 Additional information on connectors used
Add of calibration frame example and HC unit correction in table to get
V2.00 I 31/08/10
data and status
Out of range O2 limit update
V2.00 J 04/10/10
Add of CO2 display on 1 or 2 significant digits

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CAP3300 SERIAL COMMUNICATION PROTOCOL,

INSTALLATION & MAINTENANCE

I. COMMUNICATION PROTOCOL ................................................................................................................ 5

1 General specification ................................................................................................................................. 5
1.1 Type of communication : RS 232 .................................................................................................. 5
1.2 General command: ......................................................................................................................... 5
1.3 General answer ............................................................................................................................... 6
1.4 DATA TYPE:.................................................................................................................................. 6
2 List of the commands ................................................................................................................................ 8
2.1 Command ‘G’ : Set the baud rate ................................................................................................... 8
2.2 Command ‘O’ : Toggle PUMPS and SOLENOIDS ....................................................................... 8
2.3 Command ‘Z’ : Send a ZERO ........................................................................................................ 8
2.4 Command ‘T’ : GET DATA AND STATUS in text format ............................................................ 9
2.5 Command ‘I’ : GET DATA AND STATUS in integer format .......................................................11
2.6 Command ‘A’ : GET DATA AND STATUS in float format ......................................................... 12
2.7 Command ‘S’ : Start the continuous mode ................................................................................... 13
2.8 Command ‘Q’ : Stop the continuous mode .................................................................................. 13
2.9 Command ‘C’ : Calibrate ............................................................................................................. 14
2.10 Command ‘D’ or ‘U’ : Internal calibration ................................................................................. 14
2.11 Command ‘B’ : Get gas curves ................................................................................................... 16
2.12 Command ‘P’ : Ask PEF for a given HC concentration (Text format) ....................................... 16
2.13 Command ‘N’ : Read Serial Number, Soft Version, Date in text format.................................... 16
2.14 Command ‘L’ : Switch the auxiliary COM on............................................................................ 17
2.15 Command ‘M’ : Switch the auxiliary COM off.......................................................................... 17
3 EEPROM mapping .................................................................................................................................. 18
II. INSTALLATION & MAINTENANCE ........................................................................................................ 19
1 Outline 19
1.1 Overall view ................................................................................................................................. 19
1.2 Configuration ............................................................................................................................... 20
1.3 Block Diagram ............................................................................................................................. 24
1.4 Specifications ............................................................................................................................... 24
2 Installation, connections and start-up ...................................................................................................... 25
2.1 Operating conditions .................................................................................................................... 25
2.2 Gas circuit .................................................................................................................................... 26
2.3 Most common procedures ............................................................................................................ 27
2.3.1 Gas measurement .............................................................................................................. 27
2.3.2 Calibrate the CAP3300...................................................................................................... 27
3 Gas analysis ............................................................................................................................................. 28
3.1 Technical characteristics............................................................................................................... 28
3.2 Detect a low flow ......................................................................................................................... 29
3.3 Use of the Real Time PEF ............................................................................................................ 29
3.4 Detect a leak ................................................................................................................................. 30
4 Error meanings, precautions .................................................................................................................... 31
STATBYTE1 ...................................................................................................................................... 31
STATBYTE2 ...................................................................................................................................... 31
STATBYTE3 ...................................................................................................................................... 32
STATBYTE4 ...................................................................................................................................... 32
4.1 Lambda formula used internally................................................................................................... 33
III OPTIONS SUGGESTED for CAP3300........................................................................................................ 34

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I. COMMUNICATION PROTOCOL

1 General specification

1.1 Type of communication : RS 232

SPEED: 9600/19200 Baud selectable
Parity: NON
Stop Bit : 1
Data : 8 bits
Only Tx, Rx and GND pins are used with this protocol.
Timeout = 100 ms.
Interbyte timeout = 5 ms.

1.2 General command:

FORMAT: <command><size><data><checksum>
<command>: 1 byte type: CAPITAL LETTER from ‘A’ to ‘Z’
<size> : 1 byte type: char between 0 and 255
<data> : String composed of <size > bytes. Format is depending on the command.

<checksum> : Calculated as follow :checksum = -(command + size + Σ (d(i)) ) modulo 0x100.

Checksum calculation example :

Command example : “0x43 , 0x10 , 0x87 , 0x31 , 0x2E , 0x35 , Checksum”
First add all data values : 0x43 + 0x10 + 0x87 + 0x31 + 0x2E + 0x35 = 0x16E
Then calculate it complement : - 0x16E = 0xE92
Then : checksum = 0xE92 modulo 0x100 = 0x92

Be careful : this example of command is only an example and can’t be use to

communicate with the gas bench.

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1.3 General answer

FORMAT: <command><size><data><checksum>
<command> : 1 octet type: CAPITAL LETTER from ‘A’ to ‘Z’
<size> : 1 octet type: char between 0 and 255
<data> : String composed of <size > bytes. Format is depending on the command.
<checksum> : Calculated as follow :checksum = -(command + size + Σ (d(i) ) modulo 0x100.

NON ACKNOLEDGE COMMAND: (NACK ANSWER)

<command> <0x01><0x15><checksum>
An answer with only one data equal to 0x15 (NACK) has to be considered as a wrong
command, a non defined command or a not available command.

1.4 DATA TYPE:

In order to help the developer to fasten the design, the CAPBENCH can send the gas data in 3
different formats:

1.4.1 TEXTE format

A data sent in text format takes 5 bytes and the value is coded directly in a string which can be
displayed without any change. The strings is completed with space character 0x20 before the
value.
Ex: CO sent in text format will be received as :" 1.47". (display 1.47 % vol.)
HC sent in text format will be received as :" 27" (display 27 ppm vol.)

1.4.2 Integer format

Depending on the application, it may be helpful to reduce the time required to get the value by
reducing the frames. For this reason, the data can also be sent in integer format. Each data in
this case is received as an integer and has to be divided and put in a float depending on the
resolution.
Ex: CO at 2 digits:
1-The host receive 128 in the CO channel (coded in 2 chars: {0x00,0x80} )
2-Divide by 100
3- display: 1.28 % vol.

Ex: CO at 3 digits:
1-The host receive 1285 in the CO channel (coded in 2 chars: {0x05,0x05} )
2-Divide by 1000
3- display: 1.285 % vol.

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1.4.3 Float format

Coded on 4 bytes which can be cast in a float.
If commands using float format has been chosen in your development, a 4 bytes string received
has to be cast in float format. This example shows how to proceed in C language:

Ex :
{
char RxDbuf[4]={0x40,0x00,0xA3,0xD7};
float *floatpt;
float COval;
floatpt=(float *)&(RxDbuf[0]);
COval= *floatpt;
/* at final, COval is equal to 2.01 %vol. in this example */
}

Other examples:
CO2=12.9 %vol. will be coded on 4 bytes as :
char RxDbuf[4]={0x41,0x4E,0x66,0x66}

HC=1498 ppm vol. will be coded on 4 bytes as :

char RxDbuf[4]={0x44,0xBB,0x40,0x00}

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2 List of the commands

2.1 Command ‘G’ : Set the baud rate

This command set the baud rate to 9600 baud or 19200 baud.
The new baud rate is applied once after using this command, receiving a positive answer and
switching OFF and ON the bench.

Command: <’G’, 0x01, Baud rate, Checksum >

Positive answer : <’G’, 0x00, Checksum >.

- Baud rate = 0x00 Serial communication set at 9600 (DEFAULT).

- Baud rate = 0x01 Serial communication set at 19200.

2.2 Command ‘O’ : Toggle PUMPS and SOLENOIDS

This command changes the status of the pumps. Check the status bits to know if the
pumps are running or not.
Command: <’O’, 0x01, I/Ocommand, Checksum >
Answer if ok: <’O’, 0x01, I/Ostatus, Checksum >.
I/Ocommand and I/Ostatus format:
b7:PUMP1 set to 1 if pump1 ON. Bit cleared if pump1 OFF
b6:PUMP2 set to 1 if pump1 ON. Bit cleared if pump2 OFF
b5: SOLENOID1 set to 1 if pump1 ON. Bit cleared if solenoid1 OFF
b4: SOLENOID2 set to 1 if pump1 ON. Bit cleared if solenoid2 OFF
b3:VACUUM SWITCH (READ ONLY) set to 1 in case of LOW FLOW
b2:CO displayed at 3 digits
b1:HC PROPANE display
b0:reserved

2.3 Command ‘Z’ : Send a ZERO

Command: <’Z’, 0x00, Checksum >
Answer if ok : <’Z’, 0x00, Checksum >.
Set all gas channels to 0 but O2 value to 20.9 %vol.
A NACK command is returned if zeroing is already in progress or if the zeroing is not
available.

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2.4 Command ‘T’ : GET DATA AND STATUS in text format

Command: <’T’, 0x01, datatype, checksum >
Answer: <’T’, 0x2D, datatype, ”xxxxx”, ”xxxxx”, ”xxxxx”, ”xxxxx”, “xxxxx”, “xxxxx”,
“xxxxx”, “xxxxx”, Errorbyte1, Errorbyte2, Errorbyte3, Errorbyte4, Checksum>.
Each data is sent by a string of 5 ASCII codes in text format. The string can be easily displayed
directly on your application.
Errorbyte1, Errorbyte2, Errorbyte3 and Errorbyte4 contains some flags describing the status
and the error message of the CAPBENCH.
Datatype format:
Datatype Data 0 Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7

0x20 CO value CO2 value Hc value Lambda value O2 value Nox value Rpm value Oil temp
value

Unit % vol. %vol. ppm vol % vol. ppm Rpm °C

Resolution 2/3 Digits* 2 Digits** 0 Digits 3 Digits 2 Digits 0 Digits 0 digits 1 Digits

0x21 CO value CO2 value Hc value Lambda value O2 value Nox value Rpm value Gas
Pressure

Unit % vol. %vol. ppm vol % vol. ppm Rpm mBar

Resolution 2/3 Digits* 2 Digits** 0 Digits 3 Digits 2 Digits 0 Digits 1 Digits

0x22 CO value CO2 value Hc value Lambda value O2 value Nox value Real time Gas
PEF Pressure

Unit % vol. %vol. ppm vol % vol. ppm MBar

Resolution 2/3 Digits* 2 Digits** 0 Digits 3 Digits 2 Digits 0 Digits 3 Digits 1 Digits

0x15 Detector Temp Gas Pressure Ambiant Vacuum PEF value % Warmup O2 Voltage unused
value value Temp value Pressure value

Unit °C mBar °C mBar % mVolt

Format 1 Digits 1 Digits 1 Digits 1 Digits 3 Digits 0 Digits 3 Digits

*
depending on I/O status (CO displayed at 2 or 3 digits)
**
depending on ‘D’ or ‘U’ command with calibrationtype=0x30 (CO2 displayed at 1 or 2
significant digits)

Status bits :
Errorbyte1={Zero in progress Bit7
Zero required Bit6
Warm-up in progress Bit5
Calibration in progress Bit4
Calibration required Bit3
Pressure O.O.R Bit2
Ambient temp O.O.R Bit1
Detector temp O.O.R Bit0 }

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Errorbyte2={ HC O.O.R Bit7

CO O.O.R Bit6
CO2 O.O.R Bit5
O2 O.O.R Bit4
NOx O.O.R Bit3
Oil temp O.O.R Bit2
Rpm O.O.R Bit1
Vacuum O.O.R Bit0 }

Errorbyte3={PUMP1 Bit7 idem I/Ostatus byte

PUMP2 Bit6
SOLENOID1 Bit5
SOLENOID2 Bit4
VACUUM SWITCH Bit3
CO3digits Bit2
HCpropane Bit1
Channel error Bit0 }

Errorbyte4={ EEPROM failed Bit7

Bad O2 sensor Bit6
Detector Low Signal Bit5
Bad nox sensor Bit4
Initial Zero in progress Bit3
New gas data Bit2
New rpm data Bit1
Lamp error Bit0 }

Note: To get EEPROM values, you must use GET DATA and STATUS in float format only.

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2.5 Command ‘I’ : GET DATA AND STATUS in integer format

Command : <’I’,0x01, datatype, checksum >

Answer : <’I’,0x15,datatype,data0high,data0low,data1hi,data1low,...,...,data7hi,data7low,
Errorbyte1, Errorbyte2, Errorbyte3, Errorbyte4, Checksum>.
If datatype >= 0x80, you read the EEPROM values. (see 3)

Errorbyte1, Errorbyte2, Errorbyte3 and Errorbyte4 contains some flags describing the status
and the error message of the CAPBENCH. The format of the status bits is identical to the
format described on the parag 2.3 ('T' command).

Datatype Data 0 Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7

0x20 CO value CO2 value Hc value Lambda O2 value Nox value Rpm value Oil temp
value value

Unit % vol. %vol. ppm vol % vol. ppm Rpm °C

Format Divide the int Divide the int Integer Divide the int Divide by Integer Integer Divide by 10
by 100/1000* by 100** by 1000 100

0x21 CO value CO2 value Hc value Lambda O2 value Nox value Rpm value Gas Pressure
value

Unit % vol. %vol. ppm vol % vol. ppm Rpm mBar

Format Divide the int Divide the int Integer Divide the int Divide by Integer Integer Divide by 10
by 100/1000* by 100** by 1000 100

0x22 CO value CO2 value Hc value Lambda O2 value Nox value Real time Gas Pressure
value PEF

Unit % vol. %vol. ppm vol % vol. ppm mBar

Format Divide the int Divide the int Integer Divide the int Divide by Integer Divide by Divide by 10
by 100/1000* by 100** by 1000 100 1000

0x15 Detector Gas Pressure Ambiant Vacuum PEF value % Warmup O2 Voltage unused
Temp value value Temp value Pressure
value

Unit °C mBar °C mBar % mVolt

Format Divide by 10 Divide by 10 Divide by 10 Divide by 10 Divide by Integer Divide by

1000 1000

*
depending on I/O status (CO displayed at 2 or 3 digits)
**
depending on ‘D’ or ‘U’ command with calibrationtype=0x30 (CO2 displayed at 1 or 2
significant digits)

Note:

To get EEPROM values, you must use GET DATA and STATUS in float format only.

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2.6 Command ‘A’ : GET DATA AND STATUS in float format

Command : <’A’, 0x01, datatype, checksum >

Answer : <’A’, 0x25, datatype, data0byte1, data0byte2, data0byte3, data0byte4, … ,
data7byte1, data7byte2, data7byte3, data7byte4, Errorbyte1, Errorbyte2,
Errorbyte3, Errorbyte4, Checksum>.
If datatype >= 0x80, you read the EEPROM values. (see chapter 3 to get the mapping of the
EEPROM)

Each data is sent by a string of 4 ASCII codes in float format. The string can be easily
displayed directly on your application by casting the four bytes in a float variable. (see parag
1.4.3)
Errorbyte1, Errorbyte2, Errorbyte3 and Errorbyte4 contains some flags describing the status
and the error message of the CAPBENCH. The format of the status bits is identical to the
format described on the parag 2.3 ('T' command).

Datatype Data0 Data1 Data2 Data3 Data4 Data5 Data6 Data7

0x20 CO value CO2 value HC value Lambda value O2 value NOx value RPM value Oil temp
value

Unit % vol. % vol. ppm vol. % vol. ppm vol RPM °C

0x21 CO value CO2 value HC value Lambda value O2 value NOx value RPM value GasPress
value

Unit % vol. % vol. ppm vol % vol. ppm vol RPM mBar

0x22 CO value CO2 value HC value Lambda value O2 value NOx value PEF value GasPress
value

Unit % vol. % vol. ppm vol % vol. ppm vol mBar

0x15 Detector Gas Pressure Ambiant Temp Vacuum PEF value % Warmup O2 Voltage unused
Temp value value value Pressure value

Unit °C MBar °C mbar % mVolt

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2.7 Command ‘S’ : Start the continuous mode

This command is to set the gas bench in a mode which sends continuously the data frame
selected. It is possible to decide the frequency of the transmission with the argument
'time'.

Use the ‘Q’ command to leave a gas test to go back to the menu
Command: <’S’, 0x03, dataformat, DATATYPE, time, Checksum >

Answer if ok and if dataformat=0:

<’S’, 0x2F, 0x00, datatype, time, ”xxxxx”, ”xxxxx”, ”xxxxx”, ”xxxxx”, “xxxxx”, “xxxxx”,
“xxxxx”, “xxxxx”, Errorbyte1, Errorbyte2, Errorbyte3, Errorbyte4, Checksum>.

Answer if ok and if dataformat =1:

<’S’,0x17,0x01,datatype,time, data1high,data1lo, data2hi, data2lo,... ... data8hi, data8lo,
Errorbyte1, Errorbyte2, Errorbyte3, Errorbyte4, Checksum>.

Dataformat:
Set to 0x00 if you want dataformat to be in text mode. (Format similar to 'T' command)
Set to 0x01 if you want to receive data in integer mode. (Format similar to 'I' command)
Set to 0x02 if you want to receive data in float mode. (Format similar to 'A' command)

Datatype:
Idem commands 'T', 'I' and 'A' . Datatype can be 0x20, 0x21, 0x22 or 0x15 depending on the
data needed.

Time:

Value from 1 to 10. Giving the frequency of sending the frames. 1=100 ms. 10= 1000 ms.

2.8 Command ‘Q’ : Stop the continuous mode

This command is used to leave the continuous mode data sending

Command: <’Q’, 0x00, Checksum >
Answer if ok : <’Q’, 0x00, Checksum >.

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2.9 Command ‘C’ : Calibrate

Command: <’C’, 0x10, calibrationtype, "xx.xx", "xx.xx", "xxxxx", Checksum >
Coval CO2val Hcval
Calibrationtype:
b7: 1 point (used in the field) calibration if set to 1
b6: 3 points calibration: low point 1 if set to 1
b5: 3 points calibration: middle point2 if set to 1
b4: 3 points calibration: high point3 if set to 1
b3: HC very high calibration if set to 1
b2: HC calibration if set to 1
b1: co2 calibration if set to 1
b0: CO calibration if set to 1

Answer if ok : <’C’, 0x00, Checksum >.

Note 1: Concentrations of CO, CO2 and HC send are stored in the EEPROM mapping at the
0x86 address.
Note 2: The 3 points calibration is made at the factory. At any case, do not start again this
calibration as it can falsify the measurements.

Notice : keep a gas flow as long as the status bit “Calibration in progress” is active (about 5
secondes). When it is cleared, you can stop the gas flow.

Example to calibrate CO=2.00% vol., CO2=13.0% vol. and HC=1500ppm vol. :

< 0x43, 0x10, 0x87, 0x30, 0x32, 0x2E, 0x30, 0x30, 0x31, 0x33, 0x2E, 0x30, 0x30, 0x30,
0x31, 0x35, 0x30, 0x30, 0x4E>

2.10 Command ‘D’ or ‘U’ : Internal calibration

Command:
Float format: <’D’, 0x05, calibrationtype, DATA, Checksum >
DATA: float type (4 bytes)
Or
Text Format :<’U’, 0x05, calibrationtype, ”xxxxx”, Checksum >

DATA: X is an ASCII code comprised between '0' and '9' (between 0x30 and 0x39 or between
48 and 57). X can be equal to '.' if a floating value has to be transmitted.

Answer if ok : <’D’, 0x00, Checksum >. or <’U’, 0x00, Checksum >.

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Calibrationtype:

Command Title Argument Argument range Argument unit

0x04 Initial zero (default EEPROM values) No

0x05 Board Temperature calibration Yes 0 – 200 °C

0x06 Detector Temperature calibration Yes -20 – 100 °C

0x07 Gas Pressure calibration. Yes Default 1013 mBars

0x08 Flow Pressure sensor calibration Yes Default 1013 mBars

0x0C Delta flow pressure sensor switching limit Yes Default 160 mBars

0x09 O2 cell ground offset calibration No

0x0A O2 0% calibration No

0x0B Air O2 concentration setting Yes Default 20,9 % vol.

0x0D NOX OFFSET calibration No

NOX 1 pt calibration concentration
0x0F setting
Yes 0 – 5000 ppm

0x10 Install and check new O2 sensor No

0x12 Set O2 voltage low limit(in mV) Yes Default 4 mV

0x11 Install and check new NOX sensor No

0x13 Set NOX voltage low limit(in mV) Yes mV

0x20 Save EEPROM as default No

Restore EEPROM default factory
0x21 calibration values
No

0x22 PEF Low calibration with Hexane Yes 0 – 2500 ppm

0x23 PEF High calibration with hexane Yes 2500 – 5000 ppm
0x0 normally open
0x24 External vacuum configuration Yes
0x1 normally closed
0x25 Install new IR emitter No
0x0 heater 16W
0x26 Heater configuration Yes
0x1 heater 8W
0x0 1significant digit
0x30 CO2 2 digits selection Yes
0x1 2 significant digits

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2.11 Command ‘B’ : Get gas curves

Command: <’B’, 0x01, channel, Checksum >
Channel: 1 byte
0x01: CO channel
0x02: CO2 channel
0x03: HC channel
0x04: ref channel
Answer if ok : <’B’,0xFF,chanel, data1, data2, ...data127, Checksum >.
Output:
Channel: char specifying the channel of the curve sent
DATAx: integer coded on 2 bytes.
Use the following scale to display in volts: 65535 = 4.096 Volts

2.12 Command ‘P’ : Ask PEF for a given HC concentration (Text format)
Command: <’P', 0x05, "xxxxx", Checksum >
Input: HC concentration in ppm text format
Answer if ok : <’P’,0x05,"x.xxx", Checksum >.

Output: PEF value for the given concentration

X is an ASCII code comprised between '0' and '9' (between 0x30 and 0x39 or between 48 and
57).

2.13 Command ‘N’ : Read Serial Number, Soft Version, Date in text format
Command: <’N', 0x01, datatype, checksum>

Datatype Selection Answer in text format

0x00 Serial Number <’N', 0x06,0x00,x,x,x,x,x, Checksum >

0x01 Soft Version <’N', 0x07,0x01,'V',x,.,x,x,x, Checksum >

0x02 Date <’N', 0x09,0x02,x,x,'/',x,x,'/',x,x, Checksum >

X is an ASCII code comprised between '0' and '9' (between 0x30 and 0x39 or between 48 and
57).

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2.14 Command ‘L’ : Switch the auxiliary COM on

Command: <’L ’, 0x06, 'A', 'U', 'X', ' ', 'O', 'N', checksum> (checksum = 0x03)
Answer if ok : <’L’, 0x00, Checksum >.

The command ‘L’ allows to communicate with an auxiliary device which use a RS232 serial
communication like CAP8510. Connect the device on the auxiliary communication port (J9
named ‘AUX’) and then use the command ‘L’ to switch the communication on this device.
When the auxiliary communication port is switched on, the RS232 communication port (J10
named RS232) allows to get bytes received from the auxiliary device.

2.15 Command ‘M’ : Switch the auxiliary COM off

Command: <’M ’, 0x07, 'A', 'U', 'X', ' ', 'O', 'F', 'F', checksum> (checksum = 0xC3)

The command ‘M’ is used to leave the auxiliary communication and comes back to the
communication with the gas bench.

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3 EEPROM mapping
Address Title Data 0 Data 1 Data 2 Data 3 Data 4 Data 5
LINE
0x80 INTOFFCAL DETTEMP GASPRESS AMBIANT TEMP FLOWPRESS

0x81 INTCALDAT DETTEMP GASPRESS AMBIANT TEMP FLOWPRESS FLOWLIM

0x82 O2CONST AIRO2CONC ZEROO2 O2OFFSET O2LOWVOLT NEWO2VOLT

0x83 CROSS_OTO124 Refcomp CO Refcomp CO2 Refcomp HC CO ideal CO2 ideal HC ideal

0x84 NOXCONST NOXCONC ZERONOX NOXOFFSET NOXLOWVOLT CALVOLTNOX PRESSCALNOX

0x85 PRESS_COMP Coef_CO Coef_CO2 Coef_HC Coef2_CO Coef2_CO2 Coef2_HC

0x86 CALPTCONC CO Cal. CO2 Cal. HC Cal.

CO CO2 HC
0x87 CALPTCOND CO+3 (DETTEMP) CO2+3 (DETTEMP) HC+3 (DETTEMP)
(GASPRESS) (GASPRESS) (GASPRESS)
CO CO2 HC
0x88 CALPTVAL
(measure/calibration) (measure/calibration) (measure/calibration)
0x89 CAL3PT1CONC CO Cal. CO2 Cal. HC Cal. CO Measure CO2 Measure HC Measure
CO CO2 HC
0x8a CAL3PT1COND CO+3 (DETTEMP) CO2+3 (DETTEMP) HC+3 (DETTEMP)
(GASPRESS) (GASPRESS) (GASPRESS)
CO CO2 HC
0x8b CAL3PT1VAL
(measure/calibration) (measure/calibration) (measure/calibration)
0x8c CAL3PT2CONC CO Cal. CO2 Cal. HC Cal. CO Measure CO2 Measure HC Measure
CO CO2 HC
0x8d CAL3PT2COND CO+3 (DETTEMP) CO2+3 (DETTEMP) HC+3 (DETTEMP)
(GASPRESS) (GASPRESS) (GASPRESS)
CO CO2 HC
0x8e CAL3PT2VAL
(measure/calibration) (measure/calibration) (measure/calibration)
0x8f CAL3PT3CONC CO Cal. CO2 Cal. HC Cal. CO Measure CO2 Measure HC Measure
CO CO2 HC
0x90 CAL3PT3COND CO+3 (DETTEMP) CO2+3 (DETTEMP) HC+3 (DETTEMP)
(GASPRESS) (GASPRESS) (GASPRESS)
CO CO2 HC
0x91 CAL3PT3VAL
(measure/calibration) (measure/calibration) (measure/calibration)
0x92 PEF_CALIBRATION VAL_HEXANE_LOW PROPANE_MESURE_LOW PEF_CALCULE_LOW VAL_HEXANE_HIGH PROPANE_MESURE_HIGH PEF_CALCULE_HIGH

0x93 POT_NUM POT_CO POT_CO2 POT_HC POT_REF AMPLITUDE VARIATION

0x94 POT_NUM_SAVE POT_CO POT_CO2 POT_HC POT_REF FLAG_FIRST_ADJUST FLAG_INITIAL_ZERO

0x95 DET_COMP Coef_CO Coef_CO2 Coef_HC Coef2_CO Coef2_CO2 Coef2_HC

0x96 DIVERS TMPDET_START TMP_CAL_GASPRESS TMP_CAL_FLOWPRESS CONFIG_VACUUM CONFIG_LOW_FLOW CONFIG_HEATER

0x97 CROSS COatCO2 COatHC CO2atCO CO2atHC HCatCO HCatCO2

0x98 CROSS_OTO105 Refcomp CO Refcomp CO2 Refcomp HC CO ideal CO2 ideal HC ideal

0x99 CROSS_OTO106 Refcomp CO Refcomp CO2 Refcomp HC CO ideal CO2 ideal HC ideal

0x9A CAL4PTHC HCcal HCmeasure HCgaspress HCdettemp HCmeasure_on_cal

The EEPROM data can be get by using the command 'A' and by using the argument Datatype equal
to the address of the line.

Page 18
Technical manual cap3300

II. INSTALLATION & MAINTENANCE

1 Outline

1.1 Overall view

The CAP3300 is a NDIR gas analyzer intended to be used in the measurement of
automotive exhaust gases like CO, CO2 and HC. This analyzer measure exhaust gases of
gasoline vehicles while complying with the OIML R99 CLASS 0 and ISO 3930
specifications. It communicates with external CPU by serial communication RS232 or USB.
It drives power circuit to control pumps and solenoids (1A max by output). It has also
analog ports to connect with O2 and NOx sensors, RPM probe and oil temperature sensor.
Finally, it has a vacuum switch integrated.
The CAP3300 is a real advantage for your new developments, if your main target is to
reach a high quality, low cost efficiency solution.

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Technical manual cap3300

1.2 Configuration

1
2

3 4 5 6 7 8

N° Ref / Names Descriptions Brand / Ref. *

1 GAS INPUT Gas input. Tubing has to be 2.4 mm internal diam.
2 GAS OUTPUT Gas output. Tubing has to be 2.4 mm internal diam.
The happy LED attests a good functioning when it is
3 D10 / HAPPY LED
flickering
Connector for BDM (software update)
2 4 6 1: BKGD (Pull up)
2 : GND
4 J20 / BDM
3, 5: NC (No Connected)
1 3 5 4: Reset
6:+5V
Connector for O2 sensor
1: O2- JST / XHP-3
5 J16 / O2 2:GND +
1 2 3 3:O2+ JST / SXH-001T-P0.6

Connector for NOx sensor

1: +10V JST / XHP-5
6 J17 / NOX 2: NOX+ +
1 2 3 4 5 3: GND JST / SXH-001T-P0.6
4: NOX-
5: NC (No Connected)
Connector for oil temperature sensor (See option suggested on
parag III)
JST / XHP-3
1: Input probe
7 J18 / OIL TEMP +
1 2 3 2: GND
JST / SXH-001T-P0.6
3: Input probe
Inputs may be connected indifferently because it is a resistive
sensor.
Connector for RPM probe (See option on parag III)
JST / XHP-2
8 J19 / RPM/TTL 1: +5V +
1 2 3 2: GND JST / SXH-001T-P0.6
3: Signal RPM-TTL

Page 20
Technical manual cap3300

9 10

11
12

13

14 15 16 17 18 19 20 21 22 23 24 25

N° Ref / Names Descriptions Brand/ Ref.*

9 IR Detector block
10 Insulating foam
11 Protection hood
12 IR Emitter block
13 J11 / USB USB serial PORT (PC STANDARD)
Connector to plug a RS232 serial communication
JST / XHP-3
14 J10 / RS232 1: Tx +
1 2 3 2: Rx JST / SXH-001T-P0.6
3: GND
Connector to plug an auxiliary RS232 serial communication
JST / XHP-3
15 J9 / AUX 1: Tx +
1 2 3 2: Rx JST / SXH-001T-P0.6
3: GND
Connector for the chamber heater

16 J8 / HEATER 1: Connect to heater (+12V)

2: Connect to heater (GND)
1 2

Power Connector for Pump1

JST / VRH-2N
17 J7 / PUMP1 1: +12V 1.00 Amp max. +
1 2 2: GND JST / SVH-21T-P1.1

Power Connector for Pump2

JST / VRH-2N
18 J6 / PUMP2 1: +12V 1.00 Amp max. +
1 2 2: GND JST / SVH-21T-P1.1

Power Connector for solenoid1

JST / VRH-2N
19 J5 / SOLENOID1 1: +12V 1.00 Amp max. +
1 2 2: GND JST / SVH-21T-P1.1

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Technical manual cap3300

N° Ref / Names Descriptions Brand/ Ref.

Power Connector for solenoid2
JST / VRH-2N
20 J4 / SOLENOID2 1: +12V 1.00 Amp max. +
1 2 2: GND JST / SVH-21T-P1.1

TTL outputs which can drive a power board for supplying

pumps or solenoids (external )

1: Solenoid 2 (TTL) JST / XHP-5

21 J3 / OUTPUT CTRL 2: Solenoid 1 (TTL) +
1 2 3 4 5 JST / SXH-001T-P0.6
3: Pump 2 (TTL)
4: Pump 1 (TTL)
5: GND (TTL)
TTL input for connecting an external vacuum switch
JST / XHP-2
22 J2 / VACUUM 1: External vacuum (pull up) +
1 2 2: GND JST / SXH-001T-P0.6

23 P1 / FLOW PRESS Pressure sensor to control the gas flow

24 P2 / GAS PRESS Pressure sensor to measure gas pressure
Power input connector to plug +12V ± 0.2V or +13.5V to
+30V power supply depending on the request configuration.
JST / VRH-2N
J1 / +12V ± 0.2V 1: +12V ± 0.2V or +13.5V to +30V
25 +
or +13.5V to +30V 1 2 2: GND JST / SVH-21T-P1.1

*
Housings references + the contacts references

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Technical manual cap3300

Sample Cell :

1
2

3 4 5 6 7 8

N° Descriptions
1 IR detector
2 Sample cell
3 O ring
4 Optical window
5 O ring
6 O ring
7 Optical window
8 IR emitter

Page 23
Technical manual cap3300

1.3 Block Diagram

RPM Oil
probe temperature

CPU Board IR detector Board

Serial
communication
RS232 or USB

IR Detectors

CO CO2 HC REF

IR Emitter Board CPU 4

4
Gain

Power circuit

ADC MUX Gain

Power outputs to TTL outputs to O2 NOx

control pumps & pilot pumps & sensor sensor
solenoids solenoids

1.4 Specifications
The CAP3300 has the following specifications:

- CO, CO2, HC, O2 and NOx measurement

- Preheating time < 9 minutes at 0°C (1 minute minimum)
- Sampling chamber heated to avoid humidity and temperature interferences.
- USB port optional full compatible with your RS232 windows based development
(drivers supplied).
- Response time : 5 or 6 seconds for CO, CO2, HC and 28 seconds for oxygen
(transition from 20,9% to 0,1% for a gas with 0% O2)
- Automatic correction by integrated absolute pressure sensor between 750mBar
and 1150mBar.
- Vacuum pressure for flow control integrated
- TTL input drive by an external vacuum switch
- Power circuit integrated to drive pumps and solenoids (1A max by output)
- TTL outputs to drive external power for pumps and solenoids
- Power supply : 12V ± 0,2V or 13,5V to 30V, 2A + ΣIpumps + ΣIsolenoids regulated
- Serial communication RS232 or USB
- Complies with the OIML R99 (ISO 3930) Class 0 specification
- RPM measurement
- Oil temperature measurement (connect directly the oil probe CAP0421)
- Additional RS232 which can works as a gateway for other peripherals
- Dimensions : 177mm × 80mm
- Weight: 190g
- Sample cell easily cleanable

Page 24
Technical manual cap3300

2 Installation, connections and start-up

2.1 Operating conditions

The CAP3300 has to be installed in a gas analysis system. The environmental
requirements are listed in the following list:

Operating Temperature:
The CAP3300 can work in a range of temperature ranging between 0°C and 50°C.
However, it is advised to use it in a stable temperature environment for an optimum
running.

Storage Temperature: -20 °C to 70 °C.

Ambient pressure:
Can work with ambient pressure between 850 mBar and 1100 mBar.

Required flow rate: from 0,5 l/min. to 6 l/min.

Humidity: 0 - 95 % relative

Pneumatic circuit :
Follow the recommended gas circuit mentioned on paragraph 2.2 otherwise ask
Capelec's technical support to validate other possibilities.

Vibration:
Designed to support normal vibrations and vibrations defined by ISO3930 without any
influence on the measure.

Electromagnetic field:
CE approved.

Power supply:
The supply input voltage must be 12V ± 0,2V or between 13,5V and 30V depending
on the request configuration :
• +12V ± 0,2V (fixed voltage)
If you choose this configuration, you will always have to supply the gas bench with
+12V ± 0,2V because the power outputs (pumps, solenoid valves and heater) are
supply with the power supply voltage. So all the devices connected on the power
outputs will be supply with the same voltage as the power supply voltage (+12V±
0,2V) .

• Between 13,5V and 30V (voltage range)

If you choose this configuration, you can supply the gas bench with +13,5V to +30V
because an internal switched power supply allows to regulate at +12V the voltage use
by the power outputs (pumps, solenoid valves and heater). So all the devices
connected on the power outputs will be supply with +12V regulated if the power
supply voltage is adjust between +13,5V and +30V.

Page 25
 Flow pressure
Zero Gas
Technical manual cap3300

Solenoid
Gas pressure Sample cell
Active coal filter
2.2 Gas circuit

Gas pump

Gas line filter

NOx O2 sensor
sensor

Water separator

Gas output

Water line filter Drain pump

Water output

Sample probe

Page 26
Measured Gas
 Technical manual cap3300

2.3 Most common procedures

2.3.1 Gas measurement

- Insert a neutral gas (ambient air) in the sample cell by switching on the gas pump and by
switching the solenoid on the “Zero gas” (see gas circuit in Installation and maintenance
paragraph 2.2).
- Wait at least 10 seconds to make sure that the sample cell is full of ambient air.
- Send the Zero command ‘Z’ (see protocol of communication paragraph 2.3) to the CAP3300.
- Wait the Zero in progress status bit to be cleared. You can check values of all status bits in the
Get data command answer of the CAP3300 (see protocol of communication paragraph 2.4, 2.5
and 2.6). The Zero in progress status bit is located in the Errorbyte1 bit 7.
- Switch the solenoid on the “Measured gas” and keep the gas pump switch on in order to have a
measured gas flow in the sample cell.
- Get the volumic concentrations of CO, CO2 and HC through the command Get Data and Status
‘T’, ‘I’ or ‘A’ with the datatypes 0x20, 0x21 or 0x22 (see protocol of communication paragraph
2.4, 2.5 and 2.6).
- Display gas data while no status bit error is set.

2.3.2 Calibrate the CAP3300

To calibrate the CAP3300, use the 1 point calibration command (see protocol of communication
paragraph 2.9) when the measurements become too different from the real values. To make this
calibration follow the steps described below:
- Insert a neutral gas (ambient air) in the sample cell by switching on the gas pump and by
switching the solenoid on the “Zero gas” (see gas circuit in Installation and maintenance
paragraph 2.3).
- Wait at least 10 seconds to make sure that the sample cell is full of ambient air.
- Send the Zero command ‘Z’ (see protocol of communication paragraph 2.3) to the CAP3300.
- Wait the Zero in progress status bit to be cleared. You can check values of all status bits in the
Get data command answer of the CAP3300 (see protocol of communication paragraph 2.4, 2.5
and 2.6). The Zero in progress status bit is located in the Errorbyte1 bit 7.
- Switch the solenoid on the “Measured gas” and keep the gas pump switch on in order to have a
calibration gas flow in the sample cell.
- Wait the volumic concentrations to be stable and then send the command 1 point calibration ‘C’
(see protocol of communication paragraph 2.9) to calibrate the CAP3300 with the volumic
concentration of CO, CO2 and HC. Keep a gas flow in the sample cell until the Calibration in
progress status bit will be cleared (see protocol of communication paragraph 2.4, 2.5 and 2.6.
The Calibration in progress status bit is located in the Errorbyte1 bit 4).
Note: to calibrate the CAP3300 we recommend you to use bottles with CO=2% vol., CO2=13% vol. and
HC=1500ppm vol. propane.

Page 27
Technical manual cap3300

3 Gas analysis

3.1 Technical characteristics

Characteristics Set condition

CO: -0.03% vol. to 15.50% vol.
CO2: -0.4% vol. to 21.0% vol.
Gas concentration HC: -10 ppm to 20 000 ppm as propane
range O2: -0.5% vol. to 25% vol.
NOx: -30 ppm to 5000ppm
LAMBDA: 0 to 9.999
CO: 0.01% vol. if the bit CO3digits =0
CO: 0.001% vol. if the bit CO3digits =1
CO2: 0.1% vol.
Resolution HC: 1 ppm vol.
O2: 0.01% vol.
NOx: 1 ppm
LAMBDA: 0.001
CO: 0.03% vol. absolute or 3% of value read
CO2: 0.4% vol. absolute or 4% of value read
Precision HC: 10 ppm absolute or 5% of value read
O2: 0.1% vol. absolute or 3% of value read

Page 28
Technical manual cap3300

3.2 Detect a low flow

P1 : Flow pressure P2 : Gas pressure

To detect a low flow, first connect the gas circuit like in the gas circuit (paragraph. II 2.2). The
pressure sensor named "Gas Pressure" is the component named "P2" on the CAP3300 board and the
pressure sensor named "Flow Pressure" is the component named "P1" on the CAP3300 board.
Then, when the gas circuit is connected, a low flow is detected when :
Flow pressure < ( Gas pressure - Delta P ).
When a low flow is detected, the status bit "Vacuum Switch" (errorbyte3 bit3) is activated.
The Delta P value is fixed to 160mBars and is saved in EEPROM (address line 0x81 INTCALDAT,
Data 5 = Flowlim). If you need to change this value, use the WinBench software : go in the
"EEPROM info" page and select the "IntCalDat" box. Then write the new value in the box
"Flowlim" to substitute the 160mBars value and then click on "Write".

3.3 Use of the Real Time PEF

The Gas Bench use a real time PEF. It means that the PEF is fluctuating according to the HC
concentration value.
So if HC < 200ppm propane (C3H8), PEF=LowPEF. Then for HC > 2000ppm propane (C3H8),
PEF=HighPEF. And between these two values, PEF is calculated with the following formula :

PEF =
(HighPEF − LowPEF ) ×(HCpropane _ measured − HCpropane _ low)+ LowPEF
 ( HCpropane _ high − HCpropane _ low ) 

For example if HC=1500ppm propane (C3H8), PEF will be calculated with the formula above
because 200ppm< PEF =1500ppm<2000ppm .

Note that normally the PEF calibration is made with a concentration near to 200ppm propane for low
PEF and a concentration near to 2000ppm for high PEF. However these values can change.

Page 29
Technical manual cap3300

3.4 Detect a leak

To detect a leak, first connect the gas circuit like in the gas circuit (paragraph. II 2.2). The pressure
sensor named "Gas Pressure" is the component named "P2" on the CAP3300 board and the pressure
sensor named "Flow Pressure" is the component named "P1" on the CAP3300 board.

Then, when the gas circuit is connected, the following leak detection process is used :

- First, create a leak in the pneumatic circuit on the gas inlet side.
- Then ask for the user to go in a special leak test procedure.
- Power on the pump and switch the solenoid valve on the gas circuit position.
- Save the flow sensor (P1) pressure when the gas bench is running normally like in measurement
mode ("Running pressure"). P=950mBars for example.
- Ask for the user to block the gas inlet.
- Then, the flow sensor pressure is going to decrease.
- As soon as you detect that the vacuum sensor pressure decrease at "Running pressure" - 160mBars,
stop the pump. P=950-160=790mBars for example.
- Save the new flow sensor pressure ("Block pressure").
- Wait for 10 seconds.
- If after the 10 seconds, the pressure "Block pressure" > "Block pressure" + 6mBars so there is a
leak. Otherwise if the pressure "Block pressure" < "Block pressure" + 6mBars so there is no leak.
- Finally display the result of the leak test for the customer (“Leak detected” or “Leak absent”).

Note that values 6mBars and 160mBars are adjusted to the CAPELEC gas analyzer. So create your
own leak and ajust these values to detect it.

Page 30
Technical manual cap3300

4 Error meanings, precautions

STATBYTE1

Status Meaning Set condition

Activated after asking a zero with the 'Z' command
Zero in progress Command “ZERO” in progress Wait this bit to be cleared before to go back to
measurement mode
This bit is active during the warm-up, when a gas is
Execution of the command
Zero required out of range, when the signal levels fluctuate too
“ZERO” needed.
much or every 30 minutes.
Its duration varies from 1 minutes at 9 minutes
Warm-up in progress: it is
Warm-up in progress depending on the time that the IR detector takes to
launched after the power on.
reach its regulation temperature.
Activated after asking a calibration with the 'C'
Calibration in progress Calibration in progress command. Wait this bit to be cleared before to go back
to measurement mode (about 5s).
This bit is active if the IR source intensity is not
Execution of the command
Calibration required sufficient. Wait this bit to be cleared before to go back
“CALIBRATION” needed.
to measurement mode
Pressure sensor is out of the range
Pressure O.O.R Pressure out of range
[750mBars - 1150mBars]
Ambient temperature out of Temperature sensor is out of the range
Ambient temp O.O.R
range [-15°C ; +70°C]
Detector temperature out of Temperature sensor is out of the range
Detector temp O.O.R
range [-15°C ; +70°C]

STATBYTE2

Status Meaning Limit conditions

HC O.O.R HC out of range -10ppm to 32000ppm as propane
CO O.O.R CO out of range -0.03% vol. to 15.5% vol.
CO2 O.O.R CO2 out of range -0.4% vol. to 21% vol.
O2 O.O.R O2 out of range -0.5% vol. to 25% vol.
NOx O.O.R NOX out of range -30 ppm to 10000ppm
Oil temp O.O.R Oil temp out of range 0°C to 150°C
Rpm O.O.R Rpm out of range 0 tr/min to 9999 tr/min
Vacuum O.O.R Vacuum out of range 700mBars to 1300mBars

Page 31
Technical manual cap3300

STATBYTE3

Status Meaning Set condition

Pump1 Pump 1 is running
Pump 2 Pump 2 is running
Solenoid 1 Solenoid 1 is activated
Solenoid 2 Solenoid 2 is activated
“LOW FLOW” detected or This bit is activated if flowpress < (gaspress - ∆P).
Vacuum switch external vacuum switch This switching value can be changed and is stored in
detected a low pressure. the EEPROM.
CO displays with a precision of
CO3digits If cleared, CO is displayed with 2 digits
3 digits after the comma.
HC displays in propane If this bit is at 0, it means that HC is displayed in
HC propane
equivalent hexane .
One or several channel of It means that the setting of a channel is too high
measurement (CO, CO2, HC or to low.
Channel error
or REF) has been found This bit can be also activated if at the power on
defective at the power on. there is gas (CO, CO2 or HC) in the sample cell.

STATBYTE4

Status Meaning Set condition

EEPROM failed The EEPROM is failed DATA lost in the EEPROM (bad checksum)
Activated when the voltage of the O2 cell during the
Bad O2 sensor The O2 sensor is damaged zero becomes under the limit (default limit is 4.0 mV
and can be modified - stored in the EEPROM)
Activated when the voltage of the NOX cell during a
Bad nox sensor The NOx sensor is damaged
calibration becomes under the limit
Sampling of new gas data Activated to inform that new values has been
New gas data
value, temperature and pressure calculated on gas channels
Activated after asking an Initial zero or an Install
new IR emitter with the 'D' or 'U' command. Wait
Initial Zero in progress Initial Zero in progress
this bit to be cleared before to go back to
measurement mode
Activated to inform that new RPM values has been
New rpm data Sampling of new rpm data
updated
The signal of the detector is globally too low,
Normal signal amplitude can
Detector Low Signal coming from a bad detector or, an IR source too
not be reached
low or dirtiness inside the chamber.
This bit is active when the consumption of the IR
Problem linked with the IR
Lamp error source exceeds its specifications or when the IR
source.
source is dead.

Page 32
Technical manual cap3300

4.1 Lambda formula used internally

The simplified BRETTSCHNEIDER formulae used to send a directly calculated

lambda value is:.
 
 
CO  1,7261 3,5
CO2 + + O2 + × − 0,0088  × (CO2 + CO)
2  4 CO 
 3,5 + 
λ =  CO2 
 1,7261
1 +

( )
− 0,0088  × CO2 + CO + 6 × HC × 10 − 4
 4 

(CO, CO2 et O2 are concentrations in %vol., HC is an Hexane value in ppm vol.)

Even if the LAMBDA value send is a value between 0 and 9.999, it is recommended to
display only this data when it is contained in the range [0.800-1.200]. In other cases, not
display this data on your host user interface.

Page 33
Technical manual cap3300

III OPTIONS SUGGESTED for CAP3300

Reference IR Bench with USB

communication
CAP3300-RS RS232 version
CAP3300-USB USB version
SSE 00019 Oil temperature probe
Cable to make the link between the
SSE 00265
oil temperature probe and the bench
Board adapter for connecting an
SSE 00268
inductive pickup on the TTL input
SSE 00015 Inductive pickup
PRO 00020 Tubing a 1/4 " /m
PRO 00021 Tubing a 1/8 " /m
PRO 01339 Tubing a 3/32 " /m
PRO 00329 O2 or NOx sensor manifold
PRO 00303 O2 sensor
PRO 00941 NOX sensor
PRO 00327 Solenoid valve
Additional for 12-30 VDC
SSE 00269
powering (powered by DC voltage)
PRO 01233 12 VDC 2 heads pump
PRO 01651 Power supply board
PRO 00297 Filters / 10
PRO 00310 Filter water separator / 10
PRO 00320 Water separator and main filtering
PRO 03262 Charcoal filter / 10
PRO 01281 USB cable (1.80 meters)
PRO 00030 RS232 cable (1.80 meters)
SSE 00266 Cable RS232 adapter

Page 34