GREEN INSTRUMENTS G4100 User manual

G4100
Analyzing System Manual
Document ID number.: 01271

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G4100 NOx/O2 Analyzing System
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Contents
1INTRODUCTION 4
1.1 10BABOUT THIS MANUAL 4
1.2 11BINQUIRIES AND FEEDBACK 5
2SYSTEM SPECIFICATIONS 6
3SYSTEM INSTALLATION 7
3.1 CONTROLAT DELIVERY 7
3.2 WHERE TO INSTALL THE SYSTEM 7
3.3 SAFETY ASPECTS 8
3.4 EJECTOR PROBE 8
3.5 ANALYZING BOARD 12
3.5.1 Mounting Panel 12
3.5.2 Air Supply Connection 13
3.5.3 Span NOXGas Connection 14
3.5.4 Analyzer and Electrical Connections 14
4COMMISSIONING 15
4.1 INSTALLATION CHECKS OF THE SAMPLING BOARD 15
4.2 COMMISSIONING OF THE ANALYZER 15
4.3 START OF SYSTEMS 15
5OPERATION 16
5.1 CALIBRATION MODE 16
5.2 MEASUREMENT MODE 16
6ROUTINE MAINTENANCE 17
6.1 AIR FLOW SYSTEM 17
6.2 SENSOR 17
6.3 EJECTOR PROBE 18
7PARTS LIST 21
List of Figures
FIGURE 3-1: INSTALLATION LAYOUT OF THE EJECTOR PROBE 9
FIGURE 3-2: EJECTOR PROBE DIMENSIONS 10
FIGURE 6-1: EJECTOR PROBE 18

Introduction
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1Introduction
1.1 10BAbout this Manual
This manual contains the data and instructions for the installation, operation, and mainte-
nance of the gas sampling board with the sampling probe of the G4100 NOX/O2Analyzing
System.
The G4100 NOX/O2Analyzing System consists of two parts:
•G41 NOX/O2Analyzer
•G4100 NOX/O2gas sampling board with the sampling probe
The instructions for installation, operation, and maintenance of the analyzers are provid-
ed in the separate manual –the G41 NOx/O2Analyzer manual (p# 01250 or 01819).
For the installation, operation, and maintenance of the G4100 NOX/O2Analyzing System,
both manuals must be read carefully in their entirety.
The manual has been made in general terms and do not take into consideration a specific
installation. As such, the instruction manual is designed for the standard sampling system
fitting with the G41 NOX/O2Analyzer.
The manual does not describe all possible situations but only the most common and
known situations and cannot replace the necessary instruction and education of the per-
sonnel.
Should situations not described in the manual occur, which cannot be solved in accord-
ance with normal known practice and good workmanship, the operator should contact
Green Instruments A/S for instructions.
This manual does not claim to cover all details or variations in equipment or to provide
for every possible contingency that may arise during installation, operation, or mainte-
nance.
Green Instruments A/S reserves the right to minor alterations and improvements owing to
developments without being obliged to enter the corresponding changes in this manual.
Green Instruments A/S reserves the copyright of the manual. Without prior written per-
mission of Green Instruments A/S, the manual may not be copied and given to unauthor-
ized people.

G4100 NOx/O2 Analyzing System
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1.2 11BInquiries and Feedback
All claims and inquiries for spares shall be addressed to Green Instruments A/S or our
distributors.
In all correspondence or when ordering spare parts, please carefully state the equipment
type and serial number, which you can find on the label on the right side of the blue ana-
lyzer box.
Green Instruments A/S appreciates all feedback and suggestions for improvement. If you
have any questions or find any errors in the manual, you are welcome to contact us:
Green InstrumentsA/S
Erhvervsparken 29
DK-9700 Brønderslev, Denmark
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.greeninstruments.com

System Specifications
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2System Specifications
Gas Connection
Span NOX gas connection
For 6/4 mm tubing –max. 1 bar
Air supply filter regulator
with filter 25 µm
1/8” BSP connection –max. 8 bar
Air supply quality
Instrument air quality according to ISO
8573.1.4.4.4
Analyzer
See details in the G41 NOx/O2 Analyzer Manual
Analyzing Board Dimension
Analyzing board dimension
600 × 500 × 140 mm (H × W × D)
Weight
Approx. 10.0 kg without packaging
Ejector Probe
Sensor technology
Heated zirconia type sensor
Measurement range
NOX: 0…1500 ppm (selectable range)
O2: 0.0…21 % (selectable range)
Sample temperature
0…500 oC
Probe insert length
App. 250…300 mm
for duct diameters 290…2800 mm
Socket
OD: 61.5 mm L: 200 mm
Connection - ejector air (red)
6/4 mm tubing
Connection - calibration gas (white)
6/4 mm tubing
Calibration air flow
Approx. 0.5…1 l/m
Ejector air flow
at 1 bar air supply
- App. 2 l/min Vacuum 200 mm H2O
- App. 3 l/min Vacuum 350 mm H2O
- App. 5 l/min Vacuum 500 mm H2O
Ejector probe dimension
284 x 180 x 601 mm (H x W x L)
Weight including house
Approx. 5.0 kg without packaging
Umbilical cord
Cord length
3.0 m
Tubing
In 28 mm nylon conduit
Optional Equipment
Remote display with alarm relays, Recording and visualization
Marpol Reporting System, IMO NOXFlange for testing purpose
Extension kit for umbilical cord
Specifications are subject to changes without notice.

G4100 NOx/O2 Analyzing System
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3System Installation
Read this chapter in its entirety before installing the system.
3.1 Control at Delivery
When you receive the G4100 NOX/O2Analyzing System, please inspect and confirm that
the received items are in accordance with the packing list and not damaged. Any discrep-
ancy should be reported to the supplier immediately. If any of the received parts are dam-
aged, the shipping company should be informed, and new parts should be made available
before completing the installation.
3.2 Where to Install the System
Satisfactory operation, faultless functions, and minimal maintenance of the G4100 NOX/O2
Analyzing System are achieved by paying attention to the following points:
•Make sure to install the ejector probe in a suitable location where it will extract the
gas that is going to be tested.
•The ejector probe shall be fitted at least 10 pipe diameters after the outlet of the en-
gine, the turbocharger, or the last after-treatment device –choose whichever is further
downstream. However, the ejector probe shall also be placed at least 0.5 m or 3 pipe di-
ameters upstream from the exit of the exhaust gas system –choose what provides the
greatest length. See 107H25H25HFigure 3-1 for the installation layout of the ejector probe. If you find
it difficult estimating where to install the ejector probe, please contact Green Instruments
A/S for more instructions.
•As a standard scope of supply, the analyzing board can be installed up to 3 m from
the ejector probe. If necessary, the umbilical cord can be extended.
•The analyzing board shall be placed and installed where the ambient temperature is
below 55 C at any time.
•The system shall be installed in a clean place away from dust, oil mist, and mois-
ture. The elements of the system shall be installed at viewing level so that it is easy ac-
cessible in connection with operation and service.

System Installation
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3.3 Safety Aspects
Attention
Make sure to follow the operating instructions!
Read the manual before operating and servicing the system.
Hot sensor/probe!
The sensor/probe is hot and can cause severe burning of personnel if not handled with
care.
Installation and operation!
It should be pointed out that installation and operation of the G4100 NOX/O2Analyzing
System and associated equipment must be carried out by skilled, trained, and certified
personnel, and that Green Instruments A/S does not take any responsibility for the opera-
tion of the system and associated equipment whatsoever. The successful and safe opera-
tion of this equipment is dependent upon proper handling, installation, operation, and
maintenance.
Recycling!
Please do not dispose the G4100 NOX/O2Analyzing System with regular refuse. Disposal
should be in accordance with the requirements of the current statutory regulations.
3.4 Ejector Probe
The ejector probe is supplied with a mounting socket, gasket, sample tube, connection for
ejector air, connection for test gas and back-flushing air, sensor, and housing with mount-
ing plate.
The ejector probe has a small air operated ejector, which will propel the sample gas into
the sensor and back into the stack. The sample gas flow is drawn through the sample fil-
ter element into the sensor area via a narrow passage securing quick response time. The
sample gas velocity and responding time is controlled by the flow of the ejector air.
The gas, which passes the ejector probe, must represent the gas to be tested. Holes and
leaks in the gas ducting system before and after the probe may influence the accuracy of
the measurement.
The ejector probe shall be placed so that it is protected against mechanical damage. The
flue gas temperature cannot exceed the given temperature limit of the ejector probe.
When welding the mounting socket to the stack, make sure that the mounting plate of the
ejector probe is mounted with the sampling hose connection facing down and the ejector

G4100 NOx/O2 Analyzing System
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probe protection house mounted in a vertical position of the stack. The insert length of
the ejector probe (250-300 mm) should be greater than 10 % of the duct diameter. See
26H26HFigure 3-1 for the installation layout of the ejector probe.
Exhaust Duct
Distance to the next upstream bent:
min. 3 duct diameters
Distance to the engine/turbo charger:
min. 10 duct diamters
Distance to the outlet:
min. 3 duct diamters
Distance to the next downstream bent:
min. 1 duct diameters
Sample to be drawn from the inner 80% of
the duct diameter.
NOx/O2
Probe
3
Umbilical
Cord
Insulation
Insulation
Figure 3-1: Installation layout of the ejector probe
The figure below shows the dimensions of the ejector probe.

System Installation
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Figure 3-2: Ejector probe dimensions
The figure below shows the dimensions of the board.