Fuji Electric ZBAS User manual
Instruction Manual
GAS EXTRACTOR
(High Dust Type)
TYPE:
ZBAS
INZ-TN5ZBAS-E
i
INZ-TN5ZBAS-E
We are grateful for your purchase of Fuji Electric’s Gas Extractor, TYPE: ZBAS.
• Firstreadthisinstructionmanualcarefullyuntilanadequateunderstandingisacquired,and
thenproceedtoinstallation,operationandmaintenanceofthegasextractor.Wronghandling
maycauseanaccidentorinjury.
• The specicationsofthisextractoraresubject tochangewithoutpriornoticeforfurther
productimprovement.
• Modicationofthisextractorisstrictlyprohibitedunlessawrittenapprovalisobtainedfrom
themanufacturer.FujiElectricwillnotbearanyresponsibilityforatroublecausedbysuch
amodication.
• Thisinstructionmanualshallbestoredbythepersonwhoactuallyusestheextractor.
• Afterreadingthemanual,besuretostoreitataplaceeasiertoaccess.
• Thisinstructionmanualshouldbedeliveredtotheenduserwithoutfail.
Manufacturer: FujiElectricCo.,Ltd.
Type: Describedinthenameplateonmainframe
Dateofmanufacture: Describedinthenameplateonmainframe
Productnationality: Japan
©FujiElectricCo.,Ltd.2019
IssuedinNovember,2019
PREFACE
Request
• ItisprohibitedtotransferpartorallofthismanualwithoutFuji
Electric’spermissioninwrittenformat.
• Descriptioninthismanualissubjecttochangewithoutpriornotice
forfurtherimprovement.
ii INZ-TN5ZBAS-E
First of all, read this “Caution on Safety” carefully, and then use the gas extractor in the
correct way.
• Thecautionarydescriptionslistedherecontainimportantinformationaboutsafety,sotheyshouldalways
beobserved.Thosesafetyprecautionsarerankedin3levels,“DANGER”,“CAUTION”and“PROHIBI-
TION”.
DANGER
Wronghandlingmaycauseadangeroussituation,inwhichthere
isariskofdeathorheavyinjury.
CAUTION
Wronghandlingmayinviteadangeroussituation,inwhichthere
isapossibilityofmedium-leveltroubleorslightinjuryoronly
physicaldamageispredictable.
PROHIBITION
Itemswhichmustnotbedonearenoted.
Caution on installation and transport of gas extractor
DANGER
• Thisunitisnotanexplosion-prooftype.Donotuseitina
placewithexplosivegasestopreventexplosion,reorother
seriousaccidents.
CAUTION
• Forinstallation,observetheruleonitgivenintheinstruction
manualandselectaplacewheretheweightofgasextractor
canbeendured.
Installationatanunsuitedplacemaycauseturnoverorfall
andthereisariskofinjury.
• Duringinstallationwork,careshouldbetakentokeepthe
unitfreefromcablechipsorotherforeignobjects.Other-
wise,itmaycausere,troubleormalfunctionoftheunit.
• Forliftingthegasextractor,besuretowearprotectivegloves.
Barehandsmayinviteaninjury.
• The gas extractor is heavy (approx. 20 kg). It should be
transported carefully. Otherwise, body maybe damaged
orinjured.
CAUTION ON SAFETY
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INZ-TN5ZBAS-E
Caution on piping
DANGER
◎In piping, the following precautions should be observed.
Wrongpipingmaycausegasleakage.
Iftheleakinggascontainsatoxiccomponent,thereisarisk
ofseriousaccidentbeinginduced.
Also,ifcombustiblegasiscontained,thereisadangerof
explosion,reorthelikeoccurring.
• Connect pipes correctly referring to the instruction
manual.
• Forpiping,useapipeandapressurereducingvalveto
whichoilandgreasearenotadhering.Ifsuchamaterial
isadhering,areorthelikeaccidentmaybecaused.
Caution on wiring
CAUTION
• Installation,wiringandpipingworkmustbeperformedby
specialistsoryourdealer.Incorrectinstallationmaycause
afalldevice,electricshocksorinjury.
• Before working, take off wrist watch and other metallic
objectstopreventelectricshocks.
• Wiringisallowedonlywhenallpowersuppliesareturned
off.Thisisrequiredforpreventingelectricshocks.
• Usepowersourcethatmatchestheratingoftheunit.Use
ofpowersourceoutofratingmaycausere.
• Wiresshouldbetheproperonemeetingtheratingsofthis
instrument.Ifusingawirewhichcannotenduretheratings,
aremayoccur.
• Besuretoxtheinputcablestooorsorwalls.Careless
wiringofcablesmaycauseunexpectedinjury.
• Whenxinginputcablestooors,useprotectivematerials
onthecables.Ifnotused,cablesmaybedamagedwhich
resultsinariskofelectricshocks.
• Besuretoconnectcablesusinginputterminals.Careless
connectionmaycauseariskofelectricshocks.
• Donottouchpowerterminalswithmetallicobjectsorngers
topreventelectricshocksorinjury.
iv INZ-TN5ZBAS-E
Caution on check and maintenance
DANGER
• Beforestartingwork,besuretoputonheat-proofgloves.
Workwithbarehandsorgeneral-useglovesmaycausearisk
ofburns.
• Whenthefunnelisunderpositivepressure,becarefulwith
thespoutoffunnelgastopreventinjuryorburns.
CAUTION
• Dailyinspectionisimportanttopreventburningorreac-
cident.
• Whenlterisinstalledinthefunnel,thewholeunitofthe
samplerneedstoberemovedfromthefunnelforinspection
ofthelter.Besuretouseasuitablefoothold.
Useofimproperfootholdmaycauseinjury.
• Beforeworking,takeoffawristwatch,ngerringorthelike
metallicaccessories.Andnevertouchtheinstrumentwith
awethand.Otherwise,youwillhaveelectricshocks.
• Whentheinsideofchimneyorfunnelispositivepressure
andtheextractorneedstoberemoved,becarefulwithhigh
temperatureorhazardousgasasitblowsoutwhenitisre-
moved.
Donotgetclosetheextractortopreventburnsorpoisoning.
• Thegassamplercaseandlterarehot.Whenthelterand
O-ringneedtobereplacedorinspected,turnOFFthepower.
Besuretoputonprotectiveglovestopreventburnsorinjury.
• Donotuseareplacementpartotherthanspeciedbythe
instrumentmaker.Otherwise,adequateperformancewill
notbeprovided.Besides,anaccidentorfaultmaybecaused.
• Replacement parts such as a maintenance part should be
disposedofasincombustibles.Fordetails,followthelocal
ordinance.
PROHIBITION
• Maintenanceandinspectionmustbemadeonlybyautho-
rizedengineerstopreventelectricshocksorreaccidents.
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INZ-TN5ZBAS-E
Caution to specialists
CAUTION
◎Beforestartingmaintenance,inspectionorrepair,besureto
readtheinstructionmanualcarefully.
Improperworkmaycauseariskofelectricshocksorre
accident.
• Before starting work, take off wrist watch and other
metallicobjectstopreventelectricshocksorburns.
• Duringwork,turnOFF(open)thebreakerandthepower.
EvenafterpowerisOFF(open),somepartsarestillhot.
Careshouldbetakentopreventburns.
• Donottouchlivepartswithwethandstopreventelectric
shocks.
• Themassofthedeviceisapprox.20kg.
Carelesstransferofthedevicemaycauseinjury.
Others
DANGER
• Whenthegassamplerisinstalledonahighplaceormain-
tenanceisrequired,useasuitablefootholdforthesakeof
safety.
Careshouldbetakentopreventunexpectedaccidentsuch
as a fall.
CAUTION
• Ifthecauseofanyfaultcannotbedetermineddespiterefer-
encetotheinstructionmanual,besuretocontactyourdealer
ofFujiElectric’stechnicianinchargeofadjustment.Ifthe
instrumentisdisassembledcarelessly,youmayhaveelectric
shocksorinjury.
• Donotworkonrainydaystopreventariskofelectricshocks
orafallofdevice.
vi INZ-TN5ZBAS-E
CONTENTS
PREFACE ....................................................................................................................i
CAUTION ON SAFETY ...........................................................................................ii
1. OUTLINE .............................................................................................................. 1
2. CONFIRMATION OF DELIVERED PRODUCTS..........................................1
3. CONFIRMATION OF CODE SYMBOLS AND SPECIFICATIONS ............ 2
3.1 Codesymbols............................................................................................................ 2
3.2 Specications ............................................................................................................ 2
4. NAMES OF OPERATING PARTS ..................................................................... 3
5. INSTALLATION .................................................................................................. 4
5.1 Selectionofinstallationlocation............................................................................... 4
5.2 Mountingofextractor ............................................................................................... 4
5.3 Samplingtube............................................................................................................ 5
5.4 Wiring........................................................................................................................ 6
5.5 Blowbacktimechartexample................................................................................... 7
6. OPERATION ........................................................................................................ 8
7. INSPECTION AND MAINTENANCE ............................................................. 9
7.1 Dailyinspection ........................................................................................................ 9
7.2 Periodicalinspection/maintenance(standard)........................................................... 9
7.3 Wiregauzelterremovalmethod ............................................................................. 9
7.4 Cleaningofwiregauzelter .................................................................................... 9
8. MAINTENANCE PARTS .................................................................................. 10
9. OUTLINE DIAGRAM ....................................................................................... 11
9.1 Gasextractor ........................................................................................................... 11
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INZ-TN5ZBAS-E
Thegasextractorisusedtosampleagasfromafunnelandsendittoagasanalyzer.Asitisusedunder
verysevereconditions,itmustprovidethefollowingperformance.
• Beusableattemperatureofasamplingpoint.
• Havenopropertytocausereactionwithasamplegasoractasacatalystonit.
• Notbechokedbydust,oreasilyreplaceableorcleanablewhenchoked.
• Causenoremarkablesamplingdelay.
FujiElectricoffersgasextractorsmeetingtheserequirementsonthebasisoflong-accumulatedexperience.
ThisgasextractorhasavarietyoftypessuchasthosewithY-shapedorT-shapedsamplingtubedepend-
ingontheapplication,andthereforetheactualproductmaydifferslightlyfromthecontentofthismanual
dependingonthecustomer’srequiredspecication.
Pleaserefertotheindividuallysubmittedmanufacturingspecicationsforexternaldrawings,specications,
accessories,spareparts,andconsumableparts.
1. OUTLINE
2. CONFIRMATION OF DELIVERED PRODUCTS
Delivered products list
Nameofproduct Quantity Remark
Gasextractormainunit 1
Samplingtube 1 Asspeciedlength
Packing(forange) 1
Bolt,nut,springwasher,planewasher(M16) 4 each WhenusingstandardangeJIS10K50AFF
O-ring(G50,G65) 1each
2INZ-TN5ZBAS-E
3.2 Specications
System Electricheatingsystem
Gastemperature Max.800˚C(Standardspecications)
Materialofgashandlingparts SUS316,Byton
Samplingtube SUS316(Standardspecications)
Matingange JIS10K50AFF(Standardspecications)
Filter SUS316wiregauze,lteringefciency10µm(2to100µm
canbeused)
Filteringarea About180cm2
Responsetime 90%response,about25secat3L/min
Mass Approx.20kg(withoutsamplingtube)
Samplegasoutlet Rc1/2
Heater 100VAC,400W
Installation Outdoorinstallation
3. CONFIRMATION OF CODE SYMBOLS AND
SPECIFICATIONS
3.1 Codesymbols
Z B A S 1 W 5 0 Description
System
Electric heating system (High Dust Type)
Structure
Indoor/outdoor common
1
Material of gas handling parts
SUS316, etc
W
Inserting length (L)
0mm
Y
None
Gas outlet joint
0
—
S
600mm
800mm
1000mm
1200mm
1500mm
2000mm
As specified
C
400mm
B
300mm
A
E
G
H
J
K
Z
L
1
2 3 4 5 6 7 8 9
For general use,
gas temperature max. 800°C
SUS316
digits
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INZ-TN5ZBAS-E
4. NAMES OF OPERATING PARTS
１
23
4
5
SAMPLE
CABLE
BLOW2 BLOW1
6
No. Name
①Heater
②Wiregauzelter
③Terminalblock
④O-ring(G50)
⑤O-ring(G65)
⑥Thermostat
4INZ-TN5ZBAS-E
5. INSTALLATION
5.1 Selectionofinstallationlocation
Locationofsamplingthegasformeasurement(installationlocationofgasextractor)requiresthe
followingconditions(seeJISK0095,K0103,Z8808)
① Gasinfunnelisowingcontinuously.
② Maintenanceandinspectioncaneasilybeperformed.
③ Extractorcanbeinstalledneargasanalyzer(lengthofgaspipe:lessthan20m).
④ Extractorcanbeinsertedverticallyfromtheceilingoffunnelorthroughthesidewallfor
installation.
5.2 Mountingofextractor
Mounttheextractorobservingthefollowingpoints.
(1) Samplegastemperatureshouldbewithinthespeciedrange.
(2) Matingangethatconformstothelimitofinsertionangleofextractorshouldbeprepared.
Also,protectivepipeandinstallationworkshouldbecompleted.
• Standardextractorange(JIS10K50AFF,)
• Limitofinsertionangle(Fig.5-1)
Forgeneraluse:90to0˚(Mountthegasoutletpipefacingdownward.)
Ground
Funnel
Ground
Furnace wall
Extractor
Flange
Extractor
Recommended
position
Gas outlet pipe
Furnace wall
90°
0°
Fig. 5-1 Mounting angle
(3) Whenmountingtheextractor,thetipofitshouldbeatthecenteroffunnel(morethan300mm
apartfromfurnacewalltopreventleakairfrombeingsuckedintotheextractor)(Fig.5-2).
Funnel
More than 300 mm
Furnace wall
Extractor
Fig. 5-2 Position of extractor
5
INZ-TN5ZBAS-E
5.3 Samplingtube
(1) Thesamplelinepipematerialmustnotalterthecompositionofthesamplegas,andmustbecor-
rosionresistant.
TherecommendedmaterialisaTeontube.Pleasepreparepipejoints(forRc1/2).
(2) Preparepipejoints(forRc1/2)ifusingpipessuchasSUSpipeorSGPpipe.
(3) SUSpipeisrecommendedfortheblowbacklinepipematerial.
(4) ConnectthepipestotherespectiveconnectionsasshowninFig.5-3.
1
2
3
4
Blow 2 connection
Sample connection
Blow 1 connection
Fig. 5-3
(5) RefertoFig.5-4foranexampleforablowbacklinepipe.
Sample
Blow 1
Blow 2
Motorized valve 3
Motorized valve 2
Filter
regulator
Motorized valve 1
To analyzer
(sample line)
Instrument air
or nitrogen
0.4 to 0.7 MPa
300 L/min
Fig. 5-4
(6) Ensurethatthesamplepipefromthegasextractorinclinesdownwardby15°ormoretoallow
condensedwatertoow.
(Saggingisnotpermittedatanypointinthemiddleofthepipe)Particularattentionshouldbe
paidtotheinclinationatthegasextractorexit(seeFig.5-5).
Ground Ground
Pipe
Pipe
15° or more
Extractor
Extractor
Gas analyzer system Gas analyzer system
Pay attention to sagging in middle
Fig. 5-5
6INZ-TN5ZBAS-E
(7) Whenusingtheheatingpipe,performheatingworkorthermalinsulationtreatmentasrequired
(Fig.5-6).Otherwise,condensationmaybecausedattheoutletoftheextractor.
Ifterminalprocessingisperformedinsidethegasextractorandonlyheatedpartsarepulledout-
side,heatingworkwillnotbenecessary.
Piping heating work
Teflon tube in
the heating pipe
Extractor
Heating pipe
Fig. 5-6
5.4 Wiring
Openthegasextractorbox,andsupplyheaterpowerof100VAC,400Wtotheinternalterminal.
Whenthetemperatureoftheinstallationlocationbecomeshigh,heat-proofcablesshouldbeused
forwiring.
100 V AC
400 W
Wired
Wired
Fig. 5-7 Terminal
Heater
Terminal
2
3
4
1
Thermostat
Power supply
100 V AC, 400 W
Fig. 5-8 Connection diagram
7
INZ-TN5ZBAS-E
5.5 Blowbacktimechartexample
Performblowbackperiodicallyusinginstrumentairornitrogentoeliminatedustfromthegasextractor.
AblowbackexampleisshowninFig.5-9.
Hold contact output
instructed by analyzer
Contact output during
blowback
Analyzer internal aspirator
MV3 [SAMPLE]
MV2 [BLOW2]
MV1 [BLOW1]
T0 T1 T2 T0
T4
(T1 + T2) × m times T3 T3
Fig. 5-9 Blowback time chart example
T0(blowbackcycletime) :120minutes
T1(blow1:externalblow) :1minute
T2(blow2:internalblow) :1minute
T3(blowpressurereleasetime) :1minute
T4(holdextensiontime) :5minutes
m(externalblowblowbackcount) :2times
Theabovetimechartisanexample.
Thetimemustbesettoanappropriatevaluebasedonthemeasuredgasconditions,analyzerspeci-
cations,andoperationstate.
8INZ-TN5ZBAS-E
6. OPERATION
Beforeoperatingtheextractor,besuretoobservethefollowingpoints.
•Preparationforoperation
① Makesurethatallthecablesareconnectedcorrectly.
② TurnONthepower.
③ Suckinthesamplegasaftertheextractoriswarmedupforabout1hour.
④ Whilethefurnaceisbeingdriedup,warmuptheextractorbutdonotsuckinthesamplegas.
9
INZ-TN5ZBAS-E
7. INSPECTION AND MAINTENANCE
7.1 Dailyinspection
Checktomakesurethatextractorisproperlywarmedup.
7.2 Periodicalinspection/maintenance(standard)
Item Remark
Cleaningofwiregauzelter:
Replacementonceeveryseveraldaysto3
months,orwhenuseisnolongerpossible
Cleanorreplaceaccordingtotheamountof
dustdepositsinexhaustgas.
ReplacementofO-ringorpacking:
(atinspection/replacementofwiregauze
lter),Once/6monthsforhightemperature,
onceayearforgeneraluse
7.3 Wiregauzelterremovalmethod
① TurnOFFthepowertothegasanalyzergasaspirator.
② TurnOFFthegasextractorpower,openthegasextractorunitcasecover,andwaituntilthe
unitdropstoatemperatureatwhichitcanbetouchedbyhand(50°Corlower).
Note)Wearheat-resistantgloves,etc.whencarryingoutwork.Failuretodosomayresultin
burns.
③ Removethehexagonalheadbolt.
④ Connecttheremovalttingprovidedtothescrewholeinthecenterofthehead(lterunit),
andsecurewiththeremovalttingnut.Oncesecured,pulloutthehead.
⑤ AfterreplacingthelterandO-ring,reassembleusingtheoppositeproceduretothatde-
scribedabove.(Thebolttighteningtorqueshouldbe12.5N·m.)
Removal fitting
Hexagonal head bolt
O-ring
Filter unit
Wire gauze filter
Sampling gas
Fig. 7-1 Wire gauze lter removal
7.4 Cleaningofwiregauzelter
① Putthelterinwaterwhileitisstillhot,andremovedustdeposits.
② Washthefrontandrearofthelterwithcompressedairandwaterpressure.
③ Drythelterfullyandthenmountitback.
10 INZ-TN5ZBAS-E
8. MAINTENANCE PARTS
Whenmaintenancepartsarerequired,informusoftheirarrangementcodeorcodeNo.showninthefol-
lowingtables.
Table of spare parts for 1 year use
Nameofparts Quantity Arrangementcode
Wiregauzelter(10μm) 1
ZBN5BS12O-ring(JISG50) 1
O-ring(JISG65) 1
Table of maintenance parts
Nameofparts CodeNo.
Wiregauzelter(10μm) ZBNS1112
JIS10K50AFF
Flange(forgeneraluse) TK7H4238P4
Flange(forhightemperature) TK7C8038P4
O-ring(G50) 10pcs.of1case ZBNS1122
O-ring(G65) 10pcs.of1case ZBNS1132
Packing
(forange)
11
INZ-TN5ZBAS-E
9. OUTLINE DIAGRAM
9.1 Gasextractor
(Unit : mm)
BLOW1
BLOW2 BLOW1
BLOW2
FLANGE JIS10K50AFF
CASE COVER
FOR CABLE
2-A15c
2-A30a
FOR SGP 15A PIPE
3-Rc1/2
INT-THD
THERMOSTAT
CABLE GLANDS
HEATER
PIPE
LOCK
TERMINAL
APPROX. 177
CABLESAMPLE
SAMPLE
ø120
60
ø155
ø34
4-ø19
16
125
300
(600) 120 280
APPROX. 1003
250
APPROX. 216
APPROX. 350
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan
Phone: +81-3-5435-7111
www.fujielectric.com
www.fujielectric.com/products/instruments/
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