Thermal conductivity gas analyzer thermomat (62 pages)
Summary of Contents for Fuji Electric ZKJ-2
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Instruction Manual NDIR TYPE INFRARED GAS ANALYZER TYPE: ZKJ-2 INZ-TN2ZKJ-E...
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• Modification of this analyzer is strictly prohibited unless a written approval is obtained from the manufacturer. Fuji Electric will not bear any responsibility for a trouble caused by such a modification. • This instruction manual shall be stored by the person who actually uses the analyzer.
CAUTION ON SAFETY First of all, read this “Caution on safety” carefully, and then use the analyzer in the correct way. • The cautionary descriptions listed here contain important information about safety, so they should always be observed. Those safety precautions are ranked in 3 levels, “DANGER”, “CAUTION” and “PROHIBITION”.
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Caution on piping In piping, the following precautions should be observed. DANGER Wrong piping may cause gas leakage. If the leaking gas contains a toxic component, there is a risk of serious accident being induced. Also, if combustible gas is contained, there is a danger of explosion, fire or the like occurring.
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Caution on use • Do not allow metal, finger or others to touch the input/output PROHIBITION terminals in the instrument. Otherwise, shock hazard or injury may occur. • Do not smoke nor use a flame near the gas analyzer. Otherwise, a fire may be caused.
CONTENTS PREFACE ........................i CAUTION ON SAFETY .................... ii CONTENTS ......................... v OVERVIEW ..................... 1-1 NAME AND DESCRIPTION OF EACH UNIT ..........2-1 Name and description of main unit ..............2-1 Input/Output terminal module ................2-2 INSTALLATION ..................... 3-1 Installation ......................3-2 3.1.1 Installation of analyzer main frame ............3-2 3.1.2...
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6.2.4 Setting of auto calibration component ............6-8 Alarm setting ....................6-10 6.3.1 Setting of alarm values ................6-10 6.3.2 Hysteresis setting ..................6-12 Setting of auto calibration ................. 6-13 6.4.1 Auto calibration ..................6-13 6.4.2 Forced stop of auto calibration ..............6-15 Setting of auto zero calibration .................
1. OVERVIEW This infrared gas analyzer (type: ZKJ) measures the concentration of NO, SO , CO , CO and CH con- tained in sampling gas on the principle that different atomic molecules have an absorption spectrum in the wave band of infrared rays, and the intensity of absorption is determined by the Lambert-Beer law. Since this instrument incorporates a compact paramagnetic O sensor, it allows measuring up to 5 compo- nents simultaneously by using the built-in O...
2. NAME AND DESCRIPTION OF EACH UNIT 2.1 Name and description of main unit POWER DISPLAY 〈 Rear panel 〉 Fig. 2-1 Name Description Name Description q Handle u Sector motor Used for withdrawing the main For driving the rotation of sec- unit from the panel.
2.2 Input/Output terminal module This analyzer provides input/output of various signals from the supplied input/outpt terminal module by connecting the instrument to this module. Fig. 2-2 Description Description Name Name Used for mounting input/output ter- q Mounting hole e Calibration Provides outputs of solenoid valve minal module.
3. INSTALLATION DANGER This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent explosion, fire or other serious accidents. CAUTION • Entrust the installation, movement or re-installation to a specialist or the supplier. A poor installation may cause accidental tipover, shock hazard, fire, injury, etc.
3.1 Installation 3.1.1 Installation of analyzer main frame Installation methods for the analyzer main unit are divided into 2 types; Type External dimensions Mounting dimensions Mounting method 19 inch rack mounting guide rail method Slide rail (Supports mass) 450 or more 19 inch rack mounting slide rail method...
3.1.2 Mounting input/output terminal module Mount the input/output terminal module on the panel; observing the following method. (Note) To avoid the effect of noise generated from external units, mount the I/O terminal module mounting plate on the panel for continuity at the mounting surface and connect the panel to the same ground as the analyzer main unit.
3.2 Piping Piping should be connected to the gas inlets and outlets of the front panel of the analyzer. • Use a corrosion resistant tube of Teflon, stainless or polyethylene to connect the instrument to a sampling system. Even if there is a danger of corrosion, refrain from using a tube of rubber or soft vinyl.
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Internal piping diagram Measuring unit 2 Measuring unit 1 Built-in sensor OUTLET INLET OUTLET INLET Sampling gas inlet For measuring unit 1 Sampling gas outlet Sampling cell Note) Sampling gas inlet 2 cells may be used For measuring by combination of unit 2 Sampling gas outlet range.
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Example of connecting each measuring unit • One pair of gas inlet/outlet Sampling gas Flow meter Filter 0.5L/min Sampling gas inlet Sampling gas outlet Exhaust Release to atmosphere. • Two pair of gas inlet/outlet - (1) Sampling gas converter Sampling gas Flow meter inlet Filter...
3.3 Sampling 3.3.1 Conditions of sampling gas q Dust contained in the sampling gas should be completely removed with a filter. For the final stage filter, use a filter that allows removing dust particles of 0.3µm. w Dew point of sampling gas must be lower than the ambient temperature to avoid occurrence of drain in the gas analyzer.
3.3.6 Example configuration of gas sampling system The following illustrates a typical system configuration for five component gas measurement for monitoring combustion exhaust gas from boiler, refuse incinerator, etc. Contact Fuji Electric for system configuration matching the particular use or further information. Name Description...
3.4 Wiring 3.4.1 Power inlet The power inlet is provided at the rear panel. Connect supplied power cable to this power inlet (Commercial power of 85V AC to 264V AC is available). Rear panel Power inlet Input/output terminal connector Grounding 2-pole plug When noise source is in the vicinity •...
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(1) Analog output signal (AO): terminal block 1 q to @0 , terminal block 2 e to y Output signal: 4 to 20 mADC or 0 to 1 VDC (selected when ordering) Non-insulated output Allowable load: 4 to 20 mADC, 550Ω or less 0 to 1 VDC, 100kΩ...
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(6) Description on terminal block Terminal block 2 <TN2> Terminal block 1 Terminal block for analog output (non-isolated <TN1> output) CH10 output CH5 output – – Between 1–2: CH5 output (CH5_OUT) + (CH10_OUT) Between 3–4: CH4 output CH4 output CH9 output –...
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Terminal block 3 Terminal block 3 <TN3> <TN3> Between 1–4: For internal connection. Must CH5 range identification Unassigned not be wired. (Must not be used contact output (RNG_IDCH5) as junction terminal.) CH4 range identification Unassigned contact output (RNG_IDCH4) Remote hold input CH3 range identification (R_HOLD) contact output (RNG_IDCH3)
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Terminal block 4 Terminal 4 <TN4> <TN4> Between 1–2: Peak count alarm contact output Peak count alarm Unassigned It is conductive when peak count output (PEAK_ALM) exceeds the setting time. It Auto calibration status/ maintenance status contact Unassigned remains open below the setting output (ACAL/MNT) time.
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Terminal 5 <TN5> Between 2, 3 and 4: Terminal block 5 CH3 alarm output <TN5> When the output exceeds the set value, Unassigned Unassigned it is conductive between 2 and 3, and Power disconnection CH3 alarm output open between 3 and 4. Otherwise, it is alarm output (ALM_CH3) (POWER_OFF)
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Connector <CN3> Solenoid valve drive signal output for calibration Connector <CN3> (Transister output) Contact output for sample gas selection Contact output for CH3 span calibration Contact output for CH4 span calibration Contact output for zero calibration Contact output for CH5 span calibration Contact output for CH1 span calibration...
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(7) Timing of solenoid valve drive signal for calibration q q q q q Manual calibration (see “Item 6.9 Calibration”.) • Zero calibration ZERO Calibration end Pump ON/OFFcontact Sample selection output Zero calibration Calibration gas flow output CH1 to 5 span calibration output Output hold function Output signal hold...
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w w w w w In case of automatic calibration (example shown in Item 6.4.1, Automatic calibration settings) Automatic CH1 span CH3 span calibration CH5 span calibration calibration start calibration CH4 span CH2 span Zero calibration calibration calibration Pump ON/OFF contact Sample selection output Zero gas Zero calibration output...
4. OPERATION 4.1 Preparation for operation (1) Tube and wiring check Double-check if tubes of the gas sampling and exhaust ports are correctly connected. Double-check for proper wiring. 4.2 Warm-up operation and regular operation (1) Operation procedure q Turn ON the power switch on the front panel of the analyzer unit. The measurement screen appears on the front display panel in 1 or 2 seconds.
DESCRIPTION OF DISPLAY AND OPERATION PANELS This section describes the display unit and operation panel of the analyzer unit. It also explains the name and description of function on the operation panel. 5.1 Name and description of operation panel POWER DISPLAY MODE ZERO...
5.2 Overview of display and operation panels • Measurement mode * 1) The panel configuration is changed depending on the display channel. (The measurement mode screen can be viewed by scrolling the arrow key up and down). MODE ZERO ZERO Calibration •...
5.3 Outline of display screen (1) Measurement mode screen (appears when the power is turned ON) The measurement screen depends on the number of components. The following screen configura- tion as shown as an example is for NO, SO , CO , CO and O (output: 12 channel).
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• Instantaneous value and concentration value: The concentration display of CH (component) where sampling components such as “CO ”, “CO” or “O are displayed in the component display, indicates current concentration values of the measured components contained in gas that is now under measurement. •...
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(3) Contents of measured channel (CH) The following table gives measurement channels and their contents according to the symbols. Code symbol Contents 5th digit 6th digit 21th digit CH1: NO CH1: SO CH1: CO CH1: CO CH1: CH CH1: NO, CH2: SO CH1: NO, CH2: CO CH1: CO , CH2: CO...
5.4 General operation • Measurement mode The measurement mode can be displayed 0 0 . 0-100 up to 5 channels in a single screen. If 5 0 0 . channels or more are to be displayed in a 0-100 0 0 0 single screen, press the key to 0-10...
6. SETTING AND CALIBRATION 6.1 Changeover of range This mode is used to select the ranges of mea- MODE sured components. q During measurement, press the MODE to display the User mode. w Point the cursor to “Changeover of Range”. Press the key.
6.2 Calibration setting This mode is used to set calibration concentration and actions. The calibration setting involves calibration concentration, zero calibration, calibration range and auto calibration component. 6.2.1 Setting of calibration concentration It allows you to set concentrations of the standard gas (zero and span) of each channel used for calibration.
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t In the “Calibration Concentration Selection” screen that appears, select any concentration item you want to set by pressing the key. Cursor for setting value y In the “Calibration Concentration Value Setting” screen that appears, enter calibration gas concentration values (zero and span). For value entry, press the key, and a 1-digit value increases or decreases.
6.2.2 Setting of manual zero calibration When zero calibration is made manually, set either all measurement components should be calibrated simultaneously or each component should be calibrated while selecting one by one. MODE q During measurement, press the MODE to display the User mode. w Point the cursor to “Setting about Cali- bration”...
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t In the “Manual Calibration Selection” screen that appears, select “at once” or “each” by pressing the key. When selecting “at once”, the CH (com- ponents) to be set can be zero-calibrated at the same time. When selecting “each”, either of the CH (components) to be selected is zero-calibrated.
6.2.3 Setting of calibration range This mode is used to set if the range of each CH (component) at the calibration (manual calibration or auto calibration) should be calibrated with a single range or 2 ranges. MODE q During measurement, press the MODE to display the User mode.
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t In the “Calibration Selection” screen that appears, select “both” or “current” by pressing the key. • When selecting “both”, Range 1 and Range 2 of the set CH are calibrated together. When selecting “current”, the range alone displayed at the set CH is calibrated.
6.2.4 Setting of auto calibration component It sets the CH (component) to be calibrated in the auto calibration. MODE q During measurement, press the MODE to display the User mode. w Point the cursor to “Setting about Cali- bration” by pressing the key.
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t In the “Auto Calibration Selection” screen that appears, select “enable” or “disable” by pressing the key. After setting, press the key. To close "Auto Calibration Component" setting To close “Setting of Auto Calibration Component” or to cancel this mode midway, press the key.
6.3 Alarm setting 6.3.1 Setting of alarm values This mode is used to set the upper or lower limit value to provide an alarm output during measure- ment. Before changing the alarm setting, set the ON/OFF to OFF. MODE q During measurement, press the MODE to display the User mode.
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After setting, the alarm setting is now Cursor for setting value completed by pressing the key. To close the "Alarm Setting" To close the “Alarm Setting” or to cancel this mode midway, press the key. A previous screen will return. End of Alarm Setting Description of setting items Upper limit value: Sets the upper limit value (concentration) of alarm.
6.3.2 Hysteresis setting To prevent chattering of an alarm output near the alarm setting values, set the value of hysteresis. q In the “Alarm Setting CH” Selection” screen that appears, point the cursor to “Hysteresis” by pressing the key. Press the key.
6.4 Setting of auto calibration 6.4.1 Auto calibration Auto calibration is automatically carried out at the time when zero calibration and span calibration are set. Before changing the setting of auto calibration, set the ON/OFF to OFF. q During measurement, press the MODE MODE to display the User mode.
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“Auto calibration status” and “maintenance status” contact outputs are closed during auto calibration, and are open in other cases. When hold is set to ON, the contacts are closed during holding. Example Start Time 12:00 Cycle Flow Time ON/OFF In case where auto calibration is carried out at the above setting. Sunday Monday Tuesday...
6.4.2 Forced stop of auto calibration This mode is used to cancel the auto calibration forcedly. q In the User mode that is displayed, point the cursor to “Setting of Auto Calibra- tion” by pressing the key. Press the key. w In the “Setting of Auto Calibration”...
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“Auto Calibration” screen Example In case where setting the auto calibration components (see Item 6.2.4) to “CH1: enable” and “CH2: enable” • Zero calibration ZERO cal. 0-100 A message, “Zero cal.” blinks 0 3 . ZERO cal. at CH1 and CH2. 0-100 0 0 0 0 0-10...
6.5 Setting of auto zero calibration 6.5.1 Auto zero calibration Auto zero calibration is automatically carried out at the time when zero calibration is set. Components for which a calibration is to be made are determined by setting of auto cali- bration component in Item 6.2.4.
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“Auto calibration status” and “maintenance status” contact outputs are closed during auto calibration, and are open in other cases. When hold is set to ON, the contacts are closed during holding. Example Start time 12:00 Cycle hour Flow time ON/OFF In case where auto zero calibration is carried out at the above setting.
6.5.2 Forced stop of auto zero calibration This mode is used to cancel the auto zero calibration forcedly. q In the User mode that is displayed, point the cursor to “Setting of Auto Zero Calibration” by pressing the key. Press the key.
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“Auto Zero Calibration” screen Example In case where setting the auto calibration components (see Item 6.2.4) to “CH1: enable”, “CH2: enable” and “CH3 to CH5:disable” ZERO cal. • Zero calibration 0-100 0 3 . ZERO cal. A message, “Zero cal.” blinks 0-100 at CH1 and CH2.
6.6 Peak alarm setting When the peak number of times CO concentration exceeds the upper limit value during measure- ment exceeds the set number, an alarm is provided. The peak alarm and this setting screen appear only when an option is added. MODE q Press the key in the Measurement...
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Action of peak alarm Example If CO concentration exceeds the alarm value, counting will begin. If the number of peaks is over the set times per hour, a peak alarm contact output becomes closed (ON). If it is less than the set times per hour, it is open (OFF).
6.7 Parameter setting It allows you to carry out the parameter setting such as time, key lock, etc., as required. Items to be set are as follows: Description of setting items • Current Time : Sets the current day of the week, hour and time. •...
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r In the Parameter Setting screen that appears, enter the numeric values and set the items. Entering the numeric values or setting the items should be carried out by using the key. To move the cursor to the right, press the key.
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(2) Auto calibration Auto calibration start Auto calibration end Calibration Hold extending time. Output hold Time hold set to the gas flow time (3) External hold Close Open Remote hold Output hold Note) With the external hold input, auto calibration status and maintenance status contact are conductive.
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Average period It allows you to set an average period of the average value of O correction and O average. It enables you to set an average time of 1 to 59 minutes (1-minute step) or 1 to 4 hours (1-hour step).
6.8 Maintenance mode This mode is used for check of sensor input values, display of error log files or setting of pass- words, etc. First, enter a password and then use it from the next operation. This mode is displayed by selecting the Maintenance Mode from “Item 6.7 Parameter Setting”.
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• Password Setting screen Description of Password Setting screen It enables you to set a password to be used when switching the parameter setting mode to the maintenance mode. Note) The password set herein must be managed for safety. Failure to enter the correct password will not open the Maintenance mode.
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Caution Since an interference compensation detector is not provided if the 1st range is beyond 0 to 10 vol%, no interference adjustment can be performed (no need). • Setting of O correction reference value Set the O correction reference value by selecting a numerical value by key or shifting a digit by...
6.9 Calibration ZERO 6.9.1 Zero calibration It is used for zero point adjustment. For zero calibration gas, suited for an application should be used according to “(3) Standard gas in Item 3.3 Sampling”. q Press the key on the Measurement ZERO screen to display the Manual Zero Cali- bration screen.
6.9.2 Span calibration It is used to perform a span point adjustment. Supply calibration gas with concentration set to the span value to perform the span calibration. For the span calibration gas for the NO , SO , CO CO measurement, use the standard gas with a concentration of 90% or more of the range value. For the span calibration gas for the O measurement, use the standard gas with a concentration of 90% or more of the range value when measuring with the built-in O...
7. MAINTENANCE 7.1 Daily check (1) Zero calibration and span calibration q Perform zero calibration. For the calibration procedures, refer to “Item 6.9.1 Zero calibra- tion”. w Then, perform span calibration. For the calibration procedures, refer to “Item 6.9.2 Span calibration”.
7.3 Maintenance of analyzer unit 7.3.1 Cleaning method for sample cell (pipe cell) This section is strictly factory adjusted. Handle it with utmost attention. If it is absolutely required, contact us. q Turn off the power switch, stop the sample gas, and allow the zero gas to flow for several minutes to purge the cell interior.
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Infrared transmission Bonded together window Window holder O ring Sample gas inlet Cell Sample gas outlet Fig. 7-1 Structure of sample cell (pipe cell) 7 - 3 INZ-TN2ZKJ-E...
7.3.2 Cleaning method for sample cell (block cell) q Turn off the power switch, stop the sample gas, and allow the zero gas to Top cover flow for several minutes to purge the cell interior. Loosen the setscrew (2 pieces) from the top cover and remove it.
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Cell mounting tool Window fixture O ring holder Outer O ring Inner O ring Infrared transmission window Sample gas inlet Sample gas outlet Reference cell unit Sample cell unit Hole for bolt for fixing together with distribution cell and detector Structure of sample cell (of 32, 16, 8, 4, 2 mm long) (sample cell and reference cell are integrated) Note) Use the dedicated cell mounting tool (furnished).
7.3.3 Optical zero adjustment method (optical balance adjustment) Caution If the following operation is maladjusted, the measurement may adversely be affected. If you are not trained for adjustment, do not carry out this operation but contact the distributor or our service- man.
e Carry out the adjustment in the procedure in r and subsequent. • When optical system 1 is adjusted. Get the values at a to d in 1-1 and 1-2 within ± 50 and as near 0 as possible. • When optical system 2 is adjusted. Get the values at e to h in 2-1 and 2-2 within ± 50 and as near 0 as possible.
w Display the moisture interference compensation screen of the analyzer unit (see “6.8 Mainte- nance mode”). Then, introduce bubbled N or air gas to the analyzer (shown on right). e On the screen, select a CH (component) by “ ” key, press the “ ”...
8 TROUBLE SHOOTING FOR ANALYZER 8.1 Error message If errors occur, the following contents are displayed. Error display Error contents Probable causes Error No.1 Motor rotation detection signal • Motor rotation is faulty or stopped. faulty • Motor rotation detector circuit is faulty. Note) Sector motor is a consumption part.
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In case of Error No. 5 and No. 7 • Pressing delete the error display. Calibrated forcedly Calibration is continued. Unless another calibration 9 0 8 0-25 error occurs, calibration is carried out to the end, the 1 3 6 Measurement screen returns.
SPECIFICATIONS General specifications Contact output: 1a contact (250V AC/2A, resistive load) Instrument error, calibration error, range 1. Standard specifications discrimination, auto calibration status and Measurable component and measurement range: maintenance status, pump ON/OFF, peak alarm. Minimum range Maximum range 1c contact (250V AC/2A, resistive load) 0 to 100 ppm 0 to 5000 ppm Upper/lower alarm contact output.
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2. Standard Functions Auto zero calibration cycle setting: Auto zero calibration cycle is set. Output signal holding: Setting is variable within 1 to 99 hours (in increments Output signals are held during manual and auto calibrations of 1 hour) or setting is variable within 1 to 40 days (in by activation of holding (turning "ON"...
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6. Installation Requirements Average value resetting: The above-mentioned output of average value is started • Select a place where the equipment does not receive from the initial state by applying a no-voltage rectangular direct sunshine, draft/rain or radiation from hot sub- wave to the average value resetting input terminals stances.
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17 18 19 20 21 22 23 Digit Description <Measurable range> 4th component, 1st range None 0 to 100ppm 0 to 200ppm 0 to 250ppm 0 to 500ppm 0 to 1000ppm 0 to 2000ppm 0 to 5000ppm 0 to 1% 0 to 2% 0 to 3% 0 to 5%...
9.3 Outline diagram <Analyzer main unit> <Upper> <Side> M4(for mounting slide rail) Power switch Sample gas outlet Rc1/4 or NPT1/4 Sample gas inlet Rc1/4 or NPT1/4 DISPLAY <Front> Switch for back light <Rear> Connector for input/output terminal module Power inlet 9 - 6 INZ-TN2ZKJ-E...
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* The slide rails are attached to this equipment Outline diagram of accessory slide rail (unit: mm) when designated. Closed Model: 305A-24/Accuride International Inc. Cabinet member The same or less 1.5t (22.7) Intermediate Open member Drawer member 609.6±0.3 1.5t 15.9±0.3 577.8±0.3 577.8±0.3 577.8±0.3...
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