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
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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
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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