Teledyne 7600 Operating Instructions Manual Download Page 17

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Infrared Gas Analyzer

Introduction

Teledyne

Analytical

Instruments

•

Instrument or calibration error contact outputs

•

Extra functions included such as average value computation,
O

conversion

•

Pump ON/OFF contact

1.3 Options Available

•

Percent O

detector — Paramagnetic (built-in) or ZrO

(externally installed), user preference

•

correction (the conversion of measured CO and SO

readings into values at standard O

concentration). Consult

factory for more detail for this function.

•

Communication functions:

•

RS-232C (9 pins D-Sub connector)

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Half-duplex bit serial

•

Modbus protocol

1.4 Applications

The Model 7600 Infrared Gas Analyzer is a versatile analytical

instrument tool and is ideally suited for multi-parameter gas analysis
requirements for applications such as:

•

Combustion control within the power, pulp and paper, steel,
and cement industries

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Heat treating / Inert gas blanketing atmosphere control

•

Bulk-gas impurity analysis within the air separation industry

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

•

Vent gas analysis of oxyhydrochlorination reactors (EDC)

•

Off-gas analysis on PTA and Maleic Anhydride reactors

•

Fluid Catalytic Cracker (FCC) regeneration gas analysis

•

Ammonia / Fertilizer process gas stream analysis

•

Continuous Emissions Monitoring Systems (CEMS)

Summary of Contents for 7600

Page 1: ...sonal 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 P N M7600 ECO ...

Page 2: ...r weight of any parts in so far as such alterations do not adversely affect our warranty Important Notice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the...

Page 3: ...cal Instruments iii Specific Model Information Instrument Serial Number _______________________ Instrument Range _______________ Calibrated for _______________ Background Gas _______________ Zero Gas _______________ Span Gas _______________ ...

Page 4: ...ury 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 unde...

Page 5: ...al 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 c...

Page 6: ... Choosing a Location 22 2 3 Mounting the Analyzer 23 2 4 Mounting the Input Output Terminal Module 23 2 5 Gas Connections 25 2 5 1 Internal Piping Diagram 25 2 5 2 External Piping Diagram 27 2 5 3 Gas Conditioning 28 2 5 4 Flowrate 29 2 5 5 Preparation of Calibration Gas 29 2 5 6 Purging the Analyzer 30 2 5 7 Sample Gas Pressure 30 2 5 8 Example configuration of gas sampling system 30 2 6 Electric...

Page 7: ...alibration Parameters 46 3 5 2 1 Calibration Value 46 3 5 2 2 Setting of Manual Zero Calibration 48 3 5 2 3 Setting of calibration range 50 3 5 2 4 Setting of auto calibration component range 51 3 5 3 Alarm Setting 53 3 5 3 1 Configuring the Alarms 55 3 5 3 2 Hysteresis Setting 56 3 5 4 Setting of Auto Calibration 58 3 5 4 1 Auto Calibration 58 3 5 4 2 Gas Flow Time Setting 59 3 5 4 3 Cycle Settin...

Page 8: ...nt 86 3 6 6 Output Adjustment Screen 86 3 6 7 Other Parameters 87 3 7 Calibration 90 3 7 1 Zero Calibration 90 3 7 2 Span Calibration 91 Maintenance 93 4 1 Routine Maintenance 93 4 2 Daily Check and Maintenance Procedures 93 4 3 Analyzer Maintenance 94 4 3 1 Sample Cell Cleaning 94 4 3 2 Cleaning the Cell Block 97 4 4 Optical Zero Adjustment 99 4 5 Moisture Interference Compensation Adjustment 102...

Page 9: ...ments ix A 3 Optional Functions 115 A 4 Performance 116 A 5 Standard Requirements for Sample Gas 117 A 6 Installation Requirements 118 A 7 EC Directive Compliance 118 A 8 Terminal Block Connections 119 A 9 Description on Terminal Block 120 Index 125 ...

Page 10: ...rnal Piping with Two Pair of Inlet Outlet 2 28 Figure 2 8 Five Component Analysis System 31 Figure 2 9 Model 7600 Electrical Connections 32 Figure 2 10 Noise Suppression 33 Figure 2 11 I O Cable Connection 33 Figure 3 1 Front Panel of the Model 7600 35 Figure 3 2 Interface Keys on the Front Panel 35 Figure 3 3 Display Modes and Menu Hierarchy 37 Figure 3 4 Example Screen 5 Component Analysis 12 Ch...

Page 11: ...od 80 Figure 4 1 Top Cover Removal 95 Figure 4 2 Sample Cell Removal 95 Figure 4 3 Sample Cell 96 Figure 4 4 IR Window Assembly 97 Figure 4 5 Detector Secure Nut 98 Figure 4 6 Cell Block Assembly 99 Figure 4 7 Optical Adjustment Display for Dual Optical System Option 100 Figure 4 8 Optical Zero Adjustment 101 Figure 4 9 Beam Adjustment Plate 102 Figure 4 10 Bubbler Apparatus 103 Figure 4 11 The Er...

Page 12: ...i List of Tables Table 2 1 Correspondence of Measured Components and Measuring Units 27 Table 2 2 Zero and Span Gas 29 Table 4 1 Troubleshooting and Maintenance 93 Table 4 2 Components of Optical Adjustment Screen 100 Table 4 3 Error Messages 104 ...

Page 13: ...The customer should ensure that the principles of operating this equipment are well understood by the user Misuse of this product in any manner tampering with its components or unauthorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne Instruments Analytical Instruments referred as TI AI no respon...

Page 14: ...Model 7600 Teledyne Analytical Instruments xiv ...

Page 15: ...veniently packaged in either a 19 rack mount or NEMA 4 wall mount enclosure The NEMA 4 enclosure can be X or Z purged to satisfy hazardous area installation requirements A high sensitivity mass flow type twin detector is used for infrared measurements By utilizing a single beam double path design in conjunction with a serial dual layer transmission detector the Series 7600 delivers long term drift...

Page 16: ...to facilitate any optical or maintenance adjustments required to fine tune analyzer performance 7600A Multiple in depth on screen analyzer functions easily accessible using the front panel user interface buttons Follow Hold output signal control during calibration Remote range change control Low Hi limit alarms Range ID signals Auto calibration with user adjustable frequency and gas flow time sett...

Page 17: ... Half duplex bit serial Modbus protocol 1 4 Applications The Model 7600 Infrared Gas Analyzer is a versatile analytical instrument tool and is ideally suited for multi parameter gas analysis requirements for applications such as Combustion control within the power pulp and paper steel and cement industries Heat treating Inert gas blanketing atmosphere control Bulk gas impurity analysis within the ...

Page 18: ...us area installation requirements The system uses a high sensitivity mass flow type twin detector for infrared measurements A single beam double path optical bench is installed in conjunction with a serial dual layer transmission detector The concentration of the desired gases is displayed on a large easy to read backlit LCD The user interface is very intuitive and the menu mode selection buttons ...

Page 19: ... the NPT fittings installed The standard instrument has two measuring units and a pair of inlet outlet gas connections exist for each unit See Section 2 5 Gas Connections A power receptacle on the rear panel accepts the three prong power cable supplied with the instrument The Model 7600 operates on 100 240 VAC 50 60 Hz power The power inlet conforms to EN60320 Protection Class 1 specifications ...

Page 20: ...Introduction Model 7600 Teledyne Analytical Instruments 20 ...

Page 21: ...s 6 Making electrical connections 7 Testing the installation CAUTION READ THIS CHAPTER IN ITS ENTIRETY BEFORE INSTALLING THE SYSTEM FOR INDOOR USE ONLY 2 1 Unpacking the Analyzer The Model 7600 Infrared Gas Analyzer is shipped with the following components 7600 Analyzer Input Output terminal module set Connection cable Power cable Fuse 2 Cell window mounting tool Slide rail 2 Relay board for auto ...

Page 22: ...NOT INSTALL IT IN A LOCATION WHERE EXPLOSIVE OR FLAMMABLE GASES ARE PRESENT Select an installation location that meets the following criteria This instrument should be rack mounted or mounted in a steel enclosure Indoor location Vibration free Not exposed to direct sunlight Clean and non cluttered space Depending on the options selected at the time of purchase the model 7600 requires an AC power s...

Page 23: ...he rack or enclosure for required access during maintenance Figure 2 1 Slide Rail Mounting Dimensions 2 4 Mounting the Input Output Terminal Module The input output module is the electronic interface that handles the various signals to and from the analyzer It consists of up to five terminal blocks a communications connector a cable connector and a solenoid drive output connector mounted together ...

Page 24: ...lation Model 7600 Teledyne Analytical Instruments 24 mounting surface Connect the panel to the same ground as the analyzer main unit Figure 2 2 Input Output Terminal Module Figure 2 3 Mounting the I O Module ...

Page 25: ...he tubing and connections Always use clean tubing and fittings Connect the gas tube as follows Sample gas inlet Attach the sample gas tube to the inlet fitting The sample gas should be filtered and dehumidified before passing into the analyzer This port is also used to connect the zero and span calibration gases The gas flow should be constant within the range of 0 5 L min 0 2 L min Sample gas out...

Page 26: ...ing unit 2 The diagram shows the combination of two cells used in measuring unit 2 This is possible by combining ranges When a single measuring unit is used there is only a single inlet and outlet gas connection Figure 2 4 Internal Piping with Single or Dual Measuring Units Depending on the options chosen the analyzer can be configured in several ways Table 2 1 lists the possible configurations fo...

Page 27: ... 4 component meter for NO SO2 CO2 CO NO SO2 CO2 CO 2 5 2 External Piping Diagram There are several ways to bring sample gas to the analyzer depending on the number of inlet outlet gas connections on your instrument Recommended piping diagrams are shown in Figures 2 5 2 6 and 2 7 Figure 2 5 is a schematic for an instrument with a single pair of inlet outlet gas connections Figures 2 6 and 2 7 are u...

Page 28: ...let 1 Figure 2 7 External Piping with Two Pair of Inlet Outlet 2 2 5 3 Gas Conditioning For optimum performance the sample gas should be treated as follows A filter should be installed to remove any dust or particles in the sample gas For a final stage filter use a filter that can remove dust particles of 0 3 μm ...

Page 29: ... 4 Flowrate Use a flowrate of 0 5L min 0 2L min The sample system should be designed to avoid any flow fluctuation during measurement Use a flowmeter to observe the flow reading as shown in the external piping diagrams of Figures 2 5 2 6 and 2 7 2 5 5 Preparation of Calibration Gas Routine calibration using calibration gases is required for optimizing the performance of this instrument Once a week...

Page 30: ...spheric pressure 2 5 8 Example configuration of gas sampling system A typical system configuration with five component gas analysis for monitoring combustion exhaust gas from boiler refuse incinerator etc is shown in Figure 2 8 Contact Teledyne for specific application system configuration or further information The system shown is comprised of Model 7600 with dual measuring unit option and extern...

Page 31: ...Gas a bank of calibration gases used for setting zero and span of the analyzer for each species monitored Zirconia Sensor an external zirconia sensor is used for measuring the oxygen concentration in the sample gas Some instruments use a built in paramagnetic oxygen sensor instead aof an external zirconia sensor NO2 NO Converter added to the NO analysis circuit which uses an efficient catalyst for...

Page 32: ...del 7600 requires 100 240 VAC 50 60 Hz power Avoid installing this instrument near an electrical unit that generates electrical noise such as a high frequency furnace or electric welder If using the instrument near such a noise generating unit is unavoidable use a separate power line to avoid noise Mount a noise suppressor such as varister or spark killer as shown in Figure 2 10 to the noise gener...

Page 33: ...the cable connector into the receptacle at the rear panel of the analyzer and the receptacle on the PC board of the input output module Make sure that the ferrite core attached to the I O cable goes to the analyzer See Figures 2 9 and 2 11 Figure 2 11 I O Cable Connection The I O Module carries various input and output signals A detailed list of these signals and pinout information is given in the...

Page 34: ...the power source and turn the analyzer on using the power switch on the front panel Allow the analyzer to warm up for four hours When the instrument is first turned on you will see the measurement screen While in the warm up stage the readings are inaccurate They may even be above the upper limit of range however this is not an error After the analyzer has come to equilibrium approximately four ho...

Page 35: ...face of the analyzer Figure 3 1 Shows the Model 7600 Infrared Gas Analyzer front panel The user interface consists of 8 membrane switch buttons or keys a power ON OFF switch and a display ON OFF switch The 8 user keys are shown in Figure 3 2 and described below Figure 3 1 Front Panel of the Model 7600 Figure 3 2 Interface Keys on the Front Panel ...

Page 36: ...y Used for confirmation of selected item or value and for performing a calibration ZERO key Used for zero calibration SPAN key Used for spancalibration 3 2 Display and Available Menus The display on the Model 7600 has two modes measurement mode and user mode To change between modes press the MODE key In the measurement mode the display indicates the composition of the sample gas Up to 12 channels ...

Page 37: ...Infrared Gas Analyzer Operation Teledyne Analytical Instruments 37 Figure 3 3 Display Modes and Menu Hierarchy ...

Page 38: ...f Peak Alarm Parameter Setting Figure 3 3 shows the overall structure of the Model 7600 display and menu hierarchy 3 3 The Display Screen 3 3 1 Measurement Mode The measurement mode screen is the default mode when the power is turned on It displays component and concentration information about the process The screen depends on the number of components Figure 3 4 is an example of a measurement mode...

Page 39: ... Peak alarm times Displays the alarm times exceeding the peak value 8 Peak alarm unit display Displays units of peak alarm with times H Instantaneous value and concentration value The concentration display of Ch component where sampling components such as CO2 CO or O2 are displayed in the component display indicates current concentration values of the measured components contained in gas that is n...

Page 40: ...hanged between 1 minute and 59 minutes or 1 hour and 4 hours according to the average time settings See Section 3 5 7 Parameter Setting The set time is displayed as 1h for instance in the range display The measurement ranges of O2 correction concentration value and O2 correction concentration average value are the same as that of the measuring components Also the measurement range of O2 average va...

Page 41: ...nnel number component species analyzed concentration or calculated value etc In this mode the display can show up to 5 channels on a single screen To view additional channels scroll down by pressing the DOWN key or back up using the UP key Each press scrolls the screen by one channel You can also calibrate the instrument from this mode by pressing the appropriate ZERO or SPAN button See Section 3 ...

Page 42: ...er mode from the measurement mode press the MODE key To return to the measurement mode press the MODE key again or ESC 3 5 Setting Up the Analyzer in the User Mode 3 5 1 Switch Ranges From the Switch Ranges menu you can a Manually select a desired range for any channel b Use the remote range switch contacts to select a range c Select autoranging To enter the Switch Ranges menu 1 Press the MODE key...

Page 43: ... 3 range switch modes in the second column to select from MR Manual selection RR Remote range switch AR Autoranging The selected range switch mode is highlighted for the channel you selected 4 Press the UP DOWN keys to toggle between the available switch modes 5 Then press the ENT key to confirm the selection 3 5 1 1 MANUAL RANGE SWITCHING To manually switch between analysis ranges 1 Select the MR...

Page 44: ...nding instantaneous value range is switched To abort the range selection press the ESC key and the setting operation is made invalid and the previous screen appears 3 5 1 2 RANGE IDENTIFICATION CONTACT OPERATION In all of the range switch modes MR RR AR the status of the range identification relay contact corresponding to each Ch component is closed when Range 1 is selected and open when Range 2 i...

Page 45: ... instrument for remote range selection 1 Press the MODE key to enter the user mode 2 Move the cursor to the Switch Ranges option and press ENT The Channel Selection screen appears 3 Move the cursor by pressing the UP DOWN keys to the desired channel and press ENT The selected range switch mode is highlighted for the channel you selected 4 Press the UP DOWN keys to toggle between the available swit...

Page 46: ...ngs can be configured for your particular application There are 4 submenus in the Calibration Parameters menu They are Calibration Value set the concentration of calibration gas About ZERO Calibration set each or all components to be zero calibrated during a manual zero calibration About Calibration Range sets whether each component during a zero or span calibration should be calibrated with a sin...

Page 47: ... UP or DOWN key Press the ENT key 2 Select the concentration item you want to set by pressing the UP or DOWN or SIDE key Press the ENT key and the selected value is highlighted 3 Enter the calibration gas concentration values zero and span For any numerical value entry press the UP or DOWN key to increase or decrease a single digit Select the next digit by pressing the SIDE key 4 When the concentr...

Page 48: ...rument will not accept values outside of this range For external Zirconia O2 sensors the setting range for zero gas is 5 to 25 vol and span from 0 01 to 5 vol 3 5 2 2 SETTING OF MANUAL ZERO CALIBRATION When zero calibration is performed manually you can choose whether all components are to be calibrated simultaneously or each component calibrated while selecting one by one This is configured from ...

Page 49: ... want to set by using the UP or DOWN key Press the ENT key 2 Select at once or each by pressing the UP or DOWN key to toggle between the two options Press the ENT key when the desired option is displayed To close the Cal Settings ZERO Cal screen or cancel this mode midway press the ESC key The previous screen will return Example The options each or at once can be determined for each channel When t...

Page 50: ... to display the user mode 2 Point the cursor to Calibration Parameters by pressing the UP or DOWN key and press the ENT key 3 In the Calibration Parameters screen that appears point the cursor to About Calibration Range by pressing the UP or DOWN key Press the ENT key 4 In the next screen that appears point the cursor to the channel you want to set by pressing the UP or DOWN key then press the ENT...

Page 51: ...s concentration for both ranges After setting the calibration range to both you will notice in the Manual Calibration screen see Section 3 7 that there are cursors next to both ranges whereas there would only be a single cursor next to the range for calibration if current was set For example if channel 1 and channel 4 were set to both then cursors will appear in both ranges of Ch1 and Ch4 in the M...

Page 52: ...he cursor to Calibration Parameters by pressing the UP or DOWN key and press the ENT key 3 In the Calibration Parameters screen that appears point the cursor to Auto Calibration Components Range by pressing the UP or DOWN key Press the ENT key 4 In the Calibration Parameters screen that appears point the cursor to Auto Calibration Components Range by pressing the UP or DOWN key Then press the ENT ...

Page 53: ...annel you want to enable or disable for autocalibration see steps 1 and 2 above use the SIDE key to highlight the enable or disable option 2 Use the UP or DOWN keys to toggle between the two options then select the desired status by pressing ENT To close the Auto Calibration Components Range screen or cancel this mode midway press the ESC key The previous screen will return Note The order in which...

Page 54: ...ms involves Selecting the alarm type Assigning it to a channel Establishing setpoints concentration alarms only Enabling or disabling it A channel can be configured for multiple alarms ON OFF enables the alarm function if set at ON or disables the alarm function if set at OFF 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 i...

Page 55: ...arm ON OFF setting to OFF and then change the value 1 From the measurement mode press the MODE key to display the user mode 2 Point the cursor to Alarm Setting by pressing the UP or DOWN key and press the ENT key 3 In the Alarm Setting screen that appears point the cursor to the alarm number you want to set 1 through 6 using the UP or DOWN key Press the ENT key when the cursor is on the alarm numb...

Page 56: ...le however they must be defined so that H limit value L limit value and that H limit value L limit value hysteresis 5 After setting the last feature store the values by pressing ENT again To close the Alarm Setting screen or cancel this mode midway press the ESC key The previous screen will return 3 5 3 2 HYSTERESIS SETTING The hysteresis setting is used prevent chattering of an alarm output near ...

Page 57: ... not turned OFF until the process value falls below the hysteresis width Note The hysteresis setting is common to all alarms To set the hysteresis value 1 From the Alarm No Selection screen point the cursor to Hysteresis by pressing the UP or DOWN key then press ENT 2 In the Hysteresis Value Setting screen that appears enter hysteresis values using the UP or DOWN keys to increment or decrement a d...

Page 58: ... of setting items Start Time Setting at the first calibration day of the week hour minute Cycle A period between the start time of one calibration and another unit hour day Flow Time The time required for replacement by calibration gas Time required for replacement of sample gas after the calibration is completed Set by calibration gas ON OFF Enable disable the auto calibration feature Note Before...

Page 59: ...tting change use the UP or DOWN key To change the setting use the SIDE key to move the cursor to the right 7 After changing the setting press the ENT key to accept the change Auto calibration will now be carried out using the entered setting value To close the Setting of Auto Calibration or cancel the mode midway press the ESC key A previous screen will return 3 5 4 2 GAS FLOW TIME SETTING In this...

Page 60: ...changing the value press the ENT key 5 Press the ESC key to return to the automatic calibration setting screen Note Only the channels used are displayed on this screen The Ex time is the output signal hold extension time after the completion of calibration It is valid only when the hold setting is set to ON The Ex time set here is also used in a manual calibration The auto calibration contacts are...

Page 61: ...rformed when the key lock is ON To cancel auto calibration set the key lock to OFF and then execute Stop Auto Calibration Auto Calibration Example Start Time SUN 12 00 Cycle 1 day Flow Time Zero 350 sec Ch1 Span 350 sec Ch1 Span 350 sec Ch1 Span 350 sec Ch1 Span 300 sec Ch1 Span 300 sec EX time 300 sec ON OFF ON Figure 3 7 shows the auto calibration with the above settings Figure 3 7 Example Auto ...

Page 62: ...libration is being performed Zero calibrations are performed first and all enabled channels will zero simultaneously When the zero calibrations are finished channel 1 will enter the span calibration followed by channel 2 3 5 4 4 REMOTE START An auto calibration is always available by keeping the remote start input closed for at least 1 5 seconds The remote start can initiate an auto calibration wh...

Page 63: ...Calibration by pressing the UP or DOWN key and press the ENT key 3 In the Setting of Auto Calibration item selection screen that appears point the cursor to Auto Calibration Run by pressing the UP or DOWN keys Press the ENT key 4 Run is highlighted displaying a message to confirm the execution of auto calibration Press the ENT key to execute the auto calibration or press the ESC key to cancel 3 5 ...

Page 64: ...libration Run by pressing the UP or DOWN keys Press the ENT key 8 Stop is highlighted displaying a message to confirm the stop of auto calibration Press the ENT key to stop the auto calibration or press the ESC key to cancel the abort Note During auto calibration the keys are inoperable other than key lock ON OFF and Stop Auto Calibration When the key lock is set to ON even the Auto Calibration St...

Page 65: ...le the auto zero calibration feature here Description of setting items Start Time Setting at the first calibration day of the week hour minute Cycle A period between the start time of one calibration and another unit hour day Flow Time The time required for replacement by calibration gas Time required for replacement of sample gas after the calibration is completed Set by calibration gas ON OFF En...

Page 66: ...key To change the setting use the SIDE key to move the cursor to the right 5 After changing the setting press the ENT key to accept the change Auto zero calibration will now be carried out using the entered setting value To close the Setting of Auto Calibration or cancel the mode midway press the ESC key A previous screen will return The contacts for the auto zero calibration are closed during aut...

Page 67: ... If the auto calibration period and auto zero calibration period have overlapped the auto calibration is retained ignoring the auto zero calibration of that period If the auto calibration and the auto zero calibration periods overlap the auto calibration setting is retained The instrument ignores the auto zero calibration period When the hold setting is set to ON the hold time of auto calibration ...

Page 68: ...manually 1 From the measurement mode press the MODE key to display the user mode 2 Point the cursor to Setting of Auto Zero Calibration by pressing the UP or DOWN key and press the ENT key 3 In the Setting of Auto Zero Calibration item selection screen that appears point the cursor to Auto zero Calibration Run by pressing the UP or DOWN keys Press the ENT key 4 Run is highlighted displaying a mess...

Page 69: ...int the cursor to Setting of Auto Calibration by pressing the UP or DOWN key and press the ENT key 3 In the Setting of Auto Calibration item selection screen that appears point the cursor to Auto Calibration Run by pressing the UP or DOWN keys Press the ENT key 4 Stop is highlighted displaying a message to confirm the stop of auto calibration Press the ENT key to stop the auto calibration or press...

Page 70: ...tting The optional peak alarm is triggered whenever the CO concentration exceeds the upper limit value for a preset number of times The peak number is set from within the Peak Alarm Setting menu Note Only instruments with the peak alarm option installed will have this menu The following items are set within the peak alarm menu OFF ON status of peak alarm Alarm setpoint value Alarm count number of ...

Page 71: ...ng the UP or DOWN keys Use the SIDE key to move the cursor to the right Press the ENT key to save the change To close the Peak Alarm Setting or cancel the mode midway press the ESC key A previous screen will return Description of setting items Peak Alarm ON OFF of peak alarm Alarm Value If measuring value exceeds the set alarm value in ppm a peak counter increments by 1 Alarm Count When a peak in ...

Page 72: ...value 5 times Hysteresis 0 to 20 of full scale initial value 0 of full scale Action of peak alarm If CO concentration exceeds the alarm value counting will begin If the number of peaks is over the set times per hour the peak alarm contact closes ON If it is less than the set times per hour it is open OFF Figure 3 9 Peak Alarm Example Figure 3 9 depicts the behavior of the Peak alarm where the alar...

Page 73: ...eak alarm to OFF Turning the peak alarm back ON again resets the count to 0 3 5 7 Parameter Setting This menu allows you to adjust parameter settings such as Time Key lock Output hold Reset average output Response time Average period Backlight timer Enter maintenance mode Description of setting items Current Time Current year month date day of the week hour and minute setting in this order Note Th...

Page 74: ...switch to the Maintenance mode For the maintenance mode see Section 3 6 To make parameter changes 1 From the measurement mode enter the user mode by pressing the MODE key 2 Point the cursor to Parameter Setting by pressing the UP and DOWN keys Then press ENT 3 In the Parameter Setting screen that appears point the cursor to any item you want to set by pressing the UP or DOWN key Then Press ENT 4 E...

Page 75: ...er 1 to 60 min Initial value OFF Maintenance mode 0000 to 9999 Initial value 0000 3 5 7 1 OUTPUT HOLD By setting an output hold to ON the output signal of each channel is held during the calibration manual calibration and auto calibration plus the gas flow time as shown in Figures 3 10 through 3 12 Refer to Section 3 5 4 Setting of Auto Calibration for a description of the gas flow time Regardless...

Page 76: ...e on Hold message is not displayed even if the output signal is held However on Hold message is displayed during the hold extending time shown in Figure 3 10 For both manual and auto calibration if the calibration is cancelled after the calibration gas has been directed to the analyzer the hold extending time will be performed There are two types of hold values that you can use current or setting ...

Page 77: ...or to it using the UP and Down keys Select it by pressing ENT 3 ON or OFF is highlighted If you desire to change the state press the UP or DOWN key to toggle between ON and OFF Press the ENT key to select the desired state 4 To change the hold value use the SIDE key to highlight Current or Setting Select Setting by pressing the UP or DOWN key until that option appears then press ENT The screen cha...

Page 78: ... to 1000 ppm is selected as the range and 10 FS is selected as hold setting the output equivalent of 100 ppm is output and held irrespective of the measurement value at that time Description of setting Instantaneous value display of the measurement cannot be held Only the output can be held If set value is selected for hold instantaneous O2 correction value is calculated and held based on the set ...

Page 79: ...alue Reset 3 5 7 3 RESPONSE TIME The response time of the electrical system can be changed Individual settings are available for each component Note Response time does not provide exact seconds for the setting time but rather it is a guide to the overall response 3 5 7 4 AVERAGE PERIOD This submenu allows you to set an averaging period over which the average value of O2 correction and O2 average a...

Page 80: ...the ENT key validates the resetting only for components whose setting was changed Example of average action In the example shown in Figure 3 14 the average period was set to 1 hour Figure 3 14 Example Average Period Sampling occurs every 30 seconds so 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 t...

Page 81: ... to the time value and the time setting can be changed using the UP and DOWN keys Press the ENT key to confirm the selection Note When OFF is selected the backlight remains ON and is not turned off automatically 3 5 7 6 MAINTENANCE MODE The maintenance mode is covered in section 3 6 It is a detailed password protected set of screens that allows you to check sensor input values review error logs se...

Page 82: ...arameter Setting menu See Section 3 5 7 Parameter Setting This brings up a screen for entering the password Enter the 4 digit password using the UP and DOWN keys and the SIDE key to move to the next digit Press ENT when complete If the password is entered correctly the maintenance mode screen will appear on the display offering a range of submenus Note The default password installed in new instrum...

Page 83: ...atically display Note To Factory Mode is used for factory service engineers Do not use this mode 3 6 1 Sensor Input Value Upon selecting Sensor Input Value the following screen will appear It lists the installed sensors along with the input value from the measuring sensor M and the compensating detector C Where NOx M NOx sensor input value NOx C NOx interference compensation sensor input value SO2...

Page 84: ...efer to Section 4 6 Error Messages To clear the error log select Clear Error Log and press the ENT key 3 6 3 Calibration Log The next screens detail the past calibration history on the analyzer The first screen allows you to choose the channel whose information you want displayed The next screen displays logged information on sensor input value concentration value and the dates when zero span cali...

Page 85: ...n detector at the time of calibration Con Concentration value displayed before calibration 3 6 4 Optical Adjustment CAUTION IF THE OPTICAL ADJUSTMENT IS MADE INCORRECTLY ANALYSIS MAY BE ADVERSELY AFFECTED CARRY OUT THE OPERATION WITH UTMOST ATTENTION For details of this item refer to Section4 4 Optical Zero Adjustment Press ENT key and then turn ON the solenoid valve signal for each calibration ga...

Page 86: ...heck that the gas for moisture interference compensation is flowing Change the moisture interference compensation coefficient using the UP or DOWN key Adjust the value until the value in the left column is near zero Then press the ENT key to log moisture interference compensation value Note An interference compensation detector is not provided so if the 1st range is beyond 0 to 10 vol no interfere...

Page 87: ...he adjustment press the ENT key 3 6 7 Other Parameters The last submenu of the maintenance mode menu contains a group of parameters that may be modified by the user These include Password Set Set the password used to enter the maintenance mode An arbitrary 4 digit number can be selected O2 Ref Value Set the oxygen concentration reference value at the time of oxygen correction calculation Settable ...

Page 88: ...e ENT key Note If you forget the password you will be locked out from the maintenance mode Keep a record of the password in a secure place Contact the factory for instruction on reclaiming forgotten or lost passwords To set or change the range The measuring range can be arbitrarily selected in the minimum and the maximum range specified at the time of purchase The range to be used can be selected ...

Page 89: ...r DOWN key and then press the ENT key Note The value for range 1 and range 2 must fall within or be equal to the MIN the MAX range and range 1 must be less than range 2 The number of ranges Range num is 1 or 2 4 Press the UP or DOWN key to change the value Press the SIDE key to select the next digit When the decimal point is highlighted press the UP or DOWN key and the decimal point position can b...

Page 90: ...ction press the ENT key and zero gas will be supplied Note For channels that are set to both in the Zero Calibration of the Calibration Setting mode the zero calibrations are carried out at the same time 3 Wait until the display has stabilized with the zero gas flowing After stabilization press the ENT key At this point the zero calibration on the range indicated by the cursor is carried out Note ...

Page 91: ...er 1 From the measurement screen press the SPAN key to display the Manual Span Calibration screen 2 Select the channel to be calibrated by pressing the UP or DOWN key Then press the ENT key and the calibration gas will be supplied Note For channels that are set to both in the Span Calibration of the Calibration Setting mode the span calibrations will be carried out for each component 3 Wait until ...

Page 92: ...Operation Model 7600 Teledyne Analytical Instruments 92 To close Span Calibration To close the Span Calibration screen or cancel this mode midway press the ESC key A previous screen will return ...

Page 93: ... Zero Calibration Then perform span calibration For the calibration procedures refer to Section 3 7 2 Span Calibration 2 Flowrate Check Sampling and purge gas flowrates are as follows Sampling gas flow 0 5L min 0 2 L min Purge gas flow About 1 L min Check and adjust if necessary every day 4 2 Daily Check and Maintenance Procedures Table 4 1 Troubleshooting and Maintenance Item to be checked Phenom...

Page 94: ...nces will the sample cell require cleaning The procedure for dismantling and cleaning the sample cell should be handled by qualified personnel only In general if it is absolutely required contact the factory The recommended procedure for cleaning the sample cell is as follows 1 Turn off the power switch stop the sample gas and allow the zero gas to flow for several minutes to purge the cell interi...

Page 95: ...he window and inside surface of the cell first eliminate coarse dust using a soft brush and then wipe with a soft rag CAUTION THE WINDOW IS EASILY SCRATCHED USE EXTREME CARE WHEN PERFORMING THIS OPERATION SO AS NOT TO DAMAGE IT Figure 4 1 Top Cover Removal Figure 4 2 Sample Cell Removal ...

Page 96: ...Maintenance Model 7600 Teledyne Analytical Instruments 96 Figure 4 3 Sample Cell ...

Page 97: ...ot use excessive force when cleaning the window Reinstall the cell after cleaning Be sure to perform an optical zero adjustment Section 4 4 and moisture interference compensation adjustment Section 4 5 prior to analysis 4 3 2 Cleaning the Cell Block 1 Turn off the power switch stop the sample gas and allow the zero gas to flow for several minutes to purge the cell interior 2 Loosen the 2 setscrews...

Page 98: ...aning the infrared transmission window and cell inside surface first eliminate coarse dust using a soft brush and then wipe clean with a soft rag CAUTION THE WINDOW IS EASILY SCRATCHED USE EXTREME CARE WHEN PERFORMING THIS OPERATION SO AS NOT TO DAMAGE IT 7 After cleaning reinstall the sample cell and perform an optical zero adjustment see Section 4 4 and moisture interference compensation adjustm...

Page 99: ...bsequent analysis may adversely be affected This operation should be performed by a trained technician or the unit sent back to the factory for service The following adjustment is performed at reassembly after removing and cleaning the sample cell 1 Remove the top cover 2 Allow dry N2 or air to flow through the analyzer sample gas inlet until the reading stabilizes The sample gas is ...

Page 100: ...he display falls within 100 Figure 4 7 Optical Adjustment Display for Dual Optical System Option Table 4 2 Components of Optical Adjustment Screen No Of Components to be measured a b c d e f g h 1 component meter Main Comp NO SO2 NO Main NO Comp SO2 Main SO2 Comp CO2 CO CO2 Main CO2 Comp CO Main CO Comp 2 component meter NO CO NO Main NO Comp CO Main CO Comp 3 component meter NO SO2 CO NO Main NO ...

Page 101: ...ring components should be ignored 4 Adjust the primary side of the optical system if instrument is equipped with more than 1 measuring unit so that the onscreen values for a to d in 1 1 and 1 2 of become as close to 0 as possible within 100 range 5 Adjust on the secondary side of the optical system so that the values for e to h in 2 1 and 2 2 become as close to 0 as possible within 100 range 6 Ope...

Page 102: ...djust the beam adjustment plate which is the nearest to the zero adjustment knob first and sequentially 11 After the optical balance adjustment remount the top cover of the analyzer unit then carry out a moisture interference compensation adjustment and perform zero and span calibrations Note Before moving the beam adjustment plate loosen the detector set bolts just enough to make the plate movabl...

Page 103: ...allow dry gas N2 or air to flow at 0 5 L min and zero calibrate the analyzer 2 Display the moisture interference compensation screen of the analyzer unit see Section 3 6 5 Moisture Interference Adjustment Set the dew point to 2 C by using an electronic cooler and introduce bubbled N2 or air to the analyzer shown in the Figure 4 10 Figure 4 10 Bubbler Apparatus 3 On the screen select a desired chan...

Page 104: ... components exceed the range of 0 to 10 vol no adjustment can be performed No interference compensation is required 4 6 Error Messages You may encounter an onscreen error message depending on the process state or operational error The following table describes typical error messages and their cause Table 4 3 Error Messages Error Display Error Contents Probable Cause Error No 1 Motor rotation detec...

Page 105: ...ation was performed incorrectly Dirty cell Detector sensitivity has deteriorated Error No 8 Measured values fluctuate too much during zero and span calibration Calibration gas is not supplied Time for flowing calibration gas is too short Error No 9 Calibration is abnormal during auto calibration No 4 to No 8 Error occurred during Error No 10 Output cable connection is improper Wiring is detached b...

Page 106: ...use of an error the error will be displayed again When more than one error occurs pressing the SIDE key moves to another error display 4 6 1 Error Log File If error occurs the history is saved in an error log file The error log file exists in the maintenance mode 4 6 2 Error Log Screen Up to 14 errors can be saved in the error history the oldest error will be deleted one by one each time a new err...

Page 107: ...1 The Error Log Screen If the power supply is turned OFF the contents in the error log file will not be lost or damaged 4 6 3 Deleting Error Hstory Press the ENT key on the above screen and the Error Log Clear will be inverted Pressing the ENT key again will clear the error history ...

Page 108: ...Maintenance Model 7600 Teledyne Analytical Instruments 108 ...

Page 109: ...0 100vol CO 0 50ppm 0 100vol CH4 0 200ppm 0 100vol O2 built in 0 5vol 0 25vol O2 Ext Zirconia 0 5vol 0 25vol Ranges 2 each channel user settable between Max and Min Measuring Range Ratio 1 5 O2 1 25 other than O2 Principle of measurement NO SO2 CO2 CO Non dispersion infrared ray absorption Single light source and double beam double beam system O2 Paramagnetic O2 sensor built in or zir conia O2 sen...

Page 110: ...ontact 250V AC 2A resistive load selectable 6 outputs High Low limit alarm contact output Power disconnection alarm Contact Input No voltage contact ON 0V OFF 5V DC 5mA flowing at ON Remote range switch auto calibration remote start remote holding average value resetting pump ON OFF Isolated from the internal circuit with photocoupler Contact inputs are not iso lated from one another Other Output ...

Page 111: ...prene rubber IR window CaF2 O2 sensor sample cell SUS316 Internal piping Toaron Teflon Gas Inlet Outlet Rc1 4 or NPT1 4 internal thread Purge Gas Flowrate 1L min when required A 2 Standard Functions Output signal holding Output signals are held during manual and auto calibrations by activation of holding turning ON its setting The values to be held are the ones just before start calibration mode o...

Page 112: ...Allows range to switch via an external signal when remote range switch input is received When the contact input terminals for each component are short circuited the first range is selected and it is switched to the second range when the terminals are open Range identification signal The present measuring range is identified by a contact signal The contact output terminals for each component are sh...

Page 113: ...bration is carried out only once according to an external input signal Calibration sequence is settable in the same way as the general auto calibration Auto calibration is started by opening the auto calibration remote start input termi nals after short circuiting for 1 5 seconds or longer Auto zero calibration Auto zero calibration is carried out periodically at the preset cycle This cycle is ind...

Page 114: ...Contacts close when the channel value of each channel becomes larger than the high alarm limit value or smaller than the low alarm limit value Instrument error contact output Contacts close at occurrence of analyzer error No 1 3 or 10 Calibration error contact output Contacts close at occurrence of manual or auto calibration error any of errors No 4 to 9 Auto calibration status contact outputs Con...

Page 115: ...lt of O2 correction or instanta neous O2 value can be output as an av erage value in the preset period of time The moving average method is used for averaging in which sampling is carried out at intervals of 30 seconds Output is updated every 30 seconds It is the average value in the determined period of time just before the latest update Averaging time is settable within 1 to 59 minutes in increm...

Page 116: ...mmunication function RS 232C 9 pin D sub Half duplex bit serial Start stop synchronization Modbus TM protocol Contents Read Wright parameters Read measurement concentration and instrument status Remark When connecting via RS 485 interface a RS 232C RS 485 converter should be used A 4 Performance Repeatability 0 5 of full scale Linearity 1 of full scale Zero drift 1 of full scale week 2 of full sca...

Page 117: ... Dust 100 g Nm3 in particle size of 1μm or less Mist Unallowable Moisture Below saturation at 2 C condensation un allowable Corrosive component 1 ppm or less Standard gas for calibration Zero gas Dry N2 Span gas Each sample gas having concentration 90 to 100 of its measuring range recommended Concentration above 100 FS is unusable If an external zirconia O2 sensor is installed and calibration is c...

Page 118: ...ce The product conforms to the requirements of the Low Voltage Directive 73 23 EEC 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 electromagnetic compatibility EN61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use Installation Category II...

Page 119: ...Infrared Gas Analyzer Appendix Teledyne Analytical Instruments 119 A 8 Terminal Block Connections ...

Page 120: ...Appendix Model 7600 Teledyne Analytical Instruments 120 A 9 Description on Terminal Block ...

Page 121: ...Infrared Gas Analyzer Appendix Teledyne Analytical Instruments 121 ...

Page 122: ...Appendix Model 7600 Teledyne Analytical Instruments 122 ...

Page 123: ...Infrared Gas Analyzer Appendix Teledyne Analytical Instruments 123 ...

Page 124: ...Appendix Model 7600 Teledyne Analytical Instruments 124 ...

Page 125: ...Index caution sign iv combustible gas warning xi copyright ii figures listing ix instasllation checklist 33 leak check 33 manuals additional v safety information iv serial number iii tables listing x technician symbol iv warning sign iv warranty ii website address v ...

Page 126: ...Index Model 7600 Teledyne Analytical Instruments 126 ...

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