Teledyne Infrared Gas Analyzer manual

TELEDYNE ANALYTICAL INSTRUMENTS OPERATING INSTRUCTIONS Series Model 7500 Infrared Gas Analyzer DANGER HIGHLY TOXIC AND OR FLAMMABLE LIQUID S OR GASES MAY BE PRE SENT IN THIS MONITORING SYSTEM. PERSONAL PROTECTIVE EQUIPMENT MAY BE RE QUIRED WHEN SERVI CING THIS SYSTEM. HAZARDOUS VOLTAGES EXIST ON CERTAIN CO MPONENTS INTERNALLY WHICH MAY PERSIST FOR [...]

2 Model 7500 Instruction Manual T eledyne Analytical Instruments PRELIMINAR Y We are grateful for your purchase of T eledyne Analytical Instrumentʼs Model 7500 Infrared Gas Analyzer . • First read this instruction manual carefully until an adequate understanding is acquired, and then proceed to installation, operation and maintenance of the anal[...]

3 Model 7500 Instruction Manual T eledyne Analytical Instruments SAFETY PRECAUTIONS Please read this section carefully to ensure using the analyzer in the correct way . The cautionary descriptions listed here contain important information about safety , so they should always be observed. Those safety precautions are ranked in 3 levels, “DANGER”[...]

4 Model 7500 Instruction Manual T eledyne Analytical Instruments Caution on piping DANGER In piping, the following precautions should be observed. Wrong piping may cause gas leakage. If the leaking gas contains a toxic component, there is a risk of serious accident being induced. Also, if combustible gas is contained, there is a danger of explosion[...]

5 Model 7500 Instruction Manual T eledyne Analytical Instruments Caution on use PROHIBITED • Do not allow metal, nger or others to touch the input/output terminals in the instrument. Otherwise, shock hazard or injury may occur . • Do not smoke nor use a ame near the gas analyzer . Otherwise, a re may be caused. • Do not allow water t[...]

6 Model 7500 Instruction Manual T eledyne Analytical Instruments CONTENTS PREF ACE .............................................................................................................................2 CAUTION ON SAFETY ..........................................................................................................3 1. OVERVIEW ..[...]

Teledyne Analytical Instruments 7 Model 7500 Instruction Manual 6.8 Maintenance mode ………………… ………………………………………… ……… 57 6.9 Calibration ……………………… …… ………………………………………… …….. 59 6.9.1 Zero calibration …… ………… ……………………?[...]

8 Model 7500 Instruction Manual T eledyne Analytical Instruments 1. OVER VIEW The Model 7500 infrared gas analyzer measures the concentrations of CO2, CO, CH4, SO2 and O2 contained in sample gas. CO2, CO, CH4 and SO2 are measured by non-dispersion infrared method, while O2 is measured by paramagnetic method. A maximum of 4 components including O2 ([...]

9 Model 7500 Instruction Manual T eledyne Analytical Instruments 2. NAME AND DESCRIPTION OF EACH P ART 2.1 Description of each unit Name Description 1. Handle Draws the analyzer unit from the case. 2. Power switch T urns ON/OFF this analyzer . 3. Switch for back light T urn ON/OFF the back light of display . 4. Display / Operation panel Liquid crys[...]

10 Model 7500 Instruction Manual T eledyne Analytical Instruments 3. INST ALLA TION DANGER This unit is not explosion-proof type. Do not use it in a place with explosive gases to avoid explosion, re or other serious accidents. CAUTION • For installation, observe the rule on it given in the instruction manual and select a place where the weight[...]

1 1 Model 7500 Instruction Manual T eledyne Analytical Instruments 3.2 Installation of analyzer There are two methods of installing the analyzer . For detailed dimensions, see Chapter 9.3. Note: The mounting method should be selected to meet the installation requirements since the top cover must be detached from the gas analyzer for maintenance and[...]

12 Model 7500 Instruction Manual T eledyne Analytical Instruments Observe the following when connecting the gas pipes. • The pipes should be connected to the gas inlet and outlet at the rear panel of the analyzer , respectively . • Connect the sampling system to the instrument by using corrosion-resistant tube such as T eon, stainless steel,[...]

13 Model 7500 Instruction Manual T eledyne Analytical Instruments (2) Sampling gas ow rate A ow rate of sampling gas must be 1 L/min ±0.5 L/min. A ow meter should be provided as shown in Fig. 3-2 to measure ow rate values. (3) Preparation for standard gas Prepare the standard gas for zero/span calibration. No O2 meter Built in O2 meter[...]

14 Model 7500 Instruction Manual T eledyne Analytical Instruments (6) Example of sampling system conguration The system conguration may vary depending upon the nature of measured gas, coexistent gases or application. A typical conguration diagram is shown in Fig. 3-2. Since a system conguration depends upon measured gas, consult with T [...]

15 Model 7500 Instruction Manual T eledyne Analytical Instruments 3.5 Wiring method Caution on wiring CAUTION • Wiring work must be performed with the main power set to OFF to prevent electric shocks. • Enforce construction of class-D grounding wire by all means. If the specied grounding construction is neglected, a shock hazard or fault may[...]

16 Model 7500 Instruction Manual T eledyne Analytical Instruments When a noise source is in the vicinity Do not install the analyzer near power noise generating electric equipment (such as high frequency furnace and electric welder). If the analyzer must be used near such equipment, a separate power line should be used for avoiding noise. In case n[...]

17 Model 7500 Instruction Manual T eledyne Analytical Instruments (4) Contact input (DI): terminal block 2 (13 to 20), terminal block 3 (5 to 10) • It is for a contact input at no voltage. An input is provided when switching to short circuit (on) or open (off). • No voltage is applied to the terminals (5) Contact output (DO): terminal block 3 ([...]

18 Model 7500 Instruction Manual T eledyne Analytical Instruments (7) List of terminal blocks 1 to 5 *1) Unused terminals are used for internal connection and should not be used as repeating terminals either . *2) O2 sensor input is used when an external O2 analyzer is selected.[...]

19 Model 7500 Instruction Manual T eledyne Analytical Instruments 8) Description on terminal block T erminal block 1 <TN1> T erminal block for analog output (non-isolated output) Output : 4 to 20 mA or 0 to 100V DC Between 1 – 2: CH5 output Between 3 – 4: CH4 output Between 5 – 6: CH3 output Between 7 – 8: CH2 output Between 9 – 10:[...]

20 Model 7500 Instruction Manual T eledyne Analytical Instruments T erminal block 3 <TN3> Between 1 – 4: For internal connection. Must not be wired. (Must not be used as junction terminal.) Between 5 – 6: Remote hold input. No hold when open. Output hold when short-circuited. Between 7 – 8: Average value reset input. Short- circuiting t[...]

21 Model 7500 Instruction Manual T eledyne Analytical Instruments T erminal block 4 <TN4> Between 1 – 2: CH4 span calibration contact output Between 3 – 4: CH3 span calibration contact output Between 5 – 6: CH2 span calibration contact output Between 7 – 8: CH1 span calibration contact Between 9 – 10: Zero calibration contact output[...]

22 Model 7500 Instruction Manual T eledyne Analytical Instruments T erminal block 5 <TN5> 1 and 1 1 – 14: For internal connection. Must not be wired. (Must not be used as junction terminal.) Between 2 - 3 and 3 - 4: CH3 alarm output. Conductive at 2 – 3 and open at 3 – 4 when set value is exceeded. Open at 2 – 3 and conductive at 3 ?[...]

23 Model 7500 Instruction Manual T eledyne Analytical Instruments (9) Timing of calibration contact output 1. Manual calibration (See “6.9 Calibration”) 2. In case of automatic calibration (example shown in 6.4.1, Automatic calibration settings)[...]

24 Model 7500 Instruction Manual T eledyne Analytical Instruments 4. OPERA TION 4.1 Preparation for operation (1) Check of gas sampling tube, exhaust tube and wiring Check that the pipes are correctly connected to the gas sampling port and drain port. Check that the analyzer is correctly wired as specied. 4.2 W arm-up operation and regular opera[...]

25 Model 7500 Instruction Manual T eledyne Analytical Instruments 5. DISPLA Y AND OPERA TION P ANEL This section describes the display and operation panel of the gas analyzer . It also explains the name and description of function on the operation panel. See Fig. 5-1. 5.1 Name and description of operation panel • Display: The measurement screen a[...]

26 Model 7500 Instruction Manual T eledyne Analytical Instruments 5.2 Overview of display and operation panel Figure 5.2[...]

27 Model 7500 Instruction Manual T eledyne Analytical Instruments 5.3 Overview of display screen (1) Measurement mode screen On turning on the power switch, the Measurement Mode screen will appear . The measurement screen depends on the number of components. The following screen conguration shown as an example is for CO2, CO, O2 (Output at chann[...]

28 Model 7500 Instruction Manual T eledyne Analytical Instruments • O2 correction concentration average value: CH (component) where “A V / CV” is displayed as “A V / CV CO” in the component display and O2 average value, a value obtained by averaging O2 conversion concentration value or O2 concentration value in a xed time is output eve[...]

29 Model 7500 Instruction Manual T eledyne Analytical Instruments (3) Contents of measured channel (CH) The contents in each measured CH corresponding to the type are given below: T ype code Contents 5th digit 6th digit 7th digit CH1 CH2 CH3 CH4 CH5 CH6 CH7 Y C Y O2 A Y Y SO2 B Y Y CO D Y Y CO2 E Y Y CH4 2 Y Y CO2 CO 3 Y Y CH4 CO 4 Y Y CO2 CH4 5 Y [...]

30 Model 7500 Instruction Manual T eledyne Analytical Instruments 5.4 General operation • Measurement mode The measurement mode can be displayed for up to 5 channels in a single screen. When viewing a channel beyond the 5 channels, press the ( or ) key and the screen can be scrolled one by one channel at a time. • User mode displays the followi[...]

31 Model 7500 Instruction Manual T eledyne Analytical Instruments 6. SETTING AND CALIBRA TION 6.1 Changeover of range This mode is used to select the ranges of measured components. 1. During measurement, press the MODE key to display the User mode. 2. Point the cursor to “Changeover of Range”. Press the ENT key . 3 The “Channel Selection” s[...]

32 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.2 Calibration setting This mode is used to set calibration concentration and actions. The calibration setting involves calibration concentration, zero calibration, calibration range and auto-calibration component. 6.2.1 Setting of calibration concentration It allows you to set conc[...]

33 Model 7500 Instruction Manual T eledyne Analytical Instruments 5. In the “Calibration Concentration Selection” screen that appears, select any concentration item you want to set by pressing the UP , DOWN, and RIGHT key . Note: Analyzers other than the zirconia O2 instrument cannot perform zero setting. 6. In the “Calibration Concentration [...]

34 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.2.2 Setting of manual zero calibration If zero calibration is to be made manually , select whether to calibrate all components at once or each of them separately upon selection. 1. During measurement, press the MODE key to display the User mode. 2. Point the cursor to “Setting ab[...]

35 Model 7500 Instruction Manual T eledyne Analytical Instruments 5. In the “Manual Calibration Selection” screen that appears, select “At once” or “Each” by pressing the UP or DOWN key . When selecting “Both”, the CH (components) to be set can be zero-calibrated at the same time. When selecting “Each”, either of the CH (compone[...]

36 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.2.3 Setting of calibration range This mode is used to set if the range of each CH (component) at the calibration manual calibration or auto calibration) should be calibrated with a single range or 2 ranges. 1. During measurement, press the MODE key to display the User mode. 2. Poin[...]

37 Model 7500 Instruction Manual T eledyne Analytical Instruments 5. In the “Calibration Selection” screen that appears, select “Both” or “Current” by pressing the UP or DOWN key . • When selecting “both”, Range 1 and Range 2 of the set CH are calibrated together . • When selecting “Current”, the range alone displayed at the[...]

38 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.2.4 Setting of auto-calibration component It sets the CH (component) to be calibrated in the auto- calibration. 1. During measurement, press the MODE key to display the User mode. 2. Point the cursor to “Setting about Calibration” by pressing the UP or DOWN key . Press the ENT [...]

39 Model 7500 Instruction Manual T eledyne Analytical Instruments 5. In the “Auto Calibration Selection” screen that appears, select “enable” or “disable” by pressing the UP or DOWN key . After setting, press the ENT key . T o close Auto Calibration Component setting T o close “Setting of Auto Calibration Component” or to cancel thi[...]

40 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.3 Alarm setting 6.3.1 Setting of alarm values This mode is used to set the upper and lower limit value to provide an alarm output during measurement. Before changing the alarm setting, set the ON/OFF to OFF . 1. During measurement, press the MODE key to display the User mode. 2. Po[...]

41 Model 7500 Instruction Manual T eledyne Analytical Instruments After setting, the alarm setting is now completed by pressing the ENT key . T o close the “Alarm Setting” T o close the “ Alarm Setting” or to cancel this mode midway , press the ESC key . A previous screen will return. Setting range 0 to 100% FS (Settable in each range). Des[...]

42 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.3.2 Hysteresis setting T o prevent chattering of an alarm output near the alarm setting values, set hysteresis. 1. In the “Alarm Setting CH Selection” screen that appears, point the cursor to “Hysteresis” by pressing the UP or DOWN key . Press the ENT key . 2. In the “Hys[...]

43 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.4 Setting of auto calibration 6.4.1 Auto calibration Auto calibration is automatically carried out when zero calibration and span calibration are set. Before changing the setting of auto calibration, set the ON/OFF to OFF . 1. During measurement, press the MODE key to display the U[...]

44 Model 7500 Instruction Manual T eledyne Analytical Instruments Auto calibration status contact output is closed during auto calibration, and is open in other cases. Setting range Cycle: 1 to 99 hours or 1 to 40 days (initial value 7 days) Flow time: 60 to 599 sec (initial value 300sec) CAUTION When an auto calibration starts, the measurement scr[...]

45 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.4.2 Forced stop of auto calibration This mode is used to cancel the auto calibration forcedly . 1. In the Menu mode that is displayed, point the cursor to “Setting of Auto Calibration” by pressing the UP or DOWN key . Press the ENT key . 2. In the “Setting of Auto Calibration[...]

46 Model 7500 Instruction Manual T eledyne Analytical Instruments “Auto Calibration” screen Example In case where setting the auto calibration components (see Item 6.2.4) to “CH1: enable” and “CH2: enable”. • Zero calibration A message, “Zero calibration” blinks at CH1 and CH2. • CH1 span calibration A message, “Span calibrati[...]

47 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.5 Setting of auto zero calibration 6.5.1 Auto zero calibration Auto zero calibration is automatically carried out when zero calibration are set. Components for which a calibration is to be made are determined by setting of auto calibration component in 6.2.4. Before changing the se[...]

48 Model 7500 Instruction Manual T eledyne Analytical Instruments Auto calibration status contact output is closed during auto zero calibration, and is open in other cases. Setting range Cycle: 1 to 99 hours or 1 to 40 days (initial value 7 days) Flow time: 60 to 599 sec (initial value 300 sec) Caution • When an auto zero calibration starts, the [...]

49 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.5.2 Forced stop of auto zero calibration This mode is used to cancel the auto zero calibration forcedly . 1. In the Menu mode that is displayed, point the cursor to “Setting of Auto Zero Calibration” by pressing the UP or DOWN key . Press the ENT key . 2. In the “Setting of A[...]

50 Model 7500 Instruction Manual T eledyne Analytical Instruments “Auto Zero Calibration” screen Example In case where setting the auto calibration components (see Item 6.2.4) to “CH1: enable” and “CH2: enable”. • Zero calibration A message, “Zero calibration” blinks at CH1 and CH2. CAUTION During auto zero calibration, any key op[...]

51 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.6 Peak alarm setting When the number of peaks of which CO concentration exceeds the upper limit value exceeds the setting time, a peak alarm is outputted. This section describes how to perform various settings of peak alarm. Note: The setting is optional and is valid only when peak[...]

52 Model 7500 Instruction Manual T eledyne Analytical Instruments Setting range • Alarm V alue: 0 to 1000 ppm 5 ppm step (initial value: 500 ppm) • Alarm Count: 1 to 99 times (initial value: 5 times) • Hysteresis: 0 to 20% of full scale (initial value: 0% of full scale) * The hysteresis setting is made in terms of full scale. Action of peak a[...]

53 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.7 Parameter setting It allows you to carry out the parameter setting such as time, key lock, etc., as required. Items to be set are as follows: Description of setting items • Current T ime: Sets the current day of the week, hour and time. • Key Lock: Sets with ON/OFF so that an[...]

54 Model 7500 Instruction Manual T eledyne Analytical Instruments 4. In the Parameter Setting screen that appears, enter the numeric values and set the items. Entering the numeric values or setting the items should be carried out by using the or key . T o move the cursor to the right, press the key . After setting, press the ENT key , that the para[...]

55 Model 7500 Instruction Manual T eledyne Analytical Instruments (2) Auto calibration (3) External hold (4) Screen display during holding The “Holding” message blinks on the measuring screen. Since the screen displays the process of calibration is displayed during the manual calibration, “Holding” is not displayed even if the screen is hel[...]

56 Model 7500 Instruction Manual T eledyne Analytical Instruments A verage period It allows you to set an average period of the average value of O2 correction. It enables you to set an average time of 1 to 59 minutes (1- minute step) or 1 to 4 hours (1-hour step). Changing the setting resets the average value of O2 correction and O2 average value. [...]

57 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.8 Maintenance mode This mode is used for check of sensor input values, display of error log les or setting of passwords. First, enter a password and then use it from the next operation. This mode is displayed by selecting the Maintenance Mode from “6.7 Parameter Setting” 1. [...]

58 Model 7500 Instruction Manual T eledyne Analytical Instruments • O2 correction reference value setting screen • Password Setting screen Description of Password Setting screen It enables you to set a password to be used when switching the parameter setting mode to the maintenance mode. Note: The password set herein must be managed for safety [...]

59 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.9 Calibration 6.9.1 Zero calibration It is used for zero point adjustment. For zero calibration gas, see 3.3 (3), Preparation for standard gas in Sampling. Use a gas according to application. 1. Press the ZERO key on the Measurement screen to display the Manual Zero Calibration scr[...]

60 Model 7500 Instruction Manual T eledyne Analytical Instruments 6.9.2 Span calibration It is used to perform a span point adjustment. Supply calibration gas with concentration set to the span value to perform the span calibration. For the span calibration gas for the SO2, CO2, CO, H4 measurement, use the standard gas with a concentration of 90% o[...]

61 Model 7500 Instruction Manual T eledyne Analytical Instruments 7. MAINTENANCE 7.1 Daily check (1) Zero calibration and span calibration 1. It is used for zero point adjustment. For calibration, refer to 6.9.1, Zero calibration. 2. After zero calibration, perform span calibration. For calibration, refer to 6.9.2, Span calibration. 3. Zero calibra[...]

62 Model 7500 Instruction Manual T eledyne Analytical Instruments 7.3 Cleaning of measuring cell Entry of dust or water drops in the measuring cell contaminates the interior of the cell, thus resulting in a drift. Clean the inside if dirty . Then, check the sampling device, especially the lter , to prevent the cell from being contaminated by dus[...]

63 Model 7500 Instruction Manual T eledyne Analytical Instruments Number Name 1 Screw (for xing light source unit) 2 Screw (for xing detector) 3 Screw (for xing base plate) 4 Base plate 5 Light source unit 6 Screw (for xing support) 7 Screw (for xing cell retainer) 8 Chopper motor connector (9) Filter 10 Support 1 1 Cell retainer 12 [...]

64 Model 7500 Instruction Manual T eledyne Analytical Instruments (2) How to remove block cell (See Fig. 7-2) 1. For Step 1 to 4, see Item 7.3.1, (1) How to remove pipe cell. 5. Remove the connector to the detector output cord from the printed board. For the 2-component analyzer , remove the output cord connector of the 2-component analyzer detecto[...]

65 Model 7500 Instruction Manual T eledyne Analytical Instruments Number Name 1 Screw (for xing light source unit) (2) Filter 3 Screw (for xing detector) 4 Base plate 5 Light source unit 6 Screw (for xing block cell) 7 Block cell 8 Infrared transmission window (window holder) 9 O-Ring 10 Screw (for xing base plate) 1 1 Chopper motors co[...]

66 Model 7500 Instruction Manual T eledyne Analytical Instruments 3) How to remove measuring unit (See Fig. 7-3) 1. For Step 1 to 4, see Item 7.3.1(1), How to remove pipe cell. 2. Remove the detector output cord connector from the printed board. 3. Remove wiring to the 2-pin terminals of the infrared ray light source assembly and chopper motor pin [...]

67 Model 7500 Instruction Manual T eledyne Analytical Instruments 7.3.2 How to clean cell 1. T o clean the cell inside or infrared ray transmission window , rst clear large dirt of it with a soft brush and then wipe with soft cloth lightly . Donʼt use hard cloth. Note: Handle the fragile window with care. Use care not to rub off the dirt from t[...]

68 Model 7500 Instruction Manual T eledyne Analytical Instruments 8. TROUBLESHOOTING 8.1 Error message If errors occur , the following contents are displayed. Error display Error contents Probable causes Error No. 1 Sector motor rotation detector signal is faulty . • Infrared ray light source is faulty . • Sector motor rotation is faulty or sto[...]

69 Model 7500 Instruction Manual T eledyne Analytical Instruments In case of Error No. 5 and No. 7 (2) Error log le If error occurs, the history is saved in an error log le. The error log le exists in the maintenance mode. * Up to 14 errors can be saved in the error history; the oldest error will be deleted one by one every time a new occu[...]

70 Model 7500 Instruction Manual T eledyne Analytical Instruments 9. SPECIFICA TIONS 9.1 Specications (1) Standard specications Principle of measurement: CO2, CO, CH4, SO2; Non-dispersion infrared-ray absorption method; Single light source and single beam (single beam system) O2: Paramagnetic method (O2 sensor built in) or zirconia sensor met[...]

71 Model 7500 Instruction Manual T eledyne Analytical Instruments (2) Standard functions Output signal holding: Output signals are held during manual and auto calibrations by activation of holding (turning on its setting). The values to be held are the ones just before start calibration mode. Indication values will not be held. Remote output holdin[...]

72 Model 7500 Instruction Manual T eledyne Analytical Instruments CS: measured concentration of sample gas Os : Measured O2 concentration On: Standard O2 concentration (value changeable by setting) *The upper limit value of the fractional part in this calculation is 4. The result of calculation is indicated and output in an analog output signal. A [...]

73 Model 7500 Instruction Manual T eledyne Analytical Instruments 9.2 Code symbols[...]

74 Model 7500 Instruction Manual T eledyne Analytical Instruments[...]

75 Model 7500 Instruction Manual T eledyne Analytical Instruments <Code specication for ordering> (1) Code symbols should be specied. (2) Range combination should be the one allowed in separate tables. (note 1) “Y” should be specied when only O2 measurement is necessary . (note 2) External O2 sensor signal should be 0-1VDC linear[...]

76 Model 7500 Instruction Manual T eledyne Analytical Instruments Measurable component and range - availability check table -[...]

77 Model 7500 Instruction Manual T eledyne Analytical Instruments T able 5: T riple component analyzer (CO2, CO, CH4) Covered in combination of T able 2, T able 3 and T able 4.[...]

78 Model 7500 Instruction Manual T eledyne Analytical Instruments 9.3 Outline diagram (1) Main unit[...]

79 Model 7500 Instruction Manual T eledyne Analytical Instruments (2) Accessory slide rail (unit: mm) * The slide rails are attached to this equipment when designated. Model : 305A-20/Accuride International Inc. 19-inch rack mounting method: The mass of the instrument should be supported at the bottom of the unit (or the side of the unit when mount[...]

Teledyne Analytical Instruments 80 Mo del 7500 Instruction Manual Appendix Dra wing List D79104 Outline diagram[...]