OPERATING INSTRUCTIONS FOR
Model 7500ZA
NDIR Infrared Gas Analyzer
P/N M7500ZA
4/09/14
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing.
Before conducting any maintenance or servicing, consult with authorized
supervisor/manager.
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NDIR Gas Analyzer
Specific Model Information
It is not recommended that this instrument be used for analysis on
any other gas or gas mixture than that specified at the time of purchase.
The analyzer is set up and calibrated at the factory for a specific
application using a known gas mixture that is representative of the
customers’ process. Using this instrument to analyze any other gas
mixture may result in interference and possible measurement error.
Consult the factory for additional information for gas analysis not
specified at the time of purchase.
Instrument Serial Number: _______________________
NO
SO2
CO2
CO
CH4
O2
Built-In
External
Measurable
Species:
Fuel Cell
ZrO2
Range 1:
Range 2:
Span Gas 1:
Span Gas 2:
Zero Gas:
Background:
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Model 7500ZA
Safety Messages
Your safety and the safety of others is very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the instructions
for details on the specific danger. These cautions warn of
specific procedures which if not followed could cause bodily
Injury and/or damage the instrument.
CAUTION: HOT SURFACE WARNING: This warning is
specific to heated components within the instrument. Failure
to heed the warning could result in serious burns to skin and
underlying tissue.
WARNING: ELECTRICAL SHOCK HAZARD: Dangerous
voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed this
warning could result in injury and/or death from
electrocution.
Technician Symbol: All operations marked with this symbol
are to be performed by qualified maintenance personnel only.
NOTE: Additional information and comments regarding a
specific component or procedure are highlighted in the form
of a note.
No
Symbol
CAUTION:
THE ANALYZER SHOULD ONLY BE USED FOR THE
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
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NDIR Gas Analyzer
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through
the installation, calibration operation and maintenance of your new
analyzer. Please read this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be peculiar to your
instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.
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Model 7500ZA
Additional Caution on Safety
To operate the analyzer properly, be sure to read “Caution on
Safety” carefully.
The descriptions listed here provide important information on safety.
Be sure to observe them at all times. These safety precautions are classified
into 3 levels: “DANGER,” “CAUTION” and “PROHIBITION”.
”
Improper handling may cause dangerous
situations that may result in death or serious
injury.
DANGER
Improper handling may cause dangerous
situations that may result in medium-level
troubles, minor injury, or property damage.
CAUTION
Items which must not be done are indicated.
PROHIBITION
Caution on installation and transport of analyzer
The unit is not of explosion-proof. Do not use it in an
DANGER
atmosphere of explosive gases. Otherwise, serious
accidents including explosion or fire may result.
For installation, observe the rule on it given in the
CAUTION
instruction manual, and select a place where the
weight of analyzer can be supported. Installation in
an inadequate place may cause turnover or falling,
resulting in injury.
Be sure to wear protective gloves when lifting the
analyzer. Lifting it with bare hands may result in
injury.
Be sure to fix the cover before transporting the
analyzer. Transportation in unstable state may result
in injury.
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NDIR Gas Analyzer
The gas analyzer is heavy. To transport the
analyzer, please use a hand cart or equivalent. Avoid
carrying analyzer by hand as much as possible.
Doing so may cause injury.
Take care not to let cable chips and other foreign
objects enter the unit during installation work.
Otherwise, fire, failure, or malfunction may result.
Caution on piping
Be sure to observe the following
precautions while installing piping. Improper
piping may result in gas leakage.
DANGER
If the leaking gas contains a toxic
component, serious accidents may result. If
it contains combustible gases, explosion or
fire may result.
Connect pipes correctly referring to the
instruction manual.
Discharge the exhaust gas outdoors to
prevent it from remaining within the
sampling device or indoors.
Relieve the exhaust gas from the analyzer to
the atmospheric pressure to prevent buildup
of undesirable pressure to the analyzer.
Otherwise, piping within the analyzer may be
disconnected, resulting in gas leakage.
Use pipes and pressure reducing valves to
which no oil/grease is attached to the
piping. Otherwise, fire may result.
Caution on wiring
Be sure to turn off the power before
installing wiring. Otherwise, electric shock
may result.
DANGER
Be sure to perform protective earth ground
connection. Otherwise, electric shock or
failure may result.
Select a proper wiring material that satisfies
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Model 7500ZA
the ratings of the instrument. Otherwise,
electric shock or fire may result.
Be sure to connect a power supply of
correct rating. Otherwise, fire may result.
Caution on use
Be sure to read the instruction manual for
reference gases before handling reference gases
such as calibration gas to use them properly.
DANGER
CAUTION
Leaving the analyzer unused for a long time or
restarting it after long-term suspension requires
procedures different from normal operation or
suspension procedures. Be sure to follow the
instructions in each instruction manual.
Otherwise, intended performance may not be
achieved. Also, accidents or injury may result.
Do not operate the analyzer for a long time with
its cover left open. Otherwise, dust, foreign
matter, etc. may contaminate the internal walls,
thereby causing faults.
Do not touch the input/output terminals with
metal or finger. Otherwise, electric shock or
injury may result.
PROHIBITION
Do not smoke or use flames near the analyzer.
Otherwise, fire may result.
Do not allow water to enter the analyzer.
Otherwise, electric shock or internal fire may result.
Caution on maintenance and check
Before performing work with the cover of the
analyzer open for maintenance and check, be sure
to purge completely not only within the analyzer but
also measuring gas lines using nitrogen or air.
Otherwise, poisoning, fire, or explosion may result
due to gas leakage.
DANGER
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NDIR Gas Analyzer
Be sure to observe the following to perform work
safely, avoiding electric shock or injury.
CAUTION
Remove the watch and other metallic objects before
work.
Do not touch the instrument with wet hands.
If the fuse is blown, eliminate the cause and replace
it with the one of the same capacity and type.
Otherwise, electric shock or accidents may result.
Do not use replacement parts other than those
specified by the manufacturer. Otherwise, intended
performance may not be achieved and accidents or
failures may result.
Dispose replacement parts such as maintenance
parts as incombustibles according to the local waste
disposal regulations.
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Model 7500ZA
Table of Contents
Specific Model Information ......................................................... iii
Safety Messages .......................................................................... iv
Additional Caution on Safety ...................................................... vi
List of Figures ............................................................................ xiv
List of Tables............................................................................... xv
Introduction ................................................................................... 1
1.1 Overview
1
2
1.2 Typical Applications
Items included with the Analyzer................................................. 3
2.1 Confirmation of delivered items
2.2 Name and Description of Analyzer
3
4
Installation ..................................................................................... 7
3.1 Installation Conditions
8
8
3.2 Installation
3.2.1 Installation of Analyzer Main Frame
3.3 Piping
8
9
3.4 Sampling
12
12
12
12
13
13
14
15
3.4.1 Sample Gas Conditioning
3.4.2 Sample Gas Flow
3.4.3 Preparation of Standard Gas
3.4.4 Internal Purging of the Instrument Housing
3.4.5 Pressure at Sample Outlet
3.4.6 Example Configuration of Sample System
3.5 Electrical Connections
Operation ..................................................................................... 25
4.1 Preparation for operation
25
25
4.2 Warm-up Operation and Normal Operation
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NDIR Gas Analyzer
Display And Operation Panels ...................................................27
5.1 Front Panel Description
27
29
30
34
5.2 Overview of Display and Operation Panels
5.3 Outline of Display Screen
5.4 Basic Operation
Settings and Calibration .............................................................35
6.1 Range Switch
6.1.1 Setting the Range Switch Mode
35
35
36
36
37
37
38
40
6.1.2 Manual Range Mode
6.1.3 Range Identification Contacts
6.2 Calibration Setting
6.2.1 Setting the Span Gas Concentration
6.2.2 Manual Zero Calibration
6.2.3 Setting the Calibration Range
6.2.4 Setting the Component/Range for Auto Calibration 42
6.3 Alarm setting
44
44
46
47
49
49
52
52
53
55
55
57
58
58
60
68
68
6.3.1 Setting Alarm Parameters
6.3.2 Hysteresis Setting
6.3.3 Peak Alarm Setting
6.4 Setting Up the Auto Calibration
6.4.1 Auto Calibration
6.4.2 Forced Run/Stop Of Auto Calibration
6.4.2.1 Execution of auto calibration (only once)
6.4.2.2 Forced stop of auto calibration
6.5 Setting Auto Zero Calibration
6.5.1 Auto Zero Calibration
6.5.2 Forced Run/Stop of Auto Zero Calibration
6.5.2.1 Execution of auto zero calibration (only once)
6.5.2.2 Forced stop of auto zero calibration
6.6 Parameter Setting
6.7 Maintenance Mode
6.7.1 Sensor Input Value screen
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Model 7500ZA
6.7.2 Error Log screen
68
6.7.3 Calibration Log screen
6.7.4 Output Adjustment Screen
6.7.5 Other Parameter
69
70
71
73
73
74
6.8 Calibration
6.8.1 Zero Calibration
6.8.2 Span Calibration
7. Maintenance ............................................................................ 75
7.1 Daily Check
75
76
76
78
78
79
80
82
82
84
7.2 Daily Check And Maintenance Procedures
7.3 Long Term Maintenance
7.4 Cleaning the Sample Cell
7.4.1 Sample Cell Disassembly
7.4.1.1 Pipe Cell Removal (See Fig. 7-1)
7.4.1.2 Block Cell Removal (See Fig. 7-2)
7.4.1.3 Removing the Measuring Unit
7.4.2 Cleaning the Sample Cell
7.5 Fuse Replacement
8. Error Messages ....................................................................... 85
8.1 Troubleshooting
8.2 Error Log File
86
87
9. Specifications.......................................................................... 89
9.1 General Specifications
9.1.1 Standard Specifications
9.1.2 Standard Functions
89
89
93
9.1.3 Optional Functions
94
9.1.4 Performance
98
9.1.5 EC Directive Compliance
9.1.6 Requirements for Sample Gas
9.1.7 Installation Requirements
98
99
100
9.2 Table 1 Measurable Component and Range - Availability
Check Table
101
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9.3 Code Symbols
9.4 Outline Diagram
106
109
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Model 7500ZA
List of Figures
Figure 2-1A: Model 7500ZA Front Panel......................................... 4
Figure 2-1B: Model 7500ZA Rear Panel ......................................... 5
Figure 7-1: Measuring Unit Configuration (Pipe Cell).................... 79
Figure 7-2: Measuring Unit Configuration (Block Cell) .................. 81
Figure 7-3: Measuring Unit with 2-Component Block and Pipe Cell83
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NDIR Gas Analyzer
List of Tables
Table 7.1 Maintenance and Check Table......................................76
Table 8-1: Error Messages............................................................85
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Model 7500ZA
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 contained within this
manual. It is the customer's responsibility to ensure safety
especially when combustible gases are being analyzed since
the potential of gas leaks always exist.
The customer should ensure that the principles of operating
of this equipment is well understood by the user and that the
instrument as well as any approved support equipment is
properly installed. Misuse of this product in any manner,
tampering with its components, or unauthorized substitution
of any component may adversely affect the certification and
the safety of this instrument.
Since the use of this instrument is beyond the control of
Teledyne, no responsibility by Teledyne, its affiliates, and
agents for damage or injury from misuse or neglect of this
equipment is implied or assumed.
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NDIR Gas Analyzer
Introduction
Introduction
1.1 Overview
The Model 7500ZA is designed to measure the concentration of
NO, SO2, CO2, CO and CH4 in a sample gas based on the principle that
different atomic molecules have a different absorption spectrum in the
infrared band and the intensity of absorption is determined by the
Lambert-Beer law.
When equipped with the optional O2 sensor, the Model 7500ZA is
capable of measuring up to 5 components simultaneously or up to 4
components if O2 sensor is not installed.
The Model 7500ZA is a microprocessor based analyzer with a large
LCD display, superior accuracy and a multitude of functions suitable for
applications such as:
•
•
Combustible gas emissions from boilers or incinerators
Steel gas analysis (blast furnace, steel converter, thermal
treatment furnace, sintering (pellet equipment) etc.
•
•
•
•
Coke furnace
Storage and maturity of vegetable and fruit,
Biochemistry (microbe) (fermentation)
Air pollution monitoring [incinerator, exhaust gas
desulfurization, denitration], automotive emission (excluding
tester)
•
Disaster prevention (detection of explosive gas and toxic gas,
combustion gas analysis of new building material)
•
•
Agricultural
Chemical analysis (petroleum refinery plant, petroleum
chemistry plant, gas generation plant)
•
•
Environmental analysis
Physical and chemical research
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Introduction
Model 7500ZA
1.2 Typical Applications
The Model 7500ZA is a microprocessor based analyzer with a large
LCD display, superior accuracy and a multitude of functions suitable for
a variety of applications including:
•
•
Combustible gas emissions from boilers or incinerators
Steel gas analysis (blast furnace, steel converter, thermal
treatment furnace, sintering (pellet equipment) etc.
•
•
•
•
Coke furnace
Storage and maturity of vegetable and fruit,
Biochemistry (microbe) (fermentation)
Air pollution monitoring (incinerator, exhaust gas
desulfurization, denitration)
•
•
automotive emission (excluding tester)
Disaster prevention (detection of explosive gas and toxic gas,
combustion gas analysis of new building material)
•
•
Agricultural
Chemical analysis (petroleum refinery plant, petroleum
chemistry plant, gas generation plant)
•
•
Environmental analysis
Physical and chemical research
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NDIR Gas Analyzer
Items Included with Analyzer
Items included with the Analyzer
2.1 Confirmation of delivered items
•
The following items are included with you analyzer.
Analyzer
Fuse (2pcs))
Std: IEC127-2
05x20 mm
250V/2A SB
Analog Output Connector (1)
25 pin D-sub male
M2.6x4 mm
Instruction Manual
External Input Connector (1)
(External O2/External Zirconia Sensor as
specified)
Digital Input Connector
(3 max with the no. of DIO when digital
I/O function is specified).
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Items Included with Analyzer
Model 7500ZA
RS-484 Connector
(1) (when provided with communications
function)
9 pin D-sub connector male
M2.6 x 4 mm
Ferrite Core
(1) for power cable (When terminal block
for power supply is specified)
Power Supply Cord (1) (when power input
is specified)
•
2.2 Name and Description of Analyzer
The operator interface is shown in Figure 2-1A and the various
connections to the instrument are shown in figure 2-1B.
Figure 2-1A: Model 7500ZA Front Panel
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NDIR Gas Analyzer
Operation
Figure 2-1B: Model 7500ZA Rear Panel
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Items Included with Analyzer
Model 7500ZA
[Blank page]
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NDIR Gas Analyzer
Instalation
Installation
Installation of the Model 7500ZA NDIR Analyzer includes:
Unpacking
Mounting
Gas connections
Electrical connections
Calibration
DANGER:
THIS UNIT IS NOT AN EXPLOSION-PROOF
INSTRUMENT. DO NOT USE IT IN A PLACE WITH
EXPLOSIVE GASES TO PREVENT EXPLOSION, FIRE
OR OTHER SERIOUS ACCIDENTS.
CAUTION:
ENTRUST THE INSTALLATION, MOVEMENT OR RE-
INSTALLATION TO A SPECIALIST OR THE
SUPPLIER. A POOR INSTALLATION MAY CAUSE
ACCIDENTAL TIPOVER, ELECTRIC SHOCK, FIRE,
INJURY, ETC.
•
The gas analyzer is heavy. It should be installed with utmost
care. Otherwise, it may tip over or fall, causing accident or
injury.
•
•
For lifting the gas analyzer, be sure to wear protective gloves.
Using bare hands may result in injury.
This unit should be installed in an environment conforming to
the conditions noted in the instruction manual. Otherwise,
electric shock, fire or other malfunction of the unit may occur.
•
During installation, care should be taken to keep the unit free
from entry of chips, dust, and debris. Otherwise, it may cause
fire, trouble or malfunction of the unit.
The analyzer is shipped with all the materials you need to install
and prepare the system for operation. Carefully unpack the transmitter
and inspect it for damage. Immediately report any damage to the
shipping agent.
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Installation
Model 7500ZA
3.1 Installation Conditions
To install the analyzer for optimum performance, select a location
that meets the following conditions;
1. This instrument is designed for rack mounting in a standard 19”
equipment rack.
2. Indoor use only.
3. Vibration-free.
4. Free of dust and debris and obstruction around the analyzer.
5. AC power:
Operating voltage:
Rated frequency:
100V to 240 VAC
85V to 264V AC
50/60 Hz
Power consumption: 100 VA max.
6. Operating conditions:
Ambient temperature : -5° to 45°C (max. 40°C when two optical
units are used, and the power supply is more than 200V AC)
7. Maintenance space:
When analyzer is installed by itself, adhere to the
diagram to make sure there is adequate space to
remove the cover for maintenance.
When the analyzer is installed as an unit, See
Section 3.2.1
8. A circuit breaker that meets IEC60947-1 and
IEC60947-3 specifications should be installed.
9. A breaker should be installed near the analyzer
where an operator can access it.
10. A label that clearly identifies the breaker should be visible.
11. The breaker rating should meet the analyzer rating max 2A and
conform to all necessary approvals.
3.2 Installation
3.2.1 Installation of Analyzer Main Frame
Installation methods for the analyzer main unit is shown below.
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NDIR Gas Analyzer
Instalation
•
•
The analyzer weight must be supported at the bottom of the
casing.
The analyzer should be installed in a place where ambient
temperature is within -5 to 45°C (max. 40°C when two optical
units are used, and the power supply is more than 200V AC), and
temperature fluctuation during operation is minimum.
•
Where vibration is unavoidable, protect the analyzer from
vibrating. If necessary, install rubber or other vibration absorbing
material around the case to isolate any vibration from the support
structure.
3.3 Piping
Observe the following items when making gas connections to the
rear panel:
•
Piping should be connected to the gas inlets and outlets at the
rear panel of the analyzer.
•
Use a corrosion resistant tubing comprised of Teflon, stainless
steel or polyethylene to connect the instrument to a sampling
system. Even if there is a danger of corrosion, refrain from using
rubber or soft vinyl tubing. These materials will cause inaccurate
indication due to gas absorption from the tubing.
•
Pipe connection port fittings are NPT 1/4” female thread (or 1/4”
RC). Piping should be cut as short as possible for optimum
response. About 4 mm inner diameter is recommended.
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Installation
Model 7500ZA
•
Entry of dust into the instrument may result in poor performance.
Use clean tubing and couplings.
•
Sample inlet:
Attach clean, dry sample gas to the inlet port.
Note that the calibration gases ( zero and span)
also connect to this port.
Input gas flow t should be constant within the
range of 0.5 L/min ±0.2 L/min.
Sample outlet:
Purge gas inlet:
Attach tubing for exhausting sample or calibration
gases. The exhaust line should be directed to an
appropriate safe vent depending on the nature of
the sample/calibration gas used.
Used to connect a purge gas for purging the
internal housing of the analyzer. Use dry N2 or
instrument air for purge gas. (Flow rate is 1L/min
or more. Keep dust or moisture/mist from
entering the purge line.
CAUTION:
THIS INSTRUMENT IS DESIGNED TO HANDLE
HAZARDOUS GASES. WHENEVER A FITTING IS
OPENED, USE A NEW FERRULE AND CONE TO
SECURE A GAS TIGHT SEAL. EACH FITTING MUST
BE LEAK CHECKED WHENEVER A CONNECTION
HAS BEEN OPENED OR DISTURBED IN ANY
MANNER.
The internal piping diagram for the Model 7500ZA is shown
below.
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NDIR Gas Analyzer
Instalation
Correspondence between measured components and the optical
units is as follows:
Measured
Components
Optical Bench 1
Single component
CO2/CO
Optical Bench 2
None
Single measured species:
NO, CO2, CO or CH4
Two measured species:
CO2, CO
None
Two measured species:
NO/CO, NO/SO2
NO/CO
CO/SO2
SO2/CO
SO2/CO
Three measured species:
NO/ SO2/ CO
NO
Four measured species:
NO/ SO2/ CO
NO/CO
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Installation
Model 7500ZA
3.4 Sampling
3.4.1 Sample Gas Conditioning
1. Dust from the sampling gas should be completely removed using
a filter. For the final stage filter, use a filter that removes dust
particles down to 0.3µm.
2. Dew point must be lower than the ambient temperature. If vapor
is contained in the sample, dew point should be lowered to 2°C
using a dehumidifier.
3. If SO3 mist is present in the sample gas, use a mist filter or
cooler to remove the SO3 mist. Other mists should be removed
using a mist filter or gas dryer.
4. Corrosive gases such as Cl2, F2 and HCl, if present in
considerable amounts, will shorten the life of component parts.
5. Sample gas temperature should be within 0 to 50°C. Do not flow
hot gas directly into the instrument.
3.4.2 Sample Gas Flow
Sample flow should be 0.5L/min ± 0.2L/min. Avoid any flow
fluctuation during measurement. Observe the flow reading using the
flowmeter provided as shown in the example of the sampling system
configuration (Item 3.4.6).
3.4.3 Preparation of Standard Gas
Routine calibration is required once a week using span and zero
calibration gases to keep the instrument performing optimally. Prepare a
standard gas cylinder for zero calibration and span calibration per the
table below.
Without O2
Sensor
Built-in O2
Sensor
External O2
Sensor
Zero Gas
N2
N2
Dry air
(O2 of 99.9 to 100
vol% for reverse
range O2
measurement.)
Gas with
concentration
Gas with
concentration of
Gas with
concentration of
Span gas other
than for O2
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NDIR Gas Analyzer
Instalation
Without O2
Sensor
Built-in O2
Sensor
External O2
Sensor
measurement.
of 90 to 100% on 90 to 100% on
90 to 100% on
the measuring
range.
the measuring
range
the measuring
range.
Gas with conc. of O2 gas at 1 to 2%
90 to 100% on
the measuring
Span gas for O2
measurement
range or
atmospheric air
(21% O2).
—
(O2 gas of 95 to
95.5 vol% for
reverse range O2
measurement.)
3.4.4 Internal Purging of the Instrument Housing
The internal housing does need not be purged except under the
following conditions:
1. A combustible gas component is contained in the sample gas.
2. Corrosive gas is contained in the atmospheric air at the
installation site.
3. The same gas as the sample gas component is contained in the
atmospheric air at the installation site.
In such cases, the analyzer housing should be purged with the
instrument air or dry N2.
The purge flow rate should be set to about 1L/min. The purge gas
must be free of dust and moisture.
3.4.5 Pressure at Sample Outlet
Pressure at the sample gas outlet should be atmospheric pressure.
Make sure there are no kinks or obstructions in the exhaust line.
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Installation
Model 7500ZA
3.4.6 Example Configuration of Sample System
The following illustrates a typical sample system configuration for
five component gas measurement monitoring a combustion exhaust gas
from boiler, refuse incinerator, etc.
Contact TAI for other system configurations to match your specific
application.
Name
Description
Name
Description
Gas extractor with a
heating type stainless
steel filter of standard
mesh 40µm.
Adjusts and monitors
the flow rate of the
sample gas.
(1) Gas extractor
8) Flowmeter
Removes drain, mist,
and dust.
The safety drain trap is
divided into two spaces
for positive and
Reference gas used for
calibrating zero and
span of the analyzer,
depending on the
(2) Mist filter
9) Reference gas
(3) Safety drain trap
measured gas.
negative pressure. It
monitors
and adjusts the sample
gas pressure.
10) Zirconia O2
sensor
External zirconia
oxygen sensor used for
(4) Gas aspirator
For aspiration of the
sample gas
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NDIR Gas Analyzer
Instalation
Name
Description
Name
Description
Dries the moisture in
the sample gas to a
dew point of approx.
2°C
Used for flowing the
calibration gas.
measuring the oxygen
concentration in
sample gas.
(Not used when O2
sensor is built-in.)
(5) Electronic gas
cooler
(6) Solenoid valve
(7) Membrane filter
PTFE filter used to
eliminate fine dust
particles.
Added to NOx Analyzer.
A special catalyst
material is used for
efficient conversion of
NO2 to NO
(11) NO2/NO
converter
3.5 Electrical Connections
CAUTION: To prevent electric shock or fire:
Turn off the power before wiring.
Always use a protective earth connection.
Select a proper wiring material that satisfies the
ratings of the instrument. • Be sure to connect a
power supply of correct rating.
The power terminal block and external input/output connector are
installed on the rear panel. Refer to the diagram below.
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Installation
Model 7500ZA
(1) Power Supply (standard terminal 1 to 2)
Connect the power supply to the power terminal, and connect the ground
wire to the grounding terminal (standard terminal 3). Be sure to provide
a protective earth connection. Use solderless terminals (for M4) for
connection to the terminals (power and earth). See the figure below.
For the infrared gas analyzer, install an accessory ferrite core (to
the power supply terminal stand side) on the AC power supply wiring
line. See below.
CAUTION:
AFTER WIRING IS COMPLETE, BE SURE TO
REPLACE THE PROTECTIVE COVER OVER THE
TERMINAL BLOCKS.
Note: Avoid installing this instrument near an electrical unit (high
frequency furnace or electric welder) that generates
electrical noise. If using the instrument near such a noise
generating unit is unavoidable, use a different power line.
Mount a noise suppressor such as varistor or spark
quencher to the noise
generating unit when
source of noise is due to
relays or solenoid valves.
See accompanying figure.
Mount the suppressor
near the noise source;
otherwise its effect will be
diminished.
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(2) Analog output signal: Analog output connector (A/O)
Output signal :
4 to 20 mA DC or 0 to 1 V DC (selected when
ordering) Minus lines for the insulation and signal
are common from the ground and internal circuit.
Allowable load :
4 to 20 mA DC, 550Ω or less
0 to 1 V DC, 100kΩ or more
The analog output signals of the instrument are not isolated
individually. It is recommended to isolate the signals individually to
eliminate the interference from unwanted signals or other external
interference, especially if the cable exceeds 30 meters or leads to
outdoors.
(3) O2 Sensor Input: External input connector (A/I)
Input signal:
External zirconia O2 sensor: Zirconia O2 sensor signal (Fuji ZFK7
output)
External O2 sensor:
0 to 1 VDC (DC input resistor of 1MW or
more)
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Installation
Model 7500ZA
•
•
•
Used when the external zirconia O2 sensor or the external O2
sensor is ordered. It is not required or used if the analyzer has a
built-in O2 sensor.
Connect the dedicated connector (accessory) to the output of the
external zirconia sensor or the external O2 sensor (shipped
separately).
When using an external O2 sensor, the input signal should be 0 to
1 VDC with respect to the O2 full scale of the analyzer. The O2
concentration display, output, and O2 correction can then be
performed correctly.
Note: The O2 sensor input is not isolated. TAI recommends that it
be isolated when an external O2 analyzer is installed
remote from the analyzer. The zirconia O2 sensor should
be installed at a location that is as close to the analyzer as
possible.
The figure below shows how to connect the O2 signal to the
dedicated connector (accessory).
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NDIR Gas Analyzer
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(4) Contact input/output (DIO): digital input/output connector
(DIO 1 to 3)
Contact input signal : Voltage is applied from the external 12 to 24 V
DC, max 15mA.
Photo-coupler isolation (from each DI and
ground)
Contact capacity :
C contact relay output 24V/1A AC/DC
resistive load
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Installation
Model 7500ZA
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NDIR Gas Analyzer
Instalation
•
Isolated output (from each DO and ground)
To avoid external interference, the wiring from the analog output
signal, O2 sensor input and contact input should be run separately from
that of power supply and contact output.
Note: Avoid excess noise generated by other nearby equipment,
by grounding the analyzer and using properly shielded
cables.
(5) Communication: RS-485 connector
(6) Timing of Contact Output for Calibration
1. Manual calibration: (See “Item 6.8 Calibration” if the analyzer is
equipped with the auto calibration feature).
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Installation
Model 7500ZA
2. Automatic calibration:
(See also Section 6.4: Automatic Calibration Settings)
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Instalation
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NDIR Gas Analyzer
Operation
Operation
4.1 Preparation for operation
Tube and wiring check
•
Double-check if tubes of the gas sampling and exhaust ports are
correctly connected.
•
Double-check for proper wiring.
4.2 Warm-up Operation and Normal Operation
(1) Operation Procedure
1. Turn ON the power switch on the left side when facing the front
panel of the analyzer unit. The measurement screen will appear
on the front display panel in a few seconds.
2. The instrument warm-up time is about 4 hours after which the
instrument will produce an accurate measurement.
Note: During the warm-up stage, the concentration reading may
be above the upper range limit. When this occurs, the
indication will display as a series of four dashes. However,
this is not an error.
3. During the warm up period, you can set the various instrument
parameters as described in Section 6: Setting and Calibration.
4. After the warm-up period, perform the zero/span calibration as
described in Section 6.8 Calibration.
5. After calibrating the analyzer, introduce sample gas into the
analyzer and allow the lines to purge before accepting the
measurement value.
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Installation
Model 7500ZA
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NDIR Gas Analyzer
Display and Operation Panels
Display And Operation Panels
This section describes the display unit and operation panel on the
Model 7500ZA as well as the various functions available to the user.
5.1 Front Panel Description
Display unit:
The measurement screen and the setting items are
displayed.
Operation panel: The operator interface panel is shown below.
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Display and Operation Panels
Model 7500ZA
Name
Description
Name
Description
(1) MODE key Used to switch the mode.
(5) ESC key
Used to return to the
previous screen or
cancel the setting
midway.
Used to change the selected item (by
(2) SIDE key
(6) ENT key
Used for confirmation of
selected items or
values, and for
moving the cursor) and the numeral
digit.
execution of calibration.
Used to change the selected item (by
(3) UP key
(7) ZERO key Used for zero
calibration
moving the cursor) and to increase the
numeral value.
Used to change the selected item (by
moving the cursor) and to decrease
the numeral value.
(4) DOWN key
(8) SPAN key Used for span
calibration
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Display and Operation Panels
5.2 Overview of Display and Operation Panels
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Display and Operation Panels
Model 7500ZA
5.3 Outline of Display Screen
(1) Measurement mode screen (appears when the power is
turned on)
The measurement screen depends on the number of components.
The following screen configuration is shown as an example for NO,
SO2, CO2, CO and O2 (output: 12 channels).
Scroll the UP and DOWN keys to display more than 5 channels.
No.
Name
Function
(1)
Component display
Displays the component of instantaneous value, corrected
instantaneous value, corrected average value, etc.
(2)
(3)
(4)
(5)
Concentration display
Range display
Displays the measured value of concentration.
Displays the range values.
Unit display
Displays the unit with ppm or mg/m3 and vol%.
Displays the average time.
Average time display
•
•
Instantaneous value and concentration value:
The concentration display of Ch (component) where sampling
components such as “CO2”, “CO” and “O2” are displayed in the
component display, are the current concentration values of the
measured components contained in sample gas under test.
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NDIR Gas Analyzer
Display and Operation Panels
•
•
O2 corrected concentration values:
Ch components in which “cv**” is displayed as “cv CO” in the
display are calculated values derived from the following
equation. Refer to Section 6.7 Maintenance Mode - Other
Parameter.
(21 On )
(21 Os )
C
Cs
where:
On: The value of the O2 correction reference value (set by application)
Os: Oxygen concentration (Vol%)
Cs: Concentration of relevant measured component.
Note that Os does not exceed the O2 limit value set in Section
6.7 Maintenance mode - Other parameter.
C: Sample gas concentration (O2 corrected).
The corrected sampling components are NOX , SO2 and CO only.
•
O2 corrected concentration average value:
In the Ch (component) and O2 average value where “CV/AV **” is
displayed as “ CV/AV CO” in the component display, a value obtained by
averaging O2 corrected concentration value or O2 average value in a
fixed time is output every 30 seconds.
Averaging time can be changed between 1 to 59 minutes or 1 to 4
hours according to the average time settings (See Section 6.7, Parameter
Setting).
(The averaging set time is displayed as “1h”, for instance, in the
range display).
* The measurement ranges for O2 correction concentration value
and O2 correction concentration average value are the same as
the measuring components. Also, the measurement range of the
O2 average value is the same as for O2.
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Display and Operation Panels
(2) Setting/Selection Screen
Model 7500ZA
The setting/selection screen is configured as shown below:
In the status display area, the current display item is displayed.
•
•
In the message display area, messages associated with operation
are displayed.
•
In the setting item and selection item display area, items or
values to be set are displayed, as required. To navigate through
the fields, move the cursor to any item using the UP, DOWN and
SIDE keys.
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Display and Operation Panels
(3) Contents of Measured Channel (Ch)
The following table gives measurement channels and their contents
according to the symbols.
•
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Display and Operation Panels
Model 7500ZA
5.4 Basic Operation
Measurement mode
The measurement mode can display up to
5 channels in a single screen. If 5 channels or
more are to be displayed in a single screen,
press the UP or DOWN key to scroll the
channels one by one.
•
•
•
•
•
User mode displays
•
•
•
•
•
•
•
Switch Ranges
Calibration Parameters
Alarm Setting
Setting of Auto Calibration
Setting of Auto Zero Calibration
Parameter Setting.
Press the UP or DOWN key to move
the cursor to the desired function.
•
Select the function by pressing the
ENT (ENTER) key. The screen display
will change to that of the selected
function.
•
Each function is described in Chapter
6. Settings and Calibration.
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NDIR Gas Analyzer
Settings and Calibration
Settings and Calibration
6.1 Range Switch
6.1.1 Setting the Range Switch
Mode
The range switch has three modes:
•
•
•
Manual (MR)
Remote (RR)
Auto Ranging (AR)
To set the range switch mode:
1. Press the MODE key while in
measurement mode to display the
User mode screen.
2. Move the cursor to “Switch
Ranges” and press the ENT key.
3. In the “Channel Selection” screen
that appears, move the cursor by
pressing the UP or DOWN key,
and select Ch (component).
4. Then press the ENT key.
5. The selected range switch mode
will be highlighted. Press the UP
or DOWN key to select the
desired mode.
6. Then press the ENT key to
confirm the selection.
7. If “MR” is selected, the cursor
moves to “Range Switch.”
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Settings and Calibration
Model 7500ZA
6.1.2 Manual Range Mode
The analysis range for the measured component can be switched
manually as follows:
1. (1) Select “MR” as range switch mode,
and then press the ENT key.
2. Using the UP/DOWN keys, move the
cursor to the desired range selection.
The highlighted arrow indicates the
currently selectable range.
3. Select it by pressing the ENT key, and
analysis will be carried out in that
range.
Note: If “RR” or “AR” is selected as range
switch mode, this operation cannot
be performed.
The ranges for O2 correction
value,O2 correction average value,
and O2 average value are
automatically switched according to
the instantaneous value range
switch settings. (Same as for “RR”
or “AR”.)
To return to the previous screen, press the
ESC key. If ESC is pressed in the middle of
an entry or before the ENT key was pressed
to accept a setting, it will reject the current
selection and return you the display to the
previous screen without making the changes .
6.1.3 Range Identification Contacts
The contacts for range identification on each channel are closed
when Range 1 is active, and open when Range 2 is active.
If the measurement value is held by a remote contact input or
during calibration and range switch conditions are met, the contact status
will change only after the hold condition is removed.
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Settings and Calibration
6.2 Calibration Setting
This mode is used to set
calibration parameters such as span
and zero gas concentration,
calibration range, and auto
calibration settings and range.
When <User Mode> The
“Calibration Parameters” screen that
appears, the data shown at right is
illustrated.
6.2.1 Setting the Span Gas
Concentration
This screen allows you to set
the cal gas concentrations for zero
and span on each Ch used for
calibration.
1. Select < User mode > →
< Calibration parameters >
→ < Calibration value >.
The “Calibration Value
Settings” screen will appear.
2. Select the Ch you want to
change by pressing the UP or
DOWN key. Then press the
ENT key and cursor moves
to the first editable parameter
within that field.
3. Select the concentration item
you want to set (Zero or
Span) by pressing the UP,
DOWN or SIDE (>) key.
The SIDE key only functions
within the selected channel.
Press the ENT key when the
cursor is in the desired field.
The first digit of the
parameter is highlighted.
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Settings and Calibration
Model 7500ZA
4. Enter calibration gas concentration for zero and span. Use the UP
or DOWN key to increment or decrement the displayed value
one digit at a time. When the correct number is displayed for that
digit, use the SIDE key to move to the next digit and repeat the
increment/decrement process with the UP/DOWN keys.
5. After setting, save the entry by pressing the ENT key. The saved
value becomes valid with the next calibration event.
Note: Enter calibration parameters settings for each range. If a
zirconia O2 sensor is installed, select 21.00 for the Zero if
air is used for calibration, and use the concentration listed
on the cylinder for the span value.
After saving the calibration values entered, close the Calibration
Parameter screen by pressing ESC. This will return the display to the
previous screen.
Note: Pressing ESC during an entry (before pressing ENT) will
abort the entry leaving the previous entry intact.
Calibration parameter range of value
NOx, SO2, CO2, CO, CH4, external and built in O2 sensor:
Span:
1-105% of full scale
External O2 sensor:
Zero:
Span:
0-25%
0.1%-5% (vol.)
Reverse Range:
Zero:
Span:
100% (vol.)
95.25-95.00% (vol.) O2
The settings cannot be performed beyond the range limits.
6.2.2 Manual Zero Calibration
When setting the zero calibration in manual mode, you can set all
components simultaneously or one by one.
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NDIR Gas Analyzer
Settings and Calibration
1. Select < User mode > → < Calibration parameters > → < Zero
calibration >. The Zero
Calibration screen will
appears as shown.
2. Select the Ch you want
to change using the UP
or DOWN key and then
press the ENT key. The
setting content becomes
highlighted.
3. Choose whether you
want to set the zero
values all together or
individually by toggling
“at once” or “each”
with the UP or DOWN
key. Each channel that
is set to “at once” will be zero-calibrated at the same time.
4. When “each” is selected, the specific Ch (component) can be
selected and zero-calibrated individually. Press the ENT key
after making the choice and the specified calibration is
performed.
To close the Manual Zero Calibration screen, press ESC. This will
return the display to the previous screen.
Note: Pressing ESC during an entry (before pressing ENT) will
abort the entry leaving the previous entry intact.
Example:
Set each Ch (component) to either “each” or “at once” using the steps
above.
Setting “each”
Select the Ch (component) on the manual zero calibration screen and
then perform the zero calibration.
Setting “at once”
In a manual zero calibration, Ch (components) for which “at once”
are selected will simultaneously be zero-calibrated.
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Settings and Calibration
Model 7500ZA
6.2.3 Setting the Calibration Range
This mode is used to set whether the channels use one or both of
the calibration ranges.
1. From the Calibration Parameters screen, select Calibration
Range. The following screen appears.
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NDIR Gas Analyzer
Settings and Calibration
2. Select the Ch you want to change by pressing the UP or DOWN
key, then press the ENT key. The setting content is highlighted.
3. Toggle between “both” or “current” using the UP or DOWN key.
If “both” is selected, zero or span calibration will be
performed on both Range 1 and Range 2 on the selected Ch
when the calibration is performed.
If “current” is selected, zero or span calibration will be performed
only for the range displayed when calibration is performed.
4. Press the ENT key after the selection, and the specified
calibration is performed.
To close the Calibration Range Settings screen or to abort the entry
midway, press the ESC key. The previous screen will return.
Example:
Ch1
NOx
Range 1: 0 to 200 ppm
Range 2: 0 to 2000 ppm
both
Ch 2
SO2
Range 1: 0 to 200 ppm
Range 2: 0 to 2000 ppm
current
Ch1: Range 1 and Range 2 are calibrated together
Ch2: Only the currently displayed range is calibrated
Note: When “both” is selected, the same calibration gas
concentration must be used for both ranges.
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Settings and Calibration
Model 7500ZA
6.2.4 Setting the Component/Range for Auto Calibration
In this section you can select the Ch (component) and the range to
calibrate on for those components that have the auto ranging (AR)
feature enabled.
1. From the User Mode screen
select < Calibration
parameters > → < Auto
calibration component/range >.
The “Auto Calibration
Component Range” screen
appears as shown.
2. Select the Ch you want to
change by pressing the or the
key. Press the ENT key. The
cursor will be highlighted in
the selected channel.
3. Select the range you want to
use as the main calibration
range by pressing the UP or
DOWN key to move to the
desired range.
4. Press the ENT key, and
subsequent calibrations will be
performed on the selected
range when either auto
calibration or auto zero
calibration is requested.
Note regarding Auto Calibration
Component/Range Selection
The auto calibration or manual
calibration of the component for
which auto ranging (AR) is in effect
will be performed on the range that is
selected here. In this case, once the
calibration is started, the range is
automatically switched, and on
completion of the calibration, the
original range is resumed.
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Settings and Calibration
The range identification contact is interlocked with the range after
the switch. However, if the hold setting is set to “ON,” the contact status
before calibration is maintained.
5. Press the SIDE key in the state described in (3), and the
highlight is toggled between “enable” and “disable” auto
calibration.
6. Select “enable” of “disable” by pressing the UP or DOWN key.
7. Then press the ENT key to save your selection.
To close the Auto Calibration Settings screen or to abort the entry
midway, press the ESC key. The previous screen will return.
Auto Calibration Operation
Auto calibration is performed under the following rules.
1. Zero calibration is performed at the same time, for the Ch
(component) in which “enable” is selected at the time of auto
calibration and auto zero calibration.
2. Span calibration is performed in the order from smallest Ch No.,
for the Ch (component) that have “enable” set in the Auto
Calibrations Setting screen.
Note: ZERO calibrations for components which have been set to
“enable” in the Auto Calibration Settings screen (above)
are performed in batch irrespective of the description in
“6.2.2 Manual Zero Calibration.”
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Settings and Calibration
Model 7500ZA
6.3 Alarm setting
6.3.1 Setting Alarm Parameters
The High/Low limit concentration alarms
are user adjustable. Five different alarm contact
outputs can be used. The setting range is 0-
100% full scale for each range.
To change the alarm setting, set the alarm
ON/OFF setting to OFF, and then change the
value.
1. Enter the “Alarm Setting” screen from
the user mode. The screen shown on the
right will display. Use the UP or DOWN
keys to move the cursor to the desired
Alarm No. or hysteresis. Then press
ENT.
2. After selecting the alarm the screen
shown at the right will display. Use the
UP or DOWN keys until the cursor is
aligned with the desired item and press
ENT.
Note: Set the values so that H-limit value >
L-limit value and that (H-limit value -
L-limit value) > hysteresis.
In the case where reverse range O2
measurements are used set the
values so that L-limit value > H-limit
value.
When “0” is set, the alarm is inactive.
3. After setting the parameters, press ENT
to save the settings.
To close the Alarm Settings screen or to
abort the entry midway, press the ESC key. The
previous screen will return.
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Settings and Calibration
Alarm Setting Descriptions
The alarm contact number can be assigned to any channel.
Channels can also have multiple alarms assigned to them.
Channel:
Channel setting targeted for alarm.
H-Limit value:
Sets the high limit value (concentration) for
alarm.
L-Limit value:
Kind of Alarm:
Sets the low limit value (concentration) for alarm.
Select either High limit alarm, Low limit alarm,
and High limit or Low limit alarm, HH limit
alarm, and LL limit alarm.
High, HH:
Alarm contact closes when above
H-limit alarm.
Low, LL:
Alarm contact closes when below
L-limit alarm.
High or Low: Alarm contact closes when above
H-limit value or below lower limit
value.
ON/OFF:
Enables the alarm function when set to ON, or
disables it if set to OFF.
Note: The H-limit value cannot be set below the L-limit value, and
the L-limit value cannot be set above the H-limit value.
If it is desired to set the H-limit value below the L-limit
value already stored in the memory, reduce the L-limit
value beforehand, and vice versa for setting the low limiot
above the high limit.
Note: After turning on power, the alarm logic trigger is inactive for
10 minutes.
When an H-limit alarm occurs, the
“H-alarm” message displays in the relevant
component field. Other alarm displays are:
L-alarm for Low-limit alarm, HH-
alarm for high limit alarm, HH-alarm for
high-high alarm, and LL-alarm for low-
low alarm.
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Settings and Calibration
Model 7500ZA
6.3.2 Hysteresis Setting
The alarm hysteresis can be set or changed to prevent chattering of
an alarm output about its alarm set point. To set or change the alarm
hysteresis:
1. Navigate to the “Alarm Setting” screen and
then move the cursor to “Hysteresis” using
the UP or DOWN key. Then press ENT to
display the screen shown at the right.
2. From this screen enter the hysteresis values
by increasing or decreasing the value using
the UP or DOWN keys. Move the cursor to
the next digit with the SIDE key. When the
value is correct, press ENT to save.
The hysteresis can be set from 0-20% full
scale on the selected range.
To close the Hysteresis Settings screen or to
abort the entry midway, press the ESC key. The
previous screen will return.
Note: The hysteresis is common to all alarms (components).
Hysteresis in peak alarm setting described in Item 6.3.3
should be set separately.
Hysteresis (In case of upper limit alarm)
An alarm output is turned ON if the measured value exceeds the
upper limit value as shown below. Once the alarm output has been
turned ON, it is not turned OFF until the indication falls below the
hysteresis width from the upper limit value.
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6.3.3 Peak Alarm Setting
When the peak number of times CO concentration exceeds the upper
limit value during measurement reaches the set number, an alarm is provided.
The peak alarm and this setting screen
appear only when an option is added.
1. Press the MODE key while in the
Measurement mode, and the User
mode appears.
2. Using the UP or DOWN keys move
the cursor to “Setting of Peak
Alarm”. Then press ENT.
3. In the “Peak Alarm Setting”
selection screen that appears, point
the cursor to any item you want to set
using the UP or DOWN key. Then
press ENT.
4. Enter numeric values using the UP or
DOWN keys. The setting will be
saved after pressing the ENT key.
Description of Setting Items
Peak Alarm : ON/OFF of peak alarm
Alarm Value : If measuring value exceeds
the set alarm value, a peak
counter increments by 1
time.
Alarm Count : When the alarm value is
exceeded this many times per
hour, the peak count alarm is
activated (closed).
Hysteresis :
To prevent possible
chattering when the
measuring value may exceed
the set peak concentration by
only 1 time, the peak count
has an allowance in the
hysteresis width.
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Setting Range
Alarm value: 10-1000 ppm
Alarm count: 1- 99 times/hr
Hysteresis : 0-20 % FS
→ 5 ppm step (initial value: 500 ppm)
→ (initial value: 5 times)
→ (initial value: 0% of full scale)
[% FS] represents the percentage with the CO range regarded as
100%.
Action of Peak Alarm
If the CO concentration exceeds the alarm value, counting will
begin. If the number of peaks is over the set times per hour, a peak alarm
contact output becomes closed (ON). If it is less than the set times per
hour, it is open (OFF). Since 5 peaks /hour is exceeded in the cross-
hatched area marked (1) in the above graph, the peak count alarm is
turned ON. Since peaks of more than 5 per hour occur at the interval
between (1) and (2), the peak count alarm remains ON whereas at (2),
peaks are reduced to 4 per hour, and the alarm is turned OFF.
Like the hysteresis of the alarm setting, the hysteresis prevents
possible chattering when a measured gas fluctuates about the alarm
value.
* The peak alarm counting logic is not performed during the first 10
minutes after the power is turned ON.
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Releasing peak count alarm
To release the peak count alarm, set the peak alarm to OFF.
Turning on the peak alarm initiates the count at 0.
6.4 Setting Up the Auto Calibration
6.4.1 Auto Calibration
Auto calibration is automatically carried out at the time when zero
span calibration are set. Before changing
the setting of auto calibration, set the
auto calibration function to OFF.
1. Enter the “Setting of Auto
Calibration” screen from the user
mode, and the display shown at
right appears. Use the UP and
DOWN keys to align the cursor
with the desired item and then
press the ENT key.
2. In the “Set Auto Cal” screen that
appears, enter the values for the
various settings. To make a value
entry or change, use the UP and
DOWN keys to increment or
decrement the value on digit at a
time. Use the SIDE key to move
the cursor to the next digit.
When all the settings are correct,
press the ENT key to save them.
Subsequent auto calibrations will
use the saved settings.
Description of Auto Cal Settings
•
Start Time : Setting for the first
calibration event (day of the
week, hour, minute)
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•
•
Cycle : The period between the start time of one calibration and
the next (unit: hour/day)
Flow Time : The time required for purging with calibration gas.
Time required for replacement of sample gas after the calibration
is completed (Set by calibration gas. See the next page.)
•
ON/OFF: Turns the auto calibration feature ON or OFF.
To close the Auto Cal Settings screen or to abort the entry midway,
press the ESC key. The previous screen will return.
Gas flow time setting
1. With the cursor on “Flow Time”, press the ENT key to bring up
the Flow Time screen.
2. Move the cursor to the gas
you want to change by
pressing the UP or DOWN
key, and then press ENT.
3. The highlighted value can be
changed by pressing UP or
DOWN key, and then using
the SIDE key move the
cursor to the right to alter the
next digit.
4. After changing the value,
press the ENT key to save
the setting.
5. Press the ENT key again to
return to the Auto Cal Setting screen.
Note: Only the channels used are displayed on this screen. The
Ex. time sets the output signal hold extension time that
follows the completion of calibration. It is valid only when
the hold setting is set to “ON.” The Ex. time set here is also
the hold extension time used in a manual calibration.
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Auto calibration status contact output is closed during auto
calibration (NO side), and is open in other cases.
Example:
Start Time
Cycle
Sun
1
12:00
day
Flow Time
Zero
350 sec
350 sec
CH 1 Span
CH 2 Span
350 sec
350 sec
CH 3 Span
CH 4 Span
CH 5 Span
300 sec
300 sec
300 sec
Ex. Time
ON
ON/OFF
Thus, with the above settings:
Setting Range:
Cycle:
1-99 hours or 1-40 days (default value—7days)
60-90 sec (default value—300 sec)
Flow Time:
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Caution: When an auto calibration starts, the measurement
screen appears automatically.
Any operation other than “Stop Auto Calibration”
(see Item 6.4.2) is not permitted during auto
calibration. “Stop Auto Calibration” cannot be
performed with the key lock to ON.
To force a cancel of the auto calibration, set the
key lock to OFF and then execute “Stop Auto
Calibration”.
Turn power OFF and then ON again at the time set
as the next start time in auto calibration, and then
repeat it in the set cycle.
Remote Start
Whether the auto calibration is set at ON or OFF, an auto
calibration is always available via a remote start input.
6.4.2 Forced Run/Stop Of Auto Calibration
Auto calibration can be performed just once or forcibly stopped
while the calibration is in process
6.4.2.1 EXECUTION OF AUTO
CALIBRATION (ONLY ONCE)
1. In the “Set Auto Cal
screen, move the cursor
to “Auto Cal Run” using
the UP or DOWN key,
then press ENT.
2. “Run” is highlighted,
displaying a message to
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confirm the execution of auto calibration. Press the ENT key to
execute the auto calibration or press the ESC key to cancel.
6.4.2.2 FORCED STOP OF AUTO
CALIBRATION
This mode is used to stop the
auto calibration forcibly.
1. In the “Set Auto Cal” screens
point the cursor to “Auto
Calibration Stop” using the
“UP or DOWN key. Then
press ENT. (“Auto Calibration
Stop” appears when this
screen is selected while auto
calibration is performed.)
2. “Stop” is highlighted, displaying a
message to confirm the stop of auto
calibration. Press the ENT key to stop the
auto calibration or press the ESC key to
cancel the stop auto cal action.
“Auto Calibration” screen
Example
When Ch 1 and Ch2 are enabled for auto
calibration (see Section 6.2.4):
•
Zero calibration
A message, “Zero cal.” blinks at Ch1 and
Ch2.
•
•
Ch1 span calibration
A message, “Span cal.” blinks at Ch1.
Ch2 span calibration
A message, “Span cal.” blinks at Ch2.
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Caution: During an auto calibration, all key operations are
not permitted other than key lock ON/OFF and
“Auto Calibration Stop.”
When the key lock is ON, the “Auto Calibration
Stop” is locked out as well.
To stop “Auto Calibration” forcedly, set the key
lock to OFF and then execute “Auto Calibration
Stop.”
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6.5 Setting Auto Zero Calibration
6.5.1 Auto Zero Calibration
Zero calibration can be performed automatically using the settings
applied in this screen.
The channels for which auto calibration is to be performed are
determined by the auto calibration settings described in Section 6.2.4.
Before changing any of the auto zero calibration settings, set the
auto zero calibration to OFF.
1. Enter the “Set Auto Zero Cal”
screen from the user mode. The
screen shown at the right will
appear.
2. Use the UP or Down keys to
move the cursor to the desired
item and press the ENT key. In
the “Set Auto Zero” screen that
appears, set the desired
parameter using use the UP or
DOWN key to
increment/decrement the value
and the SIDE key to move to the
next digit or field.
After the setting is correct, press
the ENT key to save the settings.
The next auto zero calibration
will use the entered values.
Description of Auto Zero Settings
•
Start Time : Setting for the first
calibration event (day of the
week, hour, minute)
•
Cycle : The period between the
start time of one calibration and
the next (unit: hour/day)
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•
•
Flow Time: The time required for purging with calibration gas.
Time required for replacement of sample gas after the calibration
is completed (Set by calibration gas. See the next page.)
ON/OFF: Turns the auto calibration feature ON or OFF.
To close the Auto Zero Settings screen or to abort the entry
midway, press the ESC key. The previous screen will return.
Auto Calibration Status Relay Contacts
The auto calibration status contact output is closed during auto zero
calibration (NO side), and open during normal operation.
Example
Start Time
Cycle
SUN
12
12:00
hour
sec
Flow Time
ON/OFF
300
ON
For an auto zero calibration using the above settings:
In this example, Ch1 through Ch5 are enabled, as shown in Section
6.2.4 “Setting the Component/Range for AutoCalibration.
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Setting the Range
Settings and Calibration
Cycle
1 to 99 hours or 1to 40 days (default: 7 days
60 to 900 sec (default: 300 sec.)
Flow Time
Caution: When an auto zero calibration starts, the
measurement screen automatically appears.
Any operation other than “Auto Zero Calibration
Stop” (see Item 6.5.2) is not permitted during auto
zero calibration. “Auto Zero Calibration Stop”
cannot be performed with the key lock set to ON.
To forcibly cancel auto zero calibration, set the
key lock to OFF and then execute “Auto Zero
Calibration Stop”.
If the auto calibration period and auto zero
calibration period overlap, the auto calibration is
retained, ignoring the auto zero calibration of that
period.
When the hold setting is set to ON, the hold time
for auto calibration contact and measurement
value output signal is extended after calibration
for gas purging.
Remote Start
A remote start input will begin a calibration event regardless of
whether the auto zero calibration is set to ON or OFF.
6.5.2 Forced Run/Stop of Auto Zero Calibration
Auto zero calibration can be performed just once, or auto zero
calibration can be forcibly stopped during calibration.
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6.5.2.1 EXECUTION OF AUTO ZERO CALIBRATION (ONLY ONCE)
1. In the “Setting of Auto Zero
Calibration” screen that
appears, point the cursor to
“Run” by pressing the UP
or DOWN key. Then press
ENT.
2. “Run” is highlighted,
displaying a message to
confirm execution of auto
zero calibration. Press the
ENT key to execute the
calibration, or the ESC key
to cancel.
6.5.2.2 FORCED STOP OF AUTO ZERO CALIBRATION
This mode is used to forcibly cancel an auto zero calibration event.
1. In the “Setting of Auto Zero
Calibration” screen that
appears, point the cursor to
“Stop” by pressing the UP
or DOWN key, then press
ENT. (“Auto Zero
Calibration Stop” appears
when the screen is selected
while auto zero calibration
is performed.)
2. “Stop” is highlighted,
displaying a message to
confirm the stop of auto
zero calibration.
Press the ENT key to stop the auto zero calibration and the ESC
key to cancel (not stopped).
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Auto Zero Calibration Screen
Example
With Ch1 and Ch2 set to enable for auto
calibration (see Section 6.2.4):
•
Zero calibration
A message, “Zero cal.” blinks at Ch1
and Ch2.
Caution: During auto zero calibration,
the only key operations allowed are key lock
ON/OFF and “Auto Zero Calibration Stop.”
When the key lock is set at ON, even the “Auto
Zero Calibration Stop” cannot be used.
To forcibly stop “auto zero calibration”, set the
key lock to OFF and then execute “Auto Zero
Calibration Stop.”
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6.6 Parameter Setting
From the Parameter Setting screen you can set or adjust various
parameters of the instrument such as time, key lock, etc. Settable items
are as follows:
Description of setting items
•
•
•
•
Current Time : Current year, month, date, day of the week, hour,
and minute setting. (The display appears in this order.)
Note: The clock backup time is 2 days. If power is turned on
after being off for 2 days or longer, the time must be set again.
Key Lock : Invalidates any key operation except canceling the
key lock.
Output Hold : Sets whether Calibration Output is held or not, and
the holding value setting.
•
•
•
Response time : Sets the response time of electrical system.
Average Period : Sets the moving average time.
Backlight Timer : Sets automatic OFF of the backlight of display
unit and its timer.
•
•
Contrast : Adjusts contrast of the LCD.
Maintenance Mode : A password protected entry screen used to
access the instrument’s maintenance mode.
* For the maintenance mode, see Section 6.7.
1. Enter the “Parameter
Setting” screen from the user
mode, and the display shown
at right appears. Use the UP
or DOWN key to move the
cursor to the desired item
and then press ENT.
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2. In the “Parameter
Setting” screen that
appears, perform the
value entry or the setting.
For the value entry or
setting change, use the
UP or DOWN key, and
the SIDE key to move
the cursor to the right.
To close the Parameter Setting
screen or to abort the entry
midway, press the ESC key. The
previous screen will return.
Setting Range
•
•
•
•
Hold setting : 0 to 100% FS
Response time : 1 - 60 sec. (default: 15 sec)
Average period : 1 - 59 min or 1 - 4 hours (default value: 1 hour)
1 - 59 minutes when the unit is set to minute and 1 - 4 hours
when is set to hour.
•
•
Backlight Timer : 1 - 60 min (default value: 5 min)
Maintenance mode : 0000 to 9999 (default value: 0000)
Output Hold
Setting an output hold to ON causes the output signal of each
channel to be held during the manual/auto calibration plus the purge
flow time (see Section 6.4, Setting of Auto Calibration). However, an
output signal can be held via an external input regardless of the Hold
ON/OFF setting.
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Manual Calibration
Auto Calibration
Remote Input
Screen Display During Holding
A “Hold ON” message will blink on the measuring screen during a
hold period.
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But during a manual calibration the screen displays the process of
calibration, therefore a “Hold ON” message will not displayed even if
the output signal is held, however the screen will display the hold
extending time.
If the calibration is cancelled after the calibration gas has been
supplied, the holding extending time will be performed in either of
manual or auto calibration operation.
You can select the hold value from the value immediately before
entering output hold. The choices are “current” or an arbitrary value
input using “setting”.
Use the procedures shown below for adjusting these settings.
1. From the “Parameter
setting” screen that
appears, select “Output
Hold”. Highlight either
“ON” or “OFF” using the
UP or DOWN key and
then press ENT to select
it and return to (1).
2. When ON/OFF is
highlighted, press the
SIDE key. Toggle
between “Current” or
“Setting” using the
UP/DOWN keys and then
press ENT when the
desired selection is
highlighted.
3. Pressing ENT when
“Current” is selected will
hold the value
immediately before the
hold was initiated and
return the highlight to (1).
Pressing the ENT key
while “Setting” is
selected will bring up the
parameter hold screen where an arbitrary hold value can be set.
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4. On the parameter hold screen that
appears, move the cursor to the Ch
(component) you want to hold using
the UP or DOWN key and then press
ENT.
5. A highlighted value indicates that it
can be changed. Adjust the
highlighted value with the UP or
DOWN key and then move the
cursor to the right to change the next
digit using the SIDE key.
6. After the value is changed, press the
ENT key.
Note: The setting is expressed as 1/1
full scale range for both
respective ranges.
When 0 to 1000 ppm is selected
as the range, and 10% FS is
selected as hold setting, the
output equivalent to 100 ppm is
held irrespective of the measured
value at that time.
7. Press the ESC key to return to the
parameter setting screen.
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Setting Description
•
The instantaneous measurement value that is displayed cannot be
held. (Output only can be held.)
Optional modbus communications “Measurement concentration”
register values are held.
•
•
If set value is selected for hold, instantaneous O2 correction
value is calculated and held based on the set value.
Range identification contact output cannot be switched even if
the range is switched during the hold.
Response time
The response time of the electrical system can be changed. Setting
is available by components.
Note: It does not provide exact
seconds for the setting
time, rather, it provides a
guide of the setting time.
The setting value can be
modified as requested
by the customer.
Average Period
This screen allows you to set an averaging period for the average
values of O2 correction and O2 average.
It enables you to set an
average time of 1 to 59 minutes
(1-minute step) or 1 to 4 hours
(1-hour step).
Changing the setting also
resets the averaging of O2
correction and O2 average value.
(Pressing the ENT key resets
averaging only for the
components whose setting were
changed.)
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Average Value Reset
This mode is used to clear all average values, i.e. O2 correction
average and O2 average, and restarts averaging. All average values are
reset simultaneously. The indication value and output value is 0 ppm,
vol% or so at the time of the reset input (based on average period
settings).
Example:
If the average period was set to 1 hour:
•
•
Sampling occurs every 30 seconds.
Every 30 seconds, the average for the last 1 hour (time setting) is
output.
•
At the instant of resetting, zero is assumed for all past values.
This means that the average value will not be correct for 1 hour
after resetting.
Backlight Timer
Automatic OFF setting of the backlight of the LCD unit is user
adjustable. When the specified time elapses during measurement screen
display, the backlight automatically switches off. Pressing any key will
turn the backlight back ON.
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On the Parameters screen, when ON is selected for the Backlight
Timer function, the time until auto OFF will also display. Press the
SIDE key when ON is
highlighted and the time setting
can be changed. Use the UP or
DOWN key to change the time
value and then press ENT to
save the value.
When OFF is selected, the
backlight always remains on
and does not automatically turn
off.
Contrast
The LCD Contrast is user
adjustable. With the contrast
function highlighted, use the UP
or DOWN keys to move the
slider representing the contrast.
When satisfied, press the ENT
key to save the setting.
Maintenance Mode
Enter the password and then press the ENT key to enter the
maintenance mode. The password can be set using the password setting
screen from Other Parameter/Password Set function while in the
maintenance mode. The next section describes in detail the functions
available in maintenance mode.
The default password is set at the factory to “0000.” You can enter
the maintenance mode with this value before changing the password in
maintenance mode to one of your choosing.
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6.7 Maintenance Mode
This mode is used to check sensor input values,
display of error log or setting of passwords, etc. This is
a password protected area. To access the maintenance
mode, enter the correct password from the Parameter
Setting/To Maintenance screen.
1. Select the Maintenance Mode from the
Parameter Setting screen to display the
Password Setting screen.
2. Enter the password, and the Maintenance Mode
item selection screen will be displayed. Point
the cursor to the item you want to set by
pressing the UP or DOWN key and then press
ENT.
Note: “To Factory Mode” is for TAI’s service
engineers only.
3. Press the ESC key to return to the Maintenance
Mode item selection screen from each screen.
6.7.1 Sensor Input Value screen
There are 5 possible inputs on the Model 7500ZA:
1. Input 1 to 4 : NDIR sensor digital value
2. Input 5 : O2 sensor digital value
6.7.2 Error Log screen
This screen displays the error history and logs the
last 14 instrument errors.
See Section 8.1 Error Message for specific
information regarding error number and its meaning.
To clear an error from the log, select Clear Error
Log and press the ENT key. The specific entry will be
removed from the list.
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6.7.3 Calibration Log screen
Calibration history can be displayed from this screen. Information
available includes sensor input value, concentration value, and the date
when zero/span calibration was performed for the last 10 calibration
events. They are logged according to component.
To clear an event, move the
cursor to Clear Calibration Log and
press the ENT key, and the
calibration log is cleared completely.
Other items appearing on the
Calibration Log screen are:
Z1 : Zero calibration (Z) of Range 1
S1 : Span calibration (S) of Range 1
Cnt : Value of measuring detector at
the time of calibration
Con : Concentration value displayed
before calibration
YDMH: Time of calibration event
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6.7.4 Output Adjustment Screen
The Analog Output Adjustment screen allows the user to adjust the
0-1 V and 4-20 mA output signal.
Connect a digital multi meter to the specific output terminal
requiring adjustment and adjust the value so that 4 mA or 0 V is output
at zero concentration and 20mA or 1V is output at
full scale or span.
1. Move the cursor using the UP or DOWN
key to the output (OUT No. and zero/span)
to be adjusted, and then press the ENT key.
The selected value is highlighted.
2. Adjust the value, while watching the
output, using the UP or DOWN key. When
the correct value appears, press the SIDE
key to select the next digit.
3. On completion of the adjustment, press
ENT to save the adjustment.
Caution: Be sure to perform zero / span
calibration when the range
setting is changed. Otherwise,
the measurement value may not
be output properly.
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6.7.5 Other Parameter
The Other Parameter screen hosts 5 user settable functions:
Password Setting
•
•
•
•
•
O2 Reference Value
O2 Reference Value Limit
Station Number
Instrument Range Setting
To change any of these items:
•
Press the UP or DOWN
key to move the cursor to
the item whose setting is to
be changed.
•
•
The values for password,
oxygen correction, limit, and station No. are highlighted.
Press the UP or DOWN key to change the value. Use the SIDE
key to move to the next digit to the right. Press the ENT to save
the new value.
Password Set
The Password Set screen is used to change the password that is required
move from the parameter setting screen to the maintenance mode. An
arbitrary 4-digit number can be set to replace the default password for
this purpose.
Note: Record the password and store in a safe place. Otherwise
you cannot enter the maintenance mode.
O2 ref. Value and Limit
This function sets the oxygen concentration reference value used in
the oxygen correction calculation*. It is settable in the range from 00 to
19%. The O2 Limit can also be set from this screen. This sets the
oxygen concentration limit at the time of oxygen correction calculation.
It is settable in the range from 01 to 20%.
* Refer to the O2 correction concentration value in “5.3 Outline of
display screen” for oxygen correction calculation procedure.
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Station No.
This function allows the user to set the station No. for MODBUS
communication. It is settable in the range from 00 to 32.
Range Setting
This function brings up a screen where the user can set the
range for which concentration measurements are made. There
are two settable ranges for each component each with a
minimum and maximum value as requested at the time of
purchase. The range to be used can be selected as Range 1 or
Range 2.
To set the range:
1. Move the cursor to the item to be set using the UP or
DOWN key, and then press ENT.
2. Move the cursor to the Ch (component) whose setting is
to be changed using the UP or DOWN key, and then
press ENT.
3. Move the cursor to the item whose setting is to be
changed using the UP or DOWN key, and then press
ENT.
The value for range 1 and range 2 must fall within the
MIN and the MAX range of the instrument (including
the MIN and the MAX range), and range 1 must be less
than range 2.
4. Press the UP or DOWN key to change the value. Use
the SIDE key to move to the next digit to the right.
Press the ENT to save the new value. The measurement
unit cannot be changed.
5. The decimal point can also be changed when it is
highlighted. Use the UP or DOWN key to change the
placement of the decimal point.
6. After all changes have been entered, press the ENT key
to save.
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NDIR Gas Analyzer
Settings and Calibration
6.8 Calibration
6.8.1 Zero Calibration
This function is used for the zero
point adjustment. A proper zero gas,
suitable for the application, should be
used. Refer to section 3.4 “Sampling”.
1. From the Measurement screen,
press the ZERO key to display the
Manual Zero Calibration screen.
2. Select the Ch (component) to be
calibrated using the UP or DOWN
key and then press the ENT key,
and zero gas will be admitted to
the analyzer.
Note: For the Ch (components)
where “both” is set in the
calibration range setting (see
section 6.2.3), zero calibration
is carried out on both ranges.
3. Wait until the indication stabilizes
on the zero gas then press ENT.
The zero calibration will be carried
out on the highlighted range(s).
Note: On Ch (components) for which
“AR” is set (see Section 6.1.1
Setting Range Switch Mode),
the cursor automatically moves
to the next range selected in
“Setting of Auto Calibration
Component/Range” (6.2.4),
and calibration is carried out
on that range.
To close the Zero Calibration screen
or to abort the entry midway, press the
ESC key. The previous screen will return.
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Settings and Calibration
Model 7500ZA
6.8.2 Span Calibration
The Model 7500ZA requires periodic span calibration at or near the
full scale value on the range of interest. It requires a prepared standard
gas containing a known concentration of the measured
species. For span calibration gas on the NOX, SO2, CO2,
CO and CH4 channels, TAI recommends using a gas source
containing 90-100% of the measured species in a
background known to be compatible with the instrument.
For the oxygen channel, with units that include a built-in
O2 sensor, use a prepared standard gas with an O2 concentration
of 90 to 100% full scale on the anticipated measuring range.
If the instrument is fitted with an external zirconia
sensor, use a prepared standard of 1-2% O2.
To perform a span calibration:
1. Press the SPAN key on the Measurement screen to
display the Manual Span Calibration screen.
2. Select the channel (component) to be calibrated
using the UP or DOWN key and then press ENT.
Calibration gas will then flow to the sensor.
Note: For the Ch (components) in which “both” is set
in the calibration range setting (Refer to Section
6.2.3), span calibration is performed on both
ranges.
3. Wait until the indication is stable. After the
indication has stabilized, press ENT. Span
calibration on the selected range will be performed.
Note: On channels for which “AR” (auto ranging) is
enabled (See Section “6.1.1) the cursor
automatically moves to the range that is
enabled. See Section 6.2.4 “Setting of auto
calibration component/range”. Calibration is
then carried out on that range.
To close the Span Calibration screen or to abort the
entry midway, press the ESC key. The previous screen will
return
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NDIR Gas Analyzer
Maintenance
7. Maintenance
7.1 Daily Check
1. Zero calibration and span calibration
1. Perform zero calibration. For the calibration procedures, refer to
Section 6.8.1 Zero calibration.
2. Following the zero calibration, perform a span calibration. For
the calibration procedures, refer to Section 6.8.2 Span
calibration.
3. Zero/span calibration should be carried out once a week, or as
required.
2. Flow rate check
1. Sample and purge gas flow rates are as follows:
Sample gas flow :
Purge gas flow :
0.5L/min ± 0.2L/min
About 1L/min
2. Instrument checks and maintenance should be carried out every
day, as required.
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Maintenance
Model 7500ZA
7.2 Daily Check And Maintenance Procedures
Table 7.1 Maintenance and Check Table
7.3 Long Term Maintenance
Create a long-term maintenance component procurement plan
based on the “Gas analyzer annual inspection plan” indicated below.
Gas Analyzer Annual Inspection Plan
The recommended replacement period of components varies
depending on the installation conditions.
1. The recommended replacement period is a recommended
standard criterion and varies depending on the environment of
the field, conditions of measuring gas and other factors.
2. The recommended replacement period is not the warranty period.
It is provided as a preventative maintenance program baseline
schedule.
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NDIR Gas Analyzer
Maintenance
Installation Conditions
1. Ambient temperature: -5°C to +40°C
2. Humidity: 90%RH or less
3. Corrosive gases: None
4. No radiated heat, direct sunlight or rain/wind
5. Dust: No more than local environmental standards permit
6. Vibration: None
Sample gas conditions
1. Temperature: +60°C to +800°C
2. Pressure: -3 to +3 kPa
3. Moisture content: 30% or less
4. Dust: 0.1 g/Nm3 or less
5. Components: 0 to 500 ppm NOX, 0 to 500 ppm SO2, 0 to 2000
ppm CO, 5% to 15% CO2, 0% to 21%O2, 0 to 100 ppm HCl,
residue N2
Please consult TAI Customer Service regarding gas analyzer
maintenance service requirements.
Annual Inspection Plan Sheet
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Maintenance
Model 7500ZA
7.4 Cleaning the Sample Cell
Entry of dust or water in the sampling cell contaminates the interior
of the cell resulting in drift. If dirty or contaminated, it must be cleaned.
Check the sampling device, especially the filter, to prevent the cell from
being dust or mist contamination.
Caution: Maintenance should be performed only by
properly trained and qualified personnel.
In addition to the following steps, the user must
adhere to any local and regional regulations.
7.4.1 Sample Cell Disassembly
There are two kinds of sampling cells used in the Model 7500ZA:,
block cells (cell length: 4 mm, 8 mm, 16 mm, 32 mm) and pipe cells
(cell length: 64 mm, 125 mm, 200 mm and 250 mm).
A two-component analyzer may incorporate both sampling cells in
one optical unit. In this case, detach the pipe cell and then block cell (see
Fig. 7-3).
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NDIR Gas Analyzer
Maintenance
7.4.1.1 PIPE CELL REMOVAL (SEE FIG. 7-1)
1. Stop all gas flow. If necessary, purge the pipe cell thoroughly
with zero gas.
2. Turn OFF the power switch and disconnect the AC power cord.
3. Remove the cover (six screws).
4. Remove the tube connected to the pipe cell.
5. Loosen and remove the screw (No. 7) holding the cell retainer
(No. 11) at both ends of the pipe cell.
6. Remove the cell from the assembly and unscrew the infrared
transmission window (No. 14) at both ends.
7. For assembly, reverse the disassembly procedure.
Figure 7-1: Measuring Unit Configuration (Pipe Cell)
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Maintenance
Model 7500ZA
7.4.1.2 BLOCK CELL REMOVAL (SEE FIG. 7-2)
For steps 1 to 4, see 7.4.1.1, Pipe Cell Removal.
5. Disconnect and remove detector output cables from detector
output circuit board (No.12). Applying identification mark on
top of removed cable connector will ensure proper pin
assignment later.
6. Unscrew the two screws (No. 10) that hold the detector to the
light source unit to remove the detector from the measuring unit.
The block cell can be removed together with the detector.
7. To remove the block cell, unscrew the two screws (No. 6)
holding the block cell to the detector. The infrared transmission
window (No. 8) is just sandwiched (not fixed) between the
detector and block cell. Keep the detector facing up, when
removing this window.
8. For assembly, reverse the disassembly procedures.
Note: The O-ring (No. 9) is placed between the window holder
and block cell. Use care in positioning the O-ring. With a
two-component analyzer, install the two-component
detector last. Make sure that no space is left between the
one-component and two-component detectors. When
inserting the detector output cable connector into the PCB
board, be careful to attach the connector with proper pin
assignment (top/bottom).
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NDIR Gas Analyzer
Maintenance
Figure 7-2: Measuring Unit Configuration (Block Cell)
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Maintenance
Model 7500ZA
7.4.1.3 REMOVING THE MEASURING UNIT
Refer to Fig. 7-3. For step 1 to 4, see 7.4.1.1, Pipe Cell Removal.
5. Disconnect and remove detector output cables from detector
output circuit board (No.12). Applying identification mark on
top of removed cable connector will ensure proper pin
assignment later.
6. Disconnect wiring to the 2-pin terminals of the IR light source
assembly and chopper motor pin connector from the PCB (No. 17).
7. Detach the six screws (No. 16) fastening the base plate (No. 3) to
remove the measuring unit. .
8. For assembly, reverse the disassembly procedures.
Note: Special care should be taken when assembling or
disassembling the measuring cell to avoid using excessive
force to the detector pipe or light source unit pipe. If the pipe
is deformed or damaged by excessive force, there is a
potential for gas leaks and this, in addition to creating a
potential toxic hazard, will result in inaccurate measurement.
7.4.2 Cleaning the Sample Cell
1. To clean the sample cell or IR transmission window, first clear
away any dirt using a soft brush and then lightly wipe using a
soft cloth. Do not use abrasive or paper towels.
Note: The window is fragile. Handle with care. Avoid scratching
the window. Do not rub the dirt from the window roughly.
2. If the window or the sample cell interior is very dirty, use a soft
line-free cloth moistened with absolute alcohol.
3. If the window is corroded, rub off any scale from the window
lightly with a soft cloth to which chrome oxide powder is
applied. If it is excessively corroded, it should be replaced.
4. When the cleaning operation is complete, assemble according to
the sample cell assembly/disassembly procedures. Assemble the
pipe carefully. If it becomes bent or damaged, replace it with a
new part.
5. Do not wash the sample cell components with water.
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NDIR Gas Analyzer
Maintenance
Figure 7-3: Measuring Unit with 2-Component Block and Pipe Cell
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Maintenance
Model 7500ZA
7.5 Fuse Replacement
1. Turn “OFF” the main power supply switch to the analyzer.
2. Rotate the fuse holder cap (shown in the figure above)
counterclockwise and pull it out. The cap (fuse holder) will
contain the fuse. Remove the blown fuse from the holder and
replace it with a new one (250VAC/2A, Slo-Blo).
3. Reinstall the fuse holder cap, turn ON the power supply switch.
The analyzer will power up normally.
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NDIR Gas Analyzer
Error Messages
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 closes. When errors No. 4 to No. 9 occur, the calibration
error contact output closes.
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Error Messages
Model 7500ZA
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 analyzer failure or fault. Contact TAI
for assistance.
Errors 4-8 indicate that the calibration procedure may be incorrect.
Check the following items, and if the error still occurs, contact TAI.
1. Is the calibration gas flowing to the analyzer?
2. Does the calibration operation match the supplied gas? (For
example, zero calibration is performed while flowing the span
gas.)
3. Does the supplied gas concentration match the gas concentration
set in the calibration concentration setting?
Also, if errors 5 and 7 occur, you can perform calibration forcibly,
following the procedure. This is used as a fault recovery when
calibration fails and calibration contents are invalid or wrong.
Typical Error Screen Display
For Errors 1-4, 6, and 8-10:
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NDIR Gas Analyzer
Error Messages
•
•
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 display.
For errors 5 and 7:
8.2 Error Log File
When an error occurs, the history is saved in an error log file. The
error log file is accessible in the maintenance mode.
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Error Messages
Model 7500ZA
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 damaged.
Deleting Error History
Press the ENT key on the above screen, and the “Clear Error Log”
will be highlighted. Pressing ENT again will clear the error history.
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NDIR Gas Analyzer
Specifications
9. Specifications
9.1 General Specifications
9.1.1 Standard Specifications
Measurement Method:
NO, SO2, CO2, CO, CH4:
Non-dispersion infrared-ray absorption
method
Single light source and single beams (single
beam system)
O2:
Fuel cell O2 analyzer (built-in) or
paramagnetic O2 analyzer (built-in) or
zirconia O2 analyzer (externally installed
TYPE: ZFK7)
Measured Gas/Range:
Min Range
0-200 ppm
0-200 ppm
0-100 ppm
0-200 ppm
0-500 ppm
0-10 vol.%
Max Range
0-5000ppm
0-10 vol.%
0-100 vol.%
0-100 vol.%
0-100 vol.%
0-25 vol.%
NO
SO2
CO2
CO
CH4
O2
(built in)
Fuel Cell
O2
(built in)
Paramag.
0-5 vol.%
None
0-100 vol.%
100-95 vol.%
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Specifications
Model 7500ZA
O2
0-5 vol.%
0-25 vol.%
External
Zirconia
Max. 5 components measurement
including O2.
For reverse range O2 measurement, IR gas
measurement is not available (single range
O2 only).
Measuring range ratio max. 1:10 (except
O2)
User adjustable ranges between the
specified minimum and maximum range.
Settable one range or two ranges, low
range (Range 1) and high range (Range 2).
See Table 1 for possible combinations of
components and ranges.
Display Indication:
Digital indication in 4 digits (LCD panel
with LED back light)
Instantaneous value of each component
Instantaneous value after O2 correction
(only in NO, SO2, CO measurement with
O2)
Average value after O2 correction (only in
NO, SO2, CO measurement with O2)
O2 average value
Analog Output Signals:
4 to 20mA DC or 0 to 1V DC, isolated
internally from circuit and ground. Output
lines are non-isolated; 12 outputs max.
Allowable load 550Ω for 4 to 20mA DC
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NDIR Gas Analyzer
Specifications
Allowable load 100KΩ 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
O2 sensor.
Signal requirement:
(1) Signal from Zirconia O2 sensor
(TYPE: ZFK7)
(2) 0 to 1V DC from an O2 sensor. Input
section is not isolated. This feature is
present when an O2 sensor is not built
in.
*
Externally installed O2 sensor must be
purchased separately.
Digital Output: (option)
1C contact (24V DC/1A, resistive load)
max.15 outputs
Instrument error, calibration error,
range identification, auto calibration
status, solenoid valve drive for auto
calibration, High/Low limit alarm
contact output.
All relay contacts are isolated mutually
and from the internal circuit.
Digital Input: (option)
Voltage contact (supply 12-24VDC
(15mA Max.)) Max. 9 inputs
Remote range change over, auto
calibration remote start, remote hold,
average value reset, Isolated from the
internal circuit with photocoupler.
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Specifications
Model 7500ZA
Power Supply:
Voltage rating:
Allowable range:
Frequency:
100V to 240V AC
85V to 264V AC
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
source)
Ambient humidity:
90% RH max.,
non-condensing
Storage Conditions:
Ambient temperature: -20˚C to 60˚C
Ambient humidity: 100% RH max.,
non-condensing
Dimensions (H × W × D): 133 x 483 x 382mm
Mass:
Approx. 9 kg
Enclosure:
Steel casing, for indoor use
Material for Wetted Parts:
Gas inlet/outlet; SUS304
Sample cell; SUS304,chloroprene rubber
Infrared-ray transmitting window: CaF2
Internal piping: Toaron, Teflon,
Polypropylene
Paramagnetic O2 sensor cell : SUS316
Fuel cell O2 sensor cell: ABS resin
Gas inlet/outlet:
Rc1/4 or NPT 1/4 internal thread
1L/min ( when required)
Purge gas flow rate:
Life time of Fuel Cell O2 Sensor: 2 years
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NDIR Gas Analyzer
Specifications
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 selectable.
Indication of instantaneous values will not
be held.
Range Switching:
Range switch function is available in
manual, auto, and remote modes. Only
preset switch method is effective.
Manual: Allows range to switch by key operation.
Auto: Automatically switched from first range to
second range when the measured value
exceeds 90%FS of first range.
Automatically switched from second
range to first range when the measured
value drops to 80% or less first range.
Remote (option): Voltage contact input allows the range to
switch via an external signal when a
remote range switch input is received.
When the contact input terminals for each
component are input voltage, the first
range is selected, and it is switched to the
second range when the terminals are open.
* The switch range values are settable
between the first range and second range
values (low/high range values).
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Specifications
Model 7500ZA
9.1.3 Optional 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. Indication of
instantaneous values are not held.
Range Identification Signal:
The present measuring range is identified
by a contact position.The contact output
terminals close for each component when
the first range is selected, and open when
the second range is selected.
Auto Calibration:
Auto calibration is carried out periodically
at the preset cycle. When a standard gas
cylinder for calibration and a solenoid
valve for opening/closing the gas flow line
are installed externally by the customer,
calibration will be carried out using the
solenoid valve drive contacts for zero and
span calibration and will be cycled on/off
sequentially at the set auto calibration
timing.
Auto Cal Cycle Setting: Auto calibration cycle is user defined.
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 user defined and
settable between 60 to 900 seconds (in
increments of 1 second).
Auto Cal Remote Start:
Auto calibration starts by opening the auto
cal remote start input terminal after short
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NDIR Gas Analyzer
Specifications
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.
When zero calibration gas and solenoid
valve for opening/closing the calibration
gas flow line are installed by the customer,
zero calibration will be carried out at the
set auto zero calibration timing.
Auto Zero Cal Cycle Setting: Auto zero calibration cycle is user settable.
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 timing for flowing zero gas in an auto
zero calibration is user settable from 60 to
900 seconds (in increments of 1 second)
High/Low Limit Alarm:
Alarm contact output turns on when
measurement value reaches the preset high
or low limit alarm value. Contacts close
when the instantaneous value of each
channel exceeds the high alarm limit value
or falls below the low alarm limit value.
Instrument Error Contact Output: Contacts turn on when analyzer
error No. 1, 2, 3 or 10 occurs.
Calibration Error Contact Output: Contacts turn on at occurrence of
manual or auto calibration errors from 4-9.
Auto Cal Status Contact Outputs: Contacts turn on during auto
calibration.
O2 Correction:
Correction of measured NO, SO2 and CO
gas concentrations into values at reference
O2 concentration
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Specifications
Model 7500ZA
Correction formula:
21 On
21 Os
C
Cs
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 0 - 19% O2).
Average value after O2 correction and O2 average value
calculation:
The result of O2 correction or instantaneous
O2 value can be output as an average value
over the preset period of time.
Moving average method is used. Sampling
interval is 30 seconds (Output is updated
every 30 seconds.
Update is the averaged value of the most
recent elapsed averaging time period.)
Averaging time period is settable from 1-59
minutes (in increments of 1 minute) or 1-4
hours (in increments of 1 hour).
Average Value Resetting:
The above-mentioned output of average
value is started from the initial state by
opening the average value resetting input
terminals after short circuiting for 1.5 sec
or longer.
Output is reset by input voltage and the
terminal circuit.
Communication Function:
RS-485 (9pins D-sub connector)
Half-duplex bit serial
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NDIR Gas Analyzer
Specifications
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 Pressure Correction:
Measure atmospheric pressure and
calculate compensation (for use, exhaust
port of analyzer must be at atmospheric
pressure.
After atmospheric pressure correction:
Zero point: Not affected.
Span point: Change is 0.5% measured
value or less relative to a 1%
change in atmospheric
pressure.
Correction range: 700hPa-1050hPa
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Specifications
Model 7500ZA
9.1.4 Performance
Repeatability:
Linearity:
±0.5% of full scale
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% of full scale/week
Response time (for 90% FS response):
1 to 15 sec electrical response. Within 10-
30 seconds including purge time of sample
gas.
Gas replacement time depends on the
number of measuring components and
measuring range.
Interference from other gases:
9.1.5 EC Directive Compliance
This product conforms to the requirements of the Low Voltage Directive
2006/95/EC and EMC directive 89/336/EEC (as amended by Directive
92/31/EEC), both as amended by Directive 93/68/EEC.
It conforms to following standards for product safety and
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NDIR Gas Analyzer
Specifications
Electromagnetic Compatibility ;
EN61010-1 : 2010 Safety requirements for electrical
equipment for measurement, control and
laboratory use.
“Installation Category II”
“Pollution Degree 2”
EN61326-1 : 2006
Electrical equipment for measurement,
control and laboratory use — EMC
requirements.
9.1.6 Requirements for Sample Gas
Flow rate:
Temperature:
Pressure:
0.5L / min ±0.2L / min
0 to 50˚C
10 kPa or less (Gas outlet side should be at
atmospheric pressure).
Dust:
100 µg/Nm3 or less in particle size of 0.3
µm or less.
Mist:
Not allowed
Moisture:
For sample gases NO, SO2, CO(0-200
ppm range): less than 2°C saturation point.
For most other sample gases: less than
standard room temperature saturation
point.
Corrosive component:
1 ppm or less
Standard gas for calibration:
1) Infrared-ray measurable component, standard O2
Zero gas: Dry N2
Span gas ; Each sample gas having
concentration 90 to 100% of its
measuring range recommended).
For external zirconia O2 sensor use the
same calibration gas line:
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Specifications
Model 7500ZA
Zero gas ; Dry air or atmospheric air (Do
not use with CO2 measurement)
Span gas ; For other than O2 measurement,
each sample gas having
concentration 90 to 100% of its
measuring range.
For O2 measurement, O2 gas of
1 to 2 vol% /remainder N2 gas
2) Reverse range O2 measurement
Zero gas; 100vol% O2
Span gas ; For O2 measurement, O2 gas of
95.0%~95.5vol%/ remainder
N2 gas
*For reverse range O2 measurement,
infrared measurable component is not
measurable.
9.1.7 Installation Requirements
•
Indoor use (Select a place where the equipment does not receive
direct sunlight, draft/rain or radiation from hot substances. If
such a place cannot be found, a roof or cover should be prepared
for protection).
•
•
Avoid sites where unit receives heavy vibration.
Select a site where atmospheric air is clean
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NDIR Gas Analyzer
Specifications
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 components analyzer:
1. The 2nd range in the tables for two and more components is
maximum available range.
2. Select the 2nd range less than or equal to the “2nd range (max)”.
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9.3 Code Symbols
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note1) When “D” is specified at 4th digit, Power supply cord is supplied
in the scope of supply. Cord specification should be specified at
the 20th digit.
note2) When only O2 measurement is necessary, “Y” should be
specified at 6th digit.
note3) When “1” is specified at 7th digit, O2 pt analyzer signal has to be
set as 0-1V DC linear corresponding to full scale.
External zirconia O2 analyzer and external O2 analyzer are not
included in the scope of supply, and has to be separately ordered.
note4) Refer to Table 1 for possible combination of measuring
components and ranges in this manual. When “Y” is specified at
6th digit, “Y” should be specified at 9th to 16th digit. For fuel
cell O2 analyzer, range is 0-10vol% or more.
note5) Select the type of voltage rating, plug type and applicable
standard of the power supply cord by 20th digit. Select a power
supply cord for using at the location of end-user. When “A” is
specified at 4th digit, Power supply cord will not be included in
scope of delivery. When English is specified for display
language, “E” should be selected at 20th digit.
note6) O2 correction is calculated only for NO, SO2 and CO.
note7) When 5 components measurement is specified, “H” must not be
specified at 22nd digit.
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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 case NO, SO2 and CO
measuring range are corresponding range in mg/m3. Please refer
to the table shown below for the corresponding range code based
on “mg/m3”.
note9) When A to D is specified at 25th digit, the analyzer will be
adjusted and delivered with the following gases.
Standard “A”: balance gas N2.
For heat treatment furnace “C”: balance gas 30vol%
H2/remaining N2.
For converter “D”: balance gas CO, CO2.
When other adjustment is required, please specify “Z”.
When “Z” is specified, please attach a list of gas composition
contained in the measuring gas.
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9.4 Outline Diagram
<Analyzer main unit>
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