GREEN INSTRUMENTS G4100 User manual

REVISION JAN 2015
PART NUMBER: 01271
G4100 ANALYZING
SYSTEM MANUAL

2

G4100 NOx/O2 Analyzing System
3
Content
1INTRODUCTION 4
1.1 10BABOUT THIS MANUAL 4
1.2 11BINQUIRIES AND FEEDBACK 5
2SYSTEM SPECIFICATIONS 6
3SYSTEM INSTALLATION 8
3.1 CONTROL AT DELIVERY 8
3.2 WHERE TO INSTALL THE SYSTEM 8
3.3 SAFETY ASPECTS 9
3.4 EJECTOR PROBE 9
3.5 ANALYZING BOARD 13
3.5.1 Mounting Panel 13
3.5.2 Air Supply Connection 15
3.5.3 Span NOXGas Connection 15
3.5.4 Analyzer and Electrical Connections 15
4COMMISSIONING 16
4.1 INSTALLATION CHECKS OF THE SAMPLING BOARD 16
4.2 COMMISSIONING OF THE ANALYZER 16
4.3 START OF SYSTEMS 16
5SYSTEM OPERATION 17
5.1 CALIBRATION MODE 17
5.2 MEASUREMENT MODE 18
6ROUTINE MAINTENANCE 19
6.1 AIR FLOW SYSTEM 19
6.2 SENSOR 19
6.3 EJECTOR PROBE 21
7PARTS LIST 23

Introduction
4
1 Introduction
1.1 10BAbout this Manual
This manual contains the data and instructions for the installation, operation, and
maintenance 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
G4100NOX/O2gas sampling board with the sampling probe
The instructions for installation, operation, and maintenance of the analyzers are
provided in the separate manual – the G41 NOx/O2 Analyzer 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 personnel.
Should situations not described in the manual occur, which cannot be solved in
accordance 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, opera-
tion, or maintenance.

G4100 NOx/O2 Analyzing System
5
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
permission of Green Instruments A/S, the manual may not be copied and given to
unauthorized people.
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 analyzer 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 Instruments A/S
Erhvervsparken 29
DK-9700 Brønderslev
Denmark
Phone:
Fax:
[phone]
[phone]
E-mail:
Web:
[e-mail]
HU www.greeninstruments.com

System Specifications
6
2 System 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 G
41
NOx/O
2
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)
O
2
: 0.0…21 % (selectable range)
Sample temperature 0…500
o
C
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

G4100 NOx/O2 Analyzing System
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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.

System Installation
8
3 System 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 con-
firm that the received items are in accordance with the packing list and not dam-
aged. Any discrepancy should be reported to the supplier immediately. If any of
the received parts are damaged, 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
engine, 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 diameters 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.

G4100 NOx/O2 Analyzing System
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The analyzing board shall be placed and installed where the ambient tempera-
ture is below 55 °C at any time.
The system shall be installed in a clean place away from dust, oil mist, and
moisture. The elements of the system shall be installed at viewing level so that
it is easy accessible in connection with operation and service.
3.3 Safety Aspects
Warning
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/O2Ana-
lyzing System and associated equipment must be carried out by skilled, trained,
and certified personnel, and that Green Instruments A/S does not take any respon-
sibility for the operation of the system and associated equipment whatsoever. The
successful and safe operation of this equipment is dependent upon proper han-
dling, 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, con-
nection for ejector air, connection for test gas and back-flushing air, sensor, and
housing with mounting 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 filter 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.

System Installation
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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 dam-
age. 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 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

G4100 NOx/O2 Analyzing System
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The figure below shows the dimensions of the ejector probe.
Figure 3-2: Ejector probe dimensions

System Installation
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The figure below shows the dimensions of the board.
Figure 3-3: Analyzing Board with G41 NOX/O2Analyzer mounted on board

G4100 NOx/O2 Analyzing System
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3.5 Analyzing Board
3.5.1 Mounting Panel
The analyzer board has two angle iron mounting brackets. The brackets are made
of ordinary mild steel and can be welded or bolted directly to a chosen location
structure as required.
Figure 3-4: The G4100 NOX/O2analyzing board
The two mounting brackets are mounted horizontal and parallel with a distance of
580 mm.
When the analyzing board and the ejector probe are installed in appropriate loca-
tions, the instrument air and power can be connected as described below.

System Installation
14
The figure below shows the piping and connection of the system.
Figure 3-5: Piping and connection diagram

G4100 NOx/O2 Analyzing System
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3.5.2 Air Supply Connection
For air ejection, back-flushing, and zero calibration, the instrument air is connect-
ed directly to the air supply filter regulator. The filter regulator has a filter and a
drain. The air supply connection to the filter regulator is a 1/8” BSP female con-
nection.
The pressure of the air supply must not exceed 8 bar. To see the layout of the ana-
lyzing board see 27H27H Figure 3-3.
3.5.3 Span NOXGas Connection
For span calibration, span NOXgas with a certain percent of NOXand without the
content of O2is connected to the span NOXgas port. The connection is arranged
on the left upper corner of the analyzing board. The connection is a 1/8” BSP fe-
male connection.
The pressure of the Span NOX gas must not exceed 1 bar. The gas flow should be
approximately 0.5…1 l/m. To see the layout of the analyzing board see 28H28HFigure 3-3.
3.5.4 Analyzer and Electrical Connections
The G41 NOX/O2Analyzer is mounted on the right upper corner of the analyzing
board. To see the layout of the analyzing board see 29H29HFigure 3-3.
The instructions for electrical connections are described in the G41 NOx/O2Ana-
lyzer manual.

Commissioning
16
4 Commissioning
Before starting the system for the first time after completing the installation,
please check the installation and setup of the system.
4.1 Installation Checks of the Sampling Board
Check that the ejector probe is installed in accordance with the instructions i.e.
in a suitable location that represents the gas to be tested. Make sure there is no
leaks and that the installation is in accordance with good installation practice.
Check that the air supply is connected to the air supply filter regulator without
leaking and in accordance with good installation practice.
Re-check all connections to make sure there is no air leaking. A leaking con-
nection will result in a loss of air or calibration gas and may result in poor cali-
bration.
4.2 Commissioning of the Analyzer
Check that all electrical connections and analyzer settings are correct according
to section 3110H33 and 5 in the G41 NOx/O2Analyzer manual.
4.3 Start of Systems
Using the G41 NOx/O2 Analyzer manual, follow the instructions for commission-
ing of the analyzer and start the system. For calibration, follow the instructions in
section 6.

G4100 NOx/O2 Analyzing System
17
5 System Operation
5.1 Calibration Mode
In the calibration mode (both Zero and Span), the selector valve must stay at the
Calibration position.
For zero calibration
Turn the selector valve to Zero position.
Check that the instrument air (zero NOXgas) is connected to the air supply fil-
ter regulator.
The pressure of the zero NOXgas must not exceed 8 bar and should be reduced
to 0.3-1 bar at the air supply filter regulator station. The flow of zero NOXgas
should be approximately 0.5…1 l/min. which can be adjusted at the calibration
flow meter.
For span calibration
Turn the selector valve to Span position.
Check that the span NOXgas is connected to the span NOXgas connection.
The pressure of the span NOXgas should be approximately 1 bar. The flow of
the calibration gases should be approximately 0.5…1 l/min. which can be ad-
justed at the calibration flow meter, or at the fixed flow valve of the test gas
bottle.
After calibration, remember to turn both selector valves back to the Operation
position.

System Operation
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5.2 Measurement Mode
In the measurement mode, both selector valves must point to the Operation posi-
tion.
To adjust the sample air flow, you have to adjust the flow of the ejector air at the
sampling flow meter. In the normal condition, the ejector air flow shall be approx-
imately 2 l/min. at the pressure of 1 bar. If you need more suction, see section 116H2
for ejector probe specifications.
The instrument air for back-flushing is regulated by the solenoid valve which is
controlled by the analyzer. For back-flushing, the solenoid valve will be opened
automatically to allow the ejector probe back-flushing with high air flow. To set
up the back-flushing interval, see the instruction in the analyzer manual.

G4100 NOx/O2 Analyzing System
19
6 Routine Maintenance
6.1 Air Flow System
Routine inspection and maintenance of the air flow system and connections is re-
quired to make sure no gas is leaking from the system. It is important that air flow
and pressure are stable. Failure to periodically inspect and maintain the air flow
system and connections may lead to imprecise analyzer readings and thus a mal-
function of the system.
Make sure that the instrument air that is supplied at the air supply filter regulator
is maximum 8 bar and has a temperature of maximum 60 oC. Always prevent ul-
traviolet rays from reaching the air supply filter regulator.
Before cleaning and servicing the air flow system, depressurize the air supply fil-
ter regulator. When cleaning do not use an adhesion of organic solvents to the air
supply filter regulator.
The flow meter and the control valve do not require any special maintenance. Dirt
and oil on the surface of the flow meters are to be removed carefully using neutral
detergent and a clean dry rag.
6.2 Sensor
Warning
The analyzer must be turned off and the air supply must be disconnect-
ed before you start changing the sensor.
If you remove the sensor while there is exhaust gas in the stack, there is
a risk that hot exhaust gas will come out of the sensor house.
The probe and the sensor are hot and can cause severe burning of per-
sonnel if not handled with care.

Routine Maintenance
20
To change the sensor, please go through the following steps:
Turn off the analyzer and disconnect the air supply.
Unscrew the nuts and remove the blue cover plate of the ejector probe.
To disconnect the sensor electronic control unit (ECU) press the small button
on the plug at the end of the cable to the ECU and pull out the plug.
To dismount the ECU, loosen the two nuts on the back of the mounting plate.
Use a spanner to loosen the sensor.
Insert a new sensor into the sensor house.
Mount the ECU back on the mounting plate.
Reconnect the cable to the ECU.
Looking f rom si de
Screws on the f ront
of the mou nting
pl ate to rem ove the
probe f romthe stack
Sensor ele ctronic
control unit (ECU)
Figure 6-1: Ejector probe