GREEN INSTRUMENTS G4130 NOX/O2 User manual

PART NUMBER: 02156
G4130 NOX/O2 ANALYZING
SYSTEM WITH DIFFUSION
PROBE MANUAL

Version 1.1 –Revision Jan 2019 –Part nr.: 02156 2

G4130 NOx/O2 Analyzing System
3
Content
1INTRODUCTION 5
1.1 ABOUT THIS MANUAL 5
1.2 INQUIRIES AND FEEDBACK 6
2SYSTEM SPECIFICATIONS 7
3SYSTEM INSTALLATION 9
3.1 CONTROLAT DELIVERY 9
3.2 WHERE TO INSTALL THE SYSTEM 9
3.3 SAFETY ASPECTS 11
3.4 DIFFUSION PROBE 12
3.5 ANALYZING BOARD 15
3.5.1 Mounting Panel 15
3.5.2 Air Supply Connection 15
3.5.3 Span NOXGas Connection 15
3.5.4 Analyzer and Electrical Connections 15
4COMMISSIONING 18
4.1 INSTALLATIONAND SET-UP PRE-CHECKS 18
4.2 START OF SYSTEMS 18
5SYSTEM OPERATION 19
5.1 CALIBRATION MODE 19
5.2 MEASUREMENT MODE 20
6ROUTINE MAINTENANCE 21
6.1 CALIBRATION 21
6.2 AIR FLOW SYSTEM 21
6.3 SENSOR 22
6.4 DIFFUSION PROBE 23
7PARTS LIST 25

Content
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 4
TABLE OF FIGURE
FIGURE 3-1: INSTALLATION LAYOUT OF THE DIFFUSION PROBE –WELDING TYPE 10
FIGURE 3-2: INSTALLATION LAYOUT OF THE DIFFUSION PROBE –THREAD TYPE 11
FIGURE 3-3: DIFFUSION PROBE STANDARD –WELDING TYPE 13
FIGURE 3-4: DIFFUSION PROBE SHORT –WELDING TYPE 13
FIGURE 3-5: DIFFUSION PROBE STANDARD –THREAD TYPE 14
FIGURE 3-6: DIFFUSION PROBE SHORT –THREAD TYPE 14
FIGURE 3-7:ANALYZING BOARD DIMENSIONS 16
FIGURE 3-8: PIPINGAND CONNECTION DIAGRAM 17
FIGURE 6-1: DIFFUSION PROBE 22

G4130 NOx/O2 Analyzing System
5
1 Introduction
1.1 10BAbout this Manual
This manual contains data and instructions for the installation, operation, and
maintenance of the gas sampling board with the sampling probe of the G4130
NOX/O2Analyzing System.
The G4100 NOX/O2Analyzing System consists of two parts:
G41 NOX/O2Analyzer
G4130 NOX/O2gas analyzing board with the diffusion probe
The instructions for installation, operation, and maintenance of the analyzer are
provided in a separate manual –the G41 NOX/O2 Analyzer manual.
For the installation, operation, and maintenance of the G4130 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 fitted 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.

Introduction
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 6
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

G4130 NOx/O2 Analyzing System
7
2 System Specifications
Gas Connection
Span NOX gas connection
For 6/4 mm tubing –max. 1 bar
Air supply filter regulator
1/8” BSP connection –max. 8 bar
Air supply quality
Instrument air quality according to ISO 8573-1,
class 3
Analyzer
See details in the G41 NOx/O2 Analyzer manual
Analyzing Board
Analyzing board dimension
600 × 500 × 140 mm (H × W × D)
Weight
Approx. 10.0 kg without packaging
Approval & Certificate
Lloyd´s Register Type Approval Certificate
Diffusion Probe
Sensor technology
Heated zirconia type sensor
Measurement range
NOX: 0…1500 ppm
O2: 0.0…21 %
Sample temperature
0…500 C
Probe insert length
Approx. 208…338 mm
for duct diameters 235…2800 mm
Mounting type
Welding socket size OD: 70.0 mm L: 190 mm; or
thread size: 1½” BSP
Connection for
calibration gas and back-flushing
6/4 mm tubing
Calibration air flow
Approx. 0.5…1 l/m
Diffusion probe dimension –short
285 x 180 x 475 mm (H x W x D)
Diffusion probe dimension –long
285 x 180 x 600 mm (H x W x D)
Weight including house
Approx. 6.0 kg without packaging

System Specifications
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 8
Umbilical cord
Cord length
3.0 m
Tubing
In 28 mm nylon conduit
Optional Equipment
Remote display with alarm relays
Recording and visualization
Extension kit for umbilical cord
Specifications are subject to changes without notice.

G4130 NOx/O2 Analyzing System
9
3 System Installation
Read this chapter in its entirety before installing the system.
3.1 Control at Delivery
When you receive the G4130 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 G4130
NOX/O2 Analyzing System are achieved by paying attention to the following
points:
Make sure to install the probe in a suitable location where it will extract
the gas that is going to be tested.
The probe shall be fitted at least 10 pipe diameters after the outlet of the
engine, the turbocharger, or the last after-treatment device –choose which-
ever is further downstream. However, the 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 Figure 3-1 and
Figure 3-2 for the installation layout of the probe. If you find it difficult es-
timating where to install the 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 probe. If necessary, the umbilical cord can be extended.

System Installation
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 10
The analyzing board shall be placed and installed where the ambient tem-
perature 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.
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
Maintenance
space: 700 mm
600 mm
285 mm
600 × 285 × 180 mm
Figure 3-1: Installation layout of the diffusion probe –welding type

G4130 NOx/O2 Analyzing System
11
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
Maintenance
space: 700 mm
600 mm
285 mm
600 × 285 × 180 mm
Socket: Yard supply
to be welded
Thread size:
1½” BSP
Figure 3-2: Installation layout of the diffusion probe –thread type
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 G4130 NOX/O2Ana-
lyzing System and associated equipment must be carried out by skilled, trained,

System Installation
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 12
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 G4130 NOX/O2Analyzing System with regular refuse.
Disposal should be in accordance with the requirements of the current statutory
regulations.
3.4 Diffusion Probe
The sample gas flow is diffused through the sample filter element into the sensor
area. The gas, which passes the probe, must represent the gas to be tested and
extracted from a location with laminar flow. Holes and leaks in the gas ducting
system before and after the probe may influence the accuracy of the measurement.
The probe shall be placed so that it is protected against mechanical damage. The
flue gas temperature cannot exceed the given temperature limit of the diffusion
probe.
For mounting of the diffusion probe, there are two mounting types:
Probe with welding socket (see Figure 3-3 and Figure 3-4)
Probe with thread (see Figure 3-5 and Figure 3-6)
When mounting the probe on the stack, make sure that the back plate of the probe
is mounted with the sampling hose connection facing down and the probe protec-
tion house mounted in a vertical position of the stack. Please see Figure 3-1 and
Figure 3-2 for the installation of the probes.

G4130 NOx/O2 Analyzing System
13
Figure 3-3: Diffusion probe standard –welding type
Figure 3-4: Diffusion probe short –welding type

System Installation
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 14
Figure 3-5: Diffusion probe standard –Thread type
Figure 3-6: Diffusion probe short –Thread type

G4130 NOx/O2 Analyzing System
15
3.5 Analyzing Board
3.5.1 Mounting Panel
The analyzing board is designed for mounting with the G41 NOXAnalyzer (see
Figure 3-7). The 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.
The two mounting brackets are mounted horizontal and parallel with a distance of
577 mm.
When the analyzing board and the probe are installed in appropriate locations, the
instrument air and power can be connected as described below.
The figure below shows the piping and connection of the system.
3.5.2 Air Supply Connection
For back-flushing and zero calibration, the instrument air is connected 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 connection. The
maximum pressure for the air supply inlet is 8 bar (see Figure 3-8).
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 for 6/4 mm tub-
ing. 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 Figure
3-8.
3.5.4 Analyzer and Electrical Connections
The G41 NOX/O2Analyzer is mounted on the right upper corner of the analyzing
board. For the layout of the analyzing board, see Figure 3-7.
The instructions for electrical connections are described in the G41 NOX/O2Ana-
lyzer manual. Note that the analyzer includes two cable glands for 11-44 mm di-
ameter cable.

System Installation
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 16
Figure 3-7: Analyzing board dimensions

G4130 NOx/O2 Analyzing System
17
Figure 3-8: Piping and connection diagram

Commissioning
Version 1.1 –Revision Jan 2019 –Part nr.: 02156 18
4 Commissioning
4.1 Installation and Set-up Pre-checks
After completing the installation and before starting the system for the first time,
please check the following:
Check and confirm that all electrical connections are carried out according to
the manuals and the technical drawings.
Check that the air supply is connected to the air supply filter regulator without
leaking and in accordance with good installation practice.
Check that the probe is installed in accordance with the instructions i.e. in a
suitable location representing the gas to be tested, without leaking and in ac-
cordance with good installation practice.
Check the settings of the analyzer’s input and output signal. Please see the ana-
lyzer manual for the settings.
Re-check all connections to make sure there is no air leaking. A leaking con-
nection will result in loss of air and may result in poor calibration
4.2 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
the section 5.1 of this manual and section 6 of the analyzer manual.

G4130 NOx/O2 Analyzing System
19
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
filter regulator.
The pressure of the zero NOXgas must not exceed 8 bar and should be re-
duced 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 adjust-
ed 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 adjusted 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.