Teledyne 7500 Series User manual

TELEDYNE
ANALYTICAL INSTRUMENTS
OPERATING INSTRUCTIONS
Series Model 7500
Infrared Gas Analyzer
DANGER
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS
MONITORING SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
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
07/07/11

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Teledyne Analytical Instruments
PREFACE
We are grateful for your purchase of Teledyne Analytical Instrumentʼs Model 7500 Infrared Gas
Analyzer.
• First read this instruction manual carefully until an adequate understanding is acquired, and then
proceed to installation, operation and maintenance of the analyzer. Wrong handling may cause an
accident or injury.
• The specications of this analyzer are subject to change without prior notice for further product
improvement.
• Modication of this analyzer is strictly prohibited unless a written approval is obtained from the
manufacturer. Teledyne will not bear any responsibility for a trouble caused by such a modication.
• This instruction manual shall be stored by the person who actually uses the analyzer.
• After reading the manual, be sure to store it at a place easier to access.
• This instruction manual should be delivered to the end user without fail
Delivered Items:
Analyzer main frame (1)
Power cable (1)
Fuse (2) Rating : 1 A
Instruction manual (1)
Side rail (2) Option
• It is prohibited to transfer part or all of this manual without Teledyneʼs permission.
• Description in this manual is subject to change without prior notice for further improvement.

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SAFETY PRECAUTIONS
Please read this section carefully to ensure using the analyzer in the correct way.
The cautionary descriptions listed here contain important information about safety, so they should
always be observed. Those safety precautions are ranked in 3 levels, “DANGER”, “CAUTION” and
“PROHIBITED”.
DANGER Wrong handling may cause a dangerous situation,
in which there is a risk of death or heavy injury.
CAUTION Wrong handling may invite a dangerous situation,
in which there is a possibility of medium-level
trouble or slight injury or only physical damage is
predictable.
PROHIBITED Items which must not be done are noted.
Caution on installation and transport of gas analyzer
DANGER • This unit is not explosion-proof type. Do not
use it in a place with explosive gases to prevent
explosion, re or other serious accidents.
CAUTION • For installation, observe the rule on it given in the
instruction manual and select a place where the
weight of gas analyzer can be endured. Installation
at an unsuited place may cause turnover or fall
and there is a risk of injury.
• For lifting the gas analyzer, be sure to wear
protective gloves. Bare hands may invite an injury.
• Before transport, x the casing so that it will not
open. Otherwise, the casing may be separated
and fall to cause an injury.
• During installation work, care should be taken to
keep the unit free from cable chips or other foreign
objects. Otherwise, it may cause re, trouble or
malfunction of the unit.

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Caution on piping
DANGER In piping, the following precautions should be
observed. Wrong piping may cause gas leakage. If
the leaking gas contains a toxic component, there
is a risk of serious accident being induced. Also, if
combustible gas is contained, there is a danger of
explosion, re or the like occurring.
• Connect pipes correctly referring to the
instruction manual.
• Exhaust should be led outdoors so that it will not
remain in the locker and installation room.
• Exhaust from the analyzer should be relieved in
the atmospheric air in order that an unnecessary
pressure will not be applied to the analyzer.
Otherwise, any pipe in the analyzer may be
disconnected to cause gas leakage.
• For piping, use a pipe and a pressure reducing
valve to which oil and grease are not adhering.
If such a material is adhering, a re or the like
accident may be caused.
Caution on wiring
CAUTION • Wiring work must be performed with the main
power set to OFF to prevent electric shocks.
• Enforce construction of class-D rounding wire by
all means. If the specied grounding construction
is neglected, a shock hazard or fault may be
caused.
• Wires should be the proper one meeting the
ratings of this instrument. If using a wire which
cannot endure the ratings, a re may occur.
• Be sure to use a power supply of correct rating.
Connection of power supply of incorrect rating may
cause re.
Caution on use
DANGER • For correct handling of calibration gas or other
reference gases, carefully read their instruction
manuals beforehand. Otherwise, carbon monoxide
or other hazardous gases may cause an
intoxication particularly.
CAUTION • Before leaving unused for a long time or
restarting after left at such a status for an
extended length of time, follow the directions of
each instruction manual because they are different
from normal starting or shutdown. Otherwise, the
performance may be poor and accidents or injuries
may be caused.
• Do not operate the analyzer for a long time with
its door left open. Otherwise, dust, foreign matter,
etc. may stick on internal walls, thereby causing
faults.

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Caution on use
PROHIBITED • Do not allow metal, nger or others to touch the
input/output terminals in the instrument. Otherwise,
shock hazard or injury may occur.
• Do not smoke nor use a ame near the gas
analyzer. Otherwise, a re may be caused.
• Do not allow water to go into the gas analyzer.
Otherwise, hazard shock or re in the instrument
may be caused.
Caution on maintenance and check
DANGER • When doors are open during maintenance or
inspection, be sure to purge sufciently the inside
of the gas analyzer as well as the measuring
gas line with nitrogen or air, in order to prevent
poisoning, re or explosion due to gas leak.
CAUTION Be sure to observe the following for safe operation
avoiding the shock hazard and injury.
• Remove the watch and other metallic objects
before work.
• Do not touch the instrument wet-handed.
• If the fuse is blown, eliminate the cause, and then
replace it with the one of the same capacity and
type as before. Otherwise, shock hazard or fault
may be caused.
• Do not use a replacement part other than
specied by the instrument maker. Otherwise,
adequate performance will not be provided.
Besides, an accident or fault may be caused.
• Replacement parts such as a maintenance part
should be disposed of as incombustibles. For
details, follow the local ordinance.
Others
CAUTION • If the cause of any fault cannot be determined
despite reference to the instruction manual, be
sure to contact the factory. If the instrument is
disassembled carelessly, you may have a shock
hazard or injury.

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CONTENTS
PREFACE .............................................................................................................................2
CAUTION ON SAFETY ..........................................................................................................3
1. OVERVIEW.........................................................................................................................8
2. NAME AND DESCRIPTION OF EACH PART ...................................................................9
2.1 Description of each unit ......................................................................................9
3. INSTALLATION ................................................................................................................10
3.1 Installation conditions ........................................................................................10
3.2 Installation of analyzer .......................................................................................11
3.3 Piping .................................................................................................................11
3.4 Sampling ............................................................................................................12
3.5 Wiring method ....................................................................................................15
4. OPERATION ................................................................................................... ..................24
4.1 Preparation for operation ....................................................................................24
4.2 Warm-up operation and regular operation ..........................................................24
5. DESCRIPTION OF DISPLAY AND OPERATION PANEL .................................................25
5.1 Name and description of operation panel ...........................................................25
5.2 Overview of display and operation panel ............................................................26
5.3 Overview of display screen .................................................................................27
5.4 General operation................................................................................................30
6. SETTING AND CALIBRATION...........................................................................................31
6.1 Changeover of range ..........................................................................................31
6.2 Calibration setting ...............................................................................................32
6.2.1 Setting of calibration concentration......................................................32
6.2.2 Setting of manual zero calibration ...................................................... 34
6.2.3 Setting of calibration range ..................................................................36
6.2.4 Setting of auto-calibration component .................................................38
6.3 Alarm setting ........................................................................................................40
6.3.1 Setting of alarm values ........................................................................40
6.3.2 Hysteresis setting ................................................................................42
6.4 Setting of auto calibration ....................................................................................43
6.4.1 Auto calibration ....................................................................................43
6.4.2 Forced stop of auto calibration ............................................................45
6.5 Setting of auto zero calibration ............................................................................47
6.5.1 Auto zero calibration ............................................................................47
6.5.2 Forced stop of auto zero calibration ....................................................49
6.6 Peak alarm setting ...............................................................................................51
6.7 Parameter setting ................................................................................................53

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6.8 Maintenance mode …………………………………………………………………… 57
6.9 Calibration …………………………………………………………………………….. 59
6.9.1 Zero calibration …………………………………………………………… 59
6.9.2 Span calibration ………………………………………………………….. 60
7. MAINTENANCE ................................................................................................... 61
7.1 Daily check ............................................................................................ 61
7.2 Daily check and maintenance procedures ............................................ 61
7.3 Cleaning of measuring cell .................................................................... 62
7.3.1 Disassembly and assembly of measuring cell ....................... 62
7.3.2 How to clean cell ……………………………………………….. 67
8. TROUBLESHOOTING ......................................................................................... 68
8.1 Error message .......................................................................................... 68
9. SPECIFICATIONS ............................................................................................... 70
9.1 Specifications ………………………………………………………………. 70
9.2 Code symbols ………………………………………………………………. 73
9.3 Outline diagram …………………………………………………………….. 78
APPENDIX ………………………………………………………………………………… 80
Drawing List ............................................................................................................. 80

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1. OVERVIEW
The Model 7500 infrared gas analyzer measures the concentrations of CO2, CO, CH4, SO2 and O2
contained in sample gas. CO2, CO, CH4 and SO2 are measured by non-dispersion infrared method,
while O2 is measured by paramagnetic method. A maximum of 4 components including O2 (a maximum
of 3 components for other than O2 measurement) are simultaneously measurable.
A high-sensitivity mass ow sensor is used in the detector unit of infrared method. Due to use of single
beam system for measurement, maintenance is easy and an excellent stability is ensured for a long
period of time.
In addition, a microprocessor is built in and a large sized liquid crystal display is provided for easier
operation, higher accuracy and more functions.
This analyzer is thus optimum for combustion control of various industrial furnaces, botanical study and
global atmospheric research.

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2. NAME AND DESCRIPTION OF EACH PART
2.1 Description of each unit
Name Description
1. Handle Draws the analyzer unit from the case.
2. Power switch Turns ON/OFF this analyzer.
3. Switch for back light Turn ON/OFF the back light of display.
4. Display / Operation panel Liquid crystal display and keys for various
operational settings are arranged.
5. Sampling gas inlet Port for connecting the sample gas injection pipe.
6. Sampling gas outlet Port for connecting the pipe for discharging the
gas after analysis.
7. Purge gas inlet Port for connecting the purge gas pipe.
8. Terminal block 1 Analog output terminals
9. Terminal block 2 Analog signal and contact input terminals
10. Terminal block 3 Contact output terminals
11. Terminal block 4 Contact output terminal
12. Terminal block 5 Alarm output terminal
13. Connector 2 Communication interface
14. Power inlet Used to connect the power cable.

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3. INSTALLATION
DANGER
This unit is not explosion-proof type. Do not use it in a place with explosive gases to avoid explosion, re
or other serious accidents.
CAUTION
• For installation, observe the rule on it given in the instruction manual and select a place where the
weight of gas analyzer can be endured. Installation at an unsuited place may cause turnover or fall and
there is a risk of injury.
• For lifting the gas analyzer, be sure to wear protective gloves. Bare hands may invite an injury.
• Before transport, x the casing so that it will not open. Otherwise, the casing may be separated and fall
to cause an injury.
• The gas analyzer is heavy. It should be transported carefully by two or more persons if manually
required. Otherwise, body may be damaged or injured.
• During installation work, care should be taken to keep the unit free from cable chips or other foreign
objects. Otherwise, it may cause re, trouble or malfunction of the unit.
3.1 Installation conditions
To install the analyzer for optimum performance, select a location that meets the following conditions:
(1) Use this instrument indoors.
(2) A vibration-free place
(3) A place which is clean around the analyzer.
(4) Power supply
Rated voltage: 100V to 240VAC
Operating voltage: 85V to 264VAC
Rated frequency: 50/60 Hz
Power consumption: 70 VA max.
Inlet: Conformity to EN60320 class I type 3-pin inlet
(5) Operation conditions
Ambient temperature: -5 to 45°C
Ambient humidity: 90% RH or less, no condensation

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3.2 Installation of analyzer
There are two methods of installing the analyzer.
For detailed dimensions, see Chapter 9.3.
Note: The mounting method should be selected to meet the installation requirements since the top cover
must be detached from the gas analyzer for maintenance and check.
Mounting method Conditions Remarks
Slide rail No maintenance space is
provided at the top.
These methods must be rigid enough to
withstand the mass (about 10 kg) of the
gas analyzer.
Guide rail Maintenance space is provided
at the top
Recommended slide rail: 305A-20, Accuride International Inc.
3.3 Piping
Caution on piping
CAUTION In piping, the following precautions should be observed.
Wrong piping may cause gas leakage.
If the leaking gas contains a toxic component, there is a risk of serious accident being
induced.
Also, if combustible gas is contained, there is a danger of explosion, re or the like
occurring.
• Connect pipes correctly referring to the instruction manual.
• Exhaust should be led outdoors so that it will not remain in the locker and installation
room.
• Exhaust from the analyzer should be relieved in the atmospheric air in order that an
unnecessary pressure will not be applied to the analyzer. Otherwise, any pipe in the
analyzer may be disconnected to cause gas leakage.
• For piping, use a pipe and a pressure reducing valve to which oil and grease are not
adhering. If such a material is adhering, a re or the like accident may be caused.

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Observe the following when connecting the gas pipes.
• The pipes should be connected to the gas inlet and outlet at the rear panel of the analyzer, respectively.
• Connect the sampling system to the instrument by using corrosion-resistant tube such as Teon,
stainless steel, or polyethylene. In case where there is no danger of corrosion, donʼt use rubber or soft
vinyl tube. Analyzer indication may become inaccurate due to the adsorption of gases.
• Piping connections are Rc1/4 (NPT1/4) female-threaded. Cut the pipe as short as possible for quick
response. Pipe of ø 4mm (inside diameter) is recommendable.
• Entry of dust in the instrument may cause operation fault. Use clean pipes and couplings.
Sampling gas inlet: Connect the pipe so that zero/span calibration standard gas or measured gas
pre-treated with dehumidication is supplied properly. The gas ow rate should
be kept constant within the range of 1 L/min ±0.5 L/min.
Sampling gas outlet: Measured gas is exhausted after measurement.
Connect the pipe so that the gas may escape through the gas outlet into the
atmosphere.
Purge gas inlet: It is used for purging the inside of the total gas analyzer. When the analyzer must
be purged, refer to Item 3.4, Purging inside Analyzer. Use dry gas N2 or
instrumentation air for purge gas. (ow rate of 1 L/min or more should be used
and no dust or mist is contained).
3.4 Sampling
(1) Conditions of sample gas
1. The dust contained in sample gas should be eliminated completely with lters. The lter at the
nal stage should be capable of eliminating dust of 0.3 microns.
2. The dew point of sample gas must be lower than the ambient temperature for preventing
formation of drain in the analyzer. If water vapor is contained in sample gas, its dew point should be
reduced down to about 0°C through a dehumidier.
3 If SO3 mist is contained in sample gas, the mist should be eliminated with a mist lter, cooler, etc.
Eliminate other mist in the same way.
4. If a large amount of highly corrosive gas such as Cl2, F2 or HCl is contained in sample gas, the
service life of analyzer will be shortened. So, avoid such gases.
5. Sample gas temperature is allowed within a range from 0 to 50°C. Pay attention not to ow hot
gas directly into the analyzer.

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(2) Sampling gas ow rate
A ow rate of sampling gas must be 1 L/min ±0.5 L/min. A ow meter should be provided as
shown in Fig. 3-2 to measure ow rate values.
(3) Preparation for standard gas
Prepare the standard gas for zero/span calibration.
No O2 meter Built in O2 meter Externally mounted
zirconia O2 meter
Zero gas N2 gas N2 gas Dry air or air (No
calibration performed
with CO2 meter)
Span gas except for O2 Gas with concentration
of 90% or more of full
scale
Gas with concentration
of 90% or more of full
scale
Gas with concentration
of 90% or more of full
scale
Span gas for O2 Gas with concentration
of 90% or more of full
scale
1 to 2% of O2 gas
(4) Purging of instrument inside
The inside of instrument need not be purged generally except for the following cases.
1. A combustible gas component is contained in 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 as above, the inside of analyzer should be purged with the air for instrumentation or N2.
Purging ow rate should be about 1L/min.
If dust or mist is contained in purging gas, it should be eliminated completely in advance.
(5) Pressure at sampling gas outlet
Pressure at the sampling gas outlet should be set to atmospheric pressure.

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(6) Example of sampling system conguration
The system conguration may vary depending upon the nature of measured gas, coexistent gases or
application. A typical conguration diagram is shown in Fig. 3-2. Since a system conguration depends
upon measured gas, consult with Teledyne.
Fig. 3-2 A typical example of sampling system

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3.5 Wiring method
Caution on wiring
CAUTION • Wiring work must be performed with the main
power set to OFF to prevent electric shocks.
• Enforce construction of class-D grounding wire
by all means.
If the specied grounding construction is
neglected, a shock hazard or fault may be caused.
• Wires should be the proper one meeting the
ratings of this instrument. If using a wire which
cannot endure the ratings, a re may occur.
• Be sure to use a power supply of correct rating.
Connection of power supply of incorrect rating may
cause re.
Each external terminal is provided on the rear panel of the analyzer. (See Fig. 3-3)
Wire each terminal, referring to Fig. 3-3 and (1) to (7).
Fig. 3-3 Rear panel
(1) Power inlet
When using supplied power cable, connect the female side to the power inlet at the rear panel of the
analyzer, and insert the male side into a receptacle matching the rating.

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When a noise source is in the vicinity
Do not install the analyzer near power noise generating electric equipment (such as high frequency
furnace and electric welder). If the analyzer must be used near such equipment, a separate power line
should be used for avoiding noise. In case noise may enter from a relay, solenoid valve, etc. through
power supply, connect a varistor (such as ENA211-2 made by Fuji Electric) or spark killer (like S1201
made by OKAYA) to the noise source as shown below. If the varistor or spark killer is located away from
the noise source, no effect is obtainable. So, locate near the noise source.
(2) Analog output signal (AO): terminal block 1 (1 to 10, 15 to 20)
Output signal: 4 to 20 mADC or 0 to 1 VDC (selected when ordering)
Non-insulated output
Allowable load: 4 to 20 mADC, 550Ω or less
0 to 1 VDC, 100kΩ or less
• Analog output is provided from each terminal corresponding to the channel displayed in the
measurement screen.
Note: All of analog output signals for the instrument are not isolated. It is recommended to isolate
signals individually to prevent interference from unnecessary signals or to prevent external interference,
especially leading the cable of more than 30 meters or to outdoor.
(3) O2 sensor input: terminal block 2 (1 – 2)
Input signal:
External zirconia O2 analyzer: Zirconia O2 sensor signal (Teledyne output)
External O2 analyzer: 0 to 1 VDC (DC input resistor of 1MΩ or more)
• It is used when the external zirconia O2 analyzer or external O2 analyzer is specied as order.
• To connect to the output of the external Zirconia analyzer or external O2 analyzer prepared separately.
• In case of an external O2 analyzer, input a signal of 0 to 1 VDC with respect to O2 full scale of the
analyzer.
• In case of built-in O2 analyzer, do not use the terminals.
Note: O2 sensor input is not isolated. It is recommended to isolate input signal to prevent interference
from unnecessary signals or to prevent external interference. Zirconia O2 sensor should be installed at a
location that is as close to this instrument as possible.

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(4) Contact input (DI): terminal block 2 (13 to 20), terminal block 3 (5 to 10)
• It is for a contact input at no voltage. An input is provided when switching to short circuit (on) or
open (off).
• No voltage is applied to the terminals
(5) Contact output (DO): terminal block 3 (13 to 20), terminal block 4 and terminal block 5
• Contact rating: 250VAC / 2A, load resistance
• An output is for a relay contact output. An output is provided when switching to conductive (on)
or open (off).
Note: The wires of analog output signals, O2 sensor input and contact input should be xed separately
from power supply wiring and contact output wiring.
(6) Communication interface: connector 2
• Please refer to the manual for communication function.

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(7) List of terminal blocks 1 to 5
*1) Unused terminals are used for internal
connection and should not be used as repeating
terminals either.
*2) O2 sensor input is used when an external O2
analyzer is selected.

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8) Description on terminal block
Terminal block 1 <TN1>
Terminal block for analog output (non-isolated output)
Output : 4 to 20 mA or 0 to 100V DC
Between 1 – 2: CH5 output
Between 3 – 4: CH4 output
Between 5 – 6: CH3 output
Between 7 – 8: CH2 output
Between 9 – 10: CH1 output
Between 11 – 14: For internal connection. Must not be
wired. (Must not be used as junction
terminal.)
Between 15 – 16: CH8 output
Between 17– 18: CH7 output
Between 19 – 20: CH6 output
Terminal block 2 <TN2>
Between 1– 2: For O2 sensor input. (Input for our
Zirconia oxygen sensor or external
O2 sensor. Must not be used unless
O2 meter is added.)
Between 3 –12: For internal connection. Must not be
wired. (Must not be used as junction
terminal.)
Between 13 – 14: CH4 remote range changeover input
Between 15 – 16: CH3 remote range changeover input
Between 17 – 18: CH2 remote range changeover input
Between 19 – 20: CH1 remote range changeover input
Note: High range is selected when open. Low range is
selected when short-circuited. For details of action, refer to “6.7
Parameters Setting, “Remote Range”.

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Terminal block 3 <TN3>
Between 1 – 4: For internal connection. Must not be
wired. (Must not be used as junction
terminal.)
Between 5 – 6: Remote hold input. No hold when open.
Output hold when short-circuited.
Between 7 – 8: Average value reset input. Short-
circuiting the contact input (for at 1.5 sec
or more) resets O2 average and O2
correction average simultaneously.
Opening it restarts the average value.
Between 9 – 10: Automatic calibration remote start
input. Open input after strapping for
at least 1.5 seconds starts the automatic
calibration whether automatic calibration
setting is ON or OFF.
Between 11 – 12: Conductive when analyzer unit error
is producted. Normally open.
Between 13 – 14: CH4 range identication signal
Between 15 – 16: CH3 range identication signal
Between 17– 18: CH2 range identication signal
Between 19– 20: CH1 range identication signal
Note: Range identication signal is conductive at Low range
or open at High range. In case of 1-range system, the signal
remains open.