Fuji Labs Welding Consumables ZSP User Manual

Instruction Manual

INFRARED GAS

ANALYZER

TYPE: ZSP

INZ-TN4ZSPb-E

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CAUTION ON SAFETY

Before use, carefully read this “Caution on safety” so that the product is usable correctly.

• The precautions given here are of great significance to safety. Therefore, they should be observed without fail.

The precautions on safety are classified into ranks “Danger”, “Caution” and “Prohibition.”

Danger

Items which pertains to incorrect handling that may lead to personal death

or serious injury

Caution

Items which pertains to incorrect handling that may lead to medium trouble,

injury or physical damage

Prohibition

Items which pertains to prohibition (DO NOT)

Installation, carrying, relocation and storage of gas analyzer

Danger

• This product is not explosion-proof. Do not use it in explosive gas-rich atmosphere. Otherwise,

serious accidents such as explosion and fire may be caused.

Caution

• Installation, carrying and relocation must be made by a qualified contractor or your dealer.

Incorrect installation results in falling accidents, electric shocks or fire accidents.

• The gas analyzer is heavy. Special care should be taken for installation to prevent trouble or injury due

to falling or dropping of the analyzer.

• When the gas analyzer needs to be lifted, be sure to put on gloves. Do not hold it with bare hands to

prevent injury.

• This product must be installed in a place that meets the conditions specified in the ‘instruction manual’

Use in a place that is outside the given installation conditions may cause an electric shock, fire or

malfunction.

• During installation work, attention should be paid not to allow entrance of wire fragments, etc. into the

product. Otherwise, a fire, trouble or malfunction may be caused.

– ii –

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Caution on wiring

Caution

• Request an installation company or your dealer to carry out wiring.

If wiring is incomplete, shock hazard or injury may be caused.

• Class D grounding construction is mandatory. Otherwise, shock hazard may be caused.

< Caution for wiring company >

For preventing shock hazard, fire and injury, be sure to observe the following.

• Before wiring, be sure to turn off the primary power supply. If this is neglected, you may receive an

electric shock.

• For grounding, use a 600 V-IV wire having a diameter of 2 mm²or more and an adequate dielectric

strength.

• Connect the power supply which meets the rating of product. Connection of other power supply may

cause a fire.

• Select the diameter of input and output wires, which matches the rated current of gas analyzer.

• Be sure to use solderless terminals for connection to the input and output terminal block.

• Use the terminal block for branching the output wire.

• Be sure to fix the input and output wires onto the floor, wall surface, etc. and use a protective device

for wires.

Caution on use

Danger

• If you notice malodor or abnormal sound, stop the instrument immediately. If this is neglected, fire

may occur.

Caution

• When the analyzer is to be operated after it has been left unused for a long time, the operating proce-

dure is different from the normal stop/start procedure. It should be handled according to the procedure

shown in the instruction manual to ensure its proper performance and to prevent trouble or injury.

• Do not operate the analyzer for a long time with its door left open to avoid entry of dust into the

analyzer. Dust deposits will result in damage to the analyzer.

– iii –

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Caution on use

Prohibition

• Do not insert a rod or your finger into the fan (electronic cooler at ceiling), otherwise injury may be

caused by the rotating blades.

• Do not touch metal, finger, etc. to the input and output terminal block of analyzer. Otherwise, shock

hazard or injury may be caused.

• Smoking and use of fire/flame is prohibited in the vicinity of the gas analyzer. Otherwise, a fire may

occur.

• A water-filled container such as a bucket should not be placed on the roof of the gas analyzer having

indoor specifications. If such a container turns over, spilled water may cause shock hazard or burning

inside the analyzer.

Caution on maintenance / inspection

Danger

• When handling standard gas such as calibration gas, read the instruction manual for the standard gas

for correct handling. Special care should be taken when handling hazardous gas such as CO gas and

the like to prevent poisoning.

• During maintenance or inspection, be sure to turn ON the ventilation fan in the analyzer to prevent

poisoning due to gas leakage.

• When the gas filter of the analyzer is to be replaced or the washing unit needs maintenance, be sure to

close the calibration gas valve. Especially, if the calibration gas valve is located at the sample gas

inlet, the replacing or washing shall be done after closing the calibration gas valve to prevent poison-

ing or other trouble.

Caution

• The gas converter is heated to about 220°C. When the catalytic agent needs to be replaced, turn OFF

the power for the converter and use heat-proof gloves about 30 minutes later.

• When the fuse is blown off, check the cause of it and replace it with the same type of fuse having the

same capacity to prevent electric shocks or other trouble.

• When the analyzer is provided with a power leak relay, press the test button to confirm proper opera-

tion before making maintenance or inspection to prevent electric shocks.

• Be sure to lock the door. Do not allow unauthorized persons to use the door key. Do not touch the

door carelessly to prevent electric shocks and other trouble.

The following items must be observed to prevent electric shocks or injury and to ensure safety.

• Take off metallic objects such as wrist watch before starting the work.

• Do not touch the device with wet hands.

– iv –

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Others

Caution

• When trouble cannot be remedied even after following the instruction manual, contact your dealer or

Fuji's service station (serivice engineer). Do not disassemble the device, as it results in electric shocks

or injury.

• Do not use replacement parts which are not specified by makers. Use of these parts will not only

provide the required performance but also result in damage or other trouble.

• Replacement parts used for maintenance must be handled as incombustible objects.

– v –

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CONTENTS

INTRODUCTION ................................................................................................................................................... i

CAUTION ON SAFETY ....................................................................................................................................... ii

1. OUTLINE ....................................................................................................................................................... 1

2. SPECIFICATIONS ........................................................................................................................................ 1

3. COMPOSITION ............................................................................................................................................. 1

4. INSTALLATION ........................................................................................................................................... 2

4.1

4.2

4.3

4.4

4.5

Selection of installation site ................................................................................................................ 2

Selection of gas sampling location ...................................................................................................... 2

Installation work.................................................................................................................................. 3

Connection of cables ........................................................................................................................... 3

Connection of pipes............................................................................................................................. 3

5. DESCRIPTION OF EACH PART ................................................................................................................. 5

6. PREPARATION FOR OPERATION ............................................................................................................ 5

6.1

6.2

6.3

6.4

6.5

6.6

Injection of clean water ....................................................................................................................... 5

Supply of external power .................................................................................................................... 5

Check of sample piping, exhaust piping, etc....................................................................................... 5

Airtightness test ................................................................................................................................... 6

Setting of temperature inside locker.................................................................................................... 6

Warm-up time ..................................................................................................................................... 6

7. INDICATION/OPERATION PANEL ........................................................................................................... 7

7.1

7.2

7.3

Name and description of each component of indication/operation panel ........................................... 7

Function and indication of indication/operation panel........................................................................ 8

General operation of indication/operation panel ................................................................................. 9

8. CALIBRATION ........................................................................................................................................... 10

8.1

8.2

8.3

8.4

8.5

8.6

8.7

Kinds of standard gas ........................................................................................................................ 10

Preparation of standard gas ............................................................................................................... 10

Calibration concentration setting (except zirconia O₂sensor) .......................................................... 12

Calibration concentration setting (zirconia O₂sensor) ..................................................................... 14

Zero calibration (air point calibration in case of zirconia O₂sensor) ............................................... 16

Span calibration (low concentration point calibration in case of zirconia O₂sensor) ...................... 17

Auto calibration ................................................................................................................................. 18

9. OPERATION ............................................................................................................................................... 25

9.1

Operating procedure .......................................................................................................................... 25

– vi –

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10. MAINTENANCE ......................................................................................................................................... 26

10.1 Routine maintenance and inspection................................................................................................. 26

10.2 Periodic maintenance and inspection ............................................................................................... 28

10.3 Other maintenance and inspection .................................................................................................... 28

10.4 Concentration guarantee term of standard gas cylinder (for NO_x, SO₂, CO and O₂analyzer) ......... 29

10.5 Maintenance of sampling device ....................................................................................................... 29

10.6 Maintenance of zirconia O₂sensor.................................................................................................... 35

10.7 Others, major component figures ...................................................................................................... 35

11. STANDARD ACCESSORIES AND SPARES ........................................................................................... 36

11.1 Standard accessories.......................................................................................................................... 36

11.2 Spares for 1 year (optional) ............................................................................................................... 37

12. PROCESSING OF HEATING PIPE ENDS ................................................................................................ 38

12.1 Outline ............................................................................................................................................... 38

12.2 End processing method ..................................................................................................................... 39

12.3 Check after piping ............................................................................................................................. 41

12.4 Clamp support ................................................................................................................................... 41

12.5 Specifications of tube trace ............................................................................................................... 42

12.6 Specifications of heating pipe ........................................................................................................... 42

13. TROUBLESHOOTING ............................................................................................................................... 43

13.1 Troubleshooting of instrument .......................................................................................................... 43

13.2 Error codes and remedies .................................................................................................................. 44

14. SPECIFICATIONS ....................................................................................................................................... 45

CODE SYMBOLS ............................................................................................................................................... 49

SAMPLING SYSTEM BLOCK DIAGLAM ...................................................................................................... 50

OUTLINE DIAGRAM......................................................................................................................................... 52

CONNECTION DIAGRAM ................................................................................................................................ 53

– vii –

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1. OUTLINE

The infrared gas analyzer (ZSP) can continuously and accurately measure the concentration of gases such as NOx,

SO₂, CO, CO₂and O₂contained in the flue gas from a stationary generating source. The analyzer is available in

both single-component and multi-component types depending on customer’s specification. The actual analyzer

may somewhat differ from the descriptions in this manual depending on the specifications demanded by each

customer. For outline diagram, piping system, hardware configuration, specifications, standard accessories, spares

and supplies, refer to the delivery specifications submitted individually.

Note: For details of the infrared gas analyzer, refer to the instruction manual INZ-TN2 ZRG separately

prepared.

2. SPECIFICATIONS

Please refer to Chapter 14. Specifications. Note that the contents of the separately issued data sheet have priority.

3. COMPOSITION

(1) Gas sampling section

(2) Gas piping

1 set (depending on customers’ designation)

(3) Accommodation locker

Infrared gas analyzer ZRG

Zirconia O₂sensor ZFK 3, 4

Converter ZDL

1 or 2 (depending on customers’ designation)

1 (depending on customers’ designation)

1 (for NO_xmeasurement)

Sampling

1 set

Standard gas, pressure regulator

Standard accessories

1 set (depending on customers’ designation)

1 set

Spares and supplies for 1 year

1 set (depending on customer’s designation)

– 1 –

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4. INSTALLATION

Danger

• This product is not explosion-proof. Do not use it in explosive gas-rich atmosphere. Otherwise, serious

accidents such as explosion and fire may be caused.

Caution

• Installation, carrying and relocation must be made by a qualified contractor or your dealer.

Incorrect installation results in falling accidents, electric shocks or fire accidents.

• The gas analyzer is heavy. Special care should be taken for installation to prevent trouble or injury due

to falling or dropping of the analyzer.

• When the gas analyzer needs to be lifted, be sure to put on gloves. Do not hold it with bare hands to

prevent injury.

• This product must be installed in a place that meets the conditions specified in the ‘instruction manual.’

Use in a place that is outside the given installation conditions may cause an electric shock, fire or mal-

function.

• During installation work, attention should be paid not to allow entrance of wire fragments, etc. into the

product. Otherwise, a fire, trouble or malfunction may be caused.

There are a number of conditions which must be met for operating the gas analyzer stably over a long time.

4.1 Selection of installation site

A site which satisfies the following conditions should be selected for installation of the analyzer.

(1) A place which is near the gas sampling location

(2) A place which is not exposed to direct sunlight or heat radiated from a high temperature object (One

which is not exposed to rain or water splash in case of indoor type)

(3) A place which has a clean atmosphere (dust and corrosive gas not present)

(4) A place with a minimum of vibration

(5) A place where daily variation in temperature is minimum

4.2 Selection of gas sampling location

A place which satisfies the following conditions should be selected.

(1) A typical place where the gases to be analyzed exist

(2) Where the gases always flow without stagnation

(3) A place easy of access for maintenance and inspection

(4) Where the gases respond quickly to a change in the process operating conditions

(5) Where variation in pressure, temperature, etc. is minimum

– 2 –

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4.3 Installation work

For installation of the analyzer locker and the extractor, follow the piping instructions in Fig. 4-1 and the

separately issued approval drawings (outline diagrams, sampling system diagram).

(1) Countermeasures for cold climate

(a) Freeze prevention of gas piping

(b) Freeze prevention of drain pot

(2) Countermeasurement for vibration

When installing in a place where vibration is considerable, the locker should be floated on antivibration

rubber pads.

4.4 Connection of cables

Caution

• Request an installation company or your dealer to carry out wiring.

If wiring is incomplete, shock hazard or injury may be caused.

• Class D grounding construction is mandatory. Otherwise, shock hazard may be caused.

For preventing shock hazard, fire and injury, be sure to observe the following.

• Before wiring, be sure to turn off the primary power supply. If this is neglected, you may receive and

electric shock.

• For grounding, use a 600 V-IV wire having diameter of 2 mm²or more and an adequate dielectric

strength.

• Connect the power supply which meets the rating of product. Connection of other power supply may

cause a fire.

• Select the diameter of input and output wires, which matches the rated current of gas analyzer.

• Be sure to use solderless terminals for connection to the input and output terminal block.

• Use the terminal block for branching the output wire.

• Be sure to fix the input and output wires onto the floor, wall surface, etc. and use a protective device for

wires.

The lead-in for AC power cables and outlet for signal wires are provided at the bottom of the analyzer or else

at the specified place. Connect AC power cables and output signal wires according to the separately issued

wiring diagrams.

Note: Avoid connecting the analyzer power supply near devices such as high-frequency heating fur-

nace or electric welder which greatly disturb the power waveform, and avoid sharing the same

power lines with such devices. Class D grounding construction (100W ground resistance) is

required.

4.5 Connection of pipes (refer to piping instructions in Fig. 4-1 and separately issued approval

drawings)

(1) Connect gas pipe between the gas extractor and the analyzer inlet (sample gas inlet). Use a joint, etc.

for ø10/ø8 Teflon pipe when connecting to ensure there will be no leakage.

(2) Additionally tighten the joint section if necessary

– 3 –

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Fule

(Note 1)

300 or

Gas extractor

ZBAK

Note)

Vertical

300

Horizontal

installation

(Note 2)

Sampling

pipe

Leave 300mm space for inspection

and exchange of filter.

Gas outlet facing downward (or horizontal)

Use termination kit TFC-7HPT-10JM (Note 6) or

caulk with silicone bolding agent, etc. after

insulation of heater wire (for indoor installation).

Mating flange for

installing extractor

JIS 5K 65A FF

Radius 300mm

or more

Heater power supply

100V AC

* Supporting wire

Gradient of 15˚

or more (Note 4)

Teflon pipe φ10/φ8 or tube trace

(heating pipe) SE-10C1-56-1-PVC-M

or equivalent.

Outer sheath for Teflon pipe ø10/ø8 is

PVC and bundle outer sheath is ø33.

* Support

For pipe end processing, refer to Section 12.

(Note 3)

Peel off covering

by about 2m.

(φ10/φ8 teflon tube

inside heating pipe)

(Note 7)

Power connection kit

TFC-3HPT-10JM (Note 6)

Gas

conditioner

Direct lead-in

Filter

Gas

conditioner

(in panel)

(Note 7)

Gas analyzer

Sample tube

(Note 5)

60 × 120 square

hole for wiring

*Exhaust

+ Drain

Drain

* Drain port (Note 8)

Front-view diagram

The part marked by the asterisk is not supplied.

Fig. 4-1 Piping procedure

Note 1) To prevent aspiration of leaked air

Note 2) Install so that pipe end comes to nearly center of flue and is at right angle to the gas flow.

Note 3) Peel off heating pipe by about 2m in order to air-cool measured gas.

Note 4) Provide an inclination of 15° or more on the gas pipe so that drain will not accumulate in the event

of power failure, etc.

Note 5) Exhaust and drain share the same output. In the case of indoor installation, provide a drain pot

and carry out drain separation, and exhaust air outside (pipe inner diameter should be ø8 or

more).

Note 6) Use this when utilizing a heating pipe. (Maker : Fujikin, Japan)

Note 7) The gas pipe (ø10/ø8 teflon tube) should be inserted directly into the gas conditioner.

Note 8) In outdoor application or in a cold district, protect the drain pot and pipes with a heat insulating

material, etc. to prevent drain from freezing in winter.

– 4 –

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5. DESCRIPTION OF EACH PART

Please refer to Chapter 14 specification attached at the end of the manual.

6. PREPARATION FOR OPERATION

6.1 Injection of clean water

Inject clean water through the filter or air aspiration port until it overflows from the gas conditioner.

6.2 Supply of external power

Supply external power to the analyzer. And check the connections with output signal wire, etc. The exter-

nal power supply should be.........

100V±10% AC,

50/60 Hz ±1%,

with power consumption of 0.9kVA max. (excluding heating pipe).

Check with reference to the separately issued approval diagrams.

6.3 Check of sample piping, exhaust piping, etc.

Check the connection of the sample piping and if necessary, provide exhaust piping + drain piping (Pipes

with inner diameter of ø8 or more for both). When sample will be dispersed upward, then branch and water-

seal the exhaust pipe for the purpose of drain separation. Be sure to disperse the exhaust into the atmo-

sphere.

Make checks with reference to the piping instructions in Fig. 4-1 and the separately issued gas analyzer

diagram.

– 5 –

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6.4 Airtightness test

(1) Piping inside panel

Since airtightness is confirmed during tests before shipment, an Airtightness test during trial run is

usually unnecessary. When a long time has passed after shipment, then carry out the following proce-

dure.

(a) Close the drain port.

(b) Connect standard gas to the sample gas inlet.

of a manometer).

(d) Flow standard gas gradually, and after reaching a pressure of about 1961Pa, close the needle valve

of the pressure regulator.

(e) Check the water level at the air suction port of the conditioner, and if the drop in the level in less

than 147Pa/min, then the error due to insufficient airtightness is negligible.

(f) If a leak is present when measuring a harmful gas, make a check by applying soapy water to the

normal pressure section while aspirating outside air.

(2) Piping outside panel

Thoroughly check the tightened condition of pipe joints. If necessary, apply pressure from the extrac-

tor outlet side and make a test as in the preceding item (1).

(3) If the airtightness is insufficient, make a test on each section, find the faulty location and make it

completely airtight. If the faulty location is before the aspirator, then air enters the gas pipe midway to

cause a drop in the indication.

6.5 Setting of temperature inside locker

Turn on power supply to a space heater depending on the ambient temperature. Ventilation fan should

always be turned ON.

6.6 Warm-up time

Turn ON the auto breaker.

(1) Gas extractor

Turn ON the power switch and warm up the extractor for at least 1 hour.

(2) Heating pipe (option)

Turn ON the power supply auto breaker of heating pipe and warm up the pipe for at least 1 hour.

(3) Electronic gas cooler

Turn ON the power switch and warm up for at least 10 minutes.

(4) NO₂/NO converter (option)

Turn ON the switch, set the temperature regulator at 220°C, and warm up for about 30 minutes until

indication of the temperature reaches 220±2°C. 200°C for a NO/CO (+ O2) analyzer

(5) Analyzer

Turn ON the power switch and carry out warm-up.

Infrared gas analyzer: about 8 hours

Zirconia O₂sensor: about 30 minuets

– 6 –

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7. INDICATION/OPERATION PANEL

7.1 Name and description of each component of indication/operation panel

Unit indication lamp

Day indication

Sub indication

Range changeover switch

Main indication

Component indication

SU TU TH SA

MOWE FR

Vol%

ppm

RANCE

NOX

SO2

Vol%

ppm

RANCE

Vol%

HEAS

CAL SET

SET

HOLD

RANCE

AUTO SAL

CAL

Function indicator lamp

FUNC COMP

ENT

ZERO

SPAN

Function key

Component selector key

15 Calibration start key

14 Span calibration key

13 Zero calibration key

12 ENT key

10 Digit shift key

11 Numeric input key

(Three component of NOx, SO2 and O2 are indication in this figure.)

Part Name

Description

q Component indication

w Main indication

Indicates kind of gas measured.

Indicates measured concentration. Also indicates various set-points for alarm function, auto

calibration function (option), etc.

e Unit indication lamp

r Day indication

Indicates units of measured gas concentration.

Indicates current day or day of starting by means of bar in auto calibration (option) setting mode.

Indication SU

Day Sun. Mon. Tue.

Wed. Thu. Fri.

Sat.

t Sub indication

Indicates measuring range, error code, various set points, etc.

Used when changing the range. High range is set when pressing and low range is set when

pressing

y Range changeover key

u Function indicator lamp

MEAS:

Relevant lamp lights up when following functions are set.

Lights up in measuring status.

CAL SET:

Flashes in calibration concentration setting mode.

ALM SET:

Flashes in alarm setting mode.

HOLD:

Flashes in hold setting mode or lights steadily while hold function is activated.

Flashes in remote range setting mode or light steadily while remote range function is activated.

RMT RANGE:

AUTO CAL:

Flashes in auto calibration setting mode or lights steadily while auto calibration function is

activated.

i Function key

Setting mode is changed at each press of this key (Refer to Section 5).

Set component is changed for each setting mode.

o Component selector key

Digit shift key

Shift is made from highest toward lowest digit at each press of this key.

Selected digit is incremented at each press of this key.

Numeric input key

ENT key

By pressing this key after setting, the set contents are memorized and becomes valid.

Used for zero point calibration. (Lamp flashes in zero calibration mode.)

Used for span calibration (Lamp flashes in span calibration mode.)

Start key for manual calibration. Zero is calibrated by pressing ZERO and CAL keys.

Span is calibrated by pressing SPAN and CAL keys. (CAL lamp lights steadily during calibra-

tion).

Zero calibration key

Span calibration key

Calibration start key

– 7 –

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7.2 Function and indication of indication/operation panel

This panel consists of the following functions.

Key

Function

Main indication

Measuring value

Sub indication Function indication lamp

FUNC

Measuring mode

Range

MEAS lamp lights

Setting mode

FUNC

Calib.conc.setting

Calb.conc.

Range

CAL SET lamp lights

ALM SET lamp flickers*

HOLD lamp flicker

Alarm setting (option)

Hold setting

Alarm value

ON or OFF

Day

Remote range setting (option)

Current time setting

RMT RANGE lamp flickers*

Auto CAL lamp flickers

AUTO CAL lamp flickers

AUTO CAL lamp flickers*

AUTO CAL lamp flickers

Hr.min.

Auto clib.start time setting

Auto calib.cycle setting

Calib. gas flow time setting

Auto calib.changeover

Key lock changeover

HR.min.

Day

Time

Mode No.

ON or OFF

ZERO

Zero calibration

Span calibration

Measured value

Range

Zero key indication flickers

Span key indication flickers

• When the setting mode is assumed, the analog output signal is held at the value just before entering this mode.

• When optional functions are not provided, the contents of these functions are not indicated.

* Refer to the instruction manual of the infrared gas analyzer for the items marked by the asterisks.

– 8 –

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7.3 General operation of indication/operation panel

The measuring mode is assumed when

power is turned ON. The gas concentra-

tion appears on the main indication, while

the range being used appears on the sub in-

dication.

Gas concentration

indication

Range

indication

Advice on Operation

Hige rang is selected

when key is pressed

LWhen selecting the range

In the setting status, as shown in the figure

at the right, the high range is selected when

key is pressed, while the low range is

selected when key is pressed.

Low rang is selected

when

key is pressed

LWhen selecting the gas component

In the setting status, as shown in the figure

at the right, the gas component can be set

by pressing COMP key.

1st component

2rd component

3rd component

Example: When COMP key is pressed

while the 1st component is flash-

ing, the flashing moves to the

2nd component (figure at right).

The setting for the 2nd compo-

nent is now changeable.

COMP

ENT ZERO SPAN CAL

* The 1 component type analyzer is not pro-

vided with COMP key.

Pressing changes the settable gas component.

ZERO SPAN

LFor releasing zero or span

If a mistake has been made in zero or span

calibration, then perform a reset in the fol-

lowing way.

Pressed wrongly.

ZERO SPAN

The figure at the right shows an example.

If SPAN key has been pressed mistakenly

instead of ZERO key, then press SPAN

key again. Calibration is released.

The lamp blinks.

ZERO SPAN

Press again to extinguish the lamp.

Thus reset. Press the

key afresh.

ZERO

If ZERO key has been pressed mistak-

enly instead of SPAN key, the press

ZERO key again.

Calibration is released.

– 9 –

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8. CALIBRATION

Danger

• When handling standard gas such as calibration gas, read the instruction manual for the standard gas for

correct handling. Special care should be taken when handling hazardous gas such as CO gas and the like

to prevent poisoning.

8.1 Kinds of standard gas

8.1.1 When not using zirconia O₂sensor

(1) Zero gas: N₂or atmospheric air/instrument air depending on specification (when without verifi-

cation stipulated in the laws for measurement and weighing)

(2) Span gas: Gas of 90% or more full scale for each component, remainder is N₂(span gas for low

range will be delivered unless otherwise specified)

8.1.2 When using zirconia O₂sensor

(1) Zero gas: Air (Span gas of the O₂analyzer in the laws for measurement and weighing).

(2) Span gas: 1 to 2% O₂, remainder is N₂. (Zero gas of the O₂analyzer in the laws for measurement

and weighing).

Gas of 90% or more full scale for other than zirconia O₂sensor, remainder is N₂.

Note: For separately calibrating the low and high ranges of the zirconia O₂sensor, supply 9 to

10% O₂and the remainder N₂for the low range (10%) and use air for the high range

(25%).

8.2 Preparation of standard gas

The standard gas to be used for calibration is delivered in a separate package from the locker.

Check the kind of standard gas to be used according to the sampling system diagram, and set it at the

prescribed location.

Before starting calibration, attach a pressure regulator to the standard gas.

8.2.1 How to mount pressure regulator for standard gas cylinder

(1) Before mounting a pressure regulator to the gas cylinder, clean the gas cylinder adapter. Entry of

dust into the pressure regulator may result in gas leaks.

(2) If packing is not inserted in the mounting nut for the cylinder or it is damaged, replace it with

supplied spare one.

(3) Use a spanner of a proper size, fasten the cylinder mounting nut to the gas cylinder. Mount

supplied joint to the outlet according to Item “Sampling system block diagram”.

(4) Loosen the pressure controls and then tighten the outlet controls.

(5) Open a valve of the gas cylinder, and the pressure gauge on the high pressure side indicates a

pressure of the gas cylinder by flowing gas into the pressure regulator.

(6) Turn the pressure controls clockwise to increase the secondary pressure; adjust the pressure con-

trols so that a pressure gauge on the low pressure side reads 30 kPa.

(7) Open the outlet controls to release gas.

– 10 –

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Adapter

Pressure gauge on

high pressure side

Pressure gauge on

low pressure side

Pressure controls

Packing

Cylinder mounting nut

Pressure regulator

Cylinder

R1/4 joint

Output handle

Fig. 8-1 Pressure regulation for standard gas cylinder

– 11 –

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8.3 Calibration concentration setting (except zirconia O₂sensor)

Set a span value for the calibration concentration setting. (Zero point calibration concentration is fixed at

zero.)

Set the calibration gas concentration (span value).

When FUNC key is pressed in the measuring sta-

tus, the previously set span value will appear on

the main indication.

FUNC

The CAL SET LED of the function indicating

lamps will flicker.

By pressing the

key, the highest digit of the

main indication for the 1st component will flicker,

and the span value can not be set.

CAL SET

Select a range with the

keys.

After selecting the range, set a span value in this

status.

The numeric value will be incremented by press-

ing

key.

The digit to be set can be selected by pressing

key.

ENT

For selecting the 2nd and subsequent compo-

nents and the range, press the

key and

while the main indication for the 1st compo-

nent is flickering, press the COMP key and

then the main indication for the component to

be set will flicker. Now press the

select the range to be set.

keys to

When the span value has been set, press the ENT

key. Setting operation is completed.

– 12 –

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[When adjusting for each range]

(Simultaneous calibration of H and L ranges has been factory-set).

Perform setting in the following way.

By pressing CAL key while the highest digit of the

main indication for the 1st component is flickering,

CAL

then ‘

’ will appear on the main indication and

‘ ’ will appear on the sub indication.

Press

key and will change to

= Meaning of set values =

: The calibration is valid only for the selected

range, and zero and span calibration can

be made independently for each range.

By conducting zero and span calibration

for one range, the calibration will be done

automatically for the other ranges as well.

ENT

When the selection has been finished, press the ENT

key. Setting operation is completed.

– 13 –

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8.4 Calibration concentration setting (zirconia O₂sensor)

A zirconia O₂sensor sets the zero (air) point (span point stipulated in the laws for measurement and

weighing) of the O₂analyzer. For the density of calibration gas to be used, refer to “8.2 Preparation of

standard gas”.

LSetting of calibration concentration for zero (air)

point (zero stipulated in the laws for measurement

and weighing)

By pressing the FUNC key in the measuring status,

the calibration concentration previously set for the zero

(air) point will appear on the main indication.

FUNC

The CAL SET LED of the function indicating lamps

will flicker.

By pressing the

key, the higher digit of the main

indication of the O₂analyzer will flicker and zero point

setting is enabled.

CAL SET

Press the

keys to select a range.

The numeric value will be incremented by pressing

key. The digit to be set is selected by pressing the

key.

Setting ranges are 20.2 to 21.9 Vol. % for high

range and 7.0 to 21.9 Vol. % for law range.

ENT

Set the air concentration for both high and low

range.^Note)

Press the ENT key after setting the zero point. Set-

ting operation is completed.

Note: When using air for the high range and 9 to 10 Vol. % O₂/N₂for the low range, set the density

for each range.

When viewing from the zirconia O₂sensor side, the air point corresponds to the zero point.

Therefore, calibration should begin with the air point.

Also, since the air point and low concentration point can be calibrated by the zero calibra-

tion key and span calibration key, respectively, the air point and low concentration point

are regarded as the zero and span in this manual.

– 14 –

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LSetting of span calibration concentration (zero point

stipulated in the laws for measurement and weigh-

ing)

Setting of each component

Press the CAL key in the status where the digit of the

O₂analyzer main indication is flickering via the zero

(air) point calibration concentration setting.

CAL

The previously set span value will now appear on the

main indication.

The ‘CAL SET LED’ of the function indicating lamps

COMP

will flicker.

Then, press the COMP key and the highest digit of

the 0₂analyzer main indication will flicker and the

span value is now settable.

Press the

keys to select a range.

When the range has been selected, set a span value in

this status.

ENT

The numeric value will be incremented by pressing

the

key.

Press the

lected.

key and the digit to be set can be se-

Press the ENT key after setting the span value. Set-

ting operation is completed.

– 15 –

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8.5 Zero calibration (air point calibration in case of zirconia O₂sensor)

This is used for adjusting the zero point.

Flow the zero gas (0.3N/min.) by adjusting the needle

valve of pressure regulator and wait until the indica-

tion stabilizes.

When the Zirconia O₂sensor is used, use air.^Note)

ZERO

When the indication has stabilized, select the measur-

ing range to be calibrated by using the

keys.

Flickers

When using a multi-component analyzer, all the

components undergo zero calibration simulta-

neously at the selected range.

ENT ZERO SPAN CAL

CAL

ZERO

Press the ZERO key, and

flicker.

key lamp will

Lights

Next press the CAL key and conduct zero calibra-

tion.

ENT ZERO SPAN CAL

CAL

The

key lamp lights steadily during calibra-

ENT ZERO SPAN CAL

tion.

( Lamp is turned off after calibration )

Since the measuring status is resumed after the cali-

bration, carry out the calibration for other ranges if

necessary.

Note: When using different gases for the low and high ranges, apply 9 to 10 Vol. % O₂/N₂which has

been set for the low range.

When the function for automatic calibration is provided, the solenoid valve turns on and cali-

bration gas flows upon pressing the ZERO key.

– 16 –

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8.6 Span calibration (low concentration point calibration in case of zirconia O₂sensor)

Carry out span calibration by flowing calibration gas at

the concentration set as a span value.

Flow the calibration gas (0.3 N/min.) by adjusting the

needle valve of pressure regulator. Wait until the indica-

tion stabilizes, and then conduct span calibration.

SPAN

Press the SPAN key and the

key lamp flickers.

Flickers

In the case of a multi-component analyzer, the main

indication will flicker for the components which

can be calibrated.

ENT ZERO SPAN CAL

(

)

COMP

Press the COMP key and the settable gas compo-

nent will change.

When the gas component has been determined,

press the

keys and select a range.

Note: The lamp will not flicker in the case of a

single-component analyzer.

Flickers

ENT ZERO SPAN CAL

(In case of a multi component analyzer)

Next press the CAL key and conduct span calibration.

CAL

The

key lamp lights steadily during calibration.

Since the measuring status is resumed after calibration,

continue the calibration for each component and each

range.

lights

ENT ZERO SPAN CAL

( Lamp is turned off after calibration )

Note: On the low range of zirconia type O₂sensor, when zero gas is calibrated with 9 to 10 Vol. % O₂,

the zero and span calibrations interfere with each other. So, each calibration should be re-

peated a few times.

When the function for automatic calibration is provided, the solenoid valve turns on and the

span gas for the selected component flows upon pressing the SPAN key.

– 17 –

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8.7 Auto calibration

In this analyzer, the signals form the input/output terminals on the upper can be used for driving an external

solenoid valve and introducing standard gas, whereby zero point and span can be calibrated automatically.

The auto calibration is done according to 8.7.1 Current time setting, 8.7.2 Auto calibration start time setting,

8.7.3 Auto calibration cycle setting, 8.7.4 Auto calibration ON/OFF setting and 8.7.5 Output Hold setting at

Calibration.

Cautions on operation

1. When the auto calibration start time is reached during key operation, the auto calibration is given

priority and is started. All key operation will be invalid until the auto calibration is finished.

2. To forcibly interrupt the auto calibration in progress, press both the ENT and CAL keys simulta-

neously. After the forcible interrupt, the measuring mode is resumed and all the keys are operable.

Although the current auto calibration will be passed over, it will be started from the initially set

cycle from the next time onward.

Example: When auto calibration is set for 3 hour intervals starting from 8:00 a.m.

: Under auto calibration

8 : 00

11 : 00

14 : 00

17 : 00

8 : 00

11 : 00

14 : 00

17 : 00

Forcible interruption

3. Key operation is possible while calibration is not under way with the auto calibration function set.

Therefore all settings (of span, hold, remote range, time, etc.) including manual calibration can be

made. But note that if the wrong time is set on the clock, the auto calibration will not be started at

the correct time.

4. Auto calibration is able to start by applying remote start input signal, 5V DC longer than 100msec,

to remote start input terminals. In this case, auto calibration will start independent to its ON/OFF

setting. (Calibration starts at the trailing edged of signal.)

5. When measuring 4 components, or NO_x, SO₂, CO and O₂(with 2 infrared gas analyzers), the auto-

matic calibration cycle should be set on the CO/O₂analyzer side and the automatic calibration of

NO_x/SO₂analyzer should be turned OFF. After the automatic calibration of CO/O₂analyzer, the

automatic calibration of NO_x/SO₂analyzer will be started.

– 18 –

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Example of auto calibration time chart for 4-component measurement

Auto calibration start time

Under

Under auto calibration

measurement

Zero

gas

Span

gas 1

Zero

gas

Span

gas 1

Span

gas 3

Substi-

tution

Span

gas 2

Span

gas 3

SO2

Gas flow time

•

Auto calibration

gas flow time

T: settable from 100 to 599 sec. (Note)

Auto calibration cycle

Gases introduced:

Sample gas

Zero gas

Span gas 1

Span gas 2

SO²

Span gas 3

Indicator lamps

AUTO CAL.

•

Flickers

ZERO

SPAN

CAL

Flickers

Lights

HOLD

(at HOLD ON)

Auto calibration abnormality:

If an abnormality occurs during auto calibration, a contact signal for auto calibration abnormality will be

output from the input/output terminals on the upper of the analyzer. The gas which incurred the abnormality

will not be calibrated, and instead the next component will be calibrated.

Note: Usually, T is set at 360 sec. for measurement including SO₂, and at 180 sec. for other measurements.

For change of setting, refer to the separate instruction manual of infrared gas analyzer.

– 19 –

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8.7.1 Current time setting

Set the current time and day of the week.

FUNC

Press the FUNC key in the measuring status.

The AUTO CAL LED of the function indicating lamps

will flicker.

SU TU TH SA

MO WE FR

The main indication shows the hour and minute via a

24-hour indication and the decimal point flickers.

A’–’ bar lights up at the relevant weekday on the sub

indication.

AUTO CAL

Flickers

(

)

SU TU TH SA

Indication SU MO TU WE TH FR SA

MO WE FR

Day

Sun. Mon. Tue. Wed. Thu. Fri. Sat.

key and the time is now settable.

(

)

Press the

SU TU TH SA

The highest two digits of the main indication will flicker.

MO WE FR

ENT

The numeric value is incremented by pressing the ‘

’.

SU TU TH SA

MO WE FR

Press the

key and the digit can be selected.

After the time setting, press

on the sub indication.

key and the day is settable

The bar indication will flicker.

Press the

key and the bar will shift.

Press the ENT key when the time and day setting is fin-

ished. The data are saved.

Time starts from the point where ENT key is

pressed.

– 20 –

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8.7.2 Auto calibration start time setting

When FUNC key is pressed at the current time indica-

tion, the auto calibration start time and day will appear on

the main and sub indications.

SU TU TH SA

MO WE FR

Lights

The AUTO CALLED of the function indicating lamps

will flicker. In the case of start time, the decimal point on

the main indication will light steadily.

FUNC

SU TU TH SA

MO WE FR

Press the

key and the auto calibration start time is

AUTO CAL

settable, so set a start time on the main indication.

(

)

The numeric value is incremented by pressing the

key.

SU TU TH SA

MO WE FR

Press the

key and the digit can be selected.

(

)

SU TU TH SA

After setting the calibration start time, press the

key

and the calibration start day can be set on the sub indica-

tion.

MO WE FR

ENT

The bar indication will flicker.

SU TU TH SA

MO WE FR

Press the

key and the bar will shift.

The auto calibration start time is settable up to one

week ahead.

When the auto calibration start time and day have been

set, press the ENT key. The data are saved.

When the auto calibration at the set time is fin-

ished, the next auto calibration start time will be

set automatically.

To confirm the next auto calibration start time, then

carry out this operation and check the indication.

Note: When the auto calibration start time has been set, then set the auto calibration cycle.

– 21 –

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8.7.3 Auto calibration cycle setting

The calibration cycle is settable in either ‘days’s or ‘hours’.

Press the FUNC key at the calibration start time indica-

tion and ‘

’ will appear.

FUNC

The AUTO CAL LED of the function indicating lamps

will flicker.

Press the

The highest digit on the sub indication will flicker. Select

either ‘days’ or ‘hours’ by pressing the key.

key and the auto calibration cycle is settable.

AUTO CAL

(

)

‘ ’ appears on the sub indication when selecting

‘days’ and ‘ ’ appears when selecting ‘hours’.

(

)

Press the

key and the calibration cycle and be set in

the lower digits of the sub indication.

The numeric value is incremented by pressing the

key.

ENT

Press the

key and the digit can be selected.

Day is settable in a range of 1 to 7 days. Hour is

settable in a range of 1 to 99 hours.

Note

If ‘0 0’ (hours) is set, it will be automatically set

to ‘1’(hours).

Press the ENT key when the calibration cycle has been

set. The data are saved.

– 22 –

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8.7.4 Auto calibration ON/OFF setting

Select whether or not to carry out auto calibration.

’ when calibration will not be made.^Note)

Set to ‘

Press the FUNC key at the calibration gas flow mode

indication and ‘ ’ will be appear.

FUNC

The AUTO CAL LED of the function indicating lamps

will flicker.

AUTO CAL

Press the

be set.

key and auto calibration ON or OFF can

Select either ‘

’ or ‘

’ on the sub indication by

pressing the

key.

When the auto calibration ON/OFF setting is finished,

press the ENT key. Setting operation is completed.

ENT

Note: In case of 4-component (NO_x, SO₂, CO and O₂) analyzer, be sure to turn OFF the automatic

calibration of NOx/SO₂analyzer.

– 23 –

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8.7.5 Setting of output hold at calibration

This is used when calibrating for holding the output sig-

nal at the value just be before entering calibration. (The

indication is not held.)

The hold function is settable for each component.

FUNC

Press the FUNC key in the measuring status and

‘

’ will be indicated.

HOLD

The HOLD LED of the function indicating lamps will

flicker.

Press the

key and the hold function will be settable.

The sub indication will flicker.

Select hold ‘

’ or ‘

’ by pressing the

key.

Press the ENT key after setting the hold function. Set-

ting operation is completed.

ENT

Setting is valid for all the components.

At hold ON, the HOLD of the function indicating lamps

will light steadily while the hold function is activated.

At hold OFF, these lamps will go off.

In case of automatic calibration, output is held while the

automatic calibration lamp is lit.

In case of manual calibration, output is held for about half

an hour after completion of calibration.

For canceling the output hold forcibly, turn off the hold

setting once.

Note 1: When measuring 4 components, or NOx, SO₂, CO and O₂(with 2 infrared gas analyzers),

output is held by using the external hold function at the time of automatic calibration.

Note 2: In the setting mode, output is held indifferently to the ON/OFF status of hold setting.

Note 3: In case the analyzer is equipped with a maintenance switch, output is held while the switch

is turned on.

– 24 –

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9. OPERATION

Danger

• If you notice malodor or abnormal sound, stop the instrument immediately. If this is neglected, fire may

occur.

Caution

• When the analyzer is to be operated after it has been left unused for a long time, the operating procedure

is different from the normal stop/start procedure. It should be handled according to the procedure shown

in the instruction manual to ensure its proper performance and to prevent trouble or injury.

• Do not operate the analyzer for a long time with its door left open to avoid entry of dust into the analyzer.

Dust deposits will result in damage to the analyzer.

Prohibition

• Do not insert a rod or your finger into the fan (electronic cooler at ceiling), otherwise injury may be

caused by the rotating blades.

• Do not touch metal, finger, etc. to the input and output terminal block of analyzer. Otherwise, shock

hazard or injury may be caused.

• Smoking and use of fire/flame is prohibited in the vicinity of the gas analyzer. Otherwise, a fire may

occur.

• A water-filled container such as a bucket should not be placed on the roof of the gas analyzer having

indoor specifications. If such a container turns over, spilled water may cause shock hazard or burning

inside the analyzer.

9.1 Operating procedure

(1) Check if all the preparation for operation have been completed.

(2) Press the range selector switch on the indication/operation panel to select a range to be used.

(3) Press the function key “FUNC” on the indication/operation panel to light up the “MEAS” function

indicator lamp.

(4) Turn on the aspirator power supply and confirm that the ball of flow meter is at 0.4N/min.

Prescribed flow rate may be 0.5N/min. So it should be checked in the piping system diagram sepa-

rately presented.

– 25 –

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10. MAINTENANCE

Danger

• When handling standard gas such as calibration gas, read the instruction manual for the standard gas for

correct handling. Special care should be taken when handling hazardous gas such as CO gas and the like

to prevent poisoning.

• During maintenance or inspection, be sure to turn ON the ventilation fan in the analyzer to prevent

poisoning due to gas leakage.

• When the gas filter of the analyzer is to be replaced or the washing unit needs maintenance, be sure to

close the calibration gas valve. Especially, if the calibration gas valve is located at the sample gas inlet,

the replacing or washing shall be done after closing the calibration gas valve to prevent poisoning or

other trouble.

Caution

• The gas converter is heated to about 220°C. When the catalytic agent needs to be replaced, turn OFF the

power for the converter and use heat-proof gloves about 30 minutes later.

• When the fuse is blown off, check the cause of it and replace it with the same type of fuse having the

same capacity to prevent electric shocks or other trouble.

• When the analyzer is provided with a power leak relay, press the test button to confirm proper operation

before making maintenance or inspection to prevent electric shocks.

• Be sure to lock the door. Do not allow unauthorized persons to use the door key. Do not touch the door

carelessly to prevent electric shocks and other trouble.

The following items must be observed to prevent electric shocks or injury and to ensure safety.

• Take off metallic objects such as wrist watch before starting the work.

• Do not touch the device with wet hands.

10.1 Routine maintenance and inspection

Maintenance/inspection item

Procedure

Monitoring of sample flow rate

Monitoring of conditioner bubbling quantity

Prescribed flow rate: The flow rate is normal when the ball is at

0.4N/min. and there is slight bubbling at the bottom of conditioner.

Adjust the needle valve so that a flow rate of 0.4N/min. is available.

If the prescribed flow rate is unobtainable even with the needle valve

fully open though there is slight bubbling, then the capillary (sample

line) should be checked for clogging. In case there is no bubbling, the

aspirator, conditioner, electronic cooler and pipe should be checked for

clogging. And if water decreases in the conditioner because of heavy

bubbling, the capillary of bypass line should be checked for clogging.

(Note)

Good if H2 level shown in Fig. 10-1 is longer than 100mm.

If air is aspirated through the air aspiration tube, then the pressure loss at

the stage before the conditioner filter has become large. Check the gas

extractor filter (see (1) in 10.5) and gas pipes for clogging.

Conditioner

Air aspiration tube level

– 26 –

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Maintenance/inspection item

Procedure

Contamination of membrane filter

Replace the filter paper if it has blackened (see (3) in 10.5).

If contamination occurs rapidly, then check the pre-stage filters of the

gas extractor ((1) in 10.5), conditioner filter ((2) in 10.5), etc.

Electronic gas cooler

Check the fan rotation.

Temperature controller for NO₂/NO converter Check that the controlled temperature is approx. 220°C (200°C in case

of NO/CO analyzer).

Note) Bubbling will be eliminated when a pressure control valve is equipped.

Prescribed flow rate value should be checked in the piping system diagram separately presented.

Conditioner filter

O-ring (G65)

Fastening nut

Wing bolt

Sample gas

To analyzer

Water

injection

Aspirator

Upper chamber

Electronic

gas cooler

Air

aspiration

pipe

Capillary

Pressure

control valve

Bypass

Capillary

H1: Sample negative pressure

Exhaust after analysis

H2: Good when longer than 100mm.

Be careful when within 50 to 100mm.

Check extractor filter piping when

shorter than 50mm.

Lower chamber

Drain and exhaust

Slight bubbling

(Bubbling is eliminated when

the unit is provided with

pressure control valve.)

Fig. 10-1 Conditioner

– 27 –

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10.2 Periodic maintenance and inspection

Maintenance/inspection item

Analyzer calibration

Referential frequency

Weekly

Procedure

Refer to section 8.5 to 8.6.

Check of standard gas filled

pressure

It takes at least 1.5 months to deliver the standard gas. So

the gas should be ordered 2 or 3 months in advance.

Water level in upper chamber of

conditioner

Monthly

Every two months

Biannually

Supply water if level is below overflow port.

Replacement of membrane filter

paper

Replace with new filter paper (stop the aspirator when

exchanging). See 10.5 (3).

Inspection and replacement of

conditioner filter, O-ring

Replace these parts if flow rate doesn’t increase because of

adherence of dust. See 10.5 (2).

Capillary

Replace if clogged.

Check of valve and diaphagm of

aspirator (pump)

Check and clean diaphragm. Use valve by turning it to 90°

rightward (replace valve when it is turned once). See 10.5

(4).

Leak test of pressure regulator

Replacement of standard gas

Apply soapy water or the like and check for bubbles. Either

retighten or replace packings if necessary.

NO, SO₂, CO/N₂of less than 250 ppm. See 10.4.

Replacement of gas extractor filter

element, O-rings

Yearly

O-ring requires replacement. Filter element may be reusable

after cleaning. See 10.5 (1).

Catalyst of NO₂/NO converter

Replacement (when NO₂gas concentration is 10 ppm or

less)

Note: Replace once every 8 months when NO gas con-

centration is measured in the setting range of 0 to

200ppm or more at 0.5L/min.

Replacement of standard gas

Aspirator

See 10.4.

Replacement of diaphragm

Clean pipes or replace if necessary.

Contamination, leak test of piping

Exchange of water in conditioner

Overhaul

10.3 Other maintenance and inspection

(1) Space heater and ventilating fan

If the ambient temperature drops below 5°C during winter or the like, then turn ON the space heater.

The ventilating fan should always be left ON.

(2) Blowback of gas extractor (option)

Turn off the aspirator and close the measured gas line before conducting a blowback. Frequent blowback

will cause the temperature of the gas sampler to drop and result in corrosion, so it should be kept to a

minimum.

– 28 –

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10.4 Concentration guarantee term of standard gas cylinder (for NO_x, SO₂, CO and O₂analyzer)

Kind of gas

NO/N₂

SO₂/N₂

CO/N₂

O₂/N₂

Concentration range

0.4ppm or more, and less than 250ppm

250ppm or more, and less than 5%

0.4ppm or more, and less than 250ppm

250ppm or more, and less than 1 %

2.4ppm or more, and less than 100ppm

100ppm or more, and less than 15%

0.9% or more, and less than 25%

—

Guarantee term

6 months

1 year

6 months

1 year

6 months

1 year

N₂

*None

Air

—

*None

* Schedule the use for about one year under proper control.

Note: It is empirically known that standard gas concentration remains within the adequate accuracy

for 6 months or 1 year. However, gas maker’s guarantee term is as listed in the above table.

Therefore, replacement is required within the guarantee term when importance need be placed

on traceability.

10.5 Maintenance of sampling device

(1) Replacement of filter element of gas extractor (extractor type : ZBAK1)

(a) Turn off power supply to the extractor

(b) Turn off the pump of gas analyzer

(remove the wing bolt on the flange side).

(d) Remove the locking wing bolt and pull out the internal parts while gripping the handle for filter ex-

change.

Although you may feel slight stiffness in pulling out the handle for filter exchange, it should be pulled

out gradually while turning it.

(e) Remove the metallic mesh filter from the seal fixture.

(f) After mounting a new element, reverse the above procedure.

Locking wing bolt

Seal fixture

Filter case

Handle for filter exchange

O-ring

(JIS P48A Viton)

Metallic mesh filter

Fig 10-2 Gas extractor (type ZBAK1)

– 29 –

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(2) Replacement of mist filter element (See Fig. 10-1.)

(a) Loosen the butterfly bolt, and pull the head up and out of the container.

(b) Then loosen the retaining nut and remove the contaminated filter element.

(3) Replacement of membrane filter element

(a) Turn off the power to the gas aspirator (pump).

(b) Turn the lid of the membrane filter counterclockwise and remove it.

(d) Wipe dust out of the case by using a clean cloth. Be careful not to let dust enter the gas outlet side.

(e) After replacing the filter, reassemble by reversing the above steps.

(f) Attach the flouro pour filter closely to the filter supporting bracket.

(g) Apply vacuum grease about once every 6 months to the O-ring.

Filter element

Lid

Inner O-ring

Outer O-ring

Case

Supporting bracket (used with fluoro-pour filter)

Fig. 10-3 Membrane filter

– 30 –

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(4) Replacement of the valve and the diaphragm of diaphragm type aspirator

Replace the seat valve (turn 90° in six months and replace annually) and the diaphragm (replace annually)

according to the following procedure.

(a) Turn off the power supply of the aspirator and

remove the inlet and outlet piping connected to

the aspirator.

(b) Remove the four hexagon socket head cap

screws. Then cap A and cap B are separated

and the valve can be removed.

Hex. socket head

cap screw

hand and remove it.

Cap A

(d) Place a new diaphragm to the position and mount

it by turning it clockwise until it stops.

Note) When mounting, check that the dia-

phragm is securely engaged in the

screw section of the arm slot. Other-

wise malfunction may result.

Rc1/8

Seat valve

Cap B

(e) Place the valve on cap B and turn it 90∞. Check

that the notches of cap A and cap B are aligned,

and then tighten the four hexagon socket head

cap screws.

Diaphragm

Note) Since complex valve seat is adopted, re-

move the pin on the underside of the

valve from the hole to which the pin has

been inserted and reinsert it to the

other hole.

Arm lot

(f) Turn on the power of the aspirator in the inter-

face module. Check that it does not generate

abnormal sound. Check also with your hand that

the valve is normally operated, that is, air is as-

pirated from the IN side and discharged from

the OUT side. If any abnormality is observed,

repeat the procedure from the beginning.

(g) After checking that the aspirator is normally op-

erated, turn off the power of the aspirator in the

interface module, and return the piping to the

original position.

Fig. 10-4 Exploded view of diaphragm type aspirator

Note) Do not apply force abruptly to Rc1/8

screw part when returning the piping

to the original position.

– 31 –

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(5) Check and maintenance of electronic gas cooler

(a) Fan motor

This motor should be replaced periodically every 20,000 hours (about 2 years in case of continuous

operation ) as a standard though this varies with operating condition. However, if no abnormality

cannot be found at the time of a periodic replacement, the motor is further usable continuously.

(b) Gas passage cleaning procedure

When bubbling has come to diminish significantly, it can be thought that the passage has come to be

clogged by dust, etc.

In this case, the gas passage needs be cleaned in the procedure given below.

(i) When looking at the inside of INLET joint, area B of the

INLET joint

spiral guide can be seen. In the area B, a lateral hole of

1.5mm dia. is bored. So, insert the top of the furnished

OUTLET

INLET

spiral pull-out device into the hole as shown below and

extract the spiral guide.

(ii) Clean the gas passage and spiral guide. For detergent,

use a one having a chemical composition which will not

affect hard glass, hard PVC, polyethylene and fluoro-

rubber. After washing, rinse adequately with water and

dry the inside well by blowing compressed air.

Spiral pull-out

device

Spiral guide

Heat exchanger

(iii) When inserting the spiral guide to the original position,

it should be pressed lightly until area A of the spiral guide

comes in contact with the bottom. As a standard, area B

of the spiral guide should be located with a distance L of

about 15 to 20mm from the top face C of INLET joint.

Note that attention should be paid since piping is stepped.

Note) For sampling with the pressure control valve, clean

the gas passage using the above procedure when

the sample flow begins to be extremely reduced.

DRAIN

Fig. 10-5 Structure of electronic dehumidifier

– 32 –

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(6) Replacement of NO₂/NO converter catalyst

(a) Turn off power supply to the converter.

(b) After half an hour, remove q w e, and extract r

upward and downward, respectively. Pay attention

not to suffer a burn. In addition, carefully handle the

ceramic pipe for preventing breakage. When remov-

ing r , e will fall simultaneously. So prepare a

catalyst receiver.

q Connection

rubber

Ring

e Filter

r Catalyst

Filter

Fastener

the bottom together with q. Inject one pack of new

catalyst from the top. Set w e on the top side. (This

step is unnecessary when a membrane filter is pro-

vided at the later stage.)

Ceramic

pipe

q Connection

(d) Connect the pipe, set the temperature controller at

220°C (200°C for NO/CO analyzer), and turn on

power supply.

rubber

Fig. 10-6 Structure of NO₂/NO converter

(7) Setting of temperature controller for NO₂/NO converter (PXZ4)

(a) When pressing the PV/SV key, display changes over between PV and SV. (Usually, PV (Process

Variable) display is set).

(b) Under SV (Set Value) display, set 220°C by pressing the

key. (200°C need be set for NO/CO analyzer.)

key and determine it by the ENT

(d) The temperature controller controls converter temperature through the SSR relay.

(8) Setting of pressure control valve

The pressure control valve has been set the discharge about 2 N/min. of sample gas together with drain,

when the pressure at the inlet is about 50 kPa. The set pressure increases with a right turn of the setting knob

and decreases with a left turn.

Do not turn the setting knob unless the sample flow needs to be changed.

Setting knob

2-Rc1/4

Sample

OUT

Fig. 10-7 External appearance of pressure control valve

– 33 –

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(9) Washing the Permapure dryer

The Permapure dryer is used for SO₂measurement (2000 ppm or more).

The Permapure dryer has no moving sections nor consumable parts. If precautions in using it are suffi-

ciently respected, it can operate without maintenance usually. However, if its element has clogged, for

example, remedy it by the following method.

Purge IN

Header

Element tube

Purge joint

Shell joint

Sample

OUT

Sample

Shell

Sample joint

O ring presser

Tee

Purge OUT

O ring

Fig. 10-8 Structure of Permapure dryer

(a) Disassembly

q Remove an O ring presser (one side).

w Loosen a shell joint (one side).

e Push the header inward and remove the tee.

r Loosen the other shell joint and gently pull out the element.

(b) Washing

q Carry out washing with tap water (detergent, alkali solution not allowed).

w On a side, remove the sample joint, cap and tee.

e Through the opposite port and purge port, introduce tap water at 127 kPa or lower pressure and

300 to 500 mN/min of flow rate.

r Carry out washing for longer or shorter time according to the degree of clogging.

If the clogging is slight, approximately 1 hour of washing is enough.

Tap water

Element tube

Permapure dryer

Fig. 10-9 Washing of Permapure dryer

– 34 –

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10.6 Maintenance of zirconia O₂sensor

Sensor temperature

OXYGEN ANALYZER

800

POWER

OFF

–

ALM

Power SW Fuse 3A Terminal

Front view

Sample inlet Outlet (Rc 1/4)

(Rc 1/4)

Side view

(1) Appearance of zirconia O₂sensor

(2) Routine maintenance

No parts require periodic maintenance. In case sensor temperature is 800±5°C or the SO₂concentration in

sample gas is high, you should check occasionally that the outlet pipe is not clogged by the precipitation of

crystal. Because the sample outlet is at a high temperature, attention should be paid not to suffer a burn.

10.7 Others, major component figures

Rc1/4

Gas outlet

2-Ø4.5

mounting holes

Mounting direction

Ø20 panel cutout

Gas intlet

Rc1/4

Approx. 25 (when fully open)

– 35 –

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11. STANDARD ACCESSORIES AND SPARES

Caution

• Do not use replacement parts which are not specified by makers. Use of these parts will not only

provide the required performance but also result in damage or other trouble.

• Replacement parts used for maintenance must be handled as incombustible objects.

11.1 Standard accessories

Quantity (analyzer)

No.

Part name

Type of part No.

Remarks

NO_X/SO₂NO_X

SO₂

—

Other

Membrane filter paper

TK701837C6

TK741833P3

—

1 pack

1 pack 25 sheets per pack

Flouro pour filter for

membrane filter

—

Fuse (for instrument switch) Various types

2 each 2 each 2 each 2 each For 2A, 3.2A

Cooler puller

Joint

—

TK7F7627P1

1 set

Measuring number of gases + 1

For pressure regulator

Hose band

TK539474C410

100% 100% 100% 100%

For ø6 tube

For pressure regulator

Toalon tube 0.3m

Polyethylene tube 1m

Anchor bolt

TK727528P1

415966P4

1 set

For ø6 tube

ø6/ø4 For standard gas

Option

M12 x 160 x 50

10 Instruction manual

INZ-TN2ZSP

INZ-TN2ZRG

11 Analyzer accessories

1 set

Infrared analyzer fuse 2A x 2pcs.

Cell cleaning cloth x 1pc.

O₂analyzer fuse x 1pc.

12 Wash bottle

TK7H3493P1

For conditioner

Note) Part No. 8 will be shipped in connection with the solenoid valve in the locker.

– 36 –

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11.2 Spares for 1 year (optional)

Quantity (analyzer)

No.

Part name

Spare for converter

Remarks

TK726889C3

NO_X/SO₂NO_X

SO₂

—

Other

_{Note 2)}1

—

Catalyst and filter

TK7H8043P1

Conditioner filter

Conditioner O-ring

G65 chloproprene 8553765

25 sheets of TK701837C6 per pack

TK741833P3

Membrane filter paper

Fluro pour filter for membrane filter

Membrane filter rubber ring

Membrane filter O-ring

Capillary

—

pack

—

pack

—

Chloroprene

G65 chloroprene

For 0.5 K

TK733572P1

8553765

—

(only when with pressure control valve)

Capillary (for bypass)

TK729264C6 (ø1mm)

(only when without pressure control valve)

10 Capillary (for cooler out)

TK729264C7 (ø1.4mm)

(only when without pressure control valve)

11 Aspirator diaphragm

12 Aspirator valve

TK725417P5

TK725417P6

When gas extractor is

simultaneously supplied.

(ZBAK1)

13 Gas extractor filter element

TK7H8439P1

85504N3

14 Gas extractor O-ring

P48A

Note 1) The contents of standard accessories, and spares and supplies for 1 year may vary somewhat

according to the specifications.

Note 2) Two parts are required when flow rate is 0.5N and NO range is beyond 200 ppm.

Code for preparation of 1-year spares and supplies

Analysis gas

NO_x, SO₂, (CO), (O₂)

Same as above

NO_x, (CO), (O₂)

Same as above

SO₂, (O₂)

Extractor

With

Code

Remarks

ZBN4SP12

ZBN4SP22

ZBN4SP32

ZBN4SP42

ZBN4SP52

ZBN4SP62

ZBN4SP72

ZBN4SP82

SO₂meter range 200 to 1000ppm

Without

With

Without

With

SO₂meter range 200 to 1000ppm

Same as above

CO, (O₂)

Without

With

Same as above

Without

– 37 –

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12. PROCESSING OF HEATING PIPE ENDS

12.1 Outline

(1) Configuration

Power supply 100VAC, 50/60Hz

Power connection kit

About 2000

Heating pipe

Termination kit

About 500

Fig. 12-1

(2) Caution on connection of heating pipe

The clearance between clamp supports must be about 1.2 m in the horizontal direction and about 3 m in

the vertical direction.

For a bent piping, bending should be moderate enough to ensure a minimum bending radius of 300 mm

or more.

Clamp support

No good

Good

Fig. 12-2

(3) Connection diagram

A heater wire is wound around 2 isolated buses and it is brought into contact with the buses alternately at

intervals of 300 mm (heating unit).

Power supply

Heating wire

300mm

Fig. 12-3

– 38 –

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12.2 End processing method

(1) Power supply side (power connection kit)

When cutting out the heating pipe, take care not to damage the heater wire.

Pulling out on the inside of grid section provides a non-heating area of about 300 mm at maximum.

Grid

Non-heating area of 300mm long

Fig. 12-4

Peel the outer sheath covering of heater as shown below and cut off the heater wire as close to its root

as possible.

(HTP type heater has fiber glass, heater wire and thin Teflon covering under its outer sheath covering.

So the outer sheath covering should be peeled neatly.)

115 mm

Cut off at root.

Fig. 12-5

Apply RTV (silicone sealant) to the terminal boots and plug the boots into the heater. Then wind a

sealing tape across the boots and heater.

RTV

Terminal boots

Fig. 12-6

For connection with the power supply wire, use a press-fitting sleeve. If the press-fitting section is

loose, contact resistance becomes large to cause abnormal heating of the sleeve.

Fig. 12-7

– 39 –

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(2) Termination side (termination kit)

Cut the heater in the dimension shown at right.

Grid

Push back the metallic braiding and fix it with

Teflon tape.

40mm

300mm

Peel the outer sheath covering of heater and cut

off the heater wire as close to the root as pos-

sible. Expose the bus of heater wire toward the

cut end starting from a point about 40 mm away

from the nearest grid. (HTP type heater has fi-

ber glass, heater wire and thin Teflon covering

under its outer sheath convering. So the outer

sheath covering should be peeled neatly.)

150 mm

Grid area

Outer sheath

covering

Metallic

braiding

Teflon tape

Inner sheath covering

Outer sheath covering

12mm

Cut off buses at different lengths.

Bus

Cut off at root

Heater wire

Wind Teflon tape while carefully securing isola-

tion between the heater wire and buses.

6mm

Outer sheath covering

Inner sheath covering

Teflon tape

Apply RTV silicone sealant to the end cap and

the Teflon tape-wound section. Then, fit the end

cap while bleeding air.

RTV silicone sealant

Note) After fitting the cap, move it back

slightly.

Fit while turning

End cap

Seal tape

Fix the end cap by winding seal tape as many

times as possible for preventing the cap from slip-

ping off.

Note) Never short-circuit the end (bus) of

heater.

– 40 –

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12.3 Check after piping

The heating pipe is not sunk significantly due to a clamp, etc.

The bent section has an adequately large bending radius.

Electrical connections are exact.

The end of heater wire (bus) is not short-circuited (it must never be short-circuited).

All parts of the connection kit (sealing connector), etc. have been used.

Screws of the connection kit (sealing connector), etc. have been tightened completely.

12.4 Clamp support

Clamps for conduit should be used. For heating pipe profile of the tube trace, refer to 12.5.

The heating pipe should be clamped so that it will be sunk significantly.

No good

Good

Fig. 12-8

– 41 –

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12.5 Specifications of tube trace

(1) Structure of tube trace

Heater cable

PFA teflon

Heater cable (power limiting cable)

Process tube

Aluminum tape

Fiber glass heat insulator

PVC jacket

Fig. 12-9

(2) Specifications of tube trace

Heater cable

Process tube

Aluminum tape

Fiber glass

HPT 20-1 BN 35.4w/m at 100ºC (100V AC)

10/8 mm øPFA Teflon tube

50% overlap

Thermal conductivity 0.2kJ/m·h·ºC

UL 105ºC, black PVC

PVC jacket

12.6 Specifications of heating pipe

Maker: Thermon Far East

Dealer: Fujikin, Japan

– 42 –

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13. TROUBLESHOOTING

Caution

• When trouble cannot be remedied even after following the instruction manual, contact your dealer or

Fuji's service station (serivice engineer). Do not disassemble the device, as it results in electric shocks

or injury.

13.1 Troubleshooting of instrument

Trouble

Decrease of sample Filter (primary, second-

gas flow rate ary, tertiary filters)

Probable location

Check item

Remedy

Check if filter element is clogged.

Clean or replace element.

Diaphragm type aspirator Check if aspirator is working normally.

Check for abnormal sound or vibration.

Clean or replace.

Retighten screws or replace

aspirator.

Electronic gas cooler

Check if cooler is working normally,

check cooling temperature and check for

clogging of flow path.

Clean or replace.

Conditioner

Gas leakage

Flowmeter

Water decreases in lower chamber.

Inject water and check the

capillary (bypass).

Check for gas leakage in piping after

aspirator or at joints.

Retighten or replace parts.

Check for accumulation of drainage or

dust in flowmeter. Check adjustment of

needle valve.

Clean the flowmeter.

Adjust needle valve.

Piping, capillary

Check for bent or clogged piping.

Check for capillary.

Replace.

Increase of bubbling Bypass flow path

Clean or replace.

Connect properly.

Disassemble and clean.

flow rate

Piping

Check for deviated joint.

Rise of sample gas

Pressure control valve

Pressure control valve is clogged.

flow

(Note)

Indicated value is

abnormal.

Gas leakage

Check for gas leakage in parts before

aspirator such as secondary coarse filter

holder, piping, joints, etc.

Retighten or replace parts.

Diaphragm

type aspiration

Check if aspirator is normally operating

and sample gas is flowing at set value.

Clean aspirator or replace

parts such as diaphragm or

value

Adjust sample gas flow.

Conditioner

Check if water level is normal.

Check if air is aspirated.

Supply water.

Check primary filter.

Dissolution of gas

Sampling pipe

Check for accumulation of drainage in

piping.

Clean, and tilt piping so

drainage does not accumulate.

Check if SUS pipe is used (for SO₂

analyzer).

Change to teflon tube.

Note) Pressure control valve is used.

– 43 –

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Trouble

Probable location

Gas leakage

Check item

Remedy

Check for gas leakage before the

aspirator.

Retighten or replace parts.

Indicated value is

not as expected.

Interference due to

moisture

With respect to zero gas indication, the

indicated value when air is introduced

exceeds ±2% full scale.

Readjust to compensate for

moisture interference.

Measuring range

Zero, span

Check if correct range is set.

Reset the range.

Check zero and span using standard gas. Adjust for correct zero

point and span.

Cell window

Check if cloudy

Clean the window.

Replace the fuse.

Power supply, fuse

Check the power supply voltage and fuse.

Indication doesn’t

change

13.2 Error codes and remedies

This analyzer is provided with self-diagnosis functions, and an error code is displayed if an abnormality

occurs in the instrument.

Take a proper measure with reference to the instruction manual of infrared gas analyzer when an error code

appears.

– 44 –

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14. SPECIFICATIONS

Specifications

Type of cubicle:

Outdoor, self-standing, sealed type or indoor type

Non-dispersion infrared absorption (NDIR method) for NO_x, SO₂, CO and CO₂;

zirconia method for O₂.

Measuring system:

Sampling system:

Measuring range:

Dry sampling electronic cooling & dehumidification system

(Permapure dryer adopted)

NO_x— 0 to 100 .... 2000 ppm

SO₂— 0 to 100 .... 1000 ppm

(Range selection:

Max. rate 1:20

(except for O₂))

CO — 0 to 200 .... 2000 ppm

CO₂— 0 to 5 ........ 50%

O₂— 0 to 10/25%

Note: Measuring range of each gas is 50 to 5000ppm, available in

approved type (special order).

Repeatability:

Drift:

±0.5% of full scale

Zero — ±2% of full scale/week for NOx, SO₂and CO

±2% of full scale/month for O₂

Span — ±2% of full scale/week

Linearity:

±2% of full scale

Response time:

90% response from the inlet of cubicle

SO₂: 4 min. CO : 2.5 min NO : 2 min

Others : 3 min.

Output:

4 to 20mA DC (allowable load resistance 550Ω), non-isolated.

For the number of output points, see Table 1.

Contact output:

Indication:

Each NO (1a) contact (100V AC, 1A) for error (analyzer error, calibration error) and

auto calibration status

Digital indication (indicating measured value and measuring range on analyzer front

panel of infrared gas analyzer)

Sample gas extracting rate: Approx. 2 N/min.

Gas extractor:

Electrical heating type (filter built in)

Filter mesh — 40µm mesh of 316 stainless steel

Probe

— 316 stainless steel, length 600, 800 or 1000mm

— JIS 5 K65AFF

Flange

Sample inlet tube:

ø 10/ ø 8mm teflon tube for CO and O₂meter and NO_xand O₂meter

Heating tube ( ø 10/ ø 8mm teflon tube) for NO_x, SO₂and O₂meter and NO_x, SO₂, CO

and O₂meter

Standard gas (3.4 N):

Standard air gas for zero calibration and O₂span calibration

Standard analyte/remaining N₂gas for low range span calibration and O₂zero calibration

Form for all components already approved

Form verification:

Ambient temperature:

Power supply:

-5 to +40°C

100±10V AC, 50 or 60Hz

Power consumption:

Mass (weight):

Approx. 1,200 VA (excluding consent and heating tube)

Approx. 300 kg (excluding standard gas)

Finish color:

Munsell 5Y 7/1 semigloss

– 45 –

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Standard requirements

for sample gas:

Temperature —

60 to 800°C

— 100 mg/Nm3 or less

2.94 to +2.94kPa

Dust

Pressure

—

Components — SO₂0 to 1000ppm

NO_x0 to 2000ppm (NO₂100ppm or less)

CO₂several % to over 10%

CO 0 to 2000ppm

O₂0.5 to 21%

H₂O 0 to 40%

HCN 0 to 100ppm

N₂remaining percent

When other components are contained in the sample gas, consult with Fuji.

Note) NO₂/NO converter catalyst life:

1 year/NO₂, 10ppm

1 month/NO₂, 100ppm

Installation requirements:Select a location free from direct sunlight and severe vibration.

Table 1 Number of output points and kinds of outputs

Type

ZSP1L

ZSP1F

ZSP1P

ZSP1B

CO, O₂

ZSP1A

ZSP1H

ZSP1M

Measuring

component

NO_x, SO₂,

CO, O₂

NO_x, SO₂,

O₂

NO_x, O₂

SO₂, (O₂)

NO_x, CO₂, O₂

NOx, SO₂,

CO, CO₂, O₂

No. of

output points

Kind of output A, B, C,

A, B, D, E,

A, D, E

C, D, K

B, (D)

A, B, D, E, K

A, B, C,

D (2 points), E, F, H, J

D (2 points),

E, F, G, H, J,

K, L

F, G, H, J, K

A: NO_xinstantaneous value

C: CO instantaneous value

B: SO₂instantaneous value

D: O₂instantaneous value

E: NO_xinstantaneous value after O₂correction

G: CO instantaneous value after O₂correction

J: 1hr. moving average SO₂value after O₂correction

L: O₂instanteneous value

F: SO₂instantaneous value after O₂correction

H: 1hr. moving average NOx value after O₂correction

K: 4hr. moving average CO value after O₂correction

– 46 –

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(1) NO_xafter O₂correction

CO after O₂correction

(a) Calculating equation

21 - On

• Cs

21 - O_S

C: Concentration after O₂conversion

Cs: NOX or CO concentration measured

Os: O₂concentration measured

On: O₂concentration as conversion basic:

4% Oil combustion boiler

5% Gas combustion boiler

6% Solid object combustion boiler, petroleum heating furnace

12% Garbage incinerator

(b) Block diagram

NOx or

CO signal

2/NOx conversion

21 - On

21 - Os

· Cs

or CO (ppm)

Zurconia

type O²sensor

converter

signal

Full scale is the same as

instantaneous value before

conversion.

Infrared gas analyzer

(2) Moving average output

1 hr. moving average output (for NO_x, SO₂)

4 hr. moving average output (for CO)

– 47 –

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Automatic calibration

• Calibration tolerance:

±0.2% FS

• Automatic calibration output hold: Possible

(Example in 4 component analyzer):

CO zero

CO span

zero

NO^x, SO2 zero

NOx span

SO²span

span

Automatic

calibration

• Calibration cycle:

• Calibration gas feed time:

• Display:

Once/day (variable, up to 7 days)

2 to 10 min. (variable), common to each gas

Calibration failure

Error code (E-) is displayed when one-time calibration volume is more

than ± 20% FS on both zero and span and it is under calibration:

CAL lamp ON

Ordering information

1. Measuring range of analyzer

2. Length of sampling pipe

3. Insertion length of sampling tube

4. Power voltage/frequency

5. Instruction required when standard gas is not necessary

6. Instruction required when individual inspection is not necessary

7. Necessity of spares and supplies (for 1 year)

8. Additional functions

Note: When special functions such as remote range selection, output hold by external contact, auto-

matic calibration, automatic calibration start by external contact, insulation output, measured

value concentration alarm, etc. are required, they should be separately designated.

– 48 –

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CODE SYMBOLS

9 10 11 12

Descrption

Application

Combustion exhaust gas (standard condition)

Other exhaust gas

Component

NOX + (O2

)

CO + (O²

)

SO2 + (O2

)

NO^X+ SO2 + (O2

)

NO^X+ SO2 + CO + (O2

Others

)

Oxygen analyzer

Without

With ZFK

With ZKG (Non-standard)

Auto calibration

With

Type of cubicle

Indoor installation type

Outdoor installation type

External piping

Heating pipe

ø10 Teflon tube

Standard gas

3.4r

10r

3.4r + instrument air

10r+ instrument air

3.4r + atmopheric air

10r+ atmopheric air

Power supply

100V AC/50Hz

100V AC/60Hz

Others 50Hz

Others 60Hz

– 49 –

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SAMPLING SYSTEM BLOCK DIAGLAM

– 50 –

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Functions of individual components

• Gas extractor (type; ZBA):

With heating type stainless steel filter; standard diameter 40µm for filter.

• Gas conditioner (type; ZBH9)

For separating drain and removing sulfuric acid mist and oil mist or fine dust particles. Besides, for

preventing aspiration of drain at clogging of extractor filter or sampling pipe, and activating composite

operation of constant-pressure bubbler for maintaining a constant sample supply to analyzer.

• Aspirator (type; ZBG8)

For aspirating sample gas (sample gas flow rate: about 2N/min.)

• Electronic gas cooler (type; ZBC)

An electronic dehumidifier which dries the moisture in sample gas to a dew point of aproximately 2°C.

• Converter (type; ZDL):

Added to the NO_xanalyzer. A converter using a special catalyst which converts NO₂gas into NO. The

catalyst must be renewed annually (built in the temperature regulator).

• Solenoid valve (type; AB21)

Used for the introduction of calibration gas.

• Memberane filter (type; ZBBM)

Eliminates fine dust particles with glass-fiber or flouropore filter, and permits monitoring dust adher-

ing condition on the front of the body.

• Flow meter (type; ZBD)

Ajusts and monitors standard flow rate of sample gas.

• Standard gas (type; ZBM):

Reference gas used for calibrating zero and span of the analyzer. When using a zirconia oxygen meter,

this is used together with air for calibrating zero for NO, SO₂, and CO and for calibrating span for O₂.

• Zirconia O₂sensor (type; ZFK3, 4)

Used in combination with the infrared analyzer. Outputs about 0V at measurement of the air, and an

inverse logarithm of about 1V at measurement of 0.05% O₂.

• Pressure control valve (type; ZBD35)

Sample gas pressure is controlled to 49kPa to maintain a constant flow rate.

– 51 –

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OUTLINE DIAGRAM (Unit:mm)

For outdoor installation type

Anchor plan and door opening

diagram

1000

815

620

Cable inlet (60 × 120

Rear

side

rectangular hole)

with plastic resin-

cover (PVC)

Rc 3/8

Front

side

A-140-2-1

(key No.200)

Anchor bolt (option)

( 4 – M12 × 160 × 50 )

Rc 1/2

760

800

620

800

4-φ15 hole

For indoor installation type

Anchor plan and door opening

diagram

800

620

Cable inlet (60 × 120

Rear

side

rectangular hole)

with plastic resin-

cover (PVC)

Rc 3/8

Front

side

A-140-2-1

(key No.200)

Anchor bolt (option)

( 4 – M12 × 160 × 50 )

850

Rc 1/2

760

800

620

800

4- φ15hole

– 52 –

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CONNECTION DIAGRAM

Power supply

100V AC

Extractor

Heating tube

NO^xinstantaneous value

NO^xaverage value

SO2 instantaneous value

SO²average value

instantateous value

NO^Xinstantateous value

SO²corrected value

C1A

C2A

instantateous value

CO instantaneous value

CO average value

CO corrected value

D11

D12

D21

D22

Failure contact output

On maintenance and auto

calibration contact output

Note: Terminal numbers are fixed.

(only specified outputs are wired).

– 53 –

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Head Office

Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome,

Shinagawa-ku, Tokyo 141-0032, Japan

http://www.fesys.co.jp/eng

Instrumentation Div.

International Sales Dept.

No.1, Fuji-machi, Hino-city, Tokyo 191-8502, Japan

Phone: 81-42-585-6201, 6202 Fax: 81-42-585-6187

http://www.fic-net.jp/eng

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