Teledyne 7500ZA User Manual
OPERATING INSTRUCTIONS FOR
Model 7500ZA
NDIR Infrared Gas Analyzer
P/N M7500ZA
4/09/14
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing.
Before conducting any maintenance or servicing, consult with authorized
supervisor/manager.
Teledyne Analytical Instruments
Model 7500ZA
Copyright © 2014 Teledyne Analytical Instruments
All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any other language or computer language in
whole or in part, in any form or by any means, whether it be electronic, mechanical,
magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne
Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91748.
Warranty
This equipment is sold subject to the mutual agreement that it is warranted by us free from
defects of material and of construction, and that our liability shall be limited to replacing or
repairing at our factory (without charge, except for transportation), or at customer plant at
our option, any material or construction in which defects become apparent within one year
from the date of shipment, except in cases where quotations or acknowledgements provide
for a shorter period. Components manufactured by others bear the warranty of their
manufacturer. This warranty does not cover defects caused by wear, accident, misuse,
neglect or repairs other than those performed by Teledyne or an authorized service center.
We assume no liability for direct or indirect damages of any kind and the purchaser by the
acceptance of the equipment will assume all liability for any damage which may result from
its use or misuse.
We reserve the right to employ any suitable material in the manufacture of our apparatus,
and to make any alterations in the dimensions, shape or weight of any parts, in so far as
such alterations do not adversely affect our warranty.
Important Notice
This instrument provides measurement readings to its user, an d serves as a to ol by whic h
valuable data can be gathered. The information provided by the instrument may assist the user
in eliminating potential hazards caused by his process; however, it is essential that all
personnel involved in the use of the instrument or its interface, with the process being
measured, be properly trained in the process itself, as well as all instrumentation related to it.
The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent
danger, it has no control over process conditions, and it can be misused. In particular, any
alarm or control systems installed must be tested and understood, both as to how they
operate and as to how they can be defeated. Any safeguards required such as locks, labels,
or redundancy, must be provided by the user or specifically requested of Teledyne at the
time the order is placed.
Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser
is responsible for the training of personnel, for providing hazard warning methods and
instrumentation per the appropriate standards, and for ensuring that hazard warning devices
and instrumentation are maintained and operated properly.
Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept
responsibility for conditions beyond its knowledge and control. No statement expressed or
implied by this document or any information disseminated by the manufacturer or its
agents, is to be construed as a warranty of adequate safety control under the user’s process
conditions.
Teledyne Analytical Instruments ii
NDIR Gas Analyzer
Specific Model Information
It is not recommended that this instrument be used for analysis on
any other gas or gas mixture than that specified at the time of purchase.
The analyzer is set up and calibrated at the factory for a specific
application using a known gas mixture that is representative of the
customers’ process. Using this instrument to analyze any other gas
mixture may result in interference and possible measurement error.
Consult the factory for additional information for gas analysis not
specified at the time of purchase.
Instrument Serial Number: _______________________
Measurable
Species:
Range 1:
Range 2:
Span Gas 1:
Span Gas 2:
Zero Gas:
NO
SO2
CO2
CO
CH4
O2
Fuel Cell
ZrO2
Built-In External
Background:
Teledyne Analytical Instruments iii
Model 7500ZA
Safety Messages
Your safety and the safety of others is very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the instructions
for details on the specific danger. These cautions warn of
specific procedures which if not followed could cause bodily
Injury and/or damage the instrument.
CAUTION: HOT SURFACE WARNING: This warning is
specific to heated components within the instrument. Failure
to heed the warning could result in serious burns to skin and
underlying tissue.
WARNING: ELECTRICAL SHOCK HAZARD: Dangerous
voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed this
warning could result in injury and/or death from
electrocution.
Technician Symbol: All operations marked with this symbol
are to be performed by qualified maintenance personnel only.
No
Symbol
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
NOTE: Additional information and comments regarding a
specific component or procedure are highlighted in the form
of a note.
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
Teledyne Analytical Instruments iv
NDIR Gas Analyzer
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through
the installation, calibration operation and maintenance of your new
analyzer. Please read this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be peculiar to your
instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.
Teledyne Analytical Instruments v
Model 7500ZA
Additional Caution on Safety
To operate the analyzer properly, be sure to read “Caution on
Safety” carefully.
The descriptions listed here provide important information on safety.
Be sure to observe them at all times. Th ese safety p recau tions are classified
into 3 levels: “DANGER,” “CAUTION” and “PROHIBITION”.
”
Improper handling may cause dangerous
DANGER
CAUTION
situations that may result in death or serious
injury.
Improper handling may cause dangerous
situations that may result in medium-level
troubles, minor injury, or property damage.
Items which must not be done are indicated.
PROHIBITION
Caution on installation and transport of analyzer
DANGER
CAUTION
The unit is not of explosion-proof. Do not use it in an
atmosphere of explosive gases. Otherwise, serio us
accidents including explosion or fire may result.
For installation, observe the rule on it given in the
instruction manual, and select a place where the
weight of analyzer can be supported. Installation in
an inadequate place may cause turnover or falling,
resulting in injury.
Be sure to wear protective gloves when lifting the
analyzer. Lifting it with bare hands may result in
injury.
Be sure to fix the cover before transporting the
analyzer. Transportation in unstable state may result
in injury.
Teledyne Analytical Instruments vi
NDIR Gas Analyzer
The gas analyzer is heavy. To transport the
analyzer, please use a hand cart or equivalent. Avoid
carrying analyzer by hand as much as possible.
Doing so may cause injury.
Take care not to let cable chips and other foreign
objects enter the unit during installation work.
Otherwise, fire, failure, or malfunction may result.
Caution on piping
Be sure to observe the following
DANGER
precautions while installing piping. Improper
piping may result in gas leakage.
If the leaking gas contains a toxic
component, serious accidents may re sult. If
it contains combustible gases, explosion or
fire may result.
Connect pipes correctly referring to the
instruction manual.
Discharge the exhaust gas outdoors to
prevent it from remaining within the
sampling device or indoors.
Relieve the exhaust gas fro m the an alyzer t o
the atmospheric pressure to prevent buildup
of undesirable pressure to the analyzer.
Otherwise, piping within the analyzer may be
disconnected, resulting in gas leakage.
Use pipes and pressure reducing valves to
which no oil/grease is attached to the
piping. Otherwise, fire may result.
Caution on wiring
Be sure to turn off the power before
DANGER
installing wiring. Otherwise, electric shock
may result.
Be sure to perform protective earth ground
connection. Otherwise, electric shock or
failure may result.
Select a proper wiring material that satisfies
Teledyne Analytical Instruments vii
Model 7500ZA
the ratings of the instrument. Otherwise,
electric shock or fire may result.
Be sure to connect a power supply of
correct rating. Otherwise, fire may result.
Caution on use
Be sure to read the instruction manual for
DANGER
CAUTION
reference gases before handling reference gases
such as calibration gas to use them properly.
Leaving the analyzer unused for a long time or
restarting it after long-term suspension requires
procedures different from normal operation or
suspension procedures. Be sure to follow the
instructions in each instruction manual.
Otherwise, intended performance may not be
achieved. Also, accidents or injury may result.
Do not operate the analyzer for a long time with
its cover left open. Otherwise, dust, foreign
matter, etc. may contaminate the internal walls,
thereby causing faults.
PROHIBITION
Do not touch the input/output terminals with
metal or finger. Otherwise, electric shock or
injury may result.
Do not smoke or use flames near the analyzer.
Otherwise, fire may result.
Do not allow water to enter the analyzer.
Otherwise, electric shock or internal fire may result.
Caution on maintenance and check
DANGER
Before performing work with the cover of the
analyzer open for maintenance and check, be sure
to purge completely not only within the analyzer but
also measuring gas lines using nitrogen or air.
Otherwise, poisoning, fire, or explosion may result
due to gas leakage.
Teledyne Analytical Instruments viii
NDIR Gas Analyzer
CAUTION
Be sure to observe the following to perform work
safely, avoiding electric shock or injury.
Remove the watch and other metallic objects before
work.
Do not touch the instrument with wet hands.
If the fuse is blown, eliminate the cause and replace
it with the one of the same capacity and type.
Otherwise, electric shock or accidents may result.
Do not use replacement parts other than those
specified by the manufacturer. Otherwise, intended
performance may not be achieved and accidents or
failures may result.
Dispose replacement parts such as maintenance
parts as incombustibles according to the local waste
disposal regulations.
Teledyne Analytical Instruments ix
Model 7500ZA
Table of Contents
Specific Model Information ......................................................... iii
Safety Messages .......................................................................... iv
Additional Caution on Safety ...................................................... vi
List of Figures ............................................................................ xiv
List of Tables ............................................................................... xv
Introduction ................................................................................... 1
1.1 Overview 1
1.2 Typical Applications 2
Items included with the Analyzer ................................................. 3
2.1 Confirmation of delivered items 3
2.2 Name and Description of Analyzer 4
Installation ..................................................................................... 7
3.1 Installation Conditions 8
3.2 Installation 8
3.2.1 Installation of Analyzer Main Frame 8
3.3 Piping 9
3.4 Sampling 12
3.4.1 Sample Gas Conditioning 12
3.4.2 Sample Gas Flow 12
3.4.3 Preparation of Standard Gas 12
3.4.4 Internal Purging of the Instrument Housing 13
3.4.5 Pressure at Sample Outlet 13
3.4.6 Example Configuration of Sample System 14
3.5 Electrical Connections 15
Operation ..................................................................................... 25
4.1 Preparation for operation 25
4.2 Warm-up Operation and Normal Operation 25
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NDIR Gas Analyzer
Display And Operation Panels ................................................... 27
5.1 Front Panel Description 27
5.2 Overview of Display and Operation Panels 29
5.3 Outline of Display Screen 30
5.4 Basic Operation 34
Settings and Calibration ............................................................. 35
6.1 Range Switch 35
6.1.1 Setting the Range Switch Mode 35
6.1.2 Manual Range Mode 36
6.1.3 Range Identification Contacts 36
6.2 Calibration Setting 37
6.2.1 Setting the Span Gas Concentration 37
6.2.2 Manual Zero Calibration 38
6.2.3 Setting the Calibration Range 40
6.2.4 Setting the Component/Range for Auto Calibration 42
6.3 Alarm setting 44
6.3.1 Setting Alarm Parameters 44
6.3.2 Hysteresis Setting 46
6.3.3 Peak Alarm Setting 47
6.4 Setting Up the Auto Calibration 49
6.4.1 Auto Calibration 49
6.4.2 Forced Run/Stop Of Auto Calibration 52
6.4.2.1 Execution of auto calibration (only once) 52
6.4.2.2 Forced stop of auto calibration 53
6.5 Setting Auto Zero Calibration 55
6.5.1 Auto Zero Calibration 55
6.5.2 Forced Run/Stop of Auto Zero Calibration 57
6.5.2.1 Execution of auto zero calibration (only once) 58
6.5.2.2 Forced stop of auto zero calibration 58
6.6 Parameter Setting 60
6.7 Maintenance Mode 68
6.7.1 Sensor Input Value screen 68
Teledyne Analytical Instruments xi
Model 7500ZA
6.7.2 Error Log screen 68
6.7.3 Calibration Log screen 69
6.7.4 Output Adjustment Screen 70
6.7.5 Other Parameter 71
6.8 Calibration 73
6.8.1 Zero Calibration 73
6.8.2 Span Calibration 74
7. Maintenance ............................................................................ 75
7.1 Daily Check 75
7.2 Daily Check And Maintenance Procedures 76
7.3 Long Term Maintenance 76
7.4 Cleaning the Sample Cell 78
7.4.1 Sample Cell Disassembly 78
7.4.1.1 Pipe Cell Removal (See Fig. 7-1) 79
7.4.1.2 Block Cell Removal (See Fig. 7-2) 80
7.4.1.3 Removing the Measuring Unit 82
7.4.2 Cleaning the Sample Cell 82
7.5 Fuse Replacement 84
8. Error Messages ....................................................................... 85
8.1 Troubleshooting 86
8.2 Error Log File 87
9. Specifications .......................................................................... 89
9.1 General Specifications 89
9.1.1 Standard Specifications 89
9.1.2 Standard Functions 93
9.1.3 Optional Functions 94
9.1.4 Performance 98
9.1.5 EC Directive Compliance 98
9.1.6 Requirements for Sample Gas 99
9.1.7 Installation Requirements 100
9.2 Table 1 Measurable Component and Range - Availability
Check Table 101
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NDIR Gas Analyzer
9.3 Code Symbols 106
9.4 Outline Diagram 109
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Model 7500ZA
List of Figures
Figure 2-1A: Model 7500ZA Front Panel ......................................... 4
Figure 2-1B: Model 7500ZA Rear Panel ......................................... 5
Figure 7-1: Measuring Unit Configuration (Pipe Cell) .................... 79
Figure 7-2: Measuring Unit Configuration (Block Cell) .................. 81
Figure 7-3: Measuring Unit with 2-Component Block and Pipe Cell83
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NDIR Gas Analyzer
List of Tables
Table 7.1 Maintenance and Check Table ...................................... 76
Table 8-1: Error Messages ............................................................ 85
Teledyne Analytical Instruments xv
Model 7500ZA
DANGER
COMBUSTIBLE GAS USAGE
This is instrument is approved as an intrinsically safe gas
analyzer for use in a category (ia) Group IIC hazardous area.
This approval only to the equipment specified installed in
accordance with the information contained within this
manual. It is the customer's responsibility to ensure safety
especially when combustible gases are being analyzed since
the potential of gas leaks always exist.
WARNING
The customer should ensure that the principles of operating
of this equipment is well understood by the user and that the
instrument as well as any approved support equipment is
properly installed. Misuse of this product in any manner,
tampering with its components, or unauthorized substitution
of any component may adversely affect the certification and
the safety of this instrument.
Since the use of this instrument is beyond the control of
Teledyne, no responsibility by Teledyne, its affiliates, and
agents for damage or injury from misuse or neglect of this
equipment is implied or assumed.
Teledyne Analytical Instruments xvi
NDIR Gas Analyzer Introduction
Introduction
1.1 Overview
The Model 7500ZA is designed to measure the concentration of
NO, SO
different atomic molecules have a different absorption spectrum in the
infrared band and the intensity of absorption is determined by the
Lambert-Beer law.
, CO2, CO and CH4 in a sample gas based on the principle that
2
When equipped with the optional O
sensor, the Model 7500ZA is
2
capable of measuring up to 5 components simultaneously or up to 4
components if O2 sensor is not installed.
The Model 7500ZA is a microprocessor based analyzer with a large
LCD display, superior accuracy and a multitude of functions suitable for
applications such as:
• Combustible gas emissions from boilers or incinerators
• Steel gas analysis (blast furnace, steel converter, thermal
treatment furnace, sintering (pellet equipment) etc.
• Coke furnace
• Storage and maturity of vegetable and fruit,
• Biochemistry (microbe) (fermentation)
• Air pollution monitoring [incinerator, exhaust gas
desulfurization, denitration], automotive emission (excluding
tester)
• Disaster prevention (detection of explosive gas and toxic gas,
combustion gas analysis of new building material)
• Agricultural
• Chemical analysis (petroleum refinery plant, petroleum
chemistry plant, gas generation plant)
• Environmental analysis
• Physical and chemical research
Teledyne Analytical Instruments 1
Introduction Model 7500ZA
1.2 Typical Applications
The Model 7500ZA is a microprocessor based analyzer with a large
LCD display, superior accuracy and a multitude of functions suitable for
a variety of applications including:
• Combustible gas emissions from boilers or incinerators
• Steel gas analysis (blast furnace, steel converter, thermal
treatment furnace, sintering (pellet equipment) etc.
• Coke furnace
• Storage and maturity of vegetable and fruit,
• Biochemistry (microbe) (fermentation)
• Air pollution monitoring (incinerator, exhaust gas
desulfurization, denitration)
• automotive emission (excluding tester)
• Disaster prevention (detection of explosive gas and toxic gas,
combustion gas analysis of new building material)
• Agricultural
• Chemical analysis (petroleum refinery plant, petroleum
chemistry plant, gas generation plant)
• Environmental analysis
• Physical and chemical research
Teledyne Analytical Instruments 2
NDIR Gas Analyzer Items Included with Analyzer
Items included with the Analyzer
2.1 Confirmation of delivered items
• The following items are included with you analyzer.
Analyzer
Fuse (2pcs))
Std: IEC127-2
05x20 mm
250V/2A SB
Analog Output Connector (1)
25 pin D-sub male
M2.6x4 mm
Instruction Manual
External Input Connector (1)
(External O2/External Zirconia Sensor as
specified)
Digital Input Connector
(3 max with the no. of DIO when digital
I/O function is specified).
Teledyne Analytical Instruments 3
Items Included with Analyzer Model 7500ZA
RS-484 Connector
(1) (when provided with communications
function)
9 pin D-sub connector male
M2.6 x 4 mm
Ferrite Core
(1) for power cable (When terminal block
for power supply is specified)
Power Supply Cord (1) (when power input
is specified)
•
2.2 Name and Description of Analyzer
The operator interface is shown in Figure 2-1A and the various
connections to the instrument are shown in figure 2-1B.
Figure 2-1A: Model 7500ZA Front Panel
Teledyne Analytical Instruments 4
NDIR Gas Analyzer Operation
Figure 2-1B: Model 7500ZA Rear Panel
Teledyne Analytical Instruments 5
Items Included with Analyzer Model 7500ZA
[Blank page]
Teledyne Analytical Instruments 6
NDIR Gas Analyzer Instalation
Installation
Installation of the Model 7500ZA NDIR Analyzer includes:
Unpacking
Mounting
Gas connections
Electrical connections
Calibration
DANGER: THIS UNIT IS NOT AN EXPLOSION-PROOF
INSTRUMENT. DO NOT USE IT IN A PLACE WITH
EXPLOSIVE GASES TO PREVENT EXPLOSION, FIRE
OR OTHER SERIOUS ACCIDENTS.
CAUTION: ENTRUST THE INSTALLATION, MOVEMENT OR RE-
INSTALLATION TO A SPECIALIST OR THE
SUPPLIER. A POOR INSTALLATION MAY CAUSE
ACCIDENTAL TIPOVER, ELECTRIC SHOCK, FIRE,
INJURY, ETC.
• The gas analyzer is heavy. It should be installed with utmost
care. Otherwise, it may tip over or fall, causing accident or
injury.
• For lifting the gas analyzer, be sure to wear protective gloves.
Using bare hands may result in injury.
• This unit should be installed in an environment conforming to
the conditions noted in the instruction manual. Otherwise,
electric shock, fire or other malfunction of the unit may occur.
• During installation, care should be taken to keep the unit free
from entry of chips, dust, and debris. Otherwise, it may cause
fire, trouble or malfunction of the unit.
The analyzer is shipped with all the materials you need to install
and prepare the system for operation. Carefully unpack the transmitter
and inspect it for damage. Immediately report any damage to the
shipping agent.
Teledyne Analytical Instruments 7
Installation Model 7500ZA
3.1 Installation Conditions
To install the analyzer for optimum performance, select a location
that meets the following conditions;
1. This instrument is designed for rack mounting in a standard 19”
equipment rack.
2. Indoor use only.
3. Vibration-free.
4. Free of dust and debris and obstruction around the analyzer.
5. AC power: 100V to 240 VAC
Operating voltage: 85V to 264V AC
Rated frequency: 50/60 Hz
Power consumption: 100 VA max.
6. Operating conditions:
Ambient temperature : -5° to 45°C (max. 40°C when two optical
units are used, and the power supply is more than 200V AC)
7. Maintenance space:
When analyzer is installed by itself, adhere to the
diagram to make sure there is adequate space to
remove the cover for maintenance.
When the analyzer is installed as an unit, See
Section 3.2.1
8. A circuit breaker that meets IEC60947-1 and
IEC60947-3 specifications should be installed.
9. A breaker should be installed near the analyzer
where an operator can access it.
10. A label that clearly identifies the breaker should be visible.
11. The breaker rating should meet the analyzer rating max 2A and
conform to all necessary approvals.
3.2 Installation
3.2.1 Installation of Analyzer Main Frame
Installation methods for the analyzer main unit is shown below.
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NDIR Gas Analyzer Instalation
• The analyzer weight must be supported at the bottom of the
casing.
• The analyzer should be installed in a place where ambient
temperature is within -5 to 45°C (max. 40°C when two optical
units are used, and the power supply is more than 200V AC), and
temperature fluctuation during operation is minimum.
• Where vibration is unavoidable, protect the analyzer from
vibrating. If necessary, install rubber or other vibration absorbing
material around the case to isolate any vibration from the support
structure.
3.3 Piping
Observe the following items when making gas connections to the
rear panel:
• Piping should be connected to the gas inlets and outlets at the
rear panel of the analyzer.
• Use a corrosion resistant tubing comprised of Teflon, stainless
steel or polyethylene to connect the instrument to a sampling
system. Even if there is a danger of corrosion, refrain from using
rubber or soft vinyl tubing. These materials will cause inaccurate
indication due to gas absorption from the tubing.
• Pipe connection port fittings are NPT 1/4” female thread (or 1/4”
RC). Piping should be cut as short as possible for optimum
response. About 4 mm inner diameter is recommended.
Teledyne Analytical Instruments 9
Installation Model 7500ZA
• Entry of dust into the instrument may result in poor performance.
Use clean tubing and couplings.
•
Sample inlet: Attach clean, dry sample gas to the inlet port.
Note that the calibration gases ( zero and span)
also connect to this port.
Input gas flow t should be constant within the
range of 0.5 L/min ±0.2 L/min.
Sample outlet: Attach tubing for exhausting sample or calibration
gases. The exhaust line should be directed to an
appropriate safe vent depending on the nature of
the sample/calibration gas used.
Purge gas inlet: Used to connect a purge gas for purging the
internal housing of the analyzer. Use dry N
or
2
instrument air for purge gas. (Flow rate is 1L/min
or more. Keep dust or moisture/mist from
entering the purge line.
CAUTION: THIS INSTRUMENT IS DESIGNED TO HANDLE
HAZARDOUS GASES. WHENEVER A FITTING IS
OPENED, USE A NEW FERRULE AND CONE TO
SECURE A GAS TIGHT SEAL. EACH FITTING MUST
BE LEAK CHECKED WHENEVER A CONNECTION
HAS BEEN OPENED OR DISTURBED IN ANY
MANNER.
The internal piping diagram for the Model 7500ZA is shown
below.
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NDIR Gas Analyzer Instalation
Correspondence between measured components and the optical
units is as follows:
Measured
Components
Single measured species:
, CO
2
2
2
2
, CO or CH4
2
/ CO
/ CO
NO, CO
Two measured species:
CO
Two measured species:
NO/CO, NO/SO
Three measured species:
NO/ SO
Four measured species:
NO/ SO
Optical Bench 1 Optical Bench 2
Single component None
CO
/CO None
2
NO/CO CO/SO
NO SO
NO/CO SO
/CO
2
/CO
2
2
Teledyne Analytical Instruments 11
Installation Model 7500ZA
3.4 Sampling
3.4.1 Sample Gas Conditioning
1. Dust from the sampling gas should be completely removed using
a filter. For the final stage filter, use a filter that removes dust
particles down to 0.3µm.
2. Dew point must be lower than the ambient temperature. If vapor
is contained in the sample, dew point should be lowered to 2°C
using a dehumidifier.
3. If SO3 mist is present in the sample gas, use a mist filter or
cooler to remove the SO3 mist. Other mists should be removed
using a mist filter or gas dryer.
4. Corrosive gases such as Cl2, F2 and HCl, if present in
considerable amounts, will shorten the life of component parts.
5. Sample gas temperature should be within 0 to 50°C. Do not flow
hot gas directly into the instrument.
3.4.2 Sample Gas Flow
Sample flow should be 0.5L/min ± 0.2L/min. Avoid any flow
fluctuation during measurement. Observe the flow reading using the
flowmeter provided as shown in the example of the sampling system
configuration (Item 3.4.6).
3.4.3 Preparation of Standard Gas
Routine calibration is required once a week using span and zero
calibration gases to keep the instrument performing optimally. Prepare a
standard gas cylinder for zero calibration and span calibration per the
table below.
Without O
2
Sensor
Zero Gas N2 N
Span gas other
than for O
2
Gas with
concentration
Built-in O
2
Sensor
2
(O
of 99.9 to 100
2
vol% for reverse
range O
measurement.)
Gas with
concentration of
2
External O
2
Sensor
Dry air
Gas with
concentration of
Teledyne Analytical Instruments 12
NDIR Gas Analyzer Instalation
Without O
2
Sensor
measurement. of 90 to 100% on
the measuring
range
Span gas for O2
measurement
—
Built-in O
2
Sensor
90 to 100% on
the measuring
range.
Gas with conc. of
90 to 100% on
the measuring
range or
atmospheric air
(21% O
(O
95.5 vol% for
reverse range O
measurement.)
).
2
gas of 95 to
2
90 to 100% on
the measuring
range.
O
2
3.4.4 Internal Purging of the Instrument Housing
The internal housing does need not be purged except under the
following conditions:
External O
2
Sensor
gas at 1 to 2%
2
1. A combustible gas component is contained in the sample gas.
2. Corrosive gas is contained in the atmospheric air at the
installation site.
3. The same gas as the sample gas component is contained in the
atmospheric air at the installation site.
In such cases, the analyzer housing should be purged with the
instrument air or dry N
.
2
The purge flow rate should be set to about 1L/min. The purge gas
must be free of dust and moisture.
3.4.5 Pressure at Sample Outlet
Pressure at the sample gas outlet should be atmospheric pressure.
Make sure there are no kinks or obstructions in the exhaust line.
Teledyne Analytical Instruments 13
Installation Model 7500ZA
3.4.6 Example Configuration of Sample System
The following illustrates a typical sample system configuration for
five component gas measurement monitoring a combustion exhaust gas
from boiler, refuse incinerator, etc.
Contact TAI for other system configurations to match your specific
application.
Name Description Name Description
(1) Gas extractor
(2) Mist filter
(3) Safety drain trap
(4) Gas aspirator For aspiration of the
Teledyne Analytical Instruments 14
Gas extractor with a
heating type stainless
steel filter of standard
mesh 40µm.
Removes drain, mist,
and dust.
The safety drain trap is
divided into two spaces
for positive and
negative pressure. It
monitors
and adjusts the sample
gas pressure.
sample gas
8) Flowmeter
9) Reference gas
10) Zirconia O
sensor
2
Adjusts and monitors
the flow rate of the
sample gas.
Reference gas used for
calibrating zero and
span of the analyzer,
depending on the
measured gas.
External zirconia
oxygen sensor used for
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