Teledyne 7600 User Manual

OPERATING INSTRUCTIONS FOR

Model 7600

NDIR Infrared Gas Analyzer

P/N M7600

ECO:

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 7600

Copyright © 2005 Teledyne Instruments/ Analytical Instruments

All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any other language or computer language in
whole or in part, in any form or by any means, whether it be electronic, mechanical,
magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne
Instruments/ Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-

1580.

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 TI/AI 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, and serves as a tool by which
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 TI/AI 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 Instruments/ 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

Infrared Gas Analyzer

Specific Model Information

Instrument Serial Number: _______________________

Instrument Range: _______________

Calibrated for: _______________

Background Gas: _______________

Zero Gas: _______________

Span Gas: _______________

Teledyne Analytical Instruments iii

Model 7600

Safety Messages

Your safety and the safety of others is very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.

A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:

GENERAL WARNING/CAUTION: Refer to the instructions

for details on the specific danger. These cautions warn of
specific procedures which if not followed could cause bodily
Injury and/or damage the instrument.

CAUTION: HOT SURFACE WARNING: This warning is

specific to heated components within the instrument. Failure
to heed the warning could result in serious burns to skin and
underlying tissue.

WARNING: ELECTRICAL SHOCK HAZARD: Dangerous

voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed this
warning could result in injury and/or death from
electrocution.

Technician Symbol: All operations marked with this symbol

are to be performed by qualified maintenance personnel only.

No

Symbol

CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE

NOTE: Additional information and comments regarding a

specific component or procedure are highlighted in the form
of a note.

PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.

Teledyne Analytical Instruments iv

Infrared 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
TI/AI 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 7600

Table of Contents

List of Figures ...............................................................................x

List of Tables...............................................................................xii

Introduction.................................................................................15

1.1 Overview 15

1.2 Main Features of the Analyzer 15

1.3 Options Available 17

1.4 Applications 17

1.5 Description of the Main Unit 18

Installation................................................................................... 21

2.1 Unpacking the Analyzer 21

2.2 Choosing a Location 22

2.3 Mounting the Analyzer 23

2.4 Mounting the Input/Output Terminal Module 23

2.5 Gas Connections 25

2.5.1 Internal Piping Diagram 25

2.5.2 External Piping Diagram 27

2.5.3 Gas Conditioning 28

2.5.4 Flowrate 29

2.5.5 Preparation of Calibration Gas 29

2.5.6 Purging the Analyzer 30

2.5.7 Sample Gas Pressure 30

2.5.8 Example configuration of gas sampling system 30

2.6 Electrical Connections 32

2.6.1 Power Inlet 32

2.6.2 Input/Output Terminal Module 33

2.7 Testing the System 34

Teledyne Analytical Instruments vi

Infrared Gas Analyzer

Operation .....................................................................................35

3.1 General Information 35

3.2 Display and Available Menus 36

3.3 The Display Screen 38

3.3.1 Measurement Mode 38

3.3.2 Setting/Selection Screen 40

3.4 Basic Operation 41

3.5 Setting Up the Analyzer in the User Mode 42

3.5.1 Switch Ranges 42

3.5.1.1 Manual Range Switching 43

3.5.1.2 Range identification contact operation 44

3.5.1.3 Remote Range Selection 45

3.5.1.4 Autoranging 46

3.5.2 Calibration Parameters 46

3.5.2.1 Calibration Value 46

3.5.2.2 Setting of Manual Zero Calibration 48

3.5.2.3 Setting of calibration range 50

3.5.2.4 Setting of auto calibration component/range 51

3.5.3 Alarm Setting 53

3.5.3.1 Configuring the Alarms 55

3.5.3.2 Hysteresis Setting 56

3.5.4 Setting of Auto Calibration 58

3.5.4.1 Auto Calibration 58

3.5.4.2 Gas Flow Time Setting 59

3.5.4.3 Cycle Setting Range 60

3.5.4.4 Remote Start 62

3.5.4.5 Forced Run/Stop of Auto Calibration 62

3.5.5 Setting of Auto Zero Calibration 65

3.5.5.1 Auto Zero Calibration 65

3.5.5.2 Forced run/stop of auto zero calibration 68

3.5.6 Peak Alarm Setting 70

3.5.7 Parameter Setting 73

Teledyne Analytical Instruments vii

Model 7600

3.5.7.1 Output Hold 75

3.5.7.2 Average Value Reset: 78

3.5.7.3 Response Time 79

3.5.7.4 Average Period 79

3.5.7.5 Backlight Timer 80

3.5.7.6 Maintenance mode 81

3.6 Maintenance Mode 82

3.6.1 Sensor Input Value 83

3.6.2 Error Log 84

3.6.3 Calibration Log 84

3.6.4 Optical Adjustment 85

3.6.5 Moisture Interference Adjustment 86

3.6.6 Output Adjustment Screen 86

3.6.7 Other Parameters 87

3.7 Calibration 90

3.7.1 Zero Calibration 90

3.7.2 Span Calibration 91

Maintenance ................................................................................93

4.1 Routine Maintenance 93

4.2 Daily Check and Maintenance Procedures 93

4.3 Analyzer Maintenance 94

4.3.1 Sample Cell Cleaning 94

4.3.2 Cleaning the Cell Block 97

4.4 Optical Zero Adjustment 99

4.5 Moisture Interference Compensation Adjustment 102

4.6 Error Messages 104

4.6.1 Error Log File 106

4.6.2 Error Log Screen 106

4.6.3 Deleting Error Hstory 107

Appendix.................................................................................... 109

A.1 SPECIFICATIONS 109
A.2 Standard Functions 111

Teledyne Analytical Instruments viii

Infrared Gas Analyzer

A.3 Optional Functions 115
A.4 Performance: 116
A.5 Standard Requirements for Sample Gas 117
A.6 Installation Requirements 118
A.7 EC Directive Compliance 118
A.8 Terminal Block Connections 119
A.9 Description on Terminal Block 120

Index...........................................................................................125

Teledyne Analytical Instruments ix

Model 7600

List of Figures

Figure 1-1: Model 7600A Infrared Gas Analyzer...........................16

Figure 1-2: Model 7600 Description..............................................19

Figure 2-1: Slide Rail Mounting Dimensions .................................23

Figure 2-2: Input/Output Terminal Module.....................................24

Figure 2-3: Mounting the I/O Module............................................. 24

Figure 2-4: Internal Piping with Single or Dual Measuring Units ... 26

Figure 2-5: External Piping with Single Inlet and Outlet................27

Figure 2-6: External Piping with Two Pair of Inlet/Outlet (1).......... 28

Figure 2-7: External Piping with Two Pair of Inlet/Outlet (2).......... 28

Figure 2-8: Five Component Analysis System .............................. 31

Figure 2-9: Model 7600 Electrical Connections.............................32

Figure 2-10: Noise Suppression.................................................... 33

Figure 2-11: I/O Cable Connection................................................ 33

Figure 3-1: Front Panel of the Model 7600.................................... 35

Figure 3-2: Interface Keys on the Front Panel...............................35

Figure 3-3: Display Modes and Menu Hierarchy...........................37

Figure 3-4: Example Screen—5 Component Analysis 12

Channels................................................................................38

Figure 3-5: Setting/Selection Screen Areas .................................. 41

Figure 3-6: Hysteresis Example for a High Limit Alarm................. 57

Figure 3-7: Example Auto Calibration ........................................... 61

Figure 3-8: Example Auto Zero Calibration................................... 67

Figure 3-9: Peak Alarm Example ..................................................72

Figure 3-10: Output Hold for Manual Calibration........................... 75

Teledyne Analytical Instruments x

Infrared Gas Analyzer

Figure 3-11: Output Hold for Auto Calibration ...............................76

Figure 3-12: Output Hold for External Hold ...................................76

Figure 3-13: Average Value Reset................................................79

Figure 3-14: Example Average Period ..........................................80

Figure 4-1: Top Cover Removal....................................................95

Figure 4-2: Sample Cell Removal..................................................95

Figure 4-3: Sample Cell.................................................................96

Figure 4-4: IR Window Assembly..................................................97

Figure 4-5: Detector Secure Nut....................................................98

Figure 4-6: Cell Block Assembly....................................................99

Figure 4-7: Optical Adjustment Display for Dual Optical System

Option...................................................................................100

Figure 4-8: Optical Zero Adjustment............................................101

Figure 4-9: Beam Adjustment Plate.............................................102

Figure 4-10: Bubbler Apparatus ..................................................103

Figure 4-11: The Error Log Screen..............................................107

Teledyne Analytical Instruments xi

Model 7600

List of Tables

Table 2-1: Correspondence of Measured Components and

Measuring Units..................................................................... 27

Table 2-2: Zero and Span Gas......................................................29

Table 4.1 Troubleshooting and Maintenance................................ 93

Table 4-2: Components of Optical Adjustment Screen ............... 100

Table 4-3: Error Messages .......................................................... 104

Teledyne Analytical Instruments xii

Infrared Gas Analyzer

DANGER

COMBUSTIBLE GAS USAGE

This is a general purpose instrument designed for use in a
non-hazardous area. It is the customer's responsibility to
ensure safety especially when combustible gases are being
analyzed since the potential of gas leaks always exist.

The customer should ensure that the principles of operating
this equipment are well understood by the user. Misuse of
this product in any manner, tampering with its components,
or unauthorized substitution of any component may
adversely affect the safety of this instrument.

WARNING

Since the use of this instrument is beyond the control of
Teledyne Instruments/ Analytical Instruments, referred as
TI/AI, no responsibility by TI/AI, its affiliates, and agents for
damage or injury from misuse or neglect of this equipment is
implied or assumed.

Teledyne Analytical Instruments xiii

Model 7600

Teledyne Analytical Instruments xiv

Infrared Gas Analyzer Introduction

Introduction

1.1 Overview

The Model 7600 Infrared Gas Analyzer is a microprocessor based
infrared gas analyzer used to measure the concentration of NO, SO
CO

, CO and CH4 contained in sample gas. It is based on the principle

2

that different molecular species have unique absorption spectrum in the
infrared, and the intensity of absorption is determined by the Lambert­Beer law.

In addition to the infrared analyzer, the Model 7600 can also be
equipped with a built-in compact paramagnetic O2 sensor or employ an
external zirconia oxygen sensor to increase to 5 the number of
simultaneous component species the unit can analyze.

,

2

Teledyne's Series 7600 Infrared (IR) Gas Analyzer is conveniently
packaged in either a 19" rack mount or NEMA-4 wall mount enclosure.
The NEMA-4 enclosure can be X or Z-purged to satisfy hazardous area
installation requirements.

A high-sensitivity mass flow type twin detector is used for infrared
measurements. By utilizing a single beam, double path design in
conjunction with a serial dual-layer transmission detector, the Series
7600 delivers long term, drift-free performance.

The concentration of the desired gases is displayed on a large, easy­to-read back-lit LCD. Figure 1-1 shows the standard rack mountable
Model 7600. The user interface is very intuitive and the menu / mode
selection buttons, which are readily accessible, provide the operator with
dynamic control and extensive diagnostic capabilities.

1.2 Main Features of the Analyzer

The Model 7600 Infrared Gas Analyzer is designed for accurate
and reliable gas analysis and is easy to operate. The following features
are standard on the 7600 instrument:

Teledyne Analytical Instruments 15

Introduction Model 7600

Figure 1-1: Model 7600A Infrared Gas Analyzer

• Simultaneous measurement of up to five components

• Excellent long-term stability

• Large, easy to read LCD display showing all simultaneous

measurements and computations

• Slide-out, chassis design to facilitate any optical or

maintenance adjustments required to fine tune analyzer
performance (7600A)

• Multiple, in-depth on-screen analyzer functions easily

accessible using the front-panel user interface buttons

• Follow & Hold output signal control (during calibration)

• Remote range change control

• Low / Hi limit alarms

• Range ID signals

• Auto-calibration with user adjustable frequency and gas flow

time setting programming capabilities

• Remote auto-calibration initiation

• Auto-calibration status contacts

Teledyne Analytical Instruments 16

Infrared Gas Analyzer Introduction

• Instrument or calibration error contact outputs

• Extra functions included such as average value computation,

O2 conversion

• Pump ON/OFF contact

1.3 Options Available

• Percent O

detector — Paramagnetic (built-in) or ZrO2

2

(externally installed), user preference

• O

correction (the conversion of measured CO and SO2

2

readings into values at standard O2 concentration). Consult
factory for more detail for this function.

• Communication functions:

• RS-232C (9 pins D-Sub connector)

• Half-duplex bit serial

• Modbus protocol

1.4 Applications

The Model 7600 Infrared Gas Analyzer is a versatile analytical
instrument tool and is ideally suited for multi-parameter gas analysis
requirements for applications such as:

• Combustion control within the power, pulp and paper, steel,

and cement industries

• Heat treating / Inert gas blanketing atmosphere control

• Bulk-gas impurity analysis within the air separation industry

• Anaerobic digester / Bio-gas / Land-fill gas analysis

• Vent gas analysis of oxyhydrochlorination reactors (EDC)

• Off-gas analysis on PTA and Maleic Anhydride reactors

• Fluid Catalytic Cracker (FCC) regeneration gas analysis

• Ammonia / Fertilizer process gas stream analysis

• Continuous Emissions Monitoring Systems (CEMS)

Teledyne Analytical Instruments 17

Introduction Model 7600

• Biochemistry and fermentation,

• Automotive emission analysis

• Explosive and toxic gas analysis

• Chemical analysis

• Refinery operation

• Research applications

1.5 Description of the Main Unit

Teledyne's Series 7600 Infrared Gas Analyzer measures the
concentration of NO, SO2, CO2, CO, and CH4 in a gas mixture on a
continuous basis. The Series 7600 can also be supplied with an oxygen
sensor, which allows the simultaneous measurement of oxygen
concentration as well. The NEMA-4 enclosure can be X or Z-purged to
satisfy hazardous area installation requirements.

The system uses a high-sensitivity mass flow type twin detector for
infrared measurements. A single beam, double path optical bench is
installed in conjunction with a serial dual-layer transmission detector.

The concentration of the desired gases is displayed on a large, easy­to-read backlit LCD. The user interface is very intuitive and the menu /
mode selection buttons, which are readily accessible, provide the
operator with dynamic control and extensive diagnostic capabilities. See
Figure 1-2.

The front panel mounted power switch turns the instrument on and
off while the display switch controls power to the display.

Front panel mounted handles make sliding the instrument out of the
panel rack or enclosure a simple task for easy maintenance.

Teledyne Analytical Instruments 18

Infrared Gas Analyzer Introduction

Figure 1-2: Model 7600 Description

Gas connections for the 7600 instrument are made on the rear panel
of the instrument using the ¼” NPT fittings installed. The standard
instrument has two measuring units and a pair of inlet/outlet gas

connections exist for each unit. See Section 2.5 Gas Connections.

A power receptacle on the rear panel accepts the three-prong power
cable supplied with the instrument. The Model 7600 operates on 100­240 VAC 50/60 Hz power. The power inlet conforms to EN60320
Protection Class 1 specifications.

Teledyne Analytical Instruments 19

Introduction Model 7600

Teledyne Analytical Instruments 20

Infrared Gas Analyzer Installation

Installation

Installation of the analyzer includes:

1. Unpacking the system.

2. Choosing a suitable location

3. Mounting the analyzer

4. Mounting the terminal module

5. Installing gas connections

6. Making electrical connections

7. Testing the installation.

CAUTION: READ THIS CHAPTER IN ITS ENTIRETY BEFORE

INSTALLING THE SYSTEM.

FOR INDOOR USE ONLY.

2.1 Unpacking the Analyzer

The Model 7600 Infrared Gas Analyzer is shipped with the
following components:

• 7600 Analyzer

• Input/Output terminal module set

• Connection cable

• Power cable

• Fuse (2)

• Cell window mounting tool

• Slide rail (2)*

• Relay board for auto calibration*

• Relay board connection cable*

• Instruction manual

Teledyne Analytical Instruments 21

Installation Model 7600

* These optional items are included if specified at the time of purchase

As soon as you receive the instrument, carefully unpack and inspect
the analyzer and components for damage. Immediately report any
damage to the shipping agent. The analyzer is shipped with all the
materials you need to install and prepare the system for operation.

2.2 Choosing a Location

CAUTION: THIS UNIT IS NOT EXPLOSION-PROOF. DO NOT

INSTALL IT IN A LOCATION WHERE EXPLOSIVE OR
FLAMMABLE GASES ARE PRESENT.

Select an installation location that meets the following criteria:

• This instrument should be rack mounted, or mounted in a

steel enclosure.

• Indoor location.

• Vibration-free.

• Not exposed to direct sunlight.

• Clean and non-cluttered space.

• Depending on the options selected at the time of purchase,

the model 7600 requires an AC power source of 100V to
240V AC.

• Operating voltage: 85V to 264V AC

• Rated frequency: 50/60 Hz

• Power consumption: 250 VA max.

• Plug: Comformity to EN60320 class I type 3-pin inlet

• Operation conditions:

• Ambient temperature: -5° to 45°C

• Ambient humidity: 90 % RH or less, no condensation

Teledyne Analytical Instruments 22

Infrared Gas Analyzer Installation

2.3 Mounting the Analyzer

The 19” rack mountable 7600 analyzer is designed for either a
guide rail or slide rail mounting within a rack or cabinet. The guide rail
method supports the weight of the instrument from the bottom and can
be used when there is adequate space for removing the top cover for
maintenance. The slide rail mount supports the instrument from sliders
mounted on the side of the instrument as shown in Figure 2-1. The
instrument is then able to slide out of the rack or enclosure for required
access during maintenance.

Figure 2-1: Slide Rail Mounting Dimensions

2.4 Mounting the Input/Output Terminal Module

The input/output module is the electronic interface that handles the
various signals to and from the analyzer. It consists of up to five
terminal blocks, a communications connector, a cable connector, and a
solenoid drive output connector mounted together on a single mounting
plate. See Figure 2-2.

Mount the input/output terminal module to the rack or cabinet panel
using the six M4 screws supplied. For grounding, see Figure 2-3.

Note: To avoid noise generated from external units, mount the

I/O terminal module mounting plate to the panel making
sure there is adequate metal contact for continuity at the

Teledyne Analytical Instruments 23

Installation Model 7600

mounting surface. Connect the panel to the same ground
as the analyzer main unit.

Figure 2-2: Input/Output Terminal Module

Figure 2-3: Mounting the I/O Module

Teledyne Analytical Instruments 24

Infrared Gas Analyzer Installation

2.5 Gas Connections

Gas connections are made on the rear panel of the analyzer. Adhere
to the following guidelines when making gas connections:

• Use a corrosion resistant tube such as Teflon, stainless 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. This would result in instrument
inaccuracies due to gas absorption by the piping materials.

• Pipe connection port is Rc1/4 female thread (or NPT1/4).

Piping should be cut as short as possible for quicker
response. About 4 mm inner diameter is recommended.

• Keep out dust and debris from the tubing and connections .

Always use clean tubing and fittings.

Connect the gas tube as follows:

• Sample gas inlet: Attach the sample gas tube to the inlet

fitting. The sample gas should be filtered and dehumidified
before passing into the analyzer. This port is also used to
connect the zero and span calibration gases.

• The gas flow should be constant within the range of 0.5

L/min ±0.2 L/min.

• Sample gas outlet: Sample gas exits the analyzer through

the gas out port at atmospheric pressure. Exhaust gases must
be vented safely.

• Purge gas inlet: This connection is used for purging the

inside of the analyzer. Purging is not always required. See

Section 2.5.6 Purging the Analyzer. When required, use dry

N

or instrumentation air for the purge gas. Use a flow rate of

2

1L/min or greater).

2.5.1 Internal Piping Diagram

Note: When the purge gas inlet is provided, an internal

connection to measuring unit 2 is installed.

Teledyne Analytical Instruments 25

Installation Model 7600

An internal piping diagram for an instrument with one or two
measuring units is shown in Figure 2-4. When there are two measuring
units, if a built-in oxygen sensor is used, it must be installed in
measuring unit 2. The diagram shows the combination of two cells used
in measuring unit #2. This is possible by combining ranges. When a
single measuring unit is used, there is only a single inlet and outlet gas
connection.

Figure 2-4: Internal Piping with Single or Dual Measuring Units

Depending on the options chosen, the analyzer can be configured in
several ways. Table 2-1 lists the possible configurations for single and
dual measuring units with 1 to 4 component meters.

Teledyne Analytical Instruments 26

Infrared Gas Analyzer Installation

/

/

Table 2-1: Correspondence of Measured Components and Measuring
Units

Measuring components Measuring unit 1 Measuring unit 2

1-component meter for NO,
SO

, CO2, CO and CH4

2

2-component meter for
NO/SO

and CO

2

2

CO

2-component meter for

Each component None

2

CO

2

None

NO/SO
CO

NO CO

NO/CO
3-component meter for

NO/SO

/CO

2

4-component meter for
NO/SO

/CO2/CO

2

NO/SO

NO/SO

CO

2

CO2/CO

2

2.5.2 External Piping Diagram

There are several ways to bring sample gas to the analyzer
depending on the number of inlet/outlet gas connections on your
instrument Recommended piping diagrams are shown in Figures 2-5, 2­6 and 2-7. Figure 2-5 is a schematic for an instrument with a single pair
of inlet/outlet gas connections. Figures 2-6 and 2-7 are used when there
are two pair of inlet/outlet connections. Note that a NO2/NO converter
is used when NO measurement is used for NOx analysis.

Figure 2-5: External Piping with Single Inlet and Outlet

Teledyne Analytical Instruments 27

Installation Model 7600

Figure 2-6: External Piping with Two Pair of Inlet/Outlet (1)

Figure 2-7: External Piping with Two Pair of Inlet/Outlet (2)

2.5.3 Gas Conditioning

For optimum performance, the sample gas should be treated as

follows:

• A filter should be installed to remove any dust or particles in

the sample gas. For a final stage filter, use a filter that can
remove dust particles of 0.3 μm.

Teledyne Analytical Instruments 28

Infrared Gas Analyzer Installation

• The dew point of the sample gas must be lower than the

ambient temperature to avoid condensation in the analyzer. If
vapor is contained in the sampling gas, the dew point should
be lowered to 0°C by using a dehumidifier.

• If SO

mist is contained in the sample gas, use a mist filter or

2

cooler to remove the SO2 mist. Other mists should be
removed by using an appropriate mist filter or cooler.

• Corrosive gases such as Cl

, F2 and HCl, if contained in the

2

sample gas in considerable amounts, will shorten the life of
the instrument.

• Sample gas temperature should be within 0 to 50°C. Hot gas

should not be fed directly into the instrument.

2.5.4 Flowrate

Use a flowrate of 0.5L/min ±0.2L/min. The sample system should
be designed to avoid any flow fluctuation during measurement.

Use a flowmeter to observe the flow reading as shown in the
external piping diagrams of Figures 2.5, 2.6 and 2.7.

2.5.5 Preparation of Calibration Gas

Routine calibration using calibration gases is required for
optimizing the performance of this instrument. Once a week is a
suggested calibration frequency. Table 2-2 indicates the zero and span
gas required for calibration.

Table 2-2: Zero and Span Gas

Zero gas

Span gas
other than for
O

2

Span gas for

analysis

O

2

Teledyne Analytical Instruments 29

Analyzer without

O

2

N

gas N2 gas Dry air

2

Gas concentration
of 90% or more of
full scale

NA

Analyzer with built-in

O2

Gas concentration of
90% or more of full
scale

Gas concentration of
90% or more of full
scale

Gas concentration of 90%
or more of full scale

1 to 2% O

Analyzer with external

zirconia O2 sensor

2

Installation Model 7600

2.5.6 Purging the Analyzer

In general, purging the analyzer is not required unless one of the

following cases apply:

• A combustible gas component is contained in sample gas.

• Corrosive gas is contained in the atmospheric air at the

installation site.

• The same gas as the sample gas component is contained in

the atmospheric air at the installation site.

In the above situations, the inside of analyzer should be purged

with instrument air or N2. Use a purge flow rate of about 1 L/min.

Use a filter to remove dust or mist from the purge gas.

2.5.7 Sample Gas Pressure

The sample gas pressure at the outlet should be atmospheric

pressure.

2.5.8 Example configuration of gas sampling system

A typical system configuration with five component gas analysis
for monitoring combustion exhaust gas from boiler, refuse incinerator,
etc. is shown in Figure 2-8. Contact Teledyne for specific application
system configuration or further information.

The system shown is comprised of:

• Model 7600—with dual measuring unit option and external

zirconia oxygen sensor.

• Gas Extractor—with stainless steel filter of standard mesh 40

μm equipped with integral heater.

• Mist Filter—to remove condensate, mist and dust from the

sample before it enters the analyzer.

• Safety Drain Trap—with two compartments for positive and

negative pressure. It monitors and adjusts the sample gas
pressure.

• Gas Aspirator—to aspirate the sample gas.

• Electronic Gas Cooler—used to dry the sample gas to a dew

point of approximately 2°C (35.6°F).

Teledyne Analytical Instruments 30