Teledyne 7500ZA User Manual

Download

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

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:

SO2

CO2

CH4

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.

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

Teledyne Analytical Instruments x

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

Teledyne Analytical Instruments xii



NDIR Gas Analyzer

9.3 Code Symbols 106

9.4 Outline Diagram 109

Teledyne Analytical Instruments xiii

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

Teledyne Analytical Instruments xiv

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

When equipped with the optional O

sensor, the Model 7500ZA is

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.

Teledyne Analytical Instruments 8

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

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.

Teledyne Analytical Instruments 10

NDIR Gas Analyzer Instalation

Correspondence between measured components and the optical units is as follows:

Measured

Components

Single measured species:

, CO

, CO or CH4

/ 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 None

NO/CO CO/SO

NO SO

NO/CO SO

/CO

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

Sensor

Zero Gas N2 N

Span gas other than for O

Gas with concentration

Built-in O

Sensor

of 99.9 to 100

vol% for reverse range O measurement.)

Gas with concentration of

External O

Sensor

Dry air

Gas with concentration of

Teledyne Analytical Instruments 12

NDIR Gas Analyzer Instalation

Without O

Sensor

measurement. of 90 to 100% on

the measuring range

Span gas for O2 measurement

—

Built-in O

Sensor

90 to 100% on the measuring range.

Gas with conc. of 90 to 100% on the measuring range or atmospheric air (21% O

95.5 vol% for reverse range O measurement.)

gas of 95 to

90 to 100% on the measuring range.

3.4.4 Internal Purging of the Instrument Housing

The internal housing does need not be purged except under the

following conditions:

External O

Sensor

gas at 1 to 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

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

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

NDIR Gas Analyzer Instalation

Name Description Name Description

(5) Electronic gas cooler

(6) Solenoid valve

(7) Membrane filter

3.5 Electrical Connections

CAUTION: To prevent electric shock or fire:

Dries the moisture in the sample gas to a dew point of approx. 2°C Used for flowing the calibration gas.

PTFE filter used to eliminate fine dust particles.

(11) NO converter

/NO

measuring the oxygen concentration in sample gas. (Not used when O sensor is built-in.)

Added to NOx Analyzer. A special catalyst material is used for efficient conversion of

to NO

 Turn off the power before wiring.

 Always use a protective earth connection.

 Select a proper wiring material that satisfies the

ratings of the instrument. • Be sure to connect a

power supply of correct rating.

The power terminal block and external input/output connector are

installed on the rear panel. Refer to the diagram below.

Teledyne Analytical Instruments 15

Installation Model 7500ZA

(1) Power Supply (standard terminal 1 to 2)

Connect the power supply to the power terminal, and connect the ground wire to the grounding terminal (standard terminal 3). Be sure to provide a protective earth connection. Use solderless terminals (for M4) for connection to the terminals (power and earth). See the figure below.

For the infrared gas analyzer, install an accessory ferrite core (to the power supply terminal stand side) on the AC power supply wiring line. See below.

CAUTION: AFTER WIRING IS COMPLETE, BE SURE TO

REPLACE THE PROTECTIVE COVER OVER THE TERMINAL BLOCKS.

Note: Avoid installing this instrument near an electrical unit (high

frequency furnace or electric welder) that generates electrical noise. If using the instrument near such a noise generating unit is unavoidable, use a different power line.

Mount a noise suppressor such as varistor or spark

quencher to the noise generating unit when source of noise is due to relays or solenoid valves. See accompanying figure.

Mount the suppressor

near the noise source; otherwise its effect will be diminished.

Teledyne Analytical Instruments 16

NDIR Gas Analyzer Instalation

(2) Analog output signal: Analog output connector (A/O)

Output signal : 4 to 20 mA DC or 0 to 1 V DC (selected when

ordering) Minus lines for the insulation and signal are common from the ground and internal circuit.

Allowable load : 4 to 20 mA DC, 550Ω or less

0 to 1 V DC, 100kΩ or more

The analog output signals of the instrument are not isolated individually. It is recommended to isolate the signals individually to eliminate the interference from unwanted signals or other external interference, especially if the cable exceeds 30 meters or leads to outdoors.

(3) O2 Sensor Input: External input connector (A/I)

Input signal:

External zirconia O

sensor: Zirconia O2 sensor signal (Fuji ZFK7

output)

External O

sensor: 0 to 1 VDC (DC input resistor of 1MW or

more)

Teledyne Analytical Instruments 17

Installation Model 7500ZA

• Used when the external zirconia O

sensor or the external O2

sensor is ordered. It is not required or used if the analyzer has a built-in O2 sensor.

• Connect the dedicated connector (accessory) to the output of the

external zirconia sensor or the external O2 sensor (shipped separately).

• When using an external O2 sensor, the input signal should be 0 to

1 VDC with respect to the O2 full scale of the analyzer. The O2 concentration display, output, and O2 correction can then be performed correctly.

Note: The O2 sensor input is not isolated. TAI recommends that it

be isolated when an external O2 analyzer is installed remote from the analyzer. The zirconia O2 sensor should be installed at a location that is as close to the analyzer as possible.

The figure below shows how to connect the O

signal to the

dedicated connector (accessory).

Teledyne Analytical Instruments 18

NDIR Gas Analyzer Instalation

(4) Contact input/output (DIO): digital input/output connector (DIO 1 to 3)

Contact input signal : Voltage is applied from the external 12 to 24 V

DC, max 15mA. Photo-coupler isolation (from each DI and ground)

Contact capacity : C contact relay output 24V/1A AC/DC

resistive load

Teledyne Analytical Instruments 19

Installation Model 7500ZA

Teledyne Analytical Instruments 20

NDIR Gas Analyzer Instalation

• Isolated output (from each DO and ground)

To avoid external interference, the wiring from the analog output signal, O2 sensor input and contact input should be run separately from that of power supply and contact output.

Note: Avoid excess noise generated by other nearby equipment,

by grounding the analyzer and using properly shielded cables.

(5) Communication: RS-485 connector

(6) Timing of Contact Output for Calibration

1. Manual calibration: (See “Item 6.8 Calibration” if the analyzer is

equipped with the auto calibration feature).

Teledyne Analytical Instruments 21

Installation Model 7500ZA

2. Automatic calibration:

(See also Section 6.4: Automatic Calibration Settings)

Teledyne Analytical Instruments 22

NDIR Gas Analyzer Instalation

[Blank page]

Teledyne Analytical Instruments 23

NDIR Gas Analyzer Operation

Operation

4.1 Preparation for operation

Tube and wiring check

• Double-check if tubes of the gas sampling and exhaust ports are

correctly connected.

• Double-check for proper wiring.

4.2 Warm-up Operation and Normal Operation

(1) Operation Procedure

1. Turn ON the power switch on the left side when facing the front

panel of the analyzer unit. The measurement screen will appear on the front display panel in a few seconds.

2. The instrument warm-up time is about 4 hours after which the

instrument will produce an accurate measurement.

Note: During the warm-up stage, the concentration reading may

be above the upper range limit. When this occurs, the indication will display as a series of four dashes. However, this is not an error.

3. During the warm up period, you can set the various instrument

parameters as described in Section 6: Setting and Calibration.

4. After the warm-up period, perform the zero/span calibration as

described in Section 6.8 Calibration.

5. After calibrating the analyzer, introduce sample gas into the

analyzer and allow the lines to purge before accepting the measurement value.

Teledyne Analytical Instruments 25

Installation Model 7500ZA

[Blank page]

Teledyne Analytical Instruments 26

NDIR Gas Analyzer Display and Operation Panels

Display And Operation Panels

This section describes the display unit and operation panel on the Model 7500ZA as well as the various functions available to the user.

5.1 Front Panel Description

Display unit: The measurement screen and the setting items are

displayed.

Operation panel: The operator interface panel is shown below.

Teledyne Analytical Instruments 27

Display and Operation Panels Model 7500ZA

Name Description Name Description

(1) MODE key Used to switch the mode. (5) ESC key Used to return to the

previous screen or cancel the setting midway.

(2) SIDE key

(3) UP key

(4) DOWN key

Used to change the selected item (by moving the cursor) and the numeral digit.

Used to change the selected item (by moving the cursor) and to increase the numeral value. Used to change the selected item (by moving the cursor) and to decrease the numeral value.

(6) ENT key Used for confirmation of

selected items or values, and for execution of calibration.

(7) ZERO key Used for zero

calibration

(8) SPAN key Used for span

calibration

Teledyne Analytical Instruments 28

NDIR Gas Analyzer Display and Operation Panels

5.2 Overview of Display and Operation Panels

Teledyne Analytical Instruments 29

Display and Operation Panels Model 7500ZA

5.3 Outline of Display Screen

(1) Measurement mode screen (appears when the power is

turned on)

The measurement screen depends on the number of components. The following screen configuration is shown as an example for NO, SO2, CO2, CO and O2 (output: 12 channels).

Scroll the UP and DOWN keys to display more than 5 channels.

No. Name Function

(1) Component display Displays the component of instantaneous value, corrected

instantaneous value, corrected average value, etc. (2) Concentration display Displays the measured value of concentration. (3) Range display Displays the range values. (4) Unit display Displays the unit with ppm or mg/m3 and vol%. (5) Average time display Displays the average time.



• Instantaneous value and concentration value:

• The concentration display of Ch (component) where sampling

components such as “CO2”, “CO” and “O2” are displayed in the component display, are the current concentration values of the measured components contained in sample gas under test.

Teledyne Analytical Instruments 30

NDIR Gas Analyzer Display and Operation Panels

• O2 corrected concentration values:

• Ch components in which “cv**” is displayed as “cv CO” in the

display are calculated values derived from the following equation. Refer to Section 6.7 Maintenance Mode - Other Parameter.

)21(





C 

)21(



where:

On: The value of the O2 correction reference value (set by application) Os: Oxygen concentration (Vol%) Cs: Concentration of relevant measured component.

Note that Os does not exceed the O2 limit value set in Section

6.7 Maintenance mode - Other parameter. C: Sample gas concentration (O2 corrected). The corrected sampling components are NOX , SO2 and CO only.

• O2 corrected concentration average value:

In the Ch (component) and O2 average value where “CV/AV **” is displayed as “ CV/AV CO” in the component display, a value obtained by averaging O

corrected concentration value or O2 average value in a

fixed time is output every 30 seconds.

Averaging time can be changed between 1 to 59 minutes or 1 to 4 hours according to the average time settings (See Section 6.7, Parameter Setting).

(The averaging set time is displayed as “1h”, for instance, in the range display).

* The measurement ranges for O

correction concentration value

and O2 correction concentration average value are the same as the measuring components. Also, the measurement range of the

average value is the same as for O2.

Teledyne Analytical Instruments 31

Display and Operation Panels Model 7500ZA

(2) Setting/Selection Screen

The setting/selection screen is configured as shown below:

• In the status display area, the current display item is displayed.

• In the message display area, messages associated with operation

are displayed.

• In the setting item and selection item display area, items or

values to be set are displayed, as required. To navigate through the fields, move the cursor to any item using the UP, DOWN and SIDE keys.

Teledyne Analytical Instruments 32

NDIR Gas Analyzer Display and Operation Panels

(3) Contents of Measured Channel (Ch)

The following table gives measurement channels and their contents according to the symbols.

•

Teledyne Analytical Instruments 33

Display and Operation Panels Model 7500ZA

5.4 Basic Operation

 Measurement mode

The measurement mode can display up to 5 channels in a single screen. If 5 channels or more are to be displayed in a single screen, press the UP or DOWN key to scroll the channels one by one.

•

User mode displays

• Switch Ranges

• Calibration Parameters

• Alarm Setting

• Setting of Auto Calibration

• Setting of Auto Zero Calibration

• Parameter Setting.

• Press the UP or DOWN key to move

the cursor to the desired function.

• Select the function by pressing the

ENT (ENTER) key. The screen display will change to that of the selected function.

• Each function is described in Chapter

6. Settings and Calibration.

Teledyne Analytical Instruments 34

NDIR Gas Analyzer Settings and Calibration

Settings and Calibration

6.1 Range Switch

6.1.1 Setting the Range Switch Mode

The range switch has three modes:

• Manual (MR)

• Remote (RR)

• Auto Ranging (AR)

To set the range switch mode:

1. Press the MODE key while in

measurement mode to display the User mode screen.

2. Move the cursor to “Switch

Ranges” and press the ENT key.

3. In the “Channel Selection” screen

that appears, move the cursor by pressing the UP or DOWN key, and select Ch (component).

4. Then press the ENT key.

5. The selected range switch mode

will be highlighted. Press the UP or DOWN key to select the desired mode.

6. Then press the ENT key to

confirm the selection.

7. If “MR” is selected, the cursor

moves to “Range Switch.”

Teledyne Analytical Instruments 35

Settings and Calibration Model 7500ZA

6.1.2 Manual Range Mode

The analysis range for the measured component can be switched manually as follows:

1. (1) Select “MR” as range switch mode,

and then press the ENT key.

2. Using the UP/DOWN keys, move the

cursor to the desired range selection. The highlighted arrow indicates the currently selectable range.

3. Select it by pressing the ENT key, and

analysis will be carried out in that range.

Note: If “RR” or “AR” is selected as range

switch mode, this operation cannot be performed.

The ranges for O2 correction

value,O2 correction average value, and O2 average value are automatically switched according to the instantaneous value range switch settings. (Same as for “RR” or “AR”.)

To return to the previous screen, press the ESC key. If ESC is pressed in the middle of an entry or before the ENT key was pressed to accept a setting, it will reject the current selection and return you the display to the previous screen without making the changes .

6.1.3 Range Identification Contacts

The contacts for range identification on each channel are closed when Range 1 is active, and open when Range 2 is active.

If the measurement value is held by a remote contact input or during calibration and range switch conditions are met, the contact status will change only after the hold condition is removed.

Teledyne Analytical Instruments 36

NDIR Gas Analyzer Settings and Calibration

6.2 Calibration Setting

This mode is used to set calibration parameters such as span and zero gas concentration, calibration range, and auto calibration settings and range.

When <User Mode> The “Calibration Parameters” screen that appears, the data shown at right is illustrated.

6.2.1 Setting the Span Gas Concentration

This screen allows you to set the cal gas concentrations for zero and span on each Ch used for calibration.

1. Select < User mode > →

< Calibration parameters > → < Calibration value >. The “Calibration Value Settings” screen will appear.

2. Select the Ch you want to

change by pressing the UP or DOWN key. Then press the ENT key and cursor moves to the first editable parameter within that field.

3. Select the concentration item

you want to set (Zero or Span) by pressing the UP, DOWN or SIDE (>) key. The SIDE key only functions within the selected channel. Press the ENT key when the cursor is in the desired field. The first digit of the parameter is highlighted.

Teledyne Analytical Instruments 37

Settings and Calibration Model 7500ZA

4. Enter calibration gas concentration for zero and span. Use the UP

or DOWN key to increment or decrement the displayed value one digit at a time. When the correct number is displayed for that digit, use the SIDE key to move to the next digit and repeat the increment/decrement process with the UP/DOWN keys.

5. After setting, save the entry by pressing the ENT key. The saved

value becomes valid with the next calibration event.

Note: Enter calibration parameters settings for each range. If a

zirconia O2 sensor is installed, select 21.00 for the Zero if air is used for calibration, and use the concentration listed on the cylinder for the span value.

After saving the calibration values entered, close the Calibration Parameter screen by pressing ESC. This will return the display to the previous screen.

Note: Pressing ESC during an entry (before pressing ENT) will

abort the entry leaving the previous entry intact.

Calibration parameter range of value

NOx, SO2, CO2, CO, CH4, external and built in O2 sensor:

Span: 1-105% of full scale

External O2 sensor:

Zero: 0-25% Span: 0.1%-5% (vol.)

Reverse Range:

Zero: 100% (vol.) Span: 95.25-95.00% (vol.) O

The settings cannot be performed beyond the range limits.

6.2.2 Manual Zero Calibration

When setting the zero calibration in manual mode, you can set all components simultaneously or one by one.

Teledyne Analytical Instruments 38

NDIR Gas Analyzer Settings and Calibration

1. Select < User mode > → < Calibration parameters > → < Zero

calibration >. The Zero Calibration screen will appears as shown.

2. Select the Ch you want

to change using the UP or DOWN key and then press the ENT key. The setting content becomes highlighted.

3. Choose whether you

want to set the zero values all together or individually by toggling “at once” or “each” with the UP or DOWN key. Each channel that is set to “at once” will be zero-calibrated at the same time.

4. When “each” is selected, the specific Ch (component) can be

selected and zero-calibrated individually. Press the ENT key after making the choice and the specified calibration is performed.

To close the Manual Zero Calibration screen, press ESC. This will

return the display to the previous screen.

Note: Pressing ESC during an entry (before pressing ENT) will

abort the entry leaving the previous entry intact.

Example:

Set each Ch (component) to either “each” or “at once” using the steps above.

 Setting “each”

Select the Ch (component) on the manual zero calibration screen and then perform the zero calibration.

 Setting “at once”

In a manual zero calibration, Ch (components) for which “at once” are selected will simultaneously be zero-calibrated.

Teledyne Analytical Instruments 39

Settings and Calibration Model 7500ZA

6.2.3 Setting the Calibration Range

This mode is used to set whether the channels use one or both of the calibration ranges.

1. From the Calibration Parameters screen, select Calibration

Range. The following screen appears.

Teledyne Analytical Instruments 40

NDIR Gas Analyzer Settings and Calibration

2. Select the Ch you want to change by pressing the UP or DOWN

key, then press the ENT key. The setting content is highlighted.

3. Toggle between “both” or “current” using the UP or DOWN key.  If “both” is selected, zero or span calibration will be

performed on both Range 1 and Range 2 on the selected Ch when the calibration is performed.

 If “current” is selected, zero or span calibration will be performed

only for the range displayed when calibration is performed.

4. Press the ENT key after the selection, and the specified calibration is performed.

To close the Calibration Range Settings screen or to abort the entry

midway, press the ESC key. The previous screen will return.

Example:

Ch1 NOx

Ch 2 SO2

Ch1: Range 1 and Range 2 are calibrated together Ch2: Only the currently displayed range is calibrated

Note: When “both” is selected, the same calibration gas

Range 1: 0 to 200 ppm Range 2: 0 to 2000 ppm

concentration must be used for both ranges.

both

current

Teledyne Analytical Instruments 41

Settings and Calibration Model 7500ZA

6.2.4 Setting the Component/Range for Auto Calibration

In this section you can select the Ch (component) and the range to calibrate on for those components that have the auto ranging (AR) feature enabled.

1. From the User Mode screen

select < Calibration parameters > → < Auto calibration component/range >. The “Auto Calibration Component Range” screen appears as shown.

2. Select the Ch you want to

change by pressing the or the key. Press the ENT key. The cursor will be highlighted in the selected channel.

3. Select the range you want to

use as the main calibration range by pressing the UP or DOWN key to move to the desired range.

4. Press the ENT key, and

subsequent calibrations will be performed on the selected range when either auto calibration or auto zero calibration is requested.

Note regarding Auto Calibration Component/Range Selection

The auto calibration or manual calibration of the component for which auto ranging (AR) is in effect will be performed on the range that is selected here. In this case, once the calibration is started, the range is automatically switched, and on completion of the calibration, the original range is resumed.

Teledyne Analytical Instruments 42

NDIR Gas Analyzer Settings and Calibration

The range identification contact is interlocked with the range after the switch. However, if the hold setting is set to “ON,” the contact status before calibration is maintained.

5. Press the SIDE key in the state described in (3), and the

highlight is toggled between “enable” and “disable” auto calibration.

6. Select “enable” of “disable” by pressing the UP or DOWN key.

7. Then press the ENT key to save your selection.

To close the Auto Calibration Settings screen or to abort the entry midway, press the ESC key. The previous screen will return.

Auto Calibration Operation

Auto calibration is performed under the following rules.

1. Zero calibration is performed at the same time, for the Ch

(component) in which “enable” is selected at the time of auto calibration and auto zero calibration.

2. Span calibration is performed in the order from smallest Ch No.,

for the Ch (component) that have “enable” set in the Auto Calibrations Setting screen.

Note: ZERO calibrations for components which have been set to

“enable” in the Auto Calibration Settings screen (above) are performed in batch irrespective of the description in “6.2.2 Manual Zero Calibration.”

Teledyne Analytical Instruments 43

Settings and Calibration Model 7500ZA

6.3 Alarm setting

6.3.1 Setting Alarm Parameters

The High/Low limit concentration alarms are user adjustable. Five different alarm contact outputs can be used. The setting range is 0100% full scale for each range.

To change the alarm setting, set the alarm ON/OFF setting to OFF, and then change the value.

1. Enter the “Alarm Setting” screen from

the user mode. The screen shown on the right will display. Use the UP or DOWN keys to move the cursor to the desired Alarm No. or hysteresis. Then press ENT.

2. After selecting the alarm the screen

shown at the right will display. Use the UP or DOWN keys until the cursor is aligned with the desired item and press ENT.

Note: Set the values so that H-limit value >

L-limit value and that (H-limit value L-limit value) > hysteresis.

In the case where reverse range O

measurements are used set the values so that L-limit value > H-limit value.

When “0” is set, the alarm is inactive.

3. After setting the parameters, press ENT

to save the settings.

To close the Alarm Settings screen or to abort the entry midway, press the ESC key. The previous screen will return.

Teledyne Analytical Instruments 44

NDIR Gas Analyzer Settings and Calibration

Alarm Setting Descriptions

The alarm contact number can be assigned to any channel.

Channels can also have multiple alarms assigned to them. Channel: Channel setting targeted for alarm. H-Limit value: Sets the high limit value (concentration) for

alarm. L-Limit value: Sets the low limit value (concentration) for alarm. Kind of Alarm: Select either High limit alarm, Low limit alarm,

and High limit or Low limit alarm, HH limit

alarm, and LL limit alarm.

High, HH: Alarm contact closes when above

H-limit alarm.

Low, LL: Alarm contact closes when below

L-limit alarm.

High or Low: Alarm contact closes when above

H-limit value or below lower limit value.

ON/OFF: Enables the alarm function when set to ON, or

disables it if set to OFF.

Note: The H-limit value cannot be set below the L-limit value, and

the L-limit value cannot be set above the H-limit value.

If it is desired to set the H-limit value below the L-limit

value already stored in the memory, reduce the L-limit value beforehand, and vice versa for setting the low limiot above the high limit.

Note: After turning on power, the alarm logic trigger is inactive for

10 minutes.

When an H-limit alarm occurs, the “H-alarm” message displays in the relevant component field. Other alarm displays are:

L-alarm for Low-limit alarm, HHalarm for high limit alarm, HH-alarm for high-high alarm, and LL-alarm for lowlow alarm.

Teledyne Analytical Instruments 45

Settings and Calibration Model 7500ZA

6.3.2 Hysteresis Setting

The alarm hysteresis can be set or changed to prevent chattering of an alarm output about its alarm set point. To set or change the alarm hysteresis:

1. Navigate to the “Alarm Setting” screen and

then move the cursor to “Hysteresis” using the UP or DOWN key. Then press ENT to display the screen shown at the right.

2. From this screen enter the hysteresis values

by increasing or decreasing the value using the UP or DOWN keys. Move the cursor to the next digit with the SIDE key. When the value is correct, press ENT to save.

The hysteresis can be set from 0-20% full scale on the selected range.

To close the Hysteresis Settings screen or to abort the entry midway, press the ESC key. The previous screen will return.

Note: The hysteresis is common to all alarms (components).

Hysteresis in peak alarm setting described in Item 6.3.3 should be set separately.

Hysteresis (In case of upper limit alarm)

An alarm output is turned ON if the measured value exceeds the upper limit value as shown below. Once the alarm output has been turned ON, it is not turned OFF until the indication falls below the hysteresis width from the upper limit value.

Teledyne Analytical Instruments 46

NDIR Gas Analyzer Settings and Calibration

6.3.3 Peak Alarm Setting

When the peak number of times CO concentration exceeds the upper

limit value during measurement reaches the set number, an alarm is provid ed.

The peak alarm and this setting screen

appear only when an option is added.

1. Press the MODE key while in the

Measurement mode, and the User mode appears.

2. Using the UP or DOWN keys move

the cursor to “Setting of Peak Alarm”. Then press ENT.

3. In the “Peak Alarm Setting”

selection screen that appears, point the cursor to any item you want to set using the UP or DOWN key. Then press ENT.

4. Enter numeric values using the UP or

DOWN keys. The setting will be saved after pressing the ENT key.

Description of Setting Items

Peak Alarm : ON/OFF of peak alarm Alarm Value : If measuring value exceeds

the set alarm value, a peak counter increments by 1 time.

Alarm Count : When the alarm value is

exceeded this many times per hour, the peak count alarm is activated (closed).

Hysteresis : To prevent possible

chattering when the measuring value may exceed the set peak concentration by only 1 time, the peak count has an allowance in the hysteresis width.

Teledyne Analytical Instruments 47

Settings and Calibration Model 7500ZA

Setting Range

Alarm value: 10-1000 ppm → 5 ppm step (initial value: 500 ppm) Alarm count: 1- 99 times/hr → (initial value: 5 times) Hysteresis : 0-20 % FS → (initial value: 0% of full scale)

[% FS] represents the percentage with the CO range regarded as 100%.

Action of Peak Alarm

If the CO concentration exceeds the alarm value, counting will begin. If the number of peaks is over the set times per hour, a peak alarm contact output becomes closed (ON). If it is less than the set times per hour, it is open (OFF). Since 5 peaks /hour is exceeded in the crosshatched area marked (1) in the above graph, the peak count alarm is turned ON. Since peaks of more than 5 per hour occur at the interval between (1) and (2), the peak count alarm remains ON whereas at (2), peaks are reduced to 4 per hour, and the alarm is turned OFF.

Like the hysteresis of the alarm setting, the hysteresis prevents possible chattering when a measured gas fluctuates about the alarm value.

* The peak alarm counting logic is not performed during the first 10

minutes after the power is turned ON.

Teledyne Analytical Instruments 48

NDIR Gas Analyzer Settings and Calibration

Releasing peak count alarm

To release the peak count alarm, set the peak alarm to OFF. Turning on the peak alarm initiates the count at 0.

6.4 Setting Up the Auto Calibration

6.4.1 Auto Calibration

Auto calibration is automatically carried out at the time when zero span calibration are set. Before changing the setting of auto calibration, set the auto calibration function to OFF.

1. Enter the “Setting of Auto

Calibration” screen from the user mode, and the display shown at right appears. Use the UP and DOWN keys to align the cursor with the desired item and then press the ENT key.

2. In the “Set Auto Cal” screen that

appears, enter the values for the various settings. To make a value entry or change, use the UP and DOWN keys to increment or decrement the value on digit at a time. Use the SIDE key to move the cursor to the next digit.

When all the settings are correct, press the ENT key to save them. Subsequent auto calibrations will use the saved settings.

Description of Auto Cal Settings

• Start Time : Setting for the first

calibration event (day of the week, hour, minute)

Teledyne Analytical Instruments 49

Settings and Calibration Model 7500ZA

• Cycle : The period between the start time of one calibration and

the next (unit: hour/day)

• Flow Time : The time required for purging with calibration gas.

Time required for replacement of sample gas after the calibration is completed (Set by calibration gas. See the next page.)

• ON/OFF: Turns the auto calibration feature ON or OFF.

To close the Auto Cal Settings screen or to abort the entry midway,

press the ESC key. The previous screen will return.

Gas flow time setting

1. With the cursor on “Flow Time”, press the ENT key to bring up

the Flow Time screen.

2. Move the cursor to the gas

you want to change by pressing the UP or DOWN key, and then press ENT.

3. The highlighted value can be

changed by pressing UP or DOWN key, and then using the SIDE key move the cursor to the right to alter the next digit.

4. After changing the value,

press the ENT key to save the setting.

5. Press the ENT key again to

return to the Auto Cal Setting screen.

Note: Only the channels used are displayed on this screen. The

Ex. time sets the output signal hold extension time that follows the completion of calibration. It is valid only when the hold setting is set to “ON.” The Ex. time set here is also the hold extension time used in a manual calibration.

Teledyne Analytical Instruments 50

NDIR Gas Analyzer Settings and Calibration

Auto calibration status contact output is closed during auto calibration (NO side), and is open in other cases.

Example:

Start Time Sun 12:00 Cycle 1 day Flow Time Zero 350 sec CH 1 Span

CH 2 Span 350 sec CH 3 Span 350 sec CH 4 Span CH 5 Span

350 sec

300 sec

300 sec Ex. Time 300 sec ON/OFF ON

Thus, with the above settings:

Setting Range:

Cycle: 1-99 hours or 1-40 days (default value—7days) Flow Time: 60-90 sec (default value—300 sec)

Teledyne Analytical Instruments 51

Settings and Calibration Model 7500ZA

Caution: When an auto calibration starts, the measurement

screen appears automatically.

Any operation other than “Stop Auto Calibration”

(see Item 6.4.2) is not permitted during auto calibration. “Stop Auto Calibration” cannot be performed with the key lock to ON.

To force a cancel of the auto calibration, set the

key lock to OFF and then execute “Stop Auto Calibration”.

Turn power OFF and then ON again at the time set

as the next start time in auto calibration, and then repeat it in the set cycle.



Remote Start

Whether the auto calibration is set at ON or OFF, an auto

calibration is always available via a remote start input.

6.4.2 Forced Run/Stop Of Auto Calibration

Auto calibration can be performed just once or forcibly stopped

while the calibration is in process

6.4.2.1 EXECUTION OF AUTO

CALIBRATION

(ONLY ONCE)

1. In the “Set Auto Cal

screen, move the cursor to “Auto Cal Run” using the UP or DOWN key, then press ENT.

2. “Run” is highlighted,

displaying a message to

Teledyne Analytical Instruments 52

NDIR Gas Analyzer Settings and Calibration

confirm the execution of auto calibration. Press the ENT key to execute the auto calibration or press the ESC key to cancel.

6.4.2.2 FORCED STOP OF AUTO

CALIBRATION

This mode is used to stop the

auto calibration forcibly.

1. In the “Set Auto Cal” screens

point the cursor to “Auto Calibration Stop” using the “UP or DOWN key. Then press ENT. (“Auto Calibration Stop” appears when this screen is selected while auto calibration is performed.)

2. “Stop” is highlighted, displaying a

message to confirm the stop of auto calibration. Press the ENT key to stop the auto calibration or press the ESC key to cancel the stop auto cal action.

“Auto Calibration” screen

Example

When Ch 1 and Ch2 are enabled for auto

calibration (see Section 6.2.4):

• Zero calibration

A message, “Zero cal.” blinks at Ch1 and Ch2.

• Ch1 span calibration

A message, “Span cal.” blinks at Ch1.

• Ch2 span calibration

A message, “Span cal.” blinks at Ch2.

Teledyne Analytical Instruments 53

Settings and Calibration Model 7500ZA

Caution: During an auto calibration, all key operations are

not permitted other than key lock ON/OFF and “Auto Calibration Stop.”

When the key lock is ON, the “Auto Calibration

Stop” is locked out as well.

To stop “Auto Calibration” forcedly, set the key

lock to OFF and then execute “Auto Calibration Stop.”

Teledyne Analytical Instruments 54

NDIR Gas Analyzer Settings and Calibration

6.5 Setting Auto Zero Calibration

6.5.1 Auto Zero Calibration

Zero calibration can be performed automatically using the settings

applied in this screen.

The channels for which auto calibration is to be performed are

determined by the auto calibration settings described in Section 6.2.4.

Before changing any of the auto zero calibration settings, set the

auto zero calibration to OFF.

1. Enter the “Set Auto Zero Cal”

screen from the user mode. The screen shown at the right will appear.

2. Use the UP or Down keys to

move the cursor to the desired item and press the ENT key. In the “Set Auto Zero” screen that appears, set the desired parameter using use the UP or DOWN key to increment/decrement the value and the SIDE key to move to the next digit or field.

After the setting is correct, press the ENT key to save the settings. The next auto zero calibration will use the entered values.

Description of Auto Zero Settings

• Start Time : Setting for the first

calibration event (day of the week, hour, minute)

• Cycle : The period between the

start time of one calibration and the next (unit: hour/day)

Teledyne Analytical Instruments 55

Settings and Calibration Model 7500ZA

• Flow Time: The time required for purging with calibration gas.

Time required for replacement of sample gas after the calibration is completed (Set by calibration gas. See the next page.)

• ON/OFF: Turns the auto calibration feature ON or OFF.

To close the Auto Zero Settings screen or to abort the entry

midway, press the ESC key. The previous screen will return.

Auto Calibration Status Relay Contacts

The auto calibration status contact output is closed during auto zero

calibration (NO side), and open during normal operation.

Example

Start Time Cycle Flow Time ON/OFF

SUN 12:00 12 hour 300 sec ON

For an auto zero calibration using the above settings:

In this example, Ch1 through Ch5 are enabled, as shown in Section

6.2.4 “Setting the Component/Range for AutoCalibration.

Teledyne Analytical Instruments 56

NDIR Gas Analyzer Settings and Calibration

Setting the Range

Cycle 1 to 99 hours or 1to 40 days (default: 7 days Flow Time 60 to 900 sec (default: 300 sec.)

Caution: When an auto zero calibration starts, the

measurement screen automatically appears.

Any operation other than “Auto Zero Calibration

Stop” (see Item 6.5.2) is not permitted during auto zero calibration. “Auto Zero Calibration Stop” cannot be performed with the key lock set to ON. To forcibly cancel auto zero calibration, set the key lock to OFF and then execute “Auto Zero Calibration Stop”.

If the auto calibration period and auto zero

calibration period overlap, the auto calibration is retained, ignoring the auto zero calibration of that period.

When the hold setting is set to ON, the hold time

for auto calibration contact and measurement value output signal is extended after calibration for gas purging.

Remote Start

A remote start input will begin a calibration event regardless of

whether the auto zero calibration is set to ON or OFF.

6.5.2 Forced Run/Stop of Auto Zero Calibration

Auto zero calibration can be performed just once, or auto zero

calibration can be forcibly stopped during calibration.

Teledyne Analytical Instruments 57

Settings and Calibration Model 7500ZA

6.5.2.1 EXECUTION OF AUTO ZERO CALIBRATION (ONLY ONCE)

1. In the “Setting of Auto Zero

Calibration” screen that appears, point the cursor to “Run” by pressing the UP or DOWN key. Then press ENT.

2. “Run” is highlighted,

displaying a message to confirm execution of auto zero calibration. Press the ENT key to execute the calibration, or the ESC key to cancel.

6.5.2.2 FORCED STOP OF AUTO ZERO CALIBRATION

This mode is used to forcibly cancel an auto zero calibration event.

1. In the “Setting of Auto Zero

Calibration” screen that appears, point the cursor to “Stop” by pressing the UP or DOWN key, then press ENT. (“Auto Zero Calibration Stop” appears when the screen is selected while auto zero calibration is performed.)

2. “Stop” is highlighted,

displaying a message to confirm the stop of auto zero calibration.

Press the ENT key to stop the auto zero calibration and the ESC key to cancel (not stopped).



Teledyne Analytical Instruments 58

NDIR Gas Analyzer Settings and Calibration

Auto Zero Calibration Screen

Example

With Ch1 and Ch2 set to enable for auto

calibration (see Section 6.2.4):

• Zero calibration

A message, “Zero cal.” blinks at Ch1 and Ch2.

Caution: During auto zero calibration,

the only key operations allowed are key lock ON/OFF and “Auto Zero Calibration Stop.”

When the key lock is set at ON, even the “Auto

Zero Calibration Stop” cannot be used.

To forcibly stop “auto zero calibration”, set the

key lock to OFF and then execute “Auto Zero Calibration Stop.”

Teledyne Analytical Instruments 59

Settings and Calibration Model 7500ZA

6.6 Parameter Setting

From the Parameter Setting screen you can set or adjust various parameters of the instrument such as time, key lock, etc. Settable items are as follows:

Description of setting items

• Current Time : Current year, month, date, day of the week, hour,

and minute setting. (The display appears in this order.)

• Note: The clock backup time is 2 days. If power is turned on

after being off for 2 days or longer, the time must be set again.

• Key Lock : Invalidates any key operation except canceling the

key lock.

• Output Hold : Sets whether Calibration Output is held or not, and

the holding value setting.

• Response time : Sets the response time of electrical system.

• Average Period : Sets the moving average time.

• Backlight Timer : Sets automatic OFF of the backlight of display

unit and its timer.

• Contrast : Adjusts contrast of the LCD.

• Maintenance Mode : A password protected entry screen used to

access the instrument’s maintenance mode.

* For the maintenance mode, see Section 6.7.

1. Enter the “Parameter

Setting” screen from the user mode, and the display shown at right appears. Use the UP or DOWN key to move the cursor to the desired item and then press ENT.

Teledyne Analytical Instruments 60

NDIR Gas Analyzer Settings and Calibration

2. In the “Parameter

Setting” screen that appears, perform the value entry or the setting. For the value entry or setting change, use the UP or DOWN key, and the SIDE key to move the cursor to the right.

To close the Parameter Setting screen or to abort the entry midway, press the ESC key. The previous screen will return.

Setting Range

• Hold setting : 0 to 100% FS

• Response time : 1 - 60 sec. (default: 15 sec)

• Average period : 1 - 59 min or 1 - 4 hours (default value: 1 hour)

• 1 - 59 minutes when the unit is set to minute and 1 - 4 hours

when is set to hour.

• Backlight Timer : 1 - 60 min (default value: 5 min)

• Maintenance mode : 0000 to 9999 (default value: 0000)

Output Hold

Setting an output hold to ON causes the output signal of each channel to be held during the manual/auto calibration plus the purge flow time (see Section 6.4, Setting of Auto Calibration). However, an output signal can be held via an external input regardless of the Hold ON/OFF setting.

Teledyne Analytical Instruments 61

Settings and Calibration Model 7500ZA

Manual Calibration

Auto Calibration

Remote Input

Screen Display During Holding

A “Hold ON” message will blink on the measuring screen during a

hold period.

Teledyne Analytical Instruments 62

NDIR Gas Analyzer Settings and Calibration

But during a manual calibration the screen displays the process of calibration, therefore a “Hold ON” message will not displayed even if the output signal is held, however the screen will display the hold extending

time.

If the calibration is cancelled after the calibration gas has been supplied, the holding extending time will be performed in either of manual or auto calibration operation.

You can select the hold value from the value immediately before entering output hold. The choices are “current” or an arbitrary value input using “setting”.

Use the procedures shown below for adjusting these settings.

1. From the “Parameter

setting” screen that appears, select “Output Hold”. Highlight either “ON” or “OFF” using the UP or DOWN key and then press ENT to select it and return to (1).

2. When ON/OFF is

highlighted, press the SIDE key. Toggle between “Current” or “Setting” using the UP/DOWN keys and then press ENT when the desired selection is highlighted.

3. Pressing ENT when

“Current” is selected will hold the value immediately before the hold was initiated and return the highlight to (1).

Pressing the ENT key while “Setting” is selected will bring up the parameter hold screen where an arbitrary hold value can be set.

Teledyne Analytical Instruments 63

Settings and Calibration Model 7500ZA

4. On the parameter hold screen that

appears, move the cursor to the Ch (component) you want to hold using the UP or DOWN key and then press ENT.

5. A highlighted value indicates that it

can be changed. Adjust the highlighted value with the UP or DOWN key and then move the cursor to the right to change the next digit using the SIDE key.

6. After the value is changed, press the

ENT key.

Note: The setting is expressed as 1/1

full scale range for both respective ranges.

When 0 to 1000 ppm is selected

as the range, and 10% FS is selected as hold setting, the output equivalent to 100 ppm is held irrespective of the measured value at that time.

7. Press the ESC key to return to the

parameter setting screen.

Teledyne Analytical Instruments 64

NDIR Gas Analyzer Settings and Calibration

Setting Description

• The instantaneous measurement value that is displayed cannot be

held. (Output only can be held.) Optional modbus communications “Measurement concentration” register values are held.

• If set value is selected for hold, instantaneous O2 correction

value is calculated and held based on the set value.

• Range identification contact output cannot be switched even if

the range is switched during the hold.

Response time

The response time of the electrical system can be changed. Setting is available by components.

Note: It does not provide exact

seconds for the setting time, rather, it provides a guide of the setting time.

The setting value can be

modified as requested by the customer.

Average Period

This screen allows you to set an averaging period for the average values of O

correction and O2 average.

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 also resets the averaging of O correction and O

average value.

(Pressing the ENT key resets averaging only for the components whose setting were changed.)

Teledyne Analytical Instruments 65

Settings and Calibration Model 7500ZA

Average Value Reset

This mode is used to clear all average values, i.e. O2 correction average and O2 average, and restarts averaging. All average values are reset simultaneously. The indication value and output value is 0 ppm, vol% or so at the time of the reset input (based on average period settings).

Example:

If the average period was set to 1 hour:

• Sampling occurs every 30 seconds.

• Every 30 seconds, the average for the last 1 hour (time setting) is

output.

• At the instant of resetting, zero is assumed for all past values.

This means that the average value will not be correct for 1 hour after resetting.

Backlight Timer

Automatic OFF setting of the backlight of the LCD unit is user adjustable. When the specified time elapses during measurement screen display, the backlight automatically switches off. Pressing any key will turn the backlight back ON.

Teledyne Analytical Instruments 66

NDIR Gas Analyzer Settings and Calibration

On the Parameters screen, when ON is selected for the Backlight Timer function, the time until auto OFF will also display. Press the SIDE key when ON is highlighted and the time setting can be changed. Use the UP or DOWN key to change the time value and then press ENT to save the value.

When OFF is selected, the backlight always remains on and does not automatically turn off.

Contrast

The LCD Contrast is user adjustable. With the contrast function highlighted, use the UP or DOWN keys to move the slider representing the contrast. When satisfied, press the ENT key to save the setting.

Maintenance Mode

Enter the password and then press the ENT key to enter the maintenance mode. The password can be set using the password setting screen from Other Parameter/Password Set function while in the maintenance mode. The next section describes in detail the functions available in maintenance mode.

The default password is set at the factory to “0000.” You can enter the maintenance mode with this value before changing the password in maintenance mode to one of your choosing.

Teledyne Analytical Instruments 67

Settings and Calibration Model 7500ZA

6.7 Maintenance Mode

This mode is used to check sensor input values, display of error log or setting of passwords, etc. This is a password protected area. To access the maintenance mode, enter the correct password from the Parameter Setting/To Maintenance screen.

1. Select the Maintenance Mode from the

Parameter Setting screen to display the Password Setting screen.

2. Enter the password, and the Maintenance Mode

item selection screen will be displayed. Point the cursor to the item you want to set by pressing the UP or DOWN key and then press ENT.

Note: “To Factory Mode” is for TAI’s service

engineers only.

3. Press the ESC key to return to the Maintenance

Mode item selection screen from each screen.

6.7.1 Sensor Input Value screen

There are 5 possible inputs on the Model 7500ZA:

1. Input 1 to 4 : NDIR sensor digital value

2. Input 5 : O2 sensor digital value

6.7.2 Error Log screen

This screen displays the error history and logs the last 14 instrument errors.

See Section 8.1 Error Message for specific information regarding error number and its meaning.

To clear an error from the log, select Clear Error Log and press the ENT key. The specific entry will be removed from the list.

Teledyne Analytical Instruments 68

NDIR Gas Analyzer Settings and Calibration

6.7.3 Calibration Log screen

Calibration history can be displayed from this screen. Information available includes sensor input value, concentration value, and the date when zero/span calibration was performed for the last 10 calibration events. They are logged according to component.

To clear an event, move the cursor to Clear Calibration Log and press the ENT key, and the calibration log is cleared completely.

Other items appearing on the Calibration Log screen are:

Z1 : Zero calibration (Z) of Range 1 S1 : Span calibration (S) of Range 1 Cnt : Value of measuring detector at

the time of calibration

Con : Concentration value displayed

before calibration

YDMH: Time of calibration event

Teledyne Analytical Instruments 69

Settings and Calibration Model 7500ZA

6.7.4 Output Adjustment Screen

The Analog Output Adjustment screen allows the user to adjust the

0-1 V and 4-20 mA output signal.

Connect a digital multi meter to the specific output terminal requiring adjustment and adjust the value so that 4 mA or 0 V is output at zero concentration and 20mA or 1V is output at full scale or span.

1. Move the cursor using the UP or DOWN

key to the output (OUT No. and zero/span) to be adjusted, and then press the ENT key. The selected value is highlighted.

2. Adjust the value, while watching the

output, using the UP or DOWN key. When the correct value appears, press the SIDE key to select the next digit.

3. On completion of the adjustment, press

ENT to save the adjustment.

Caution: Be sure to perform zero / span

calibration when the range setting is changed. Otherwise, the measurement value may not be output properly.

Teledyne Analytical Instruments 70

NDIR Gas Analyzer Settings and Calibration

6.7.5 Other Parameter

The Other Parameter screen hosts 5 user settable functions:

• Password Setting

• O2 Reference Value

• O

Reference Value Limit

• Station Number

• Instrument Range Setting

To change any of these items:

• Press the UP or DOWN

key to move the cursor to the item whose setting is to be changed.

• The values for password,

oxygen correction, limit, and station No. are highlighted.

• Press the UP or DOWN key to change the value. Use the SIDE

key to move to the next digit to the right. Press the ENT to save the new value.

Password Set The Password Set screen is used to change the password that is required

move from the parameter setting screen to the maintenance mode. An arbitrary 4-digit number can be set to replace the default password for this purpose.

Note: Record the password and store in a safe place. Otherwise

you cannot enter the maintenance mode.

O2 ref. Value and Limit

This function sets the oxygen concentration reference value used in the oxygen correction calculation*. It is settable in the range from 00 to 19%. The O2 Limit can also be set from this screen. This sets the oxygen concentration limit at the time of oxygen correction calculation. It is settable in the range from 01 to 20%.

* Refer to the O2 correction concentration value in “5.3 Outline of display screen” for oxygen correction calculation procedure.

Teledyne Analytical Instruments 71

Settings and Calibration Model 7500ZA

Station No.

This function allows the user to set the station No. for MODBUS

communication. It is settable in the range from 00 to 32.

Range Setting

This function brings up a screen where the user can set the range for which concentration measurements are made. There are two settable ranges for each component each with a minimum an d maximum value as requested at the time of purchase. The range to be used can be selected as Range 1 or Range 2.

To set the range:

1. Move the cursor to the item to be set using the UP or

DOWN key, and then press ENT.

2. Move the cursor to the Ch (component) whose setting is

to be changed using the UP or DOWN key, and then press ENT.

3. Move the cursor to the item whose setting is to be

changed using the UP or DOWN key, and then press ENT.

The value for range 1 and range 2 must fall within the MIN and the MAX range of the instrument (including the MIN and the MAX range), and range 1 must be less than range 2.

4. Press the UP or DOWN key to change the value. Use

the SIDE key to move to the next digit to the right. Press the ENT to save the new value. The measurement unit cannot be changed.

5. The decimal point can also be changed when it is

highlighted. Use the UP or DOWN key to change the placement of the decimal point.

6. After all changes have been entered, press the ENT key

to save.

Teledyne Analytical Instruments 72

NDIR Gas Analyzer Settings and Calibration

6.8 Calibration

6.8.1 Zero Calibration

This function is used for the zero point adjustment. A proper zero gas, suitable for the application, should be used. Refer to section 3.4 “Sampling”.

1. From the Measurement screen,

press the ZERO key to display the Manual Zero Calibration screen.

2. Select the Ch (component) to be

calibrated using the UP or DOWN key and then press the ENT key, and zero gas will be admitted to the analyzer.

Note: For the Ch (components)

where “both” is set in the calibration range setting (see section 6.2.3), zero calibration

is carried out on both ranges.

3. Wait until the indication stabilizes

on the zero gas then press ENT. The zero calibration will be carried out on the highlighted range(s).

Note: On Ch (components) for which

“AR” is set (see Section 6.1.1 Setting Range Switch Mode), the cursor automatically moves to the next range selected in “Setting of Auto Calibration Component/Range” (6.2.4), and calibration is carried out on that range.

To close the Zero Calibration screen or to abort the entry midway, press the ESC key. The previous screen will return.

Teledyne Analytical Instruments 73

Settings and Calibration Model 7500ZA

6.8.2 Span Calibration

The Model 7500ZA requires periodic span calibration at or near the full scale value on the range of interest. It requires a prepared standard gas containing a known concentration of the measured species. For span calibration gas on the NOX, SO2, CO2, CO and CH4 channels, TAI recommends using a gas source containing 90-100% of the measured species in a background known to be compatible with the instrument.

For the oxygen channel, with units that include a built-in O2 sensor, use a prepared standard gas with an O2 concentration of 90 to 100% full scale on the anticipated measuring range.

If the instrument is fitted with an external zirconia sensor, use a prepared standard of 1-2% O2.

To perform a span calibration:

1. Press the SPAN key on the Measurement screen to

display the Manual Span Calibration screen.

2. Select the channel (component) to be calibrated

using the UP or DOWN key and then press ENT. Calibration gas will then flow to the sensor.

Note: For the Ch (components) in which “both” is set

in the calibration range setting (Refer to Section

6.2.3), span calibration is performed on both ranges.

3. Wait until the indication is stable. After the

indication has stabilized, press ENT. Span calibration on the selected range will be performed.

Note: On channels for which “AR” (auto ranging) is

enabled (See Section “6.1.1) the cursor automatically moves to the range that is enabled. See Section 6.2.4 “Setting of auto calibration component/range”. Calibration is then carried out on that range.

To close the Span Calibration screen or to abort the entry midway, press the ESC key. The previous screen will return

Teledyne Analytical Instruments 74

NDIR Gas Analyzer Maintenance

7. Maintenance

7.1 Daily Check

1. Zero calibration and span calibration

1. Perform zero calibration. For the calibration procedures, refer to

Section 6.8.1 Zero calibration.

2. Following the zero calibration, perform a span calibration. For

the calibration procedures, refer to Section 6.8.2 Span calibration.

3. Zero/span calibration should be carried out once a week, or as

required.

2. Flow rate check

1. Sample and purge gas flow rates are as follows:

Sample gas flow : 0.5L/min ± 0.2L/min Purge gas flow : About 1L/min

2. Instrument checks and maintenance should be carried out every

day, as required.

Teledyne Analytical Instruments 75

Maintenance Model 7500ZA

7.2 Daily Check And Maintenance Procedures

Table 7.1 Maintenance and Check Table

7.3 Long Term Maintenance

Create a long-term maintenance component procurement plan based on the “Gas analyzer annual inspection plan” indicated below.

Gas Analyzer Annual Inspection Plan

The recommended replacement period of components varies depending on the installation conditions.

1. The recommended replacement period is a recommended

standard criterion and varies depending on the environment of the field, conditions of measuring gas and other factors.

2. The recommended replacement period is not the warranty period.

It is provided as a preventative maintenance program baseline schedule.

Teledyne Analytical Instruments 76

NDIR Gas Analyzer Maintenance

Installation Conditions

1. Ambient temperature: -5°C to +40°C

2. Humidity: 90%RH or less

3. Corrosive gases: None

4. No radiated heat, direct sunlight or rain/wind

5. Dust: No more than local environmental standards permit

6. Vibration: None

Sample gas conditions

1. Temperature: +60°C to +800°C

2. Pressure: -3 to +3 kPa

3. Moisture content: 30% or less

4. Dust: 0.1 g/Nm3 or less

5. Components: 0 to 500 ppm NOX, 0 to 500 ppm SO2, 0 to 2000

ppm CO, 5% to 15% CO2, 0% to 21%O2, 0 to 100 ppm HCl, residue N2

Please consult TAI Customer Service regarding gas analyzer

maintenance service requirements.

Annual Inspection Plan Sheet

Teledyne Analytical Instruments 77

Maintenance Model 7500ZA

7.4 Cleaning the Sample Cell

Entry of dust or water in the sampling cell contaminates the interior of the cell resulting in drift. If dirty or contaminated, it must be cleaned. Check the sampling device, especially the filter, to prevent the cell from being dust or mist contamination.

Caution: Maintenance should be performed only by

properly trained and qualified personnel.

In addition to the following steps, the user must

7.4.1 Sample Cell Disassembly

block cells (cell length: 4 mm, 8 mm, 16 mm, 32 mm) and pipe cells (cell length: 64 mm, 125 mm, 200 mm and 250 mm).

one optical unit. In this case, detach the pipe cell and then block cell (see Fig. 7-3).

adhere to any local and regional regulations.

There are two kinds of sampling cells used in the Model 7500ZA:,

A two-component analyzer may incorporate both sampling cells in

Teledyne Analytical Instruments 78

NDIR Gas Analyzer Maintenance

7.4.1.1 PIPE CELL REMOVAL (SEE FIG. 7-1)

1. Stop all gas flow. If necessary, purge the pipe cell thoroughly

with zero gas.

2. Turn OFF the power switch and disconnect the AC power cord.

3. Remove the cover (six screws).

4. Remove the tube connected to the pipe cell.

5. Loosen and remove the screw (No. 7) holding the cell retainer

(No. 11) at both ends of the pipe cell.

6. Remove the cell from the assembly and unscrew the infrared

transmission window (No. 14) at both ends.

7. For assembly, reverse the disassembly procedure.

Figure 7-1: Measuring Unit Configuration (Pipe Cell)

Teledyne Analytical Instruments 79

Maintenance Model 7500ZA

7.4.1.2 BLOCK CELL REMOVAL (SEE FIG. 7-2)

For steps 1 to 4, see 7.4.1.1, Pipe Cell Removal.

5. Disconnect and remove detector output cables from detector

output circuit board (No.12). Applying identification mark on top of removed cable connector will ensure proper pin assignment later.

6. Unscrew the two screws (No. 10) that hold the detector to the

light source unit to remove the detector from the measuring unit. The block cell can be removed together with the detector.

7. To remove the block cell, unscrew the two screws (No. 6)

holding the block cell to the detector. The infrared transmission window (No. 8) is just sandwiched (not fixed) between the detector and block cell. Keep the detector facing up, when removing this window.

8. For assembly, reverse the disassembly procedures.

Note: The O-ring (No. 9) is placed between the window holder

and block cell. Use care in positioning the O-ring. With a two-component analyzer, install the two-component detector last. Make sure that no space is left between the one-component and two-component detectors. When inserting the detector output cable connector into the PCB board, be careful to attach the connector with proper pin assignment (top/bottom).

Teledyne Analytical Instruments 80

NDIR Gas Analyzer Maintenance

Figure 7-2: Measuring Unit Configuration (Block Cell)

Teledyne Analytical Instruments 81

Maintenance Model 7500ZA

7.4.1.3 REMOVING THE MEASURING UNIT

Refer to Fig. 7-3. For step 1 to 4, see 7.4.1.1, Pipe Cell Removal.

5. Disconnect and remove detector output cables from detector

output circuit board (No.12). Applying identification mark on top of removed cable connector will ensure proper pin assignment later.

6. Disconnect wiring to the 2-pin terminals of the IR light source

assembly and chopper motor pin connector from the PCB (No. 17).

7. Detach the six screws (No. 16) fastening the base plate (No. 3) to

remove the measuring unit. .

8. For assembly, reverse the disassembly procedures.

Note: Special care should be taken when assembling or

disassembling the measuring cell to avoid using excessive force to the detector pipe or light source unit pi pe. If the pipe is deformed or damaged by excessive force, there is a potential for gas leaks and this, in addition to creating a potential toxic hazard, will result in inaccurate measurement.

7.4.2 Cleaning the Sample Cell

1. To clean the sample cell or IR transmission window, first clear

away any dirt using a soft brush and then lightly wipe using a soft cloth. Do not use abrasive or paper towels.

Note: The window is fragile. Handle with care. Avoid scratching

the window. Do not rub the dirt from the window roughly.

2. If the window or the sample cell interior is very dirty, use a soft

line-free cloth moistened with absolute alcohol.

3. If the window is corroded, rub off any scale from the window

lightly with a soft cloth to which chrome oxide powder is applied. If it is excessively corroded, it should be replaced.

4. When the cleaning operation is complete, assemble according to

the sample cell assembly/disassembly procedures. Assemble the pipe carefully. If it becomes bent or damaged, replace it with a new part.

5. Do not wash the sample cell components with water.

Teledyne Analytical Instruments 82

NDIR Gas Analyzer Maintenance

Figure 7-3: Measuring Unit with 2-Component Block and Pipe Cell

Teledyne Analytical Instruments 83

Maintenance Model 7500ZA

7.5 Fuse Replacement

1. Turn “OFF” the main power supply switch to the analyzer.

2. Rotate the fuse holder cap (shown in the figure above)

counterclockwise and pull it out. The cap (fuse holder) will contain the fuse. Remove the blown fuse from the holder and replace it with a new one (250VAC/2A, Slo-Blo).

3. Reinstall the fuse holder cap, turn ON the power supply switch.

The analyzer will power up normally.

Teledyne Analytical Instruments 84

Teledyne 7500ZA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual