Teledyne 7500ZA - Manuals

NDIR Gas Analyzer Teledyne Analytical Instruments v 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, ca...

Model 7500ZA Teledyne Analytical Instruments vi 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. These safety precautions are class...

NDIR Gas Analyzer Teledyne Analytical Instruments vii 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 ...

Model 7500ZA Teledyne Analytical Instruments viii 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 DANGER Be sure to read the instruction manual for reference gases before hand...

NDIR Gas Analyzer Teledyne Analytical Instruments ix 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 ...

Model 7500ZA Teledyne Analytical Instruments x Table of Contents Specific Model Information ......................................................... iii   Safety Messages .......................................................................... iv   Additional Caution on Safety ......................

Model 7500ZA Teledyne Analytical Instruments xiv 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) ..................

NDIR Gas Analyzer Teledyne Analytical Instruments xv List of Tables Table 7.1 Maintenance and Check Table ...................................... 76   Table 8-1: Error Messages ............................................................ 85  

Model 7500ZA Teledyne Analytical Instruments xvi DANGER COMBUSTIBLE GAS USAGE WARNING 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 c...

NDIR Gas Analyzer Introduction Teledyne Analytical Instruments 1 Introduction 1.1 Overview The Model 7500ZA is designed to measure the concentration of NO, SO 2 , CO 2 , CO and CH 4 in a sample gas based on the principle that different atomic molecules have a different absorption spectrum in the inf...

Introduction Model 7500ZA Teledyne Analytical Instruments 2 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...

NDIR Gas Analyzer Items Included with Analyzer Teledyne Analytical Instruments 3 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...

Items Included with Analyzer Model 7500ZA Teledyne Analytical Instruments 4 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 ...

NDIR Gas Analyzer Instalation Teledyne Analytical Instruments 7 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 ...

Installation Model 7500ZA Teledyne Analytical Instruments 8 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. Vi...

NDIR Gas Analyzer Instalation Teledyne Analytical Instruments 9 • 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 t...

Installation Model 7500ZA Teledyne Analytical Instruments 10 • 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....

NDIR Gas Analyzer Instalation Teledyne Analytical Instruments 11 Correspondence between measured components and the optical units is as follows: Measured Components Optical Bench 1 Optical Bench 2 Single measured species: NO, CO 2 , CO or CH 4 Single component None Two measured species: CO 2 , CO CO...

Installation Model 7500ZA Teledyne Analytical Instruments 12 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 a...

NDIR Gas Analyzer Instalation Teledyne Analytical Instruments 13 Without O 2 Sensor Built-in O 2 Sensor External O 2 Sensor measurement. of 90 to 100% on the measuring range 90 to 100% on the measuring range. 90 to 100% on the measuring range. Span gas for O 2 measurement — Gas with conc. of 90 to 1...

Installation Model 7500ZA Teledyne Analytical Instruments 14 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...

NDIR Gas Analyzer Instalation Teledyne Analytical Instruments 15 Name Description Name Description (5) Electronic gas cooler Dries the moisture in the sample gas to a dew point of approx. 2°C measuring the oxygen concentration in sample gas. (Not used when O 2 sensor is built-in.) (6) Solenoid valve...

Installation Model 7500ZA Teledyne Analytical Instruments 16 (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 termi...

Installation Model 7500ZA Teledyne Analytical Instruments 18 • Used when the external zirconia O 2 sensor or the external O 2 sensor is ordered. It is not required or used if the analyzer has a built-in O 2 sensor. • Connect the dedicated connector (accessory) to the output of the external zirconia ...

Installation Model 7500ZA Teledyne Analytical Instruments 22 2. Automatic calibration: (See also Section 6.4: Automatic Calibration Settings )

NDIR Gas Analyzer Operation Teledyne Analytical Instruments 25 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) Operati...

NDIR Gas Analyzer Display and Operation Panels Teledyne Analytical Instruments 27 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 measure...

Display and Operation Panels Model 7500ZA Teledyne Analytical Instruments 28 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 Used to change the selected item (by moving the cursor) an...

NDIR Gas Analyzer Display and Operation Panels Teledyne Analytical Instruments 29 5.2 Overview of Display and Operation Panels

Display and Operation Panels Model 7500ZA Teledyne Analytical Instruments 30 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, S...

NDIR Gas Analyzer Display and Operation Panels Teledyne Analytical Instruments 31 • O 2 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 Para...

Display and Operation Panels Model 7500ZA Teledyne Analytical Instruments 32 (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 ...

NDIR Gas Analyzer Display and Operation Panels Teledyne Analytical Instruments 33 (3) Contents of Measured Channel (Ch) The following table gives measurement channels and their contents according to the symbols. •

Display and Operation Panels Model 7500ZA Teledyne Analytical Instruments 34 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 ...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 35 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 m...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 37 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 Parameter...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 38 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 t...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 39 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 ...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 40 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.

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 41 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 ...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 42 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 ...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 43 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 describe...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 44 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 0-100% full scale for each range. To change th...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 46 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 m...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 48 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 wit...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 49 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 auto...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 50 • 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...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 52 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 ...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 53 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 F ORCED STOP OF AUTO CALIBRATION This mode is used to stop the auto calibration forcibly....

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 54 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 Calibra...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 55 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 determ...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 56 • 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 f...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 57 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 o...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 59 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...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 60 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 : Curren...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 61 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 Param...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 62 Manual Calibration Auto Calibration Remote Input Screen Display During Holding A “Hold ON” message will blink on the measuring screen during a hold period.

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 63 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. I...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 64 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 v...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 65 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 ...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 68 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 Para...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 70 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...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 71 6.7.5 Other Parameter The Other Parameter screen hosts 5 user settable functions: • Password Setting • O 2 Reference Value • O 2 Reference Value Limit • Station Number • Instrument Range Setting To change any of these item...

Settings and Calibration Model 7500ZA Teledyne Analytical Instruments 72 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 con...

NDIR Gas Analyzer Settings and Calibration Teledyne Analytical Instruments 73 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, ...

NDIR Gas Analyzer Maintenance Teledyne Analytical Instruments 75 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...

Maintenance Model 7500ZA Teledyne Analytical Instruments 76 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 Ana...

Maintenance Model 7500ZA Teledyne Analytical Instruments 78 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 th...

NDIR Gas Analyzer Maintenance Teledyne Analytical Instruments 79 7.4.1.1 P IPE C ELL R EMOVAL (S EE F IG . 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...

Maintenance Model 7500ZA Teledyne Analytical Instruments 80 7.4.1.2 B LOCK C ELL R EMOVAL (S EE F IG . 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 c...

NDIR Gas Analyzer Maintenance Teledyne Analytical Instruments 83 Figure 7-3: Measuring Unit with 2-Component Block and Pipe Cell

Maintenance Model 7500ZA Teledyne Analytical Instruments 84 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 ...

NDIR Gas Analyzer Error Messages Teledyne Analytical Instruments 85 8. Error Messages Table 8-1 lists the error messages that may occur onscreen along with the probable cause for the error. Table 8-1: Error Messages When errors No. 1 to No. 3 and No. 10 occur, analyzing block error contact output cl...

Error Messages Model 7500ZA Teledyne Analytical Instruments 86 8.1 Troubleshooting When error No. 1 occurs, remove the top cover of the analyzer and check the LED on the light source PCB. If the LED is off, then the error is caused by a light source disconnection. Errors 1-3 and10 indicate an analyz...

NDIR Gas Analyzer Error Messages Teledyne Analytical Instruments 87 • Press the ECS key to delete the error display. • If the ESC key is pressed without removing the cause of an error, the error will be displayed again. • When more than one error occurs, use the SIDE key to move to the next error di...

Error Messages Model 7500ZA Teledyne Analytical Instruments 88 Error Log Screen * Up to 14 errors can be saved in the error history; the oldest error will be deleted one by one every time a new error occurs. * If the power supply is turned OFF, the contents in the error log file will not be lost or ...

NDIR Gas Analyzer Specifications Teledyne Analytical Instruments 89 9. Specifications 9.1 General Specifications 9.1.1 Standard Specifications Measurement Method: NO, SO 2 , CO 2 , CO, CH 4 : Non-dispersion infrared-ray absorption method Single light source and single beams (single beam system) O 2 ...

Specifications Model 7500ZA Teledyne Analytical Instruments 90 O 2 ExternalZirconia 0-5 vol.% 0-25 vol.% Max. 5 components measurement including O 2 . For reverse range O 2 measurement, IR gas measurement is not available (single range O 2 only). Measuring range ratio max. 1:10 (except O 2 ) User ad...

NDIR Gas Analyzer Specifications Teledyne Analytical Instruments 91 Allowable load 100K Ω for 0 to 1V DC  Refer to Table2 for the channel No. of displayed values and analog output signals. Analog Input Signal: For signal input from externally installed O 2 sensor. Signal requirement: (1) Signal fro...

Specifications Model 7500ZA Teledyne Analytical Instruments 92 Power Supply: Voltage rating: 100V to 240V AC Allowable range: 85V to 264V AC Frequency: 50Hz/60Hz Power consumption: 100VA max. Operating Conditions: Ambient temperature: -5˚C to 45˚C (40˚C max. when 2 optical system at 200V AC power so...

NDIR Gas Analyzer Specifications Teledyne Analytical Instruments 93 9.1.2 Standard Functions Output Signal Hold: Output signals are held unchanged during manual and auto calibrations when HOLD function is ON. The values held are those just before start of calibration mode or setting value. User sele...

Specifications Model 7500ZA Teledyne Analytical Instruments 94 9.1.3 O ptional Functions   Remote Output Holding: Output signal is held at the last value or preset value by a voltage input to the remote output holding input terminals. Holding is maintained while the voltage is input to the terminals...

NDIR Gas Analyzer Specifications Teledyne Analytical Instruments 95 circuiting for 1.5 sec or longer. Auto calibration initiates when contacts open. Auto Zero Calibration: Auto zero calibration is carried out periodically at the preset cycle. This cycle is independent from “Auto Calibration” cycle. ...

Specifications Model 7500ZA Teledyne Analytical Instruments 96 Correction formula: C : Sample gas concentration after O 2 correction. Cs : Measured concentration of sample gas. Os : Measured O 2 concentration (Limit setting: 1 to 20% O 2 ) On : Reference O 2 concentration (value changeable by settin...

NDIR Gas Analyzer Specifications Teledyne Analytical Instruments 97 Start-stop synchronization ModbusTM protocol Contents : Read/Write parameters Read measurement conc. and instrument status Remark : When connecting via RS-232C interface, an RS-232C ↔ RS485 converter should be used. Atmospheric Pres...

Specifications Model 7500ZA Teledyne Analytical Instruments 98 9.1.4 Performance Repeatability: ±0.5% of full scale Linearity: 1% of full scale prior to atmospheric pressure correction (option) Zero drift: ±2% of full scale/week. For auto zero calibration use 500ppm or lower range. Span drift: ±2% o...

NDIR Gas Analyzer Specifications Teledyne Analytical Instruments 101 9.2 Table 1 Measurable Component and Range - Availability Check Table Procedure for range selection One component analyzer: 1. First determine 1st range, then select 2nd range from the corresponding right column. More than two comp...

Specifications Model 7500ZA Teledyne Analytical Instruments 108 When 4 components measurement is specified and “H” is specified at 22nd digit, 3 points is maximum for alarm output function. note8) When “B” is specified at 24th digit, measuring range should be specified by ppm range code. In this cas...