Fuji Electric ZPB User manual

Instruction Manual
NDIR TYPE
INFRARED GAS
ANALYZAR
TYPE:  ZPB
INZ-TN2ZPB-E

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INZ-TN2ZPB-E
Thank you very much for purchasing Fuji’s Infrared Gas Analyzer (Type: ZPB).
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injury.
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PREFACE
Request
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ii INZ-TN2ZPB-E
CAUTION ON SAFETY
To operate the analyzer properly, be sure to read “Caution on Safety” carefully.
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damage.
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CAUTION
DANGER
PROHIBITION
Caution on installation and transport of gas analyzer
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DANGER
CAUTION
CAUTION

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Caution on piping
Be sure to observe the following precautions while installing
piping. Improper piping may result in gas leakage.
If the leaking gas contains a toxic component, serious acci-
dents may result. If it contains combustible gases, explosion
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Caution on wiring
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Caution on use
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erly.
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CAUTION
CAUTION

iv INZ-TN2ZPB-E
Caution on maintenance and check
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Be sure to observe the following to perform work safely,
avoiding electric shock or injury.
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Others
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Caution on use
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CAUTION
CAUTION
DANGER
PROHIBITION

v
INZ-TN2ZPB-E
1. Scope of application
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2. Operating conditions and environment
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3. Precautions and prohibitions
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4. Warranty
4-1. Period of warranty
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4-2. Scope of warranty
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from:
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vi INZ-TN2ZPB-E
5. Failure diagnosis
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7. Maintenance plan
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maintenance
Daily inspection
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maintenance
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vii
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8. Limited-life parts and consumable parts
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accessories.
10. Period for repair and provision of spare parts after product dis-
continuation (maintenance period)
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viii INZ-TN2ZPB-E
CONTENTS
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1
INZ-TN2ZPB-E
1. OVERVIEW
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2INZ-TN2ZPB-E
2. NAME OF DELIVERED ITEMS AND EACH PARTS
&RQ¿UPDWLRQRIGHOLYHUHGLWHPV
Analyzer: 1 unit
Standard: IEC127-2
Size: ø5 × 20mm
Rating: 250V/2A delay type
Part No.: R75796N17
Instruction manual (this manual): 1 copy
(INZ-TN2ZPB-E)
Fuse: 2 pcs
Analog output connector: 1
Fixing screws: 2
Power supply cord: 1
(When power inlet is specified)
Standard inlet type
External input connector: 1
(External O2analyzer and External
zirconia O2analyzer are specified)
Digital input/output connector: 3 max.
with the number of DIO
Fixing screws: 6 max.
(When digital input/output function is
specified)
RS-485 connector: 1
Fixing screws: 2
(When provided with communication
function)
25 pin D-sub connector (male)
Part No.: R77256N262
M2.6×4mm
25 pin D-sub connector (male)
Part No.: R77256N262
M2.6×4mm
9 pin D-sub connector (male)
Part No.: R77256N284
M2.6×4mm
Part No.: R77240N35
Part No.: R77419Ｎ14
Ferrite core: 1
For power cable
(When terminal block for power supply
is specified) Part No.: R79181N14
Max.
3 sets
Instruction Manual
NDIR TYPE
INFRARED GAS
ANALYZAR
TYPE: 
ZPB
INZ-TN2ZPB-E

3
INZ-TN2ZPB-E
2.2 Name and description of analyzer
(unit mm)
(3) Flowmeter
< Rear panel >
< Front panel >
(2) Display/operation panel
(4) Purge gas inlet
(5) Sampling gas inlet
(6) Sampling gas and
reference gas outlet
(12) Analog output connector (A/O) (D-sub25 pin)
(11) Communication connector (RS-485)
(10) External input connector
(7) Fuse
(8) Power supply (Inlet Type)
(13) Digital input/output connector (DIO1 to 3) (D-sub25 pin)
(1) Power switch
Power supply
(M4 Terminal
Block Type)
(9) Reference gas inlet
Name
(1) Power switch Used for ON/OFF the analyzer.
(2) Display/operation
panel
Liquid crystal display and keys
for setting various functions.
(3) Flow meter For checking the flow rate of
sampling gas and reference gas.
(4) Purge gas inlet For connecting to the purge gas
tube.
(5) Sampling gas inlet For connecting to the measuring
gas tube.
(6) Sampling gas and
reference gas outlet
For connecting to the exhaust
line.
(7) Fuse Fuse inside
(8) Terminal block for
power supply
For connecting to the power
supply line.
(9) Reference gas inlet For connecting to the reference
gas tube.
(10) External input
connector
For connecting to the output of
externally installed O2analyzer.
(11) Communication
connector
RS-485 connector for
communication.
(12) Analog output
connector
(D-sub25 pin)
Connector for the analog output
(13) Digital input/output
connector
(D-sub25 pin)
Connector for the digital
input/output
Description Name Description

4INZ-TN2ZPB-E
3.1 Installation conditions
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3. INSTALLATION
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injury.
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DANGER
CAUTION
analyzer
(drawer out)
analyzer
(installed)
unit : mm
400
500

5
INZ-TN2ZPB-E
3.2 Installation
3.2.1 Installation of analyzer main frame
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Support
External dimensions Mounting dimensions Mounting method
(Unit : mm)
Type
19-inch rack
mounting
450 or more
465
M6
415
483
132.5
A
“A” : 57.2 (EIA)
57.2

6INZ-TN2ZPB-E
3.3 Piping
Purge gas inlet
Reference gas inlet
Sampling gas inlet 1
Sampling gas and
reference gas outlet 1
Sampling gas inlet 2
Sampling gas outlet 2
For special case only
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coupling.
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FDOLEUDWLRQWRWKLVLQOHW
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/PLQ
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VXUHGJDVRXWGRRUVRUWRWKHDWPRVSKHUH
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8VHGU\JDV1RULQVWUXPHQWDWLRQDLUIRUSXUJHJDV)ORZUDWHLV/PLQRU
PRUHDQGGXVWRUPRLVWXUHPLVWDUHXQDOORZDEOH
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,QDGGLWLRQWRDVDPSOHUHIHUHQFHJDVLQOHWDQGRXWOHWWKHUHLVDSXUJHJDVLQOHWDWWKHUHDU
SDQHORIWKHDQDO\]HU
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IXPHVPD\EHDFFXPXODWHGLQWRWKHDQDO\]HU
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CAUTION

7
INZ-TN2ZPB-E
Internal piping diagram
Correspondence of measured components and optical units
Optical unit 2 (IR Unit 2) Optical unit 1 (IR Unit 1)
Sampling cell
Sampling gas inlet
Reference gas inlet
Note)
2 cells may be used
by combination of
range.
INLET1REFERENCE OUTLET1
FL1
(Left)
FL2
(Right)
Sample gas outlet/
Reference gas outlet
Built-in
O2sensor
SV1
NO
IN NC
SV2
NO
IN NC
0HDVXULQJFRPSRQHQWV 2SWLFDOXQLW 2SWLFDOXQLW
FRPSRQHQWIRU12
62&2&2DQG&+4
(DFKFRPSRQHQW 1RQH
FRPSRQHQWVIRU
&2&2 &2&2 1RQH
FRPSRQHQWVIRU
12&21262
12
12
&2
62
FRPSRQHQWVIRU
1262&2 12 62&2
FRPSRQHQWVIRU
1262&2&2 12 62&2&2

8INZ-TN2ZPB-E
3.4 Sampling
3.4.1 Conditions of sampe gas
 'XVWFRQWDLQHGLQWKHVDPSOHJDVVKRXOGEHFRPSOHWHO\UHPRYHGZLWKD¿OWHU)RUWKH¿QDO
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RIGUDLQLQWKHJDVDQDO\]HU,IYDSRULVFRQWDLQHGLQWKHVDPSOHJDVGHZSRLQWVKRXOGEHORZ-
HUHGWRÛ&E\XVLQJDGHKXPLGL¿HU
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2WKHUPLVWVVKRXOGEHUHPRYHGE\XVLQJDPLVW¿OWHURUJDVGU\HU
 &RUURVLYHJDVHVVXFKDV&O)DQG+&OLIWKH\DUHFRQWDLQHGLQWKHVDPSOHJDVLQ consider-
DEOHDPRXQWVZLOOVKRUWHQWKHOLIHRIFRPSRQHQWSDUWV
 7HPSHUDWXUHRIWKHVDPSOHJDVVKRXOGEHZLWKLQWRÛ&3D\DWWHQWLRQQRWWRÀRZKRWJDV
GLUHFWO\LQWRWKHLQVWUXPHQW
 6DPSOHJDVÀRZ
)ORZRIVDPSOHJDVVKRXOGEH/PLQ/PLQ
$YRLGÀRZÀXFWXDWLRQGXULQJPHDVXUHPHQW
2EVHUYHWKHÀRZUHDGLQJE\DÀRZPHWHUSURYLGHGDVVKRZQLQWKHH[DPSOHRIWKHVDPSOLQJV\V-
WHPFRQ¿JXUDWLRQ6HFWLRQ
3.4.3 Preparation of standard gas
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FRQGLWLRQRQFHDZHHN3UHSDUHDVWDQGDUGJDVF\OLQGHUIRU]HURFDOLEUDWLRQDQGVSDQFDOLEUDWLRQ
3.4.4 Purging of instrument inside
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WLRQVLWH
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RUGU\1.
3XUJLQJÀRZUDWHVKRXOGEHDERXW/PLQ
3XUJLQJJDVLIXVHGPXVWQRWFRQWDLQGXVWRUPRLVWXUH
$QDO\]HUZLWKRXW2mea-
VXUHPHQW
$QDO\]HUZLWKEXLOWLQ2
sensor
$QDO\]HUZLWKH[WHUQDO]LU-
FRQLD2sensor
Zero gas 1gas 1gas Dry air
6SDQJDVRWKHUWKDQ
IRU2PHDVXUHPHQW
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LQJUDQJHEDUDQFH1.
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DLU2).
2JDVRIWR

9
INZ-TN2ZPB-E
 ([DPSOHFRQ¿JXUDWLRQRIJDVVDPSOLQJV\VWHP
7KHIROORZLQJLOOXVWUDWHVDW\SLFDOV\VWHPFRQ¿JXUDWLRQIRUFRPSRQHQWJDVPHDVXUHPHQWIRU
PRQLWRULQJFRPEXVWLRQH[KDXVWJDVIURPERLOHUUHIXVHLQFLQHUDWRUHWF
&RQWDFW)XML(OHFWULFIRUV\VWHPFRQ¿JXUDWLRQPDWFKLQJWKHSDUWLFXODUXVHRUIXUWKHULQIRUPDWLRQ
3.4.5 Pressure at sampling gas outlet
3UHVVXUHDWWKHVDPSOLQJJDVRXWOHWVKRXOGEHDGMXVWHGWRWKHDWPRVSKHULFSUHVVXUH
1DPH 'HVFULSWLRQ 1DPH 'HVFULSWLRQ
 *DVH[WUDFWRU *DVH[WUDFWRUZLWKDKHDWLQJ
W\SHVWDLQOHVVVWHHO¿OWHURI
VWDQGDUGPHVKP
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UDWH RI WKH VDPSOH JDV UHIHU-
HQFHJDVDQGVWDQGDUGJDV IRU
FDOLEUDWLRQ

0LVW¿OWHU 5HPRYHVGUDLQPLVWDQGGXVW  6WDQGDUGJDV 6WDQGDUGJDVXVHGIRUFDOL-
EUDWLQJ]HURDQGVSDQRIWKH
DQDO\]HUGHSHQGLQJRQWKH
PHDVXUHGFRPSRQHQW
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LQWRWZRVSDFHVIRUSRVLWLYHDQG
QHJDWLYHSUHVVXUH,WPRQL-
WRUVDQGDGMXVWVWKHVDPSOHJDV
pressure.
 *DVDVSLUDWRU )RUDVSLUDWLRQRIWKHVDPSOHJDV
and reference gas
=LUFRQLD2
analyzer
([WHUQDO]LUFRQLDR[\JHQ
sensor used for measuring
WKHR[\JHQFRQFHQWUDWLRQLQ
sample gas.
7KLVLVQRWQHFHVVDU\LQFDVH
ZKHQ2VHQVRULVEXLOWLQ
 (OHFWURQLFJDV
cooler
'ULHVWKHPRLVWXUHLQWKH
VDPSOHJDVDQGUHIHUHQFHJDVWR
DGHZSRLQWRIDSSUR[Û&
(6)
Solenoid valve 8VHGIRUÀRZLQJWKHVWDQGDUG
gas.
 0HPEUDQH¿OWHU 37)(¿OWHUXVHGWRHOLPLQDWH
¿QHGXVWSDUWLFOHV
1212FRQ-
YHUWHU
$GGHGWR12[DQDO\]HU
$VSHFLDOFDWDO\VWPDWHULDOIRU
HI¿FLHQWFRQYHUVLRQRI12
JDVWR12LVXVHG
(1) Gas extractor
ø10/ø8
Teflon
tube
*1
*2
ÛRUODUJHU
(6) 2-way
solenoid
valve
(6) 2-way
solenoid
valve
(2) Mist filter
Air filter (4) Gas aspirator
(4) Gas
aspirator
Drain
(3) Safety
drain trap
Electronic
JDVFRROHU
(5)
(8) Flowmeter
,QIUDUHGJDV
analyzer
main frame
(O2)
ZPB unit
(7) Membrane
filter
Exhaust
(10)
Zirconia
O2analyzer
Ball value
Drain pot
(11) NOX/NO converter
(for NOX measurement)
 %HVXUHWRUHPRYHWKHPRLVWXUHWREHWHPSHUDWXUH&RUORZHUIURPPHDVXULQJJDVE\HOHFWURQLFFRROHUDQGZDWHUFRQFHQWUDWLRQ
 VKRXOGEHHTXDOL]HGLQUHIHUHQFHJDVDQGVDPSOHJDV
*2) Be sure to use NO212FRQYHUWHULQFDVHRIPHDVXULQJ12x
 &RQQHFWWRWKHFRQWDFWIRU]HURFDOLEUDWLRQ
6WDQGDUGJDV
for zero calibration 6WDQGDUGJDVIRU
span calibration
5HIHUHQFHJDV
(Wet N2 or
atmospheric air)
NO
NC
com
SV1
*3
3-way
solenoid
valve

10 INZ-TN2ZPB-E
3.4.7 Gas requirements for measurement and calibration
From reference
gas inlet
From sample gas
inlet Remarks
Calibration
Zero calibration Dry N2or dry air Dry N2or dry air Use dry gas (cylinder) for
both zero and span cali-
brations.
Span calibration Dry N2or dry air Dry span gas
Measurement
When sample
gas is wet
N2or air dehu-
PLGL¿HGWRWKHGHZ
point of 2 degrees
Celsius or lower
Sample gas dehu-
PLGL¿HGWRWKHGHZ
point of 2 degrees
Celsius or lower
If the sample gas contains
moisture, dehumidify both
the reference gas and the
sample gas to the dew
point of 2 degrees Celsius
or lower.
When sample
gas is dry Dry N2or dry air Dry sample gas
Calibration
Zero calibration: dry N2or dry air
Span calibration: dry span gas
Zero calibration: dry N2or dry air
Span calibration: dry N2or dry air
Measurement
(wet sample gas)
Measurement
(dry sample gas)
Dry sample gas
Dry N2or dry air
Sample gas dehumidified to the dew
point of 2 degrees Celsius or lower
N2or air dehumidified to the dew
point of 2 degrees Celsius or lower
Infrared-ray
light source
Sample gas
Detector
Measuring
cell
Solenoid valve
for switching
Reference gas
Chopper
Motor
Gas flow NC: Normal Close NO: Normal Open
com NO
NO
NC
NC
SV2
SV1
Exhaust
com
Infrared-ray
light source
Sample gas
Detector
Measuring
cell
Solenoid valve
for switching
Reference gas
Chopper
Motor
Gas flow NC: Normal Close NO: Normal Open
com NO
NO
NC
NC
SV2
SV1
Exhaust
com
Infrared-ray
light source
Sample gas
Detector
Measuring
cell
Solenoid valve
for switching
Reference gas
Chopper
Motor
Gas flow NC: Normal Close NO: Normal Open
com NO
NO
NC
NC
SV2
SV1
Exhaust
com