Fuji Labs ZSP manual

INZ-TN4ZSPb-E Instruction Manual INFRARED GAS ANALYZER TYPE: ZSP[...]

– i – 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 [...]

– ii – 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.” Dang[...]

– iii – Caution on wiring Caution •R equest an installation company or your dealer to carry out wiring. If wiring is incomplete, shock hazard or injury may be caused. •C lass D grounding construction is mandatory. Otherwise, shock hazard may be caused. < Caution for wiring company > For preventing shock hazard, fire and injury, be sur[...]

– iv – 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 i[...]

– v – 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 o[...]

– vi – CONTENTS INTRODUCTION ................................................................................................................................................... i CAUTION ON SAFETY .............................................................................................................. ......................... ii 1. OUTLIN[...]

– vii – 10. MAINTENANCE ......................................................................................................................................... 26 10.1 Routine maintenance and inspection ......................................................................................... ........ 26 10.2 Periodic maintenance and inspectio[...]

– 1 – 1. OUTLINE The infrared gas analyzer (ZSP) can continuously and accurately measure the concentration of gases such as NOx, SO 2 , CO, CO 2 and O 2 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[...]

– 2 – 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,[...]

– 3 – 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 (c) Freeze preventi[...]

– 4 – 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 acc[...]

– 5 – 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 [...]

– 6 – 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. (c) Conn[...]

– 7 – 7. INDICATION/OPERATION PANEL 7.1 Name and description of each component of indication/operation panel Part Name Description q Component indication Indicates kind of gas measured. w Main indication Indicates measured concentration. Also indicates various set-points for alarm function, auto calibration function (option), etc. e Unit indica[...]

– 8 – 7.2 Function and indication of indication/operation panel This panel consists of the following functions. Key Function Main indication Sub indication Function indication lamp FUNC Measuring mode Measuring value Range MEAS lamp lights Setting mode FUNC Calib.conc.setting Calb.conc. Range CAL SET lamp lights FUNC Alarm setting (option) Alar[...]

– 9 – 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. Advice on Operation ✩ When selecting the range In the setting status, as shown in the figure at the right, the high[...]

– 10 – 8. CALIBRATION 8.1 Kinds of standard gas 8.1.1 When not using zirconia O 2 sensor (1) Zero gas: N 2 or 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 N 2 (span gas for l[...]

– 11 – Fig. 8-1 Pressure regulation for standard gas cylinder Packing Pressure gauge on high pressure side Pressure gauge on low pressure side Adapter Cylinder mounting nut Cylinder Pressure regulator R1/4 joint Pressure controls Output handle[...]

– 12 – 8.3 Calibration concentration setting (except zirconia O 2 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 sta- tus, the previously set span value will appear on the ma[...]

– 13 – [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, then ‘ ’ will appear on the main indication and ‘ ’ will appear on the sub indication. Pre[...]

– 14 – 8.4 Calibration concentration setting (zirconia O 2 sensor) A zirconia O 2 sensor sets the zero (air) point (span point stipulated in the laws for measurement and weighing) of the O 2 analyzer. For the density of calibration gas to be used, refer to “ 8.2 Preparation of standard gas ” . ✩ Setting of calibration concentration for ze[...]

– 15 – ✩ Setting of span calibration concentration (zero point stipulated in the laws for measurement and weigh- ing) Press the CAL key in the status where the digit of the O 2 analyzer main indication is flickering via the zero (air) point calibration concentration setting. The previously set span value will now appear on the main indication[...]

– 16 – 8.5 Zero calibration (air point calibration in case of zirconia O 2 sensor) This is used for adjusting the zero point. Flow the zero gas (0.3 N /min.) by adjusting the needle valve of pressure regulator and wait until the indica- tion stabilizes. When the Zirconia O 2 sensor is used, use air. Note) When the indication has stabilized, sel[...]

– 17 – 8.6 Span calibration (low concentration point calibration in case of zirconia O 2 sensor) 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[...]

– 18 – 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 ti[...]

– 19 – 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 i[...]

– 20 – 8.7.1 Current time setting Set the current time and day of the week. Press the FUNC key in the measuring status. The AUTO CAL LED of the function indicating lamps will flicker. 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 su[...]

– 21 – 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. 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. P[...]

– 22 – 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. The AUTO CAL LED of the function indicating lamps will flicker. Press the key and the auto calibration cycle is settable. The highest dig[...]

– 23 – 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 key and auto calibration ON[...]

– 24 – 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. Press the FUNC key in the measuring status and ‘ ’ will be indicated. The HOLD LED of the function [...]

– 25 – 9. OPERATION 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) Tu[...]

– 26 – Maintenance/inspection item Monitoring of sample flow rate Monitoring of conditioner bubbling quantity (Note) Conditioner Air aspiration tube level Procedure Prescribed flow rate: The flow rate is normal when the ball is at 0.4 N /min. and there is slight bubbling at the bottom of conditioner. Adjust the needle valve so that a flow rate [...]

– 27 – Maintenance/inspection item Contamination of membrane filter Electronic gas cooler Temperature controller for NO 2 /NO converter Procedure 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), [...]

– 28 – 10.2 Periodic maintenance and inspection Procedure Refer to section 8.5 to 8.6. It takes at least 1.5 months to deliver the standard gas. So the gas should be ordered 2 or 3 months in advance. Supply water if level is below overflow port. Replace with new filter paper (stop the aspirator when exchanging). See 10.5 (3). Replace these part[...]

– 29 – Fig 10-2 Gas extractor (type ZBAK1) Seal fixture Filter case Locking wing bolt Handle for filter exchange O-ring (JIS P48A Viton) Metallic mesh filter 10.4 Concentration guarantee term of standard gas cylinder (for NO x , SO 2 , CO and O 2 analyzer) Kind of gas Concentration range Guarantee term NO/N 2 0.4ppm or more, and less than 250pp[...]

– 30 – (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 [...]

– 31 – Hex. socket head cap screw Cap A Seat valve Rc1/8 Cap B Diaphragm Arm lot Fig. 10-4 Exploded view of diaphragm type aspirator (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 pro[...]

– 32 – (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 u[...]

– 33 – (6) Replacement of NO 2 /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 p[...]

– 34 – (9) Washing the Permapure dryer The Permapure dryer is used for SO 2 measurement (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 follo[...]

– 35 – 10.6 Maintenance of zirconia O 2 sensor Sensor temperature 800 OXYGEN ANALYZER POWER ON OFF 1234567 Power SW Fuse 3A Terminal Front view Side view Sample inlet (Rc 1/4) Outlet (Rc 1/4) AG 0V + – ALM (1) Appearance of zirconia O 2 sensor (2) Routine maintenance No parts require periodic maintenance. In case sensor temperature is 800 ± [...]

– 36 – 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. No. Part name Type of part No. Q[...]

– 37 – 11.2 Spares for 1 year (optional) No. Part name Quantity (analyzer) Remarks NO X /SO 2 NO X SO 2 Other 1 Spare for converter 1 1 —— Catalyst and filter TK726889C3 2 Conditioner filter 2 2 2 2 TK7H8043P1 3 Conditioner O-ring 2 2 2 2 G65 chloproprene 8553765 4 Membrane filter paper — 1 pack — 1 pack 25 sheets of TK701837C6 per pack[...]

– 38 – 12. PROCESSING OF HEATING PIPE ENDS 12.1 Outline (1) Configuration 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[...]

– 39 – 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. Fig. 12-4 e Peel the outer sheath covering of heater as shown below and cut off the heate[...]

– 40 – (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. w 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[...]

– 41 – 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[...]

– 42 – 12.5 Specifications of tube trace (1) Structure of tube trace 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 Heater cable HPT 20-1 BN 35.4w/m at 100 º C (100V AC) w Process tube 10/8 mm ø PFA Teflon tube e Aluminum tape 50% over[...]

– 43 – Note) Pressure control valve is used. 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. Trouble Decrease of sample gas flow rate Incr[...]

– 44 – 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. Trouble Indicated value is not as expected. Indication doesn [...]

– 45 – 14. SPECIFICATIONS Specifications Type of cubicle: Outdoor, self-standing, sealed type or indoor type Measuring system: Non-dispersion infrared absorption (NDIR method) for NO x , SO 2 , CO and CO 2 ; zirconia method for O 2 . Sampling system: Dry sampling electronic cooling & dehumidification system (Permapure dryer adopted) Measuri[...]

– 46 – Standard requirements for sample gas: Temperature — 60 to 800 ° C Dust — 100 mg/Nm3 or less Pressure — - 2.94 to +2.94kPa Components — SO 2 0 to 1000ppm NO x 0 to 2000ppm (NO 2 100ppm or less) CO 2 several % to over 10% CO 0 to 2000ppm O 2 0.5 to 21% H 2 O 0 to 40% HC N 0 to 100ppm N 2 remaining percent When other components are[...]

– 47 – (1) NO x after O 2 correction CO after O 2 correction (a) Calculating equation 21 - On C= • Cs 21 - O S C: Concentration after O 2 conversion Cs: NOX or CO concentration measured Os: O 2 concentration measured On: O 2 concentration as conversion basic: 4% Oil combustion boiler 5% Gas combustion boiler 6% Solid object combustion boiler,[...]

– 48 – CO span O 2 zero NOx span SO 2 span O 2 span Automatic calibration NO x , SO 2 zero CO zero Automatic calibration • Calibration tolerance: ± 0.2% FS • Automatic calibration output hold: Possible (Example in 4 component analyzer): • Calibration cycle: Once/day (variable, up to 7 days) • Calibration gas feed time: 2 to 10 min. (va[...]

– 49 – 0 1 3 NO X + (O 2 ) CO + (O 2 ) SO 2 + (O 2 ) NO X + SO 2 + (O 2 ) NO X + SO 2 + CO + (O 2 ) NO X + SO 2 + CO + (O 2 ) With ZFK With ZKG (Non-standard) Application Combustion exhaust gas (standard condition) Other exhaust gas Others Component Oxygen analyzer Without Auto calibration With Type of cubicle Indoor installation type Outdoor i[...]

– 50 – SAMPLING SYSTEM BLOCK DIAGLAM CO Gas extracter Gas sample pipe Conditioner Aspirator Electronic gas cooler Pressure control valv e equipped depending on specification Solenoid valv e Zirconia O 2 sensor Flowmeter Con vertor Infrared gas analyzer T wo component infrared gas analyzer Solenoid valv e Pressure regulator Standard gas Sample g[...]

– 51 – Functions of individual components • Gas extractor (type; ZBA): With heating type stainless steel filter; standard diameter 40 µ m 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 f[...]

– 52 – 620 760 Rear side Front side 1000 120 815 70 1800 50 770 1400 620 800 760 800 100 4- φ 15 hole 100 A-140-2-1 (key No.200) Cable inlet (60 × 120 rectangular hole) with plastic resin- cover (PVC) 70 ( 4 – M12 × 160 × 50 ) 32 35 Anchor plan and door opening diagram 620 760 Rear side Front side Cable inlet (60 × 120 rectangular hole) [...]

– 53 – 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 30 31 32 33 34 35 36 20 21 22 23 24 25 26 27 28 29 Power supply CO av erage value O 2 instantateous value CO corrected value Failure contact output On maintenance and auto calibration contact output 100V A C NO x instantaneous value NO x av erage value SO 2 instantaneous value SO 2 av erage[...]

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[...]