Instruction Manual INFRARED GAS ANALYZER TYPE: ZSP INZ-TN4ZSPb-E
INTRODUCTION Congratulations on your purchase of Fuji Gas Analyzer. (Type:ZSP) • Read this instruction manual carefully to ensure correct installation, operation and maintenance of the gas analyzer. Incorrect handling may lead to unexpected trouble or injury. • • The specifications of the gas analyzer is subject to change without prior notice for improvement. Modification of the gas analyzer without permission is strictly prohibited.
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.
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.
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.
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.
CONTENTS INTRODUCTION ................................................................................................................................................... i CAUTION ON SAFETY ....................................................................................................................................... ii 1. OUTLINE ....................................................................................................................................................... 1 2.
10. MAINTENANCE ......................................................................................................................................... 10.1 Routine maintenance and inspection ................................................................................................. 10.2 Periodic maintenance and inspection ............................................................................................... 10.3 Other maintenance and inspection .............................................
1. OUTLINE The infrared gas analyzer (ZSP) can continuously and accurately measure the concentration of gases such as NOx, SO2, CO, CO2 and O2 contained 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.
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.
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).
Fule (Note 1) 300 or more Gas extractor ZBAK Note) Vertical Horizontal installation (Note 2) Sampling pipe Leave 300mm space for inspection and exchange of filter. Mating flange for installing extractor JIS 5K 65A FF Radius 300mm or more Heater power supply 100V AC 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).
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 external power supply should be......... 100V±10% AC, 50/60 Hz ±1%, with power consumption of 0.9kVA max.
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 procedure. (a) Close the drain port. (b) Connect standard gas to the sample gas inlet. (c) Connect the transparent tube of the conditioner air suction port (see Fig. 10-1) vertically (in place of a manometer).
7. INDICATION/OPERATION PANEL 7.
7.2 Function and indication of indication/operation panel This panel consists of the following functions. Key ▲ FUNC Function Main indication Sub indication Function indication lamp Measuring mode Measuring value Range MEAS lamp lights Calb.conc. Range CAL SET lamp lights Setting mode Calib.conc.
7.3 General operation of indication/operation panel The measuring mode is assumed when power is turned ON. The gas concentration appears on the main indication, while the range being used appears on the sub indication.
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.
Adapter Pressure gauge on low pressure side Pressure gauge on high pressure side Pressure controls Packing Cylinder mounting nut Pressure regulator Cylinder R1/4 joint Output handle Fig.
8.3 Calibration concentration setting (except zirconia O2 sensor) 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 status, the previously set span value will appear on the main indication. The CAL SET LED of the function indicating lamps will flicker.
[When adjusting for each range] (Simultaneous calibration of H and L ranges has been factory-set). Perform setting in the following way. NO By pressing CAL key while the highest digit of the main indication for the 1st component is flickering, then ‘ ’ will appear on the main indication and ‘ ’ will appear on the sub indication. Press key and will change to CAL NO .
8.4 Calibration concentration setting (zirconia O2 sensor) A zirconia O2 sensor sets the zero (air) point (span point stipulated in the laws for measurement and weighing) of the O2 analyzer. For the density of calibration gas to be used, refer to “8.2 Preparation of standard gas”.
✩Setting of span calibration concentration (zero point stipulated in the laws for measurement and weighing) Press the CAL key in the status where the digit of the O2 analyzer main indication is flickering via the zero (air) point calibration concentration setting. Setting of each component O2 CAL The previously set span value will now appear on the main indication. NO The ‘CAL SET LED’ of the function indicating lamps will flicker.
8.5 Zero calibration (air point calibration in case of zirconia O2 sensor) 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 indication stabilizes. NO When the Zirconia O2 sensor is used, use air.Note) When the indication has stabilized, select the measuring range to be calibrated by using the keys.
8.6 Span calibration (low concentration point calibration in case of zirconia O2 sensor) Carry out span calibration by flowing calibration gas at the concentration set as a span value. NO Flow the calibration gas (0.3 N/min.) by adjusting the needle valve of pressure regulator. Wait until the indication stabilizes, and then conduct span calibration. Press the SPAN key and the SPAN key lamp flickers.
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.
Example of auto calibration time chart for 4-component measurement Auto calibration start time Under measurement Under auto calibration Zero gas Span gas 1 CO Span gas 3 O2 Zero gas Span gas 1 NO Span gas 2 SO2 Span gas 3 O2 Substitution T T T T T T T T • 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 CO Span gas 1 NO Span gas 2 SO2 Span gas 3 O2 • Indicator lamps AUTO CAL.
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 NO MO WE FR The main indication shows the hour and minute via a 24-hour indication and the decimal point flickers. AUTO CAL Flickers ( A’–’ bar lights up at the relevant weekday on the sub indication. Indication SU Day MO TU WE TH FR SA Sun. Mon. Tue. Wed. Thu. Fri. Sat.
8.7.2 Auto calibration start time setting When FUNC key is pressed at the current time indication, the auto calibration start time and day will appear on the main and sub indications. 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.
8.7.3 Auto calibration cycle setting The calibration cycle is settable in either ‘days’s or ‘hours’. NO Press the FUNC key at the calibration start time indica’ will appear. tion and ‘ FUNC The AUTO CAL LED of the function indicating lamps will flicker. NO Press the key and the auto calibration cycle is settable. AUTO CAL The highest digit on the sub indication will flicker.
8.7.4 Auto calibration ON/OFF setting Select whether or not to carry out auto calibration. Set to ‘ ’ when calibration will not be made.Note) Press the FUNC key at the calibration gas flow mode indication and ‘ ’ will be appear. The AUTO CAL LED of the function indicating lamps will flicker. Press the NO FUNC NO AUTO CAL key and auto calibration ON or OFF can be set. Select either ‘ pressing the ’ or ‘ ’ on the sub indication by NO key.
8.7.5 Setting of output hold at calibration This is used when calibrating for holding the output signal 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. NO HOLD The HOLD LED of the function indicating lamps will flicker. Press the key and the hold function will be settable. NO The sub indication will flicker.
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.
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.
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).
10.2 Periodic maintenance and inspection Maintenance/inspection item Analyzer calibration Referential frequency Weekly It takes at least 1.5 months to deliver the standard gas. So the gas should be ordered 2 or 3 months in advance. Check of standard gas filled pressure Water level in upper chamber of conditioner Monthly Replacement of membrane filter paper Every two months Inspection and replacement of conditioner filter, O-ring Procedure Refer to section 8.5 to 8.6.
10.4 Concentration guarantee term of standard gas cylinder (for NO x, SO2, CO and O2 analyzer) Kind of gas Concentration range Guarantee term NO/N2 0.4ppm or more, and less than 250ppm 6 months NO/N2 250ppm or more, and less than 5% SO2/N2 0.4ppm or more, and less than 250ppm SO2/N2 250ppm or more, and less than 1 % CO/N2 2.4ppm or more, and less than 100ppm CO/N2 100ppm or more, and less than 15% 1 year O2/N2 0.
(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. (c) Replace with a new conditionor filter and O-ring, and reassemble by reversing the above steps. (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.
(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.
(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.
(6) Replacement of NO2/NO converter catalyst q Connection rubber w Ring (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 removing r , e will fall simultaneously. So prepare a catalyst receiver.
(9) Washing the Permapure dryer The Permapure dryer is used for SO2 measurement (2000 ppm or more). The Permapure dryer has no moving sections nor consumable parts. If precautions in using it are sufficiently 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 IN Shell Sample joint Tee Purge OUT O ring O ring presser Fig.
10.6 Maintenance of zirconia O2 sensor Sensor temperature OXYGEN ANALYZER 800 POWER ON 1 2 3 4 5 6 7 OFF + AG 0V – ALM Power SW Fuse 3A Terminal Sample inlet (Rc 1/4) Front view Outlet (Rc 1/4) Side view (1) Appearance of zirconia O2 sensor (2) Routine maintenance No parts require periodic maintenance. In case sensor temperature is 800±5°C or the SO2 concentration in sample gas is high, you should check occasionally that the outlet pipe is not clogged by the precipitation of crystal.
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.
11.2 Spares for 1 year (optional) No.
12. PROCESSING OF HEATING PIPE ENDS 12.1 Outline (1) Configuration Power supply 100VAC, 50/60Hz Power connection kit Heating pipe Termination kit About 2000 About 500 Fig. 12-1 (2) Caution on connection of heating pipe q The clearance between clamp supports must be about 1.2 m in the horizontal direction and about 3 m in the vertical direction. w For a bent piping, bending should be moderate enough to ensure a minimum bending radius of 300 mm or more. Clamp support No good 00 R3 Good Fig.
12.2 End processing method (1) Power supply side (power connection kit) q When cutting out the heating pipe, take care not to damage the heater wire. w 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 e Peel the outer sheath covering of heater as shown below and cut off the heater wire as close to its root as possible.
(2) Termination side (termination kit) q Cut the heater in the dimension shown at right. Push back the metallic braiding and fix it with Teflon tape. Grid Grid 40mm 300mm w Peel the outer sheath covering of heater and cut off the heater wire as close to the root as possible. 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 fiber glass, heater wire and thin Teflon covering under its outer sheath convering.
12.3 Check after piping q The heating pipe is not sunk significantly due to a clamp, etc. w The bent section has an adequately large bending radius. e Electrical connections are exact. r The end of heater wire (bus) is not short-circuited (it must never be short-circuited). t All parts of the connection kit (sealing connector), etc. have been used. y Screws of the connection kit (sealing connector), etc. have been tightened completely. 12.4 Clamp support Clamps for conduit should be used.
Finish outer diameter 33 Outer diameter of tube 10 mm 12.5 Specifications of tube trace (1) Structure of tube trace 3 5 q Heater cable (power limiting cable) w Process tube e Aluminum tape r Fiber glass heat insulator t PVC jacket Fig. 12-9 (2) Specifications of tube trace q w e r t 1 4 Heater cable PFA teflon Heater cable Process tube Aluminum tape Fiber glass PVC jacket HPT 20-1 BN 35.4w/m at 100ºC (100V AC) 10/8 mm øPFA Teflon tube 50% overlap Thermal conductivity 0.
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 gas flow rate Probable location Check item Remedy Filter (primary, secondary, tertiary filters) Check if filter element is clogged. Clean or replace element.
Trouble Indicated value is not as expected. Indication doesn’t change Probable location Check item Remedy Gas leakage Check for gas leakage before the aspirator. Retighten or replace parts. 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 Check if correct range is set. Reset the range. Zero, span Check zero and span using standard gas.
14. SPECIFICATIONS Specifications Type of cubicle: Outdoor, self-standing, sealed type or indoor type Measuring system: Non-dispersion infrared absorption (NDIR method) for NOx, SO2, CO and CO2; zirconia method for O2. Sampling system: Dry sampling electronic cooling & dehumidification system (Permapure dryer adopted) Measuring range: NOx — 0 to 100 .... 2000 ppm (Range selection: Max. rate 1:20 (except for O2)) SO2 — 0 to 100 .... 1000 ppm CO — 0 to 200 .... 2000 ppm CO2 — 0 to 5 ........
Standard requirements for sample gas: Temperature — 60 to 800°C Dust — 100 mg/Nm3 or less Pressure — -2.94 to +2.94kPa Components — SO2 0 to 1000ppm NOx 0 to 2000ppm (NO2 100ppm or less) CO2 several % to over 10% CO 0 to 2000ppm O2 0.5 to 21% H2O 0 to 40% HCN 0 to 100ppm N2 remaining percent When other components are contained in the sample gas, consult with Fuji.
(1) NOx after O2 correction CO after O2 correction (a) Calculating equation C= 21 - On 21 - OS • Cs C: Concentration after O2 conversion Cs: NOX or CO concentration measured Os: O2 concentration measured On: O2 concentration 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 21 - On · Cs 21 - Os Zurconia type O2 sensor O2 converter O2 signal O2/NOx conversio
Automatic calibration • Calibration tolerance: • Automatic calibration output hold: ±0.2% FS Possible (Example in 4 component analyzer): CO zero CO span O2 zero NOx, SO2 zero NOx span SO2 span O2 span Automatic calibration • Calibration cycle: Once/day (variable, up to 7 days) • Calibration gas feed time: 2 to 10 min.
CODE SYMBOLS 1 2 3 4 5 6 Z S P 7 8 4 9 10 11 12 Descrption Application Combustion exhaust gas (standard condition) Other exhaust gas 1 2 Component NOX + (O2) CO + (O2) SO2 + (O2) NOX + SO2 + (O2) NOX + SO2 + CO + (O2) NOX + SO2 + CO + (O2) Others P A B F H L Z Oxygen analyzer Without With ZFK With ZKG (Non-standard) 0 1 3 Auto calibration With 1 Type of cubicle Indoor installation type Outdoor installation type 1 2 External piping Heating pipe ø10 Teflon tube 1 2 Standard gas 3.4r 10r 3.
Rc 1/2 Drain outlet Sample gas inlet (Rc 3/8) Gas sample pipe Gas extracter * Conditioner * – 50 – Solenoid valve Air CO CO /N2 SO2 /N2 O2 /N2 Pressure regulator Solenoid valve Two component infrared gas analyzer NO,SO2 NO2/NO Membrane Convertor filter Standard gas NO /N2 Infrared gas analyzer Flowmeter Membrane filter Electronic gas cooler : Capillary equipped depending on specification Pressure control valve Aspirator Zirconia O2 sensor O2 SAMPLING SYSTEM BLOCK DIAGLAM
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.
OUTLINE DIAGRAM (Unit:mm) For outdoor installation type 1000 Anchor plan and door opening diagram 620 Rc 3/8 Rear side Front side Cable inlet (60 × 120 rectangular hole) with plastic resincover (PVC) 70 760 70 30° 120 815 A-140-2-1 (key No.
CONNECTION DIAGRAM 1 L1 Power supply 2 L2 100V AC 3 G 4 5 J1 6 J2 7 H1 8 H2 9 A1 10 A2 11 A3 12 A4 13 B1 14 B2 15 B3 16 B4 17 C1 18 C2 19 C3 20 C4 21 C5 22 C6 23 C1A 24 C2A 25 E1 26 E2 27 E3 28 E4 29 C7 30 C8 31 D11 32 D12 33 D21 34 D22 Extractor Heating tube NOx instantaneous value NOx average value SO2 instantaneous value SO2 average value O2 instantateous value NOX instantateous value SO2 corrected value O2 instantateous value CO instant
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.
