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.
Model 7600 Copyright © 2005 Teledyne Instruments/ Analytical Instruments All Rights Reserved.
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.
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.
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 .......................................
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.
Model 7600 3.5.7.1 Output Hold 3.5.7.2 Average Value Reset: 3.5.7.3 Response Time 3.5.7.4 Average Period 3.5.7.5 Backlight Timer 3.5.7.6 Maintenance mode 3.6 Maintenance Mode 3.6.1 Sensor Input Value 3.6.2 Error Log 3.6.3 Calibration Log 3.6.4 Optical Adjustment 3.6.5 Moisture Interference Adjustment 3.6.6 Output Adjustment Screen 3.6.7 Other Parameters 3.7 Calibration 3.7.1 Zero Calibration 3.7.2 Span Calibration 75 78 79 79 80 81 82 83 84 84 85 86 86 87 90 90 91 Maintenance ............................
Infrared Gas Analyzer A.3 Optional Functions A.4 Performance: A.5 Standard Requirements for Sample Gas A.6 Installation Requirements A.7 EC Directive Compliance A.8 Terminal Block Connections A.9 Description on Terminal Block 115 116 117 118 118 119 120 Index ...........................................................................................
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 ...
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..........................................
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..........................................................
Infrared Gas Analyzer DANGER COMBUSTIBLE GAS USAGE WARNING 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.
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, SO2, CO2, CO and CH4 contained in sample gas. It is based on the principle that different molecular species have unique absorption spectrum in the infrared, and the intensity of absorption is determined by the LambertBeer law.
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 &
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 O2 detector — Paramagnetic (built-in) or ZrO2 (externally installed), user preference • O2 correction (the conversion of measured CO and SO2 readings into values at standard O2 concentration). Consult factory for more detail for this function.
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.
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.
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.
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.
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.
Installation Model 7600 mounting surface. Connect the panel to the same ground as the analyzer main unit.
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.
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.
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, Each component SO2, CO2, CO and CH4 None 2-component meter for NO/SO2 and CO2/CO NO/SO2 CO2/CO None 2-component meter for NO/CO 3-component meter for NO/SO2/CO NO CO NO/SO2 CO 4-component meter for NO/SO2/CO2/CO NO/SO2 CO2/CO 2.5.
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.
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 SO2 mist is contained in the sample gas, use a mist filter or cooler to remove the SO2 mist. Other mists should be removed by using an appropriate mist filter or cooler.
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.
Infrared Gas Analyzer Installation • Solenoid Valve—for introducing calibration gas and OFF/ON flow of sample gas. • Membrane Filter—PTFE filter for rempval of fine dust particles. • Flowmeter—adjusts and monitors the sample gas flowrate. • Standard Gas—a bank of calibration gases used for setting zero and span of the analyzer for each species monitored. • Zirconia Sensor— an external zirconia sensor is used for measuring the oxygen concentration in the sample gas.
Installation Model 7600 2.6 Electrical Connections 2.6.1 Power Inlet The power inlet for the Model 7600 is located on the rear panel as shown in Figure 2-9. The proper 3-prong power cord has been supplied with your instrument. Connect the power cable to the power inlet. Figure 2-9: Model 7600 Electrical Connections The Model 7600 requires 100-240 VAC 50/60 Hz power.
Infrared Gas Analyzer Installation Figure 2-10: Noise Suppression 2.6.2 Input/Output Terminal Module Use the supplied cable to interface the I/O Module to the analyzer. Plug the cable connector into the receptacle at the rear panel of the analyzer and the receptacle on the PC board of the input/output module. Make sure that the ferrite core attached to the I/O cable goes to the analyzer. See Figures 2-9 and 2-11. Figure 2-11: I/O Cable Connection The I/O Module carries various input and output signals.
Installation Model 7600 2.7 Testing the System After the analyzer has been installed with gas and electrical connections but prior to powering up the unit make sure you have: • Installed the unit correctly • Checked the gas connections for leaks Once the above checks have been made, you can connect the power source and turn the analyzer on using the power switch on the front panel. Allow the analyzer to warm up for four hours.
Infrared Gas Analyzer Operation Operation 3.1 General Information This section describes the front panel interface of the analyzer. Figure 3-1 Shows the Model 7600 Infrared Gas Analyzer front panel. The user interface consists of 8 membrane switch buttons or keys, a power ON/OFF switch and a display ON/OFF switch. The 8 user keys are shown in Figure 3-2 and described below.
Operation Model 7600 MODE key: Used to switch the mode. LEFT/RIGHT Arrow key: Used to change the selected item by moving the cursor and numeral digit. UP key: Used to change the selected item by moving the cursor and to increase a numeric value. DOWN key: Used to change the selected item by moving the cursor and to decrease a numeric value. ESC key: Used to return to a previous screen or cancel the setting midway.
Infrared Gas Analyzer Operation Figure 3-3: Display Modes and Menu Hierarchy Teledyne Analytical Instruments 37
Operation Model 7600 The user mode is where the operator configures the instrument and sets up various parameters for the intended application. From the user mode the following menus are available: • Switch Ranges • Calibration Parameters • Alarm Setting • Setting of Auto Calibration • Setting of Auto Zero Calibration • Setting of Peak Alarm • Parameter Setting Figure 3-3 shows the overall structure of the Model 7600 display and menu hierarchy. 3.3 The Display Screen 3.3.
Infrared Gas Analyzer Operation The numbered call outs in Figure 3-4 refer to: No. Name Function (1) Component display Displays component of instantaneous value, corrected instantaneous value, corrected average value, etc. (2) Concentration Displays measured value of concentration. display (3) Range display Displays range values. (4) Unit display Displays unit with ppm and vol %.
Operation Model 7600 Where: On: The value of the O2 correction reference value (Value set by application) Os: Oxygen concentration (%) Cs: Concentration of relevant measured component. Note that Os does not exceed the O2 limit value set in “Other Parameter” See Section 3.6 Maintenance Mode. The corrected sampling components are NOX, SO2 and CO only.
Infrared Gas Analyzer Operation Figure 3-5: Setting/Selection Screen Areas 3.4 Basic Operation Measurement mode The measurement mode is the default mode of the instrument and appears when the unit is first turned on. It displays information about the process being analyzed such as: channel number, component species analyzed, concentration or calculated value, etc. In this mode, the display can show up to 5 channels on a single screen.
Operation Model 7600 • Set up the Auto Calibration feature • Setup an auto zero calibration • Adjust the peak alarm parameter Setting. These settings are described in Section 3.5. To enter the user mode from the measurement mode, press the MODE key. To return to the measurement mode, press the MODE key again or ESC. 3.5 Setting Up the Analyzer in the User Mode 3.5.1 Switch Ranges From the Switch Ranges menu you can: a. Manually select a desired range for any channel. b.
Infrared Gas Analyzer Operation 2. Move the cursor to the “Switch Ranges” option and press ENT. The “Channel Selection” screen appears. 3. Move the cursor by pressing the UP/DOWN keys to the desired channel and press ENT. There are 3 range switch modes in the second column to select from: MR: Manual selection RR: Remote range switch AR: Autoranging The selected range switch mode is highlighted for the channel you selected. 4. Press the UP/DOWN keys to toggle between the available switch modes. 5.
Operation Model 7600 2. Move the highlight of the cursor to range selection and select the desired range using the UP/DOWN keys. The highlighted arrow indicates the currently selected range. 3. Press ENT to accept the selection. Measurement is now carried out using the selected range.
Infrared Gas Analyzer Operation 3.5.1.3 REMOTE RANGE SELECTION The range can be selected remotely if a remote switch has been installed. To use this feature, the range mode must be switched in the display to RR (Remote Range) . To configure the instrument for remote range selection: 1. Press the MODE key to enter the user mode. 2. Move the cursor to the “Switch Ranges” option and press ENT. The “Channel Selection” screen appears. 3.
Operation Model 7600 3.5.1.4 AUTORANGING The Model 7600 can be set to autorange where the instrument will select the analysis range automatically. To use the autorange feature, AR must be selected for the switch mode. Note that each channel is independent so that autoranging can be used for some or all of the available channels. the remaining channels can be configured to manual or remote switching. To setup autoranging use the same procedure as Section 3.5.1.
Infrared Gas Analyzer Operation 4. In the “Calibration Parameters” screen that appears, point the cursor to “Calibration Value” by pressing the UP or DOWN key. Press the ENT key. To change the concentration of a calibration gas: 1. Point the cursor to the channel you want to set by using the UP or DOWN key. Press the ENT key. 2. Select the concentration item you want to set by pressing the UP or DOWN or SIDE key. Press the ENT key, and the selected value is highlighted. 3.
Operation Model 7600 Note: Enter settings that correspond to each range. If a zirconia type O2 sensor is used, select 21.00 for the field of Zero (when air is used), and select the concentration listed on the cylinder if the air contained in a cylinder is used. To close the calibration concentration value setting process or cancel this mode midway, press the ESC key. The previous screen will return.
Infrared Gas Analyzer Operation This brings up the Cal. Settings ZERO Cal. screen where you can set whether all components or individually selected components are zeroed during a manual zero calibration. The choices are: • at once—these components will be zeroed simultaneously during a manual zero. • each—these components will be zeroed individually during a manual zero. To change the manual zero setting: 1. In the “Cal. Settings ZERO Cal.
Operation Model 7600 zero calibration screen that all there are cursors on all components where “at once” is set. Note: When the cylinder air or atmospheric air is used for the zero gas, select “at once.” 3.5.2.3 SETTING OF CALIBRATION RANGE Use the “About Calibration Range” submenu to configure the instrument for calibration on one or two ranges for a channel. To set calibration one or both ranges: 1. From the measurement mode, press the MODE key to display the user mode. 2.
Infrared Gas Analyzer Operation performed only for the range displayed when calibration of the selected channel is performed. 6. Press the ENT key after the selection, and the specified calibration is set. To close the calibration range selection screen or cancel this mode midway, press the ESC key. The previous screen will return. Note: To perform calibration for “both,” set the same calibration gas concentration for both ranges.
Operation Model 7600 (AR), it will be calibrated in the range set in this menu when auto calibration is performed. From this menu you can enable or disable the auto calibration feature. To navigate to the Auto Calibration Components/Range menu: 1. From the measurement mode, press the MODE key to display the user mode. 2. Point the cursor to “Calibration Parameters” by pressing the UP or DOWN key and press the ENT key. 3.
Infrared Gas Analyzer Operation range you want to set using the UP or DOWN key. Then press the ENT. 2. The cursor next to the range of the selected channel is highlighted. Select the range to be calibrated using the UP or DOWN key. Then press the ENT key. The auto calibration will be performed on the selected range. Channels which have been set for autoranging (AR) will undergo the auto calibration and manual calibration on the range selected here.
Operation Model 7600 • High Limit: sets the upper value (concentration) above which the alarm will trigger. Has an on-screen display. • Low Limit: sets a lower value (concentration) below which the alarm will trigger. Has an on-screen display • High or Low Limit: triggers an alarm when the concentration is above the high limit or below the low limit. • High-High: sets the upper value (concentration) above which the alarm will trigger.
Infrared Gas Analyzer CAUTION: Operation ALARMS ARE INACTIVE FOR 10 MINUTES AFTER TURNING ON POWER. 3.5.3.1 CONFIGURING THE ALARMS Note: To change an alarm setting, first set the alarm ON/OFF setting to OFF, and then change the value. 1. From the measurement mode, press the MODE key to display the user mode. 2. Point the cursor to “Alarm Setting” by pressing the UP or DOWN key and press the ENT key. 3.
Operation Model 7600 4. The alarm item selection screen will appear where you can select the alarm type, assign it to a channel, define setpoints, and enable or disable the alarm. Use the UP or DOWN keys until the cursor is aligned with the desired function and press the ENT key. Note: Setpoints are adjustable form 0 to 100% of fullscale however they must be defined so that H-limit value > L-limit value and that (H-limit value- L-limit value) > hysteresis. 5.
Infrared Gas Analyzer Operation Figure 3-6: Hysteresis Example for a High Limit Alarm An alarm output is turned ON if measurement value exceeds the upper limit value as shown in Figure 3-6. Once the alarm output has been turned ON, it is not turned OFF until the process value falls below the hysteresis width. Note: The hysteresis setting is common to all alarms. To set the hysteresis value: 1. From the “Alarm No.
Operation Model 7600 To close the “Hysteresis Setting” or cancel the mode midway, press the ESC key. A previous screen will return. 3.5.4 Setting of Auto Calibration 3.5.4.1 AUTO CALIBRATION Auto calibration is automatically carried out when zero and span calibrations are set. In this menu you can set when and how frequent the auto calibration is performed. You also enable or disable the auto calibration feature here.
Infrared Gas Analyzer Operation 5. In the “Setting of Auto Calibration” screen that appears, point the cursor to any item you want to set by pressing the UP or DOWN key. Press the ENT key. 6. In the “Auto Calibration 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. To change the setting, use the SIDE key to move the cursor to the right. 7. After changing the setting, press the ENT key to accept the change.
Operation Model 7600 To set the flow time: 1. Place the cursor next to “Flow Time,” then press the ENT key. 2. On the flow time setting screen that appears, use the UP and DOWN keys to move the cursor to the gas whose settings you want to change, then press ENT. 3. The highlighted value can be changed. Change the value by pressing the UP or DOWN key, and then move the cursor to the right by pressing the SIDE key. 4. After changing the value, press the ENT key. 5.
Infrared Gas Analyzer Operation Any operation other than “Stop Auto Calibration” (see Section 3.5.4.5) is not permitted during auto calibration. “Stop Auto Calibration” cannot be performed when the key lock is ON. To cancel auto calibration, set the key lock to OFF and then execute “Stop Auto Calibration”. Auto Calibration Example Start Time SUN 12:00 Cycle 1 day Flow Time Zero 350 sec Ch1 Span 350 sec Ch1 Span 350 sec Ch1 Span 350 sec Ch1 Span 300 sec Ch1 Span 300 sec EX.
Operation Model 7600 When a channel enabled for auto calibration is in the calibration mode, a message indicating ZERO cal. or SPAN cal. will appear on the measurement screen. For example, if channels 1 and 2 have the auto calibration setting enabled, when the calibration event takes place, both channels 1 and 2 will indicate ZERO cal. when the zero calibration is being performed. Zero calibrations are performed first and all enabled channels will zero simultaneously.
Infrared Gas Analyzer Operation 3.5.4.5.1 MANUAL EXECUTION OF AUTO CALIBRATION To perform the auto calibration cycle manually: 1. From the measurement mode, press the MODE key to display the user mode. 2. Point the cursor to “Setting of Auto Calibration” by pressing the UP or DOWN key and press the ENT key. 3. In the “Setting of Auto Calibration” item selection screen that appears, point the cursor to “Auto Calibration Run” by pressing the UP or DOWN keys. Press the ENT key. 4.
Operation Model 7600 5. From the measurement mode, press the MODE key to display the user mode. 6. Point the cursor to “Setting of Auto Calibration” by pressing the UP or DOWN key and press the ENT key. 7. In the “Setting of Auto Calibration” item selection screen that appears, point the cursor to “Auto Calibration Run” by pressing the UP or DOWN keys. Press the ENT key. 8. “Stop” is highlighted, displaying a message to confirm the stop of auto calibration.
Infrared Gas Analyzer Operation 3.5.5 Setting of Auto Zero Calibration 3.5.5.1 AUTO ZERO CALIBRATION Auto zero calibration is automatically carried out when the zero calibration is set. Components for which a calibration is to be made are determined by setting of auto calibration component in Section 3.5.3. Similar to the menu choices and operation of the auto calibration, in this menu you can set when and how frequent the auto zero calibration is performed.
Operation Model 7600 3. In the “Setting of Auto Zero Calibration” screen that appears, point the cursor to any item you want to set by pressing the UP or DOWN key. Press the ENT key. 4. In the “Auto Zero Calibration 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. To change the setting, use the SIDE key to move the cursor to the right. 5. After changing the setting, press the ENT key to accept the change.
Infrared Gas Analyzer Operation Figure 3-8: Example Auto Zero Calibration Note: When an auto zero calibration starts, the measurement screen automatically appears. Any operation other than “Stop Auto Zero Calibration” (see Section 3.5.4.5 is not permitted during auto calibration. “Stop Auto Zero Calibration” cannot be performed when the key lock is ON. To cancel auto zero calibration, set the key lock to OFF and then execute “Stop Auto zero Calibration”.
Operation Model 7600 3.5.5.2 FORCED RUN/STOP OF AUTO ZERO CALIBRATION Like the auto calibration, the auto zero calibration can be performed manually or forcibly stopped while the calibration is performed. 3.5.5.2.1 MANUAL EXECUTION OF AUTO ZERO CALIBRATION To perform the auto calibration cycle manually: 1. From the measurement mode, press the MODE key to display the user mode. 2. Point the cursor to “Setting of Auto Zero Calibration” by pressing the UP or DOWN key and press the ENT key. 3.
Infrared Gas Analyzer Operation 3.5.5.2.2 FORCIBLY END AN AUTO ZERO CALIBRATION To abort an auto zero calibration event: 1. From the measurement mode, press the MODE key to display the user mode. 2. Point the cursor to “Setting of Auto Calibration” by pressing the UP or DOWN key and press the ENT key. 3. In the “Setting of Auto Calibration” item selection screen that appears, point the cursor to “Auto Calibration Run” by pressing the UP or DOWN keys. Press the ENT key. 4.
Operation Model 7600 Note: During auto zero calibration, the keys are inoperable other than key lock ON/OFF and “Stop Auto Zero Calibration.” When the key lock is set to ON, even the “Auto Zero Calibration Stop” is locked out. To stop “Auto Zero Calibration” forcedly, set the key lock to OFF and then execute “Auto Zero Calibration Stop” as detailed above. 3.5.6 Peak Alarm Setting The optional peak alarm is triggered whenever the CO concentration exceeds the upper limit value for a preset number of times.
Infrared Gas Analyzer Operation 3. Press the ENT key. 4. In the “Peak Alarm Setting” item selection screen that appears, point the cursor to any item you want to set by pressing the UP or DOWN key. Then press the ENT key. 5. Enter numeric values by using the UP or DOWN keys. Use the SIDE key to move the cursor to the right. Press the ENT key to save the change. To close the “Peak Alarm Setting” or cancel the mode midway, press the ESC key. A previous screen will return.
Operation Model 7600 the numerical value which upon reaching will trigger the peak alarm. 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. Setting range: Alarm value: 10 to 1000 ppm, 5 ppm step (initial value: 500 ppm) Alarm count: 1 to 99 times (initial value: 5 times) Hysteresis: 0 to 20 % of full scale (initial value: 0% of full scale).
Infrared Gas Analyzer Operation interval (1) and (2), the peak count alarm remains ON. At (2), the peak count has fallen to 4 per hour so the peak alarm is turned OFF. Like the hysteresis of the alarm setting , the hysteresis prevents possible chattering when measured gas is fluctuated near the alarm value. CAUTION: FOR 10 MINUTES AFTER THE POWER IS TURNED ON, A PEAK ALARM COUNTING IS NOT PERFORMED. Releasing peak count alarm: To release the peak count alarm, set the peak alarm to OFF.
Operation Model 7600 Reset Av. Output: Resets the average value. Response time: Sets the response time of the electrical system. Average Period: Sets the moving average time. Backlight Timer: Sets an automatic OFF of the backlight of display unit and the time until the backlight is turned OFF. Maintenance mode: Enters passwords to switch to the Maintenance mode. For the maintenance mode, see Section 3.6. To make parameter changes: 1.
Infrared Gas Analyzer Operation To close the “Setting of Auto Calibration” or cancel the mode midway, press the ESC key. A previous screen will return. Settings range: Hold setting: 0 to 100% FS Response time: 1 to 60 sec. (Initial value: 15 sec) Average period: 1 to 59 min or 1 to 4 hours (Initial value: 1 hour) Backlight Timer: 1 to 60 min (Initial value: OFF) Maintenance mode: 0000 to 9999 (Initial value: 0000) 3.5.7.
Operation Model 7600 Auto calibration Figure 3-11: Output Hold for Auto Calibration External hold Figure 3-12: Output Hold for External Hold Screen display during hold For Auto calibration and external holds, the “on Hold” message will be shown blinking on the measurement screen. In a manual calibration, the screen displays the process of calibration so the “on Hold” message is not displayed even if the output signal is held.
Infrared Gas Analyzer Operation 1. From the measurement screen, press the MODE key to enter the user mode then navigate to the Parameter Setting option. Press the ENT key to bring up the parameter setting screen. 2. Select the Output Hold option by moving the cursor to it using the UP and Down keys. Select it by pressing ENT. 3. “ON” or “OFF” is highlighted. If you desire to change the state, press the UP or DOWN key to toggle between ON and OFF. Press the ENT key to select the desired state. 4.
Operation Model 7600 5. On the parameter hold screen that appears, move the cursor next to the channel you want to make the setting by pressing the UP or DOWN key, and then press ENT. 6. The value is highlighted, indicating that the value can be changed. Change the numerical value by pressing the UP or DOWN key, and then move the cursor to the right by pressing the SIDE key. 7. After the value is changed, press the ENT key to save. 8. Press the ESC key to return to the parameter setting screen.
Infrared Gas Analyzer Operation perform a reset, the contacts must close for at least 1.5 seconds. See Figure 3-13. Resetting occurs as the contacts reopen. Figure 3-13: Average Value Reset 3.5.7.3 RESPONSE TIME The response time of the electrical system can be changed. Individual settings are available for each component. Note: Response time does not provide exact seconds for the setting time, but rather it is a guide to the overall response. 3.5.7.
Operation Model 7600 To modify the average period: 1. Choose the channel or channels you want to modify. You can set an average time from 1 to 59 minutes in 1-minute steps or 1 to 4 hours in 1-hour steps. 2. The UP and DOWN keys will increment or decrement the numerical values while the SIDE key will move the cursor to the right to the next digit. Press ENT when the desired value is displayed. Changing this parameter resets the average value of O2 correction and O2 average value.
Infrared Gas Analyzer Operation pressing any key will turn the backlight back ON for the specified duration. When ON is selected, the time until auto OFF is displayed. To change the backlight automatic shut off time: 1. Select Parameter Setting from the user screen. 2. With the UP or DOWN key, select Backlight Timer. and press ENT. 3. If the timer is not set to ON, change its state by pressing the ENT key when OFF is highlighted. 4.
Operation Model 7600 2. Select Parameter Setting from the user screen. 3. With the UP or DOWN key, select Maintenance Mode and press ENT. 3.6 Maintenance Mode This mode is used for checking sensor input values, error log file display, or setting of passwords, etc. A password is required to enter this mode. To get to the maintenance mode screen, select Maintenance Mode from the Parameter Setting menu. See Section 3.5.7 Parameter Setting.” This brings up a screen for entering the password.
Infrared Gas Analyzer Operation 7. Additional Parameters a. Password Set b. O2 Reference Value c. Limit d. MODBUS Communication Station No. e. Range Setting 8. Factory Mode In the maintenance mode screen, point the cursor to the item you want to set by pressing the UP or DOWN key and press the ENT key. The appropriate screen will automatically display. Note: “To Factory Mode” is used for factory service engineers. Do not use this mode. 3.6.
Operation Model 7600 CO M: CO sensor input value CO C: CO interference compensation sensor input value Temperature: temperature sensor input value O2: O2 sensor input value 3.6.2 Error Log This screen gives the error history for the last fourteen logged errors. It also shows the date and time of occurrence (year, month day, hour, minute) and the channel the error occurred on. For error number, date and time of occurrence, channel and other details of error, refer to Section 4.6 Error Messages.
Infrared Gas Analyzer Operation Z1: Zero calibration (Z) of Range 1 S1: Span calibration (S) of Range 1 M: Value of measuring detector at the time of calibration C: Value of the interference compensation detector at the time of calibration Con: Concentration value displayed before calibration 3.6.4 Optical Adjustment CAUTION: IF THE OPTICAL ADJUSTMENT IS MADE INCORRECTLY, ANALYSIS MAY BE ADVERSELY AFFECTED. CARRY OUT THE OPERATION WITH UTMOST ATTENTION. For details of this item, refer to Section4.
Operation Model 7600 3.6.5 Moisture Interference Adjustment This item is described in Section 4.5 Moisture Interference Adjustment. For the values listed in the middle column of the screen, the moisture interference for each component is already offset. The values in the right column are the interference compensation coefficients used. To change the coefficient: 1. Move the cursor to a desired channel by pressing the UP or DOWN key, and then press the ENT key.
Infrared Gas Analyzer Operation 1. From the output adjustment screen which accessible from the maintenance mode menu, move the cursor with the UP or DOWN key to the output (OUT No. and zero/ span) to be adjusted, and then press the ENT key. 2. The selected value is highlighted. Adjust the value using the UP or DOWN key while watching the output on the digital multi-meter. Press the SIDE key to select the next digit. 3. On completion of the adjustment, press the ENT key. 3.6.
Operation Model 7600 • Station No.: • Range setting: Moves to the screen on which measuring range is changed. Set the station No. for MODBUS communication. Settable in the range from 00 to 32. To adjust or make changes to these parameters: 1. Press the UP or DOWN key to move the cursor to the item whose setting is to be changed. 2. The values for password, oxygen correction, limit, and station no. are highlighted. 3. Press the UP or DOWN key to change the value and then press the ENT key.
Infrared Gas Analyzer Operation 3. Another screen appears which displays the current MIN and MAX ranges established for that component. To change the existing range move the cursor to the range you want to modify using the UP or DOWN key, and then press the ENT key. Note: The value for range 1 and range 2 must fall within or be equal to the MIN the MAX range and range 1 must be less than range 2. The number of ranges (Range num.) is 1 or 2. 4. Press the UP or DOWN key to change the value.
Operation Model 7600 3.7 Calibration 3.7.1 Zero Calibration The zero calibration is used for zero point adjustment. A suitable zero calibration gas is described in Section 2.5.5 Preparation of Calibration Gas. To zero calibrate the analyzer: 1. Press the ZERO key on the Measurement screen to display the Manual Zero Calibration screen. 2. Select the channel to be calibrated by pressing the UP or DOWN key. After selection, press the ENT key, and zero gas will be supplied.
Infrared Gas Analyzer Operation To close the “Zero Calibration” screen or cancel this mode midway, press the ESC key. A previous screen will return. 3.7.2 Span Calibration Span calibration is used to perform a span point adjustment. It requires a span gas with a known concentration, preferably 90% or more of the range value of the component being calibrated. For oxygen, when measuring with the built-in O2 use a standard gas containing 90% or more of the range value.
Operation Model 7600 To close "Span Calibration" To close the “Span Calibration” screen or cancel this mode midway, press the ESC key. A previous screen will return.
Infrared Gas Analyzer Maintenance Maintenance 4.1 Routine Maintenance Aside from normal cleaning of the instrument and making sure connections are tight and secure, the following maintenance items should be carried out on a daily basis. 1. Zero and Span Calibration: Perform a zero calibration. For the calibration procedures, refer to Section 3.7.1 Zero Calibration. Then, perform span calibration. For the calibration procedures, refer to Section 3.7.2 Span Calibration. 2.
Maintenance Item to be checked Model 7600 Phenomena Cause Remedy (2) Air is (2) Find cause absorbed of leak and midway in the repair. sampling pipe. Purge gas flow is included when purge gas in sampling gas flow rate. Standard flow is beyond the specified flow rate of 0.5 L/min, 0.3 to 0.7 L/min. Adjust using needle valve on flowmeter. Zero point of gas It is deflected. analyzer Adjust. Span point of gas analyzer Adjust. It is deflected. 4.3 Analyzer Maintenance 4.3.
Infrared Gas Analyzer Maintenance 6. For cleaning the window and inside surface of the cell, first eliminate coarse dust using a soft brush and then wipe with a soft rag. CAUTION: THE WINDOW IS EASILY SCRATCHED. USE EXTREME CARE WHEN PERFORMING THIS OPERATION SO AS NOT TO DAMAGE IT.
Maintenance Model 7600 Figure 4-3: Sample Cell Teledyne Analytical Instruments 96
Infrared Gas Analyzer Maintenance Figure 4-4: IR Window Assembly Note: If the window or the cell interior is very dirty, gently wipe it using a soft cloth moistened with absolute alcohol. A slightly corroded infrared transmission window/sample cell can be remedied by gentle rubbing with chromium oxide powder on a cleani cloth but if excessively corroded, it must be replaced. Do not use excessive force when cleaning the window. Reinstall the cell after cleaning.
Maintenance Model 7600 Figure 4-5: Detector Secure Nut 5. Using the furnished cell mounting tool, turn the window fixture to the left and remove it from the cell. See Figure 4-6. 6. For cleaning the infrared transmission window and cell inside surface, first eliminate coarse dust using a soft brush and then wipe clean with a soft rag. CAUTION: THE WINDOW IS EASILY SCRATCHED. USE EXTREME CARE WHEN PERFORMING THIS OPERATION SO AS NOT TO DAMAGE IT. 7.
Infrared Gas Analyzer Maintenance Figure 4-6: Cell Block Assembly 4.4 Optical Zero Adjustment If the following operation is not performed correctly, subsequent analysis may adversely be affected. This operation should be performed by a trained technician or the unit sent back to the factory for service. The following adjustment is performed at reassembly after removing and cleaning the sample cell. 1. Remove the top cover. 2.
Maintenance Model 7600 introduced directly to the inlet of analyzer unit through the gas cylinder. 3. Proceed to an optical adjustment as described in the maintenance mode. The display on the operation panel of the main unit is illustrated in Figure 4-7. Balance adjustment is not required if the display falls within ±100. Figure 4-7: Optical Adjustment Display for Dual Optical System Option Table 4-2: Components of Optical Adjustment Screen No.
Infrared Gas Analyzer Maintenance Where: “Main” is signal input value from the main detector of each component. “Comp” is signal input value from interference compensation detector of each component. If low range exceeds the range of 0 to 10 vol %, detector signal of “comp” is not usable. In the above table, O2 is excluded from the number of components. Sensor values which are not included in measuring components should be ignored. 4.
Maintenance Model 7600 Figure 4-9: Beam Adjustment Plate 8. Move the beam adjustment plate sidewise to change the value displayed at (c) or (g). 9. Move the beam adjustment plate sidewise to change the value displayed at (d) or (h). 10. Repeat the procedures in (6) to 9) to make all the displayed values come close to 0 as possible within ±100 range. Note: Adjust the beam adjustment plate which is the nearest to the zero adjustment knob first, and sequentially. 11.
Infrared Gas Analyzer Maintenance operation should be performed by a trained technician or the unit sent back to the factory for service. Perform an adjustment if excessively (beyond ±2% FS) affected by moisture inteference. It is also necessary to adjust moisture interference compensation after making an optical balance adjustment or whenever the cell structure is opened to moist air. 1. After warm-up, select the low range and allow dry gas (N2 or air) to flow at 0.
Maintenance Model 7600 close to 0 as possible), and then press the ENT key to save the value. Alternatively, by selecting the “ALL”option and pressing the “ ENT ” key, you can zero all components at once. You can abort the process at any time by pressing the “ ESC ” key. 5. It is sometimes easier to adjust all components by selecting ALL and then perform fine adjustment for components one by one using UP and DOWN keys.
Infrared Gas Analyzer Error Display Error No.5 Error Contents Maintenance Probable Cause Amount of zero calibration • Zero is deflected much due to dirty (indication value) is over 50% of cell. full scale. • Detector is faulty. • Optical balance is out of adjustment. Error No.6 Error No.7 Span calibration is not within the • Span gas is not supplied. allowable range. • Calibrated concentration setting does not match cylinder concentration.
Maintenance Model 7600 Pressing ENT displays the error contents screen which describes the error, indicates what channel or component is affected and suggests probable causes for the error. 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, pressing the SIDE key moves to another error display. 4.6.1 Error Log File If error occurs, the history is saved in an error log file.
Infrared Gas Analyzer Maintenance Figure 4-11: The Error Log Screen If the power supply is turned OFF, the contents in the error log file will not be lost or damaged. 4.6.3 Deleting Error Hstory Press the ENT key on the above screen, and the “Error Log Clear” will be inverted. Pressing the ENT key again will clear the error history.
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Infrared Gas Analyzer Appendix Appendix A.1 SPECIFICATIONS General Specifications Standard specifications Measurable components: Max. 5 components including O2. Minimum range Maximam range NO 0 – 50ppm 0 – 5000ppm SO2 0 – 50ppm 0 – 10vol % CO2 0 – 20ppm 0 – 100vol % CO 0 – 50ppm 0 – 100vol % CH4 0 – 200ppm 0 – 100vol % O2 (built in) 0 – 5vol % 0 – 25vol % O2 (Ext. Zirconia) 0 – 5vol % 0 – 25vol % Ranges: 2 each channel, user settable between Max. and Min.
Appendix Model 7600 Analog Output: 12 points max. 4 to 20 mA DC or 0 to 1V DC, nonisolated output max.load 550Ω for 4 to 20 mA DC min.load 100kΩ for 0 to 1VDC Analog Input: 0 to 1V DC non-isolated input from externally installed Zirconia type O2 sensor. Relay Contact Output: 1a contact (250V AC/2A, resistive load) Instrument error, calibration error, range identification, auto calibration status, pump ON/OFF, peak alarm. 1c contact (250V AC/2A, resistive load selectable 6 outputs).
Infrared Gas Analyzer Appendix Operating conditions: Ambient temperature: -5°C to 45°C Ambient humidity: 90% RH max., noncondensing Storage Conditions: Ambient temperature: -20°C to 60°C Ambient humidity: 100% RH max., non-condensing Dimensions: Analyzer main unit: 177 x 483 x 600mm Input/output module: 164 x 318 x 55mm Weight: Approx.
Appendix Model 7600 are short-circuited. Indication of instantaneous values will not be held. Range switching: Range switching is available in manual, auto, and remote modes. Only preset switch method is effective. Manual: Allows range to switch by key operation. Auto: Allows range to switch from low to high range when 90%FS or more is available in the low range. Allows range to switch from high to low range when 80%FS or less is available in the low range.
Infrared Gas Analyzer Appendix will be carried out with the solenoid valve drive contacts for zero calibration and each span calibration turned on/off sequentially at the set auto calibration timing. Auto calibration cycle setting: Auto calibration cycle is set. Setting is variable within 1 to 99 hours (in increments of 1 hour) or 1 to 40 days (in increments of 1 day). Gas flow time setting: The time for flowing each calibration gas in auto calibration is set.
Appendix Model 7600 Setting is variable within 1 to 99 hours (in increments of 1 hour) or Setting is variable within 1 to 40 days (in increments of 1 day) Gas flow time setting: The timing for flowing zero gas in auto zero calibration is set. Settable 60 to 900 seconds (in increments of 1 second) Upper/lower limit alarm: Alarm contact output turns on when measurement value reach to the preset high or low limit alarm value.
Infrared Gas Analyzer Appendix A.3 Optional Functions O2 correction: Correction of measured NO, SO2 and CO gas concentrations into values at reference O2 concentration Correction formula: C = 21 - On × Cs 21 - Os C: Sample gas concentration after O2 correction Cs: Measured concentration of sample gas Os: Measured O2 concentration (Limit setting: 1 to 20% O2) On: Reference O2 concentration (value changeable by setting.
Appendix Model 7600 CO concentration peak count alarm: (added only for CO/O2 measurement) Alarm output turns on according to the pre-set concentration and count. Whenever the instantaneous value of CO exceeds the preset concentration value, count increments. If the count exceeds the preset value in one hour, the alarm contacts close.
Infrared Gas Analyzer Appendix Response time (90%): 15 sec electrical response. Within 60 seconds including replacement time of sampling gas (with 0.5L/min gas flow rate). Gas replacement time depends on the number of components,and measuring range. A.5 Standard Requirements for Sample Gas Flowrate: 0.5L / min ±0.2 L/ min Temperature: 0 to 50°C Pressure: 10 kPa (1.45 psi) or less (Gas outlet side should be open to the atmospheric air.
Appendix Model 7600 A.6 Installation Requirements • Indoor use. Select a place where the equipment does not receive direct sunshine, draft/rain or radiation from hot substances. If such a place cannot be found, a roof or cover should be prepared for protection. • Avoid a location that is subject to heavy vibration. • Select a location where atmospheric air is clean. A.
Infrared Gas Analyzer Appendix A.
Appendix Model 7600 A.
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Infrared Gas Analyzer Index Index caution sign, iv combustible gas warning, xi copyright, ii figures listing, ix instasllation checklist, 33 leak check, 33 manuals, additional, v safety information, iv serial number, iii tables listing, x technician symbol, iv warning sign, iv warranty, ii website address, v Teledyne Analytical Instruments 125
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