Fuji Electric ZSVS-2 User manual

INZ-TN2ZSVSa-E
Instruction Manual
COMPACT TYPE
GAS ANALYZER
TYPE: ZSVS-2

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We are grateful for your purchase of Fuji Compact Type Gas Analyzer, TYPE: ZSVS.
•First read this instruction manual carefully until an adequate understanding is acquired, and
then proceed to installation, operation and maintenance of the analyzer. Wrong handling
may cause an accident or injury.
•The specifications of this analyzer are subject to change without prior notice for further
product improvement.
•Modification of this analyzer is strictly prohibited unless a written approval is obtained from
the manufacturer. Fuji Electric will not bear any responsibility for a trouble caused by such
a modification.
• This instruction manual shall be stored by the person who actually uses the analyzer.
•After reading the manual, be sure to store it at a place easier to access.
• This instruction manual should be delivered to the end user without fail.
Manufacturer: Fuji Electric Co., Ltd.
Type: Described in the nameplate on main frame
Date of manufacture: Described in the nameplate on main frame
Product nationality: Japan
© Fuji Electric Co., Ltd. 2012
Issued in September, 2012
Rev. 1st edition April, 2016
PREFACE
Request
•It is prohibited to transfer part or all of this manual without Fuji
Electric’s permission in written format.
•Description in this manual is subject to change without prior
notice for further improvement.

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First of all, read this “Caution on safety” carefully, and then use the analyzer in the correct way.
• The cautionary descriptions listed here contain important information about safety, so they should always
be observed. Those safety precautions are ranked in 3 levels, “DANGER,” “CAUTION” and “PROHIBI-
TION.”
Wrong handling may cause a dangerous situation, in which there is
a risk of death or heavy injury.
Wrong handling may invite a dangerous situation, in which there is
a possibility of medium-level trouble or slight injury or only
physical damage is predictable.
Items which must not be done are noted.
CAUTION ON SAFETY
Caution on installation, transport and storage of gas analyzer
•This unit is not explosion-proof type. Do not use it in a place
with explosive gases to prevent explosion, fire or other serious
accidents.
•The gas analyzer is heavy. It should be installed with utmost
care. Otherwise, it may tip over or drop, for example, causing
accident or injury.
•For lifting the gas analyzer, be sure to wear protective gloves.
Bare hands may invite an injury.
•This unit should be installed in a place which conforms to the
conditions noted in the instruction manual. Otherwise, it may
cause electric shocks, fire or malfunction of the unit.
•During installation work, care should be taken to keep the unit
free from entry of cable chips or other foreign objects. Other-
wise, it may cause fire, trouble or malfunction of the unit.
DANGER
CAUTION
PROHIBITION
DANGER
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 accidents
may result. If it contains combustible gases, explosion or fire
may result.
• Connect pipes correctly referring to the instruction manual.
• Discharge the exhaust gas outdoors to prevent it from remaining
within doors.
• Relieve the exhaust gas from the analyzer to the atmospheric
pressure to prevent buildup of undesirable pressure to the ana-
lyzer. Otherwise piping within the analyzer may be discon-
nected, resulting in gas leakage.
• Use pipes and pressure reducing valves to which no oil/grease is
attached for piping. Otherwise, fire may result.
Caution on wiring
• Be sure to turn off all the power before installing wiring. Other-
wise electric shock may result.
• Be sure to perform class D grounding work. Otherwise, electric
shock or failure may result.
• Select a proper wiring material that satisfies the ratings of the
instrument. Otherwise, electric shock or fire may result.
• Be sure to connect a power supply of correct rating. Otherwise,
fire may result.
Caution on use
•If unusual smell or sound has been produced, immediately stop
the instrument. Any discharge produced may cause a fire.
• Leaving the analyzer unused for a long time or restarting it after
long-term suspension requires procedures different from normal
operation or suspension procedures. Be sure to follow the
instructions in each instruction manual. Otherwise, intended
performance may not be achieved, or accidents or injury may
result.
•Do not operate the analyzer for a long time with its door left
open. Otherwise, dust, foreign matter, etc. may stick on internal
walls, thereby causing faults.
DANGER
CAUTION
CAUTION
DANGER

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Caution on use
•Do not put stick or finger into the fan (exhaust gas outlet). You
may get hurt by a turning fan.
• Do not allow metal, finger or others to touch the power and input/
output connectons in the instrument. Otherwise, faults, electric
shock or injuries may be caused.
•Do not smoke nor use a flame near the gas analyzer. Otherwise, a
fire may be caused.
Caution on maintenance and check
•For correct handling of calibration gas or other reference gases,
carefully read their instruction manuals beforehand. Otherwise,
carbon monoxide or other hazardous gases may cause an intoxi-
cation particularly.
• Before performing work for maintenance and check, be sure to
purge completely not only within the analyzer but also measuring
gas lines with nitrogen or air. Otherwise, poisoning, fire, or
explosion may result due to gas leakage.
•Before replacing the gas filter of the gas analyzer or maintaining
the washer, close the calibration gas valve and, if provided, the
valve on the sample gas suction port. Otherwise, intoxication or
accident may occur.
• If the fuse is blown, eliminate the cause, and then replace it with
the one of the same capacity and type as before. Otherwise,
shock hazard or fault may be caused.
•Do not use a replacement part other than specified by the instru-
ment maker. Otherwise, adequate performance will not be
provided. Besides, an accident or fault may be caused.
• Replacement parts such as a maintenance part should be disposed
of as incombustibles. For details, follow the local ordinance.
Be sure to observe the following for safe operation avoiding the
shock hazard and injury.
•Remove the watch and other metallic objects before work.
•Do not touch the instrument wet-handed.
Others
•If the cause of any fault cannot be determined despite reference
to the instruction manual, be sure to contact your dealer or Fuji
Electric’s technician in charge of adjustment. If the instrument is
disassembled carelessly, you may have a shock hazard or injury.
PROHIBITION
DANGER
CAUTION
CAUTION

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1. Scope of application
To use this equipment, the following conditions must be met:
• the use of the equipment incurs no risk of a serious accident even if a failure or malfunction occurs on the
equipment, and
• in case of product failure or malfunction, safety measures such as redundant design, prevention of malfunction, fail
safe system, foolproof mechanism are provided outside of the equipment.
Be sure to use this instrument under the conditions or environment mentioned in this instruction manual. Please
consult us for the use for the following applications:
Radiation-related facilities, systems related to charging or settlement, or other usages which may have large impact
on lives, bodies, property, or other rights or interests.
2. Operating conditions and environment
Refer to "Caution on safety" and Section 8, "Specifications".
3. Precautions and prohibitions
Refer to "Caution on safety"and Section 8, "Specifications".
4. Warranty
4.1 Period of warranty
(1) Warranty period for this product including accessories is one year after delivery.
(2) Warranty period for the parts repaired by our service providers is six months after the completion of repair.
4.2 Scope of warranty
(1) If any failure or malfunction attributable to Fuji Electric occurs in the period of warranty, we shall provide the
product after repairing or replacing the faulty part for free of charge at the place of purchase or delivery. The
warranty does not apply to failure or malfunctions resulting from:
1) inappropriate conditions, environment, handling or usage that is not instructed in a catalog, instruction book
or user's manual, or overuse of the product,
2) other devices not manufactured by Fuji Electric,
3) improper use, or an alteration or repair that is not performed by Fuji Electric,
4) inappropriate maintenance or replacement of expendable parts listed in the instruction book or the catalog,
5) damages incurred during transportation or fall after purchase,
6) any reason that Fuji Electric is not responsible for, including a disaster or natural disaster such as
earthquake, thunder, storm and flood damage, or inevitable accidents such as abnormal voltage.
(2) Regardless of the time period of the occurrence, Fuji Electric is not liable for the damage caused by the factors
Fuji Electric is not responsible for, opportunity loss of the purchaser caused by malfunction of Fuji Electric
product, passive damages, damage caused due to special situations regardless of whether it was foreseeable
or not, and secondary damage, accident compensation, damage to products that were not manufactured by Fuji
Electric, and compensation towards other operations.
WARRANTY AND MAINTENANCE

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5. Failure diagnosis
Regardless of the time period of the occurrence, if any failure occurs, the purchaser shall perform a primary failure
diagnosis. However, at the purchaser's request, Fuji Electric or our service providers shall provide the diagnosis
service for a fee. In such a case, the purchaser shall be charged for the service.
6. Service life
This product, excluding limited-life parts and consumable parts, is designed for a service life of 10 years under
general operating conditions (with an average ambient temperature of 30°C).
The service life may be shortened depending on operating conditions and environment. To ensure the service life, it
is important to perform planned maintenance of the product including limited-life parts and consumable parts.
7. Maintenance plan
Maintenance can be divided into "preventive maintenance" and "corrective maintenance". Preventive maintenance
can further classified into "daily inspection" and "periodic inspection". Preventive maintenance is achieved through
systematic implementation of "daily inspection" and "periodic inspection".
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 
(1) Daily inspection
Be sure to perform daily inspection prior to operation to check for any problem in daily operation. For the
specific items of daily inspection, refer to Section 7, "Maintenance".
(2) Periodic inspection
Periodic inspection is to replace limited-life parts before their service lives are over, thus preventing failure.
Recommended inspection interval is 6 months to 12 months. If you are using the instrument under harsh
environment, we recommend you to shorten the inspection interval. For the specific items of periodic inspection,
refer to Section 5, "Inspection and maintenance".
(3) Corrective maintenance
Corrective maintenance is a measure to be taken after a trouble has occurred. Refer to Section 5 "Inspection
and maintenance" and Section 7. "Troubleshooting". If the measures mentioned in this instruction manual do
not solve the problem, please contact one of our sales offices or service offices.
8. Limited-life parts and consumable parts
This product contains the following limited-life parts and consumable parts which may affect the service life of the
product itself.
(1) Aluminum electrolytic capacitor
•Design life: 5 years under general working conditions (annual average of ambient temperature: 30°C)
•Symptoms when a capacitor loses its capacity: deterioration of power quality, malfunction
• Factors which affect battery life: temperature. The life is shortened by half when the temperature rises by
10°C. (Arrhenius' law)

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•Replacement: Estimate the lifetime of capacitor according to your operating environment, and have the
capacitor replaced or overhauled at appropriate time, at least once in 10 years.
Do not use capacitors beyond its lifetime. Otherwise, electrolyte leakage or depletion may cause odor, smoke,
or fire. Please contact Fuji Electric or its service providers when an overhaul is required.
(2) LCD
•Design life: approx. three years for continuous use
• Symptoms when LCD is depleted: unclear indication, back light not working
• Factors which affect battery life: temperature. The life is shortened by half when the temperature rises by
10°C. (Arrhenius' law)
•Replacement: Estimate the lifetime of built-in battery according to your operating environment, and replace it
at appropriate time.
9. Spare parts and accessories
Refer to "Confirmation of delivered equipment" and/or Section 7 "Maintenance" for spare parts and accessories.
10. Period for repair and provision of spare parts after product
discontinuation (maintenance period)
The discontinued models (products) can be repaired for 5 years from the date of discontinuation. Also, most spare
parts used for repair are provided for five years from the date of discontinuation. However, some electric parts may
not be obtained due to their short life cycle. In this case, repair or provision of spare parts may be difficult even in
the above period.
Please contact one of our sales offices or service offices for further information.

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Checking of contents of the package
• Check that all of the following are contained in the delivered package.
(1) Analyzer main unit
(2) Standard accessories (See “Table 1 Standard accessories.”)
Note: Consumable parts for about 6 months are included.
No. Q’ty
Tubular fuse (2A)1 (100V to 250V AC)2
2
3
Power cord 1
Ground wire 1
7
Pipe for connection 1
Instruction manual (English) 1
4
Note
Cable for output signals
5
1
6
The shape varies depending on specifications.
(5m)
(5m)
INZ
- TN1ZSVS - E
(1m)
Filter paper for membrane filter (glass fiber) 5
Name
Table 1 Standard accessories
(3) Gas extractor (option)
(4) Gas tube (option)
(5) Spare parts for 1 year (by separate order) (See “6. Spare parts” for details.)

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CONTENTS
PREFACE ..................................................................................................................................i
CAUTION ON SAFETY..........................................................................................................ii
WARRANTY AND MAINTENANCE....................................................................................v
CONTENTS.............................................................................................................................ix
1. OVERVIEW......................................................................................................................1
1.1 Outline diagram ................................................................................................................... 2
1.1.1 Analyzing block (unit:mm) ......................................................................................... 2
1.1.2 Power cord and signal cable (unit:mm)....................................................................... 3
1.1.3 Non-fixed type gas extractor (unit:mm) ...................................................................... 4
1.1.4 Fixed type gas extractor (unit:mm) ............................................................................. 5
1.2 Sampling system diagram.................................................................................................... 6
1.3 Name of each part and descriptions..................................................................................... 7
1.3.1 Name of each part and descriptions............................................................................. 7
1.3.2 Names of external connectors and descriptions .......................................................... 8
1.4 Operation panel and display ................................................................................................ 9
1.4.1 Names of parts on the operation panel and descriptions ............................................. 9
1.4.2 Outline of display screen ........................................................................................... 10
2. BEFORE USE ................................................................................................................. 13
2.1 Installation ......................................................................................................................... 13
2.2 Piping in the gas analyzer .................................................................................................. 14
2.2.1 Piping procedure........................................................................................................ 14
2.2.2 Connecting gas extractor ........................................................................................... 14
2.3 Wiring ................................................................................................................................ 16
2.3.1 Power supply ............................................................................................................. 16
2.3.2 Output connector ....................................................................................................... 17
3. OPERATION ..................................................................................................................18
3.1 Warm-up operation............................................................................................................18
3.2 Zero/span calibration ......................................................................................................... 19
3.2.1 Zero calibration time and span concentration value setting
(See “4.1.2” for setting method.)............................................................................... 19
3.2.2 Switching ranges (See “4.1.4” for setting method.) .................................................. 19
3.2.3 Zero/span calibration (See “4.1.1” for calibration method.) ..................................... 19
3.2.4 Adjusting flow rate .................................................................................................... 19

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3.3 Starting and exiting measurement ..................................................................................... 20
3.3.1 Starting measurement ................................................................................................ 20
3.3.2 Exiting measurement ................................................................................................. 20
3.3.3 Stopping operation .................................................................................................... 21
4. SETTING AND MODE ..................................................................................................22
4.1 Menu mode ........................................................................................................................ 22
4.1.1 Zero/span calibration ................................................................................................. 22
4.1.2 Setting zero calibration time and span concentration value ...................................... 28
4.1.3 Setting gas change time ............................................................................................. 31
4.1.4 Switching ranges ....................................................................................................... 32
4.1.5 Canceling errors ........................................................................................................ 33
4.1.6 Setting CP calculation value conditions .................................................................... 34
4.1.7 Parameter setting ....................................................................................................... 36
4.2 Parameter mode ................................................................................................................. 37
4.2.1 Setting date/time ........................................................................................................ 38
4.2.2 Key lock..................................................................................................................... 39
4.2.3 Output hold ................................................................................................................40
4.2.4 Resetting average output value.................................................................................. 42
4.2.5 Setting indicator lamp OFF time ............................................................................... 43
4.2.6 Maintenance mode .................................................................................................... 44
4.3 Maintenance mode.............................................................................................................45
4.3.1 Selecting output type ................................................................................................. 46
4.3.2 Average output time................................................................................................... 47
4.3.3 Selecting output ......................................................................................................... 48
4.3.4 Adjusting output ........................................................................................................ 50
4.3.5 Setting O2reference value ......................................................................................... 51
4.3.6 Adjusting moisture interference
(Targeted for NOXand SO2analyzers of special specifications) ............................... 52
4.3.7 Setting transmission station No. ................................................................................ 54
4.3.8 Response time............................................................................................................ 55
4.3.9 Minus display ............................................................................................................ 56
4.3.10 Password setting ........................................................................................................ 57
4.3.11 Sensor input ............................................................................................................... 58
4.3.12 Checking coefficient.................................................................................................. 59
4.3.13 Error log file .............................................................................................................. 60
4.3.14 Factory mode ............................................................................................................. 61

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5. INSPECTION AND MAINTENANCE..........................................................................62
5.1 Daily inspection (Be sure to perform daily.) ..................................................................... 62
5.2 Periodic inspection............................................................................................................. 62
5.3 Maintaining analyzer unit .................................................................................................. 63
5.3.1 Internal composition of analyzer unit........................................................................ 63
5.3.2 Replacing power fuse ................................................................................................ 63
5.3.3 Adjusting moisture interference
(Targeted for NOXand SO2analyzers of special specifications) ............................... 64
5.3.4 Replacing galvanic O2sensor (when provided with the sensor) ............................... 66
5.3.5 Replacing filter within the analyzer unit ................................................................... 67
5.3.6 Replacing filter paper of membrane filter ................................................................. 68
5.3.7 Replacing diaphragm................................................................................................. 69
5.3.8 Cleaning measurement cell ....................................................................................... 70
5.3.9 How to mount pressure regulator for standard gas cylinder...................................... 74
5.4 Airtight test ........................................................................................................................ 75
5.4.1 Airtight test of analyzer unit...................................................................................... 75
5.5 Adjustment in heat treatment furnace................................................................................ 76
6. SPARE PARTS ............................................................................................................... 78
6.1 Spare parts for 1-year measurement .................................................................................. 78
7. TROUBLESHOOTING ..................................................................................................79
8. SPECIFICATION............................................................................................................82
8.1 Specification ...................................................................................................................... 82
8.2 Code symbols..................................................................................................................... 85

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The compact type gas analyzer with built-in pump and filter is intended for heat treat furnace, plant cultiva-
tion, and research-purpose chemical analysis. With the gas extractor, either simplified measurement probe
(non-fixed type) or continuous measurement probe (fixed type) is selectable at option. Since a high-sensitiv-
ity single-beam mass flow controller is adopted for the infrared sensor, long-term stability and maintainabil-
ity are excellent.
1. OVERVIEW

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1.1.1 Analyzing block (unit:mm)
1.1 Outline diagram
Mass : Approx. 12kg
<Top view>
<Front view> <Rear view>
<Side view>
PORTABLE ANALYZER
PORTABLE ANALYZER
500
211
194
527
365

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1.1.2 Power cord and signal cable (unit:mm)
• Power cord for domestic and North American use (North American type), rated voltage
125V AC.
Note: The standards for domestic and North American use are different, but the shape is the
same.
(2000)
•Power cord for European use (European type), rated voltage 250 V AC
•Output cable
(2000)
Area A
123456789
Brown Red Orange Yellow Green Blue
Purple
Gray White Black Brown Red Orange Yellow Green Blue
10 11 12 13 14 15 16
(1000)
Output channel
+CH1 - +CH2 - +CH3 -
Connector
1 2 3 45678910111213141516
Cable color Brown Red Orange Yellow Green Blue Purple Gray White Black Brown Red Orange Yellow Green Blue
Details of area A
+CH4 -
+CH5 - +CH6 - +CH7 - +CH8 -

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•Control input/output cable
(1000)
1.1.3 Non-fixed type gas extractor (unit:mm)
(640)
(145)
(150°)
Probe grip
Probe cap
Sampling pipe
Gas inlet
(ø6)
ø
44
20
(ø6.5)
ø6.5/ø4 hose band
Specifications
Main materials of exhaust gas block: SUS304,
polypropylene, chloroprene rubber
Mass: 0.5 kg

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1.1.4 Fixed type gas extractor (unit:mm)
Attached joint
Sampling pipe 15A
4-ø12
RC1/2
Flange
JIS 5K 25A FF
Gas inlet
10
33
(ø21.7)
95
(67)
(300) (400) (600) (800)
ø75
Specifications
Main materials of gas-contacting parts: SUS316, Teflon
Mass: 1 kg
R1/2
ø4
ø12
ø6
25
28
Attached joint (for ø6 pipe connection)
Material : Teflon

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(1) With 1 optical system
(1 to 3 component gas sampling system)
(2) With 2 optical systems
(3 to 4 component gas sampling system)
Gas extractor
Exhaust
gas port
Purge gas
port
Filter
Membrane
filter
Calibration
gas inlet
Sample gas
inlet Pump
FL
Measurement
cell
O 2
analyzer
PM
1.2 Sampling system diagram
Gas extractor
Exhaust
gas port
Purge gas
port
Filter
Membrane
filter
Calibration
gas inlet
Sample gas
inlet Pump
FL
O
2
analyzer
PM
Measurement
cell
Measurement
cell

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1.3.1 Name of each part and descriptions
(1) Analyzer unit
Name Description
(1) Handle Used for transportation of main unit.
(4) Rubber foot
Set the power to ON/OFF.(5) Power switch
Inlet for purge gas(6) Purge gas inlet
Connected to exhaust line.(7) Exhaust gas port
Connected to sampling gas.(8) Sample gas inlet
Connected to zero/span calibration gas.(9) Calibration gas inlet
Analog output signal connector(10) Output connector
Output signal connector for communication(11) Communication connector
(12) Grounding terminal
(13) Power supply connector
(14) Fuse
(15) Specification plate
For changing internal heat.
Connected to the ground.
Connect power cable.
Insert a fuse of rated capacity.
Displays serial No., components to be measured, etc.
(16) Heat exhaust port
(2) Flow checker Checks gas flow.
LCD and various setting keys(3) Display/operation unit
1.3 Name of each part and descriptions
(2) Flow checker (3) Display/operation unit
(4) Rubber foot
(5) Power switch
(9) Calibration gas inlet
(8) Sample gas inlet
(7) Exhaust gas port
(6) Purge gas inlet
(1) Handle (16) Heat exhaust port
(15) Specification plate
(10) Output connector (13) Power supply connector
(14) Fuse
(11) Communication connector
(12) Grounding terminal

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1.3.2 Names of external connectors and descriptions
<Analog output connector>
Non-isolated linear connector for 4 to 20mA DC or
0 to 1V DC
Output of up to 8 channels is allowed.
Output is made for corresponding channel No. on a
one-to-one basis.
Permissible load: 4 to 20mA DC, 550Ωor lower
0 to 1V DC, 100kΩor higher
A female connector is supplied for the main unit
(DS-25S-T-N by Japan Aviation Electronics
Industry Co., Ltd.)
Use the supplied cable (1m) (DB-25P) for connection.
<Communication output connector>
Input/output signal connector for RS232-C com-
munication
Modbus protocol (Creation of communication
program is required. Refer to separately sold
transmission specifications.)
A male connector is supplied for the main unit.
Use commercially available cross cable (DE-9S)
for connection.
1425
13 1
6
15
9
Pin No. Description
+ -
1NC
2TXD
3RXD
4NC
5GND
6NC
7NC
8NC
9NC
Pin No. Description
+ -
Between 1 and 2 Ch1 analog output
Between 3 and 4 Ch2 analog output
Between 5 and 6 Ch3 analog output
Between 7 and 8 Ch4 analog output
Between 9 and 10 Ch5 analog output
Between 11 and 12 Ch6 analog output
Between 13 and 14 Ch7 analog output
Between 15 and 16 Ch8 analog output
17 to 25 NC
Note 1: NC indicates that the pin is not used.
Note 2: Different numbers are assigned for male (P) and female (S) pins. Make connections, paying
attention to the numbers.