-
Fuji Labs ZSP - page 1
INZ-TN4ZSPb-E Instruction Manual INFRARED GAS ANALYZER TYPE: ZSP ...
-
Fuji Labs ZSP - page 2
– i – INTRODUCTION Congratulations on your purchase of Fuji Gas Analyzer. (Type:ZSP) • Read this instruction manual carefully to ensure correct installation, operation and maintenance of the gas analyzer. Incorrect handling may lead to unexpected trouble or injury. • The specifications of the gas analyzer is subject to change without prior ...
-
Fuji Labs ZSP - page 3
– ii – CAUTION ON SAFETY Before use, carefully read this “Caution on safety” so that the product is usable correctly. • The precautions given here are of great significance to safety. Therefore, they should be observed without fail. The precautions on safety are classified into ranks “Danger”, “Caution” and “Prohibition.” Dang ...
-
Fuji Labs ZSP - page 4
– iii – Caution on wiring Caution •R equest an installation company or your dealer to carry out wiring. If wiring is incomplete, shock hazard or injury may be caused. •C lass D grounding construction is mandatory. Otherwise, shock hazard may be caused. < Caution for wiring company > For preventing shock hazard, fire and injury, be sur ...
-
Fuji Labs ZSP - page 5
– iv – Caution on use Prohibition • Do not insert a rod or your finger into the fan (electronic cooler at ceiling), otherwise injury may be caused by the rotating blades. • Do not touch metal, finger, etc. to the input and output terminal block of analyzer. Otherwise, shock hazard or injury may be caused. • Smoking and use of fire/flame i ...
-
Fuji Labs ZSP - page 6
– v – Others Caution • When trouble cannot be remedied even after following the instruction manual, contact your dealer or Fuji's service station (serivice engineer). Do not disassemble the device, as it results in electric shocks or injury. • Do not use replacement parts which are not specified by makers. Use of these parts will not o ...
-
Fuji Labs ZSP - page 7
– vi – CONTENTS INTRODUCTION ................................................................................................................................................... i CAUTION ON SAFETY .............................................................................................................. ......................... ii 1. OUTLIN ...
-
Fuji Labs ZSP - page 8
– vii – 10. MAINTENANCE ......................................................................................................................................... 26 10.1 Routine maintenance and inspection ......................................................................................... ........ 26 10.2 Periodic maintenance and inspectio ...
-
Fuji Labs ZSP - page 9
– 1 – 1. OUTLINE The infrared gas analyzer (ZSP) can continuously and accurately measure the concentration of gases such as NOx, SO 2 , CO, CO 2 and O 2 contained in the flue gas from a stationary generating source. The analyzer is available in both single-component and multi-component types depending on customer ’ s specification. The actual ...
-
Fuji Labs ZSP - page 10
– 2 – 4. INSTALLATION Danger • This product is not explosion-proof. Do not use it in explosive gas-rich atmosphere. Otherwise, serious accidents such as explosion and fire may be caused. Caution • Installation, carrying and relocation must be made by a qualified contractor or your dealer. Incorrect installation results in falling accidents, ...
-
Fuji Labs ZSP - page 11
– 3 – 4.3 Installation work For installation of the analyzer locker and the extractor, follow the piping instructions in Fig. 4-1 and the separately issued approval drawings (outline diagrams, sampling system diagram). (1) Countermeasures for cold climate (a) Freeze prevention of gas piping (b) Freeze prevention of drain pot (c) Freeze preventi ...
-
Fuji Labs ZSP - page 12
– 4 – Fig. 4-1 Piping procedure Note 1) To prevent aspiration of leaked air Note 2) Install so that pipe end comes to nearly center of flue and is at right angle to the gas flow. Note 3) Peel off heating pipe by about 2m in order to air-cool measured gas. Note 4) Provide an inclination of 15 ° or more on the gas pipe so that drain will not acc ...
-
Fuji Labs ZSP - page 13
– 5 – 5. DESCRIPTION OF EACH PART Please refer to Chapter 14 specification attached at the end of the manual. 6. PREPARATION FOR OPERATION 6.1 Injection of clean water Inject clean water through the filter or air aspiration port until it overflows from the gas conditioner. 6.2 Supply of external power Supply external power to the analyzer. And ...
-
Fuji Labs ZSP - page 14
– 6 – 6.4 Airtightness test (1) Piping inside panel Since airtightness is confirmed during tests before shipment, an Airtightness test during trial run is usually unnecessary. When a long time has passed after shipment, then carry out the following proce- dure. (a) Close the drain port. (b) Connect standard gas to the sample gas inlet. (c) Conn ...
-
Fuji Labs ZSP - page 15
– 7 – 7. INDICATION/OPERATION PANEL 7.1 Name and description of each component of indication/operation panel Part Name Description q Component indication Indicates kind of gas measured. w Main indication Indicates measured concentration. Also indicates various set-points for alarm function, auto calibration function (option), etc. e Unit indica ...
-
Fuji Labs ZSP - page 16
– 8 – 7.2 Function and indication of indication/operation panel This panel consists of the following functions. Key Function Main indication Sub indication Function indication lamp FUNC Measuring mode Measuring value Range MEAS lamp lights Setting mode FUNC Calib.conc.setting Calb.conc. Range CAL SET lamp lights FUNC Alarm setting (option) Alar ...
-
Fuji Labs ZSP - page 17
– 9 – 7.3 General operation of indication/operation panel The measuring mode is assumed when power is turned ON. The gas concentra- tion appears on the main indication, while the range being used appears on the sub in- dication. Advice on Operation ✩ When selecting the range In the setting status, as shown in the figure at the right, the high ...
-
Fuji Labs ZSP - page 18
– 10 – 8. CALIBRATION 8.1 Kinds of standard gas 8.1.1 When not using zirconia O 2 sensor (1) Zero gas: N 2 or atmospheric air/instrument air depending on specification (when without verifi- cation stipulated in the laws for measurement and weighing) (2) Span gas: Gas of 90% or more full scale for each component, remainder is N 2 (span gas for l ...
-
Fuji Labs ZSP - page 19
– 11 – Fig. 8-1 Pressure regulation for standard gas cylinder Packing Pressure gauge on high pressure side Pressure gauge on low pressure side Adapter Cylinder mounting nut Cylinder Pressure regulator R1/4 joint Pressure controls Output handle ...
-
Fuji Labs ZSP - page 20
– 12 – 8.3 Calibration concentration setting (except zirconia O 2 sensor) Set a span value for the calibration concentration setting. (Zero point calibration concentration is fixed at zero.) Set the calibration gas concentration (span value). When FUNC key is pressed in the measuring sta- tus, the previously set span value will appear on the ma ...
-
Fuji Labs ZSP - page 21
– 13 – [When adjusting for each range] (Simultaneous calibration of H and L ranges has been factory-set). Perform setting in the following way. By pressing CAL key while the highest digit of the main indication for the 1st component is flickering, then ‘ ’ will appear on the main indication and ‘ ’ will appear on the sub indication. Pre ...
-
Fuji Labs ZSP - page 22
– 14 – 8.4 Calibration concentration setting (zirconia O 2 sensor) A zirconia O 2 sensor sets the zero (air) point (span point stipulated in the laws for measurement and weighing) of the O 2 analyzer. For the density of calibration gas to be used, refer to “ 8.2 Preparation of standard gas ” . ✩ Setting of calibration concentration for ze ...
-
Fuji Labs ZSP - page 23
– 15 – ✩ Setting of span calibration concentration (zero point stipulated in the laws for measurement and weigh- ing) Press the CAL key in the status where the digit of the O 2 analyzer main indication is flickering via the zero (air) point calibration concentration setting. The previously set span value will now appear on the main indication ...
-
Fuji Labs ZSP - page 24
– 16 – 8.5 Zero calibration (air point calibration in case of zirconia O 2 sensor) This is used for adjusting the zero point. Flow the zero gas (0.3 N /min.) by adjusting the needle valve of pressure regulator and wait until the indica- tion stabilizes. When the Zirconia O 2 sensor is used, use air. Note) When the indication has stabilized, sel ...
-
Fuji Labs ZSP - page 25
– 17 – 8.6 Span calibration (low concentration point calibration in case of zirconia O 2 sensor) Carry out span calibration by flowing calibration gas at the concentration set as a span value. Flow the calibration gas (0.3 N /min.) by adjusting the needle valve of pressure regulator. Wait until the indica- tion stabilizes, and then conduct span ...
-
Fuji Labs ZSP - page 26
– 18 – 8.7 Auto calibration In this analyzer, the signals form the input/output terminals on the upper can be used for driving an external solenoid valve and introducing standard gas, whereby zero point and span can be calibrated automatically. The auto calibration is done according to 8.7.1 Current time setting, 8.7.2 Auto calibration start ti ...
-
Fuji Labs ZSP - page 27
– 19 – Auto calibration abnormality: If an abnormality occurs during auto calibration, a contact signal for auto calibration abnormality will be output from the input/output terminals on the upper of the analyzer. The gas which incurred the abnormality will not be calibrated, and instead the next component will be calibrated. Note: Usually, T i ...
-
Fuji Labs ZSP - page 28
– 20 – 8.7.1 Current time setting Set the current time and day of the week. Press the FUNC key in the measuring status. The AUTO CAL LED of the function indicating lamps will flicker. The main indication shows the hour and minute via a 24-hour indication and the decimal point flickers. A ’–’ bar lights up at the relevant weekday on the su ...
-
Fuji Labs ZSP - page 29
– 21 – 8.7.2 Auto calibration start time setting When FUNC key is pressed at the current time indica- tion, the auto calibration start time and day will appear on the main and sub indications. The AUTO CALLED of the function indicating lamps will flicker. In the case of start time, the decimal point on the main indication will light steadily. P ...
-
Fuji Labs ZSP - page 30
– 22 – 8.7.3 Auto calibration cycle setting The calibration cycle is settable in either ‘ days ’ s or ‘ hours ’ . Press the FUNC key at the calibration start time indica- tion and ‘ ’ will appear. The AUTO CAL LED of the function indicating lamps will flicker. Press the key and the auto calibration cycle is settable. The highest dig ...
-
Fuji Labs ZSP - page 31
– 23 – 8.7.4 Auto calibration ON/OFF setting Select whether or not to carry out auto calibration. Set to ‘ ’ when calibration will not be made. Note) Press the FUNC key at the calibration gas flow mode indication and ‘ ’ will be appear. The AUTO CAL LED of the function indicating lamps will flicker. Press the key and auto calibration ON ...
-
Fuji Labs ZSP - page 32
– 24 – 8.7.5 Setting of output hold at calibration This is used when calibrating for holding the output sig- nal at the value just be before entering calibration. (The indication is not held.) The hold function is settable for each component. Press the FUNC key in the measuring status and ‘ ’ will be indicated. The HOLD LED of the function ...
-
Fuji Labs ZSP - page 33
– 25 – 9. OPERATION 9.1 Operating procedure (1) Check if all the preparation for operation have been completed. (2) Press the range selector switch on the indication/operation panel to select a range to be used. (3) Press the function key “ FUNC ” on the indication/operation panel to light up the “ MEAS ” function indicator lamp. (4) Tu ...
-
Fuji Labs ZSP - page 34
– 26 – Maintenance/inspection item Monitoring of sample flow rate Monitoring of conditioner bubbling quantity (Note) Conditioner Air aspiration tube level Procedure Prescribed flow rate: The flow rate is normal when the ball is at 0.4 N /min. and there is slight bubbling at the bottom of conditioner. Adjust the needle valve so that a flow rate ...
-
Fuji Labs ZSP - page 35
– 27 – Maintenance/inspection item Contamination of membrane filter Electronic gas cooler Temperature controller for NO 2 /NO converter Procedure Replace the filter paper if it has blackened (see (3) in 10.5). If contamination occurs rapidly, then check the pre-stage filters of the gas extractor ((1) in 10.5), conditioner filter ((2) in 10.5), ...
-
Fuji Labs ZSP - page 36
– 28 – 10.2 Periodic maintenance and inspection Procedure Refer to section 8.5 to 8.6. It takes at least 1.5 months to deliver the standard gas. So the gas should be ordered 2 or 3 months in advance. Supply water if level is below overflow port. Replace with new filter paper (stop the aspirator when exchanging). See 10.5 (3). Replace these part ...
-
Fuji Labs ZSP - page 37
– 29 – Fig 10-2 Gas extractor (type ZBAK1) Seal fixture Filter case Locking wing bolt Handle for filter exchange O-ring (JIS P48A Viton) Metallic mesh filter 10.4 Concentration guarantee term of standard gas cylinder (for NO x , SO 2 , CO and O 2 analyzer) Kind of gas Concentration range Guarantee term NO/N 2 0.4ppm or more, and less than 250pp ...
-
Fuji Labs ZSP - page 38
– 30 – (2) Replacement of mist filter element (See Fig. 10-1.) (a) Loosen the butterfly bolt, and pull the head up and out of the container. (b) Then loosen the retaining nut and remove the contaminated filter element. (c) Replace with a new conditionor filter and O-ring, and reassemble by reversing the above steps. (3) Replacement of membrane ...
-
Fuji Labs ZSP - page 39
– 31 – Hex. socket head cap screw Cap A Seat valve Rc1/8 Cap B Diaphragm Arm lot Fig. 10-4 Exploded view of diaphragm type aspirator (4) Replacement of the valve and the diaphragm of diaphragm type aspirator Replace the seat valve (turn 90 ° in six months and replace annually) and the diaphragm (replace annually) according to the following pro ...
-
Fuji Labs ZSP - page 40
– 32 – (5) Check and maintenance of electronic gas cooler (a) Fan motor This motor should be replaced periodically every 20,000 hours (about 2 years in case of continuous operation ) as a standard though this varies with operating condition. However, if no abnormality cannot be found at the time of a periodic replacement, the motor is further u ...
-
Fuji Labs ZSP - page 41
– 33 – (6) Replacement of NO 2 /NO converter catalyst (a) Turn off power supply to the converter. (b) After half an hour, remove q w e , and extract r upward and downward, respectively. Pay attention not to suffer a burn. In addition, carefully handle the ceramic pipe for preventing breakage. When remov- ing r , e will fall simultaneously. So p ...
-
Fuji Labs ZSP - page 42
– 34 – (9) Washing the Permapure dryer The Permapure dryer is used for SO 2 measurement (2000 ppm or more). The Permapure dryer has no moving sections nor consumable parts. If precautions in using it are suffi- ciently respected, it can operate without maintenance usually. However, if its element has clogged, for example, remedy it by the follo ...
-
Fuji Labs ZSP - page 43
– 35 – 10.6 Maintenance of zirconia O 2 sensor Sensor temperature 800 OXYGEN ANALYZER POWER ON OFF 1234567 Power SW Fuse 3A Terminal Front view Side view Sample inlet (Rc 1/4) Outlet (Rc 1/4) AG 0V + – ALM (1) Appearance of zirconia O 2 sensor (2) Routine maintenance No parts require periodic maintenance. In case sensor temperature is 800 ± ...
-
Fuji Labs ZSP - page 44
– 36 – 11. STANDARD ACCESSORIES AND SPARES Caution • Do not use replacement parts which are not specified by makers. Use of these parts will not only provide the required performance but also result in damage or other trouble. • Replacement parts used for maintenance must be handled as incombustible objects. No. Part name Type of part No. Q ...
-
Fuji Labs ZSP - page 45
– 37 – 11.2 Spares for 1 year (optional) No. Part name Quantity (analyzer) Remarks NO X /SO 2 NO X SO 2 Other 1 Spare for converter 1 1 —— Catalyst and filter TK726889C3 2 Conditioner filter 2 2 2 2 TK7H8043P1 3 Conditioner O-ring 2 2 2 2 G65 chloproprene 8553765 4 Membrane filter paper — 1 pack — 1 pack 25 sheets of TK701837C6 per pack ...
-
Fuji Labs ZSP - page 46
– 38 – 12. PROCESSING OF HEATING PIPE ENDS 12.1 Outline (1) Configuration Fig. 12-1 (2) Caution on connection of heating pipe q The clearance between clamp supports must be about 1.2 m in the horizontal direction and about 3 m in the vertical direction. w For a bent piping, bending should be moderate enough to ensure a minimum bending radius of ...
-
Fuji Labs ZSP - page 47
– 39 – 12.2 End processing method (1) Power supply side (power connection kit) q When cutting out the heating pipe, take care not to damage the heater wire. w Pulling out on the inside of grid section provides a non-heating area of about 300 mm at maximum. Fig. 12-4 e Peel the outer sheath covering of heater as shown below and cut off the heate ...
-
Fuji Labs ZSP - page 48
– 40 – (2) Termination side (termination kit) q Cut the heater in the dimension shown at right. Push back the metallic braiding and fix it with Teflon tape. w Peel the outer sheath covering of heater and cut off the heater wire as close to the root as pos- sible. Expose the bus of heater wire toward the cut end starting from a point about 40 mm ...
-
Fuji Labs ZSP - page 49
– 41 – 12.3 Check after piping q The heating pipe is not sunk significantly due to a clamp, etc. w The bent section has an adequately large bending radius. e Electrical connections are exact. r The end of heater wire (bus) is not short-circuited (it must never be short-circuited). t All parts of the connection kit (sealing connector), etc. have ...
-
Fuji Labs ZSP - page 50
– 42 – 12.5 Specifications of tube trace (1) Structure of tube trace q Heater cable (power limiting cable) w Process tube e Aluminum tape r Fiber glass heat insulator t PVC jacket Fig. 12-9 (2) Specifications of tube trace q Heater cable HPT 20-1 BN 35.4w/m at 100 º C (100V AC) w Process tube 10/8 mm ø PFA Teflon tube e Aluminum tape 50% over ...
-
Fuji Labs ZSP - page 51
– 43 – Note) Pressure control valve is used. 13. TROUBLESHOOTING Caution • When trouble cannot be remedied even after following the instruction manual, contact your dealer or Fuji's service station (serivice engineer). Do not disassemble the device, as it results in electric shocks or injury. Trouble Decrease of sample gas flow rate Incr ...
-
Fuji Labs ZSP - page 52
– 44 – 13.2 Error codes and remedies This analyzer is provided with self-diagnosis functions, and an error code is displayed if an abnormality occurs in the instrument. Take a proper measure with reference to the instruction manual of infrared gas analyzer when an error code appears. Trouble Indicated value is not as expected. Indication doesn ...
-
Fuji Labs ZSP - page 53
– 45 – 14. SPECIFICATIONS Specifications Type of cubicle: Outdoor, self-standing, sealed type or indoor type Measuring system: Non-dispersion infrared absorption (NDIR method) for NO x , SO 2 , CO and CO 2 ; zirconia method for O 2 . Sampling system: Dry sampling electronic cooling & dehumidification system (Permapure dryer adopted) Measuri ...
-
Fuji Labs ZSP - page 54
– 46 – Standard requirements for sample gas: Temperature — 60 to 800 ° C Dust — 100 mg/Nm3 or less Pressure — - 2.94 to +2.94kPa Components — SO 2 0 to 1000ppm NO x 0 to 2000ppm (NO 2 100ppm or less) CO 2 several % to over 10% CO 0 to 2000ppm O 2 0.5 to 21% H 2 O 0 to 40% HC N 0 to 100ppm N 2 remaining percent When other components are ...
-
Fuji Labs ZSP - page 55
– 47 – (1) NO x after O 2 correction CO after O 2 correction (a) Calculating equation 21 - On C= • Cs 21 - O S C: Concentration after O 2 conversion Cs: NOX or CO concentration measured Os: O 2 concentration measured On: O 2 concentration as conversion basic: 4% Oil combustion boiler 5% Gas combustion boiler 6% Solid object combustion boiler, ...
-
Fuji Labs ZSP - page 56
– 48 – CO span O 2 zero NOx span SO 2 span O 2 span Automatic calibration NO x , SO 2 zero CO zero Automatic calibration • Calibration tolerance: ± 0.2% FS • Automatic calibration output hold: Possible (Example in 4 component analyzer): • Calibration cycle: Once/day (variable, up to 7 days) • Calibration gas feed time: 2 to 10 min. (va ...
-
Fuji Labs ZSP - page 57
– 49 – 0 1 3 NO X + (O 2 ) CO + (O 2 ) SO 2 + (O 2 ) NO X + SO 2 + (O 2 ) NO X + SO 2 + CO + (O 2 ) NO X + SO 2 + CO + (O 2 ) With ZFK With ZKG (Non-standard) Application Combustion exhaust gas (standard condition) Other exhaust gas Others Component Oxygen analyzer Without Auto calibration With Type of cubicle Indoor installation type Outdoor i ...
-
Fuji Labs ZSP - page 58
– 50 – SAMPLING SYSTEM BLOCK DIAGLAM CO Gas extracter Gas sample pipe Conditioner Aspirator Electronic gas cooler Pressure control valv e equipped depending on specification Solenoid valv e Zirconia O 2 sensor Flowmeter Con vertor Infrared gas analyzer T wo component infrared gas analyzer Solenoid valv e Pressure regulator Standard gas Sample g ...
-
Fuji Labs ZSP - page 59
– 51 – Functions of individual components • Gas extractor (type; ZBA): With heating type stainless steel filter; standard diameter 40 µ m for filter. • Gas conditioner (type; ZBH9) For separating drain and removing sulfuric acid mist and oil mist or fine dust particles. Besides, for preventing aspiration of drain at clogging of extractor f ...
-
Fuji Labs ZSP - page 60
– 52 – 620 760 Rear side Front side 1000 120 815 70 1800 50 770 1400 620 800 760 800 100 4- φ 15 hole 100 A-140-2-1 (key No.200) Cable inlet (60 × 120 rectangular hole) with plastic resin- cover (PVC) 70 ( 4 – M12 × 160 × 50 ) 32 35 Anchor plan and door opening diagram 620 760 Rear side Front side Cable inlet (60 × 120 rectangular hole) ...
-
Fuji Labs ZSP - page 61
– 53 – 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 30 31 32 33 34 35 36 20 21 22 23 24 25 26 27 28 29 Power supply CO av erage value O 2 instantateous value CO corrected value Failure contact output On maintenance and auto calibration contact output 100V A C NO x instantaneous value NO x av erage value SO 2 instantaneous value SO 2 av erage ...
-
Fuji Labs ZSP - page 62
Head Office Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan http://www.fesys.co.jp/eng Instrumentation Div. International Sales Dept. No.1, Fuji-machi, Hino-city, Tokyo 191-8502, Japan Phone: 81-42-585-6201, 6202 Fax: 81-42-585-6187 http://www.fic-net.jp/eng ...
Do you have a question concerning Fuji Labs ZSP?
Use the form below
If you did not solve your problem by using a manual Fuji Labs ZSP, ask a question using the form below. If a user had a similar problem with Fuji Labs ZSP it is likely that he will want to share the way to solve it.