User's Manual IR400 Infrared Gas Analyzer IM 11G02N01-01E IM 11G02N01-01E Yokogawa Electric Corporation 3rd Edition
PREFACE We are grateful for your purchase of Yokogawa’s Infrared Gas Analyzer, Model:IR400. • First read this instruction manual carefully until an adequate understanding is acquired, and then proceed to installation, operation and maintenance of the analyzer. Wrong handling may cause an accident or injury. • The specifications of this analyzer are subject to change without prior notice for further product improvement.
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”. DANGER Improper handling may cause dangerous situations that may result in death or serious injury.
Caution on piping DANGER Be sure to observe the following precautions while installing piping. Improper piping may result in gas leakage. If the leaking gas contains a toxic component, serious accidents may result. If it contains combustible gases, explosion or fire may result. • Connect pipes correctly referring to the instruction manual. • Discharge the exhaust gas outdoors to prevent it from remaining within the sampling device or indoors.
Caution on use PROHIBITION • Do not touch the input/output terminals with metal or finger. Otherwise, electric shock or injury may result. • Do not smoke or use flames near the analyzer. Otherwise, fire may result. • Do not allow water to enter the analyzer. Otherwise, electric shock or internal fire may result.
r After - Sales Warranty d Do not modify the product. d During the warranty period, for repair under warranty carry or send the product to the local sales representative or service office. Yokogawa will replace or repair any damaged parts and return the product to you. d Before returning a product for repair under warranty, provide us with the model name and serial number and a description of the problem. Any diagrams or data explaining the problem would also be appreciated.
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CONTENTS PREFACE.............................................................................................................................. i Caution on safety ................................................................................................................. ii r After - Sales Warranty ................................................................................................... v Contents ................................................................................................
6.2.4 Setting of auto calibration component/range .......................................... 6-9 6.3 Alarm setting ................................................................................................. 6-11 6.3.1 Setting of alarm values .......................................................................... 6-11 6.3.2 Hysteresis setting ................................................................................... 6-13 6.4 Setting of auto calibration ......................................
1. OVERVIEW This infrared gas analyzer (type: IR400) measures the concentration of NO, SO2, CO2, CO and CH4 contained 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.
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2. NAME AND DESCRIPTION OF EACH UNIT 2.1 Name and description of main unit Front panel POWER (1) Handle (4) Sampling gas inlet (5) Sampling gas outlet (4) Sampling gas inlet (5) Sampling gas outlet (or purge gas inlet) (2) Power switch (3) Display/operation panel For measuring unit 1 For measuring unit 2 Back panel (6) Sector motor (10) Protective cover (9) Power inlet (7) Light source cover (8) Input/output terminal connector Fig.
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. Input/Output terminal module (2) Input/Output terminal block (TN1 to TN5) (1) Mounting hole (φ4.
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. • The gas analyzer is heavy. It should be installed with utmost care. Otherwise, it may tip over or drop, for example, causing accident or injury.
3.2 Installation 3.2.1 Installation of analyzer main frame Installation methods for the analyzer main unit are divided into 2 types; Type External dimensions Mounting dimensions (Unit : mm) Mounting method 101.6 177 19 inch rack mounting guide rail method M6 Slide rail (Supports mass) 429 19 inch rack mounting slide rail method 483 450 or more 465 Slide rail (Supports mass) Note 1 Check and maintenance of the analyzer main unit may be carried out with the top cover detached.
3.2.2 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. External dimensions 4.
3.3 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. The instrument provides inaccurate indication due to gas absorption by piping materials. • Pipe connection port is Rc1/4 female thread (or 1/4 NPT).
Internal piping diagram Measuring unit 2 Measuring unit 1 Built-in O2 sensor Built-in O2 sensor OUTLET INLET OUTLET INLET Sampling gas inlet Sampling gas outlet Sampling cell Note) 2 cells may be used by combination of range. Sampling gas inlet Sampling gas outlet For measuring unit 1 For measuring unit 2 Note) When the purge gas inlet is provided, the piping to measuring unit 2 is built inside.
Example of connecting each measuring unit ? One pair of gas inlet/outlet IR400 Sampling gas Filter Flow meter 0.5L/min Sampling gas inlet Sampling gas outlet Exhaust Release to atmosphere. ? Two pair of gas inlet/outlet - (1) IR400 Sampling gas NO2/NO converter Filter Sampling gas inlet Flow meter 0.5L/min For measuring unit 1 Sampling gas outlet Filter Sampling gas inlet Flow meter 0.
3.4 Sampling 3.4.1 Conditions of sampling gas 1. 2. 3. 4. 5. 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 0.3mm. Dew point of sampling gas must be lower than the ambient temperature to avoid occurrence of drain in the gas analyzer. If vapor is contained in the sampling gas, dew point should be lowered to 0°C by using a dehumidifier.
3.4.6 Pressure at sampling gas outlet Pressure at the sampling gas outlet should be adjusted to atmospheric pressure. 3.4.7 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 Yokogawa for system configuration matching the particular use or further information.
3.5 Wiring 3.5.1 Power inlet The power inlet is provided at the rear panel. Connect supplied power cable to this power inlet. Rear panel Power inlet Input/output terminal connector Grounding 2-pole plug When noise source is in the vicinity • Avoid installing this instrument near an electrical unit (high frequency furnace or electric welder) that generates much electrical noise.
(1) Analog output signal (AO): terminal block 1, 1 to 20, terminal block 2, 3 to 6. Output signal: 4 to 20 mA DC or 0 to 1 V DC (selected when ordering) Non-insulated output Allowable load: 4 to 20 mA DC, 550Ω or less 0 to 1 V DC, 100kΩ or more • Analog output is provided from each terminal corresponding to the channel displayed in the measurement screen. All of analog output signals for the instrument are not isolated.
(5) List of terminal blocks Terminal block 1 Ch5 output — (Ch5_OUT) + 1 11 2 12 Ch4 output — (Ch4_OUT) + 3 13 4 14 Ch3 output — (Ch3_OUT) + 5 15 6 16 Ch2 output — (Ch2_OUT) + 7 17 8 18 9 19 10 20 Ch1 output — (Ch1_OUT) + Terminal block 2 Note 1 Ch10 output (Ch10_OUT) O2 sensor input — (O2_IN) + 1 11 2 12 Ch9 output (Ch9_OUT) Ch12 output (Ch12_OUT) 3 13 4 14 — Ch8 output + (Ch8_OUT) Ch11 output (Ch11_OUT) 5 15 6 16 — Ch7 output + (Ch7_OUT) Unassigned
(6) Description on terminal block Terminal block 1 Terminal block 1 Ch5 output — (Ch5_OUT) + 1 11 2 12 Ch4 output — (Ch4_OUT) + 3 13 4 14 Ch3 output — (Ch3_OUT) + 5 15 6 16 Ch2 output — (Ch2_OUT) + 7 17 8 18 Ch1 output — (Ch1_OUT) + 9 19 10 20 — Ch10 output + (Ch10_OUT) — Ch9 output + (Ch9_OUT) — Ch8 output + (Ch8_OUT) — Ch7 output + (Ch7_OUT) — Ch6 output + (Ch6_OUT) (M3.
Terminal block 3 1 11 2 12 3 13 4 14 Remote hold input (R_HOLD) 5 15 6 16 Average value reset input (RESET) 7 17 8 18 9 19 10 20 Unassigned Unassigned Auto calibration remote start input (R_CAL) Ch5 range identification contact output (RNG_IDCh5) Terminal block 3 Between 1–4: For internal connection. Must not be wired. (Must not be used as junction terminal.) Between 5–6: Remote hold input. No hold when open. Output hold when short-circuited.
Terminal 4 Terminal block 4 Peak count alarm output (PEAK_ALM) 1 2 12 Auto calibration status/contact output (CAL) 3 13 4 14 Pump ON/OFF contact output (PUMP) 5 15 6 16 Calibration error contact output (CAL_ALM) 7 17 8 18 9 19 10 20 Instrument error contact output (FAULT) Between 1–2: 11 Unassigned It is conductive when peak count exceeds the setting time. It remains open below the setting time. For setting and operation, refer to “Item 6.6 Peak alarm setting”.
Terminal 5 Between 2, 3 and 4: Terminal block 5 Unassigned Ch3 alarm output (ALM_Ch3) Ch2 alarm output (ALM_Ch2) Ch1 alarm output (ALM_Ch1) 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 (M3.5 screw) Ch3 alarm output Unassigned Power disconnection alarm output (POWER_OFF) Ch5 alarm output (ALM_Ch5) When the output exceeds the set value, it is conductive between 2 and 3, and open between 3 and 4. Otherwise, it is open between 2 and 3 and conductive between 3 and 4.
Connector Solenoid valve drive signal output for calibration Connector (Transister output) Contact output for sample gas selection 1 Contact output for Ch3 6 span calibration Contact output for Ch4 7 span calibration Contact output for Ch5 8 span calibration 2 Contact output for zero calibration 3 Contact output for Ch1 4 span calibration Contact output for Ch2 5 span calibration 9 Power for relay drive 5V DC Connector provides outputs in combination with calibration action
(7) Timing of solenoid valve drive signal for calibration 1. Manual calibration (see “Item 6.9 Calibration”.) ¥ Zero calibration ZERO ENT Calibration end ENT on Pump ON/OFF contact off on Sample selection output off on Zero calibration output Calibration gas flow off Ch1 to 5 span calibration output off Output hold function Output signal hold (with hold ON setting) Hold extension time. ¥ Span calibration SPAN Pump ON/OFF contact When selecting Ch2 using and keys.
2. In case of automatic calibration (example shown in Item 6.4.
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 1) 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. 2) Wait for about 4 hours until the instrument is warmed up.
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5. 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 MODE ESC ZERO ENT SPAN Fig. 5-1 Name Description Name Description (1) MODE key Used to switch the mode. (5) ESCAPE key Used to return to a previous screen or cancel the setting midway.
5.2 Overview of display and operation panels • Measurement mode 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).
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 configuration as shown as an example is for NO, SO2, CO2, CO and O2 (output: 12 channel). (2) (1) (2) (1) Ch Ch Ch Ch Ch Ch Ch Ch Ch (3) * (4) (5) (6) (3) (7) (8) (4) corrected instantaneous value ..... CV. ** corrected average value ............... CV. AV. Fig.
• Instantaneous value and concentration value: The concentration display of Ch (component) where sampling components such as “CO2”, “CO” or “O2 are displayed in the component display, indicates current concentration values of the measured components contained in gas that is now under measurement.
IM 11G02N01-01E 5-5 CO CH4 NO NO CO2 NO NO NOx SO2 CO CH4 NOx NOx CO2 NOx NOx CO NO CO2 NO NO Not specified Not specified Not specified Not specified Not specified Not specified Not specified Not specified /K /K /K /K /K /K /K /K /K except /K except /K except /K except /K except /K N N N N N N N N 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 -D -F -G -H -J -K -L -A -B -D -F -G -H -J -
5.4 General operation • Measurement mode The measurement mode can be displayed up to 5 channels in a single screen. If 5 channels or more are to be displayed in a single screen, press the or key to scroll the channel one by one. Ch NOX 0-100 Ch SO2 Ch CO2 Ch CO 0-100 0-10 0-100 Ch O2 0-25 0. 0 0. 0 0. 0 0 0. 0 0. 0 0 ppm ppm vol% ppm vol% ZERO Ch NOX 0-100 Ch SO2 0-100 Ch CO2 Ch CO 0-10 0-100 Ch O2 0-25 0. 0 0. 0 0. 0 0 0. 0 0. 0 0 ppm Zero calibration See 6.9.1.
6. SETTING AND CALIBRATION 6.1 Switch of range 6.1.1 Setting of range switch mode MODE Set the range switch mode as follows. (1) Press the MODE key in measurement mode to display the User mode screen. (2) Move the cursor to “Switch Ranges” and press the ENT key. ENT (3) The “Channel Selection” screen appears. Move the cursor by pressing the or key on the channel selection the screen that appears, and select Ch (component). (4) Then press the ENT key.
6.1.2 Manual range switch The range of the measured component can be switched manually as follows. (1) Select “MR” as range switch mode, and then press the ENT key. ENT (2) Move the highlight of the cursor to range selection, and then select a desired range by pressing the or the key. (The mark indicates the currently selected range.) (3) Then press the ENT key, and the measurement is carried out in the selected range.
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. MODE (1) During measurement, press the MODE key to display the User mode.
(5) In the “Calibration Concentration Selection” screen that appears, select any concentration , item you want to set by pressing the key. Then press the ENT key, and the selected value is highlighted. ENT Cursor for setting value (6) In the “Calibration Concentration Value Setting” screen that appears, enter calibration gas concentration values (zero and span). For value entry, press the or key, and a 1-digit value increases or decreases. By pressing the , the digit moves.
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 (1) During measurement, press the to display the User mode. MODE key (2) Point the cursor to “Calibration Paramor key. Press eters” by pressing the the key.
(5) In the “Manual ZERO Calibration Selection” screen that appears, select “at or once” or “each” by pressing the key. When selecting “at once”, the Ch (components) to be set can be zerocalibrated at the same time. When selecting “each”, either of the Ch (components) to be selected is zero-calibrated. After setting, press the ENT key. To close the setting To close the manual zero calibration setting or to cancel this mode midway, press the ESC ESC key. A previous screen will return.
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 (1) During measurement, press the display the User mode. MODE key to (2) Point the cursor to “Calibration or Parameters” by pressing the key. Press the key.
(5) On the “calibration range selection” screen that appears, select “both” or “current” by pressing the or the key. • If “both” is selected, zero or span calibration is performed with Range 1 and Range 2 of the selected Ch interlocked. • If “current” is selected, zero or span calibration is performed only for the range displayed when calibration of selected Ch is performed. Press the key after the selection, and the specified calibration is performed.
6.2.4 Setting of auto calibration component/range Select the Ch (component) and the range with which auto calibration is to be performed. The Ch for which “AR” has been selected as range switch mode is calibrated in the range set here even when auto calibration is performed. MODE (1) During measurement, press the to display the User mode. MODE key (2) Point the cursor to “Calibration Parameters” by pressing the or key. key.
(5) The cursor next to the range of the selected Ch (component) is highlighted. Select the range to be calibrated mainly by pressing the or the key. (6) Then press the key, and calibration is performed in the selected range. ENT To close "Auto Calibration Component/range" setting Auto calibration and the manual calibration of the component with which “AR” has been selected as range switch mode are performed in the range selected here.
6.3 Alarm setting 6.3.1 Setting of alarm values The High/Low limit alarm output setting for the measured concentration and power off alarm (alarm 6 only) setting can be made during measurement. Arbitrary 6 alarm contact outputs can be used. To change alarm setting, set the alarm ON/OFF setting to OFF, and then change the value. MODE (1) During measurement, press the to display the User mode. MODE key (2) Point the cursor to “Alarm Setting” by or key. Press the pressing the key.
(5) After setting, the alarm setting is now completed by pressing the ENT key. Cursor for setting value To close the "Alarm Setting" To close the “Alarm Setting” or to cancel this mode midway, press the ESC key. A previous screen will return. Setting range 0% to 100% FS (Settable in each range). ENT End of Alarm Setting Description of setting items The alarm contact assigned the same number as the alarm is operated accordingly.
6.3.2 Hysteresis setting To prevent chattering of an alarm output near the alarm setting values, set the value of hysteresis. (1) In the “Alarm No. Selection” screen that appears, point the cursor to “Hysteresis” or key. Press the by pressing the key. ENT ( ) ENT (2) In the “Hysteresis Value Setting” screen that appears, enter hysteresis values. For the value entry, 1-digit value is increased or decreased by pressing the or key, and pressing the key moves the digit. After setting, 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. 1. During measurement, press the to display the User mode. MODE MODE key 2. Point the cursor to “Setting of Auto Calibration” by pressing the or key. Press the key. ENT 3.
setting (1) Press the key in a state where the cursor is placed next to “Flow Time,” and the flow time setting screen shown at right appears. ENT MODE (2) On the flow time setting screen that appears, move the cursor to the gas you want to change the setting by pressing the or the key, and then press the key. ENT ( ) ENT (3) The highlighted value can be changed. or Change the value by pressing the the key, and then move the cursor to key.
Auto calibration status contact output is closed during auto calibration (including Ex. time), and is open in other cases. Example Start Time Cycle Flow Time SUN 1 Zero Ch1 Span Ch2 Span Ch3 Span Ch4 Span Ch5 Span EX. time ON ON/OFF 12:00 day 350 sec 350 sec 350 sec 350 sec 300 sec 300 sec 300 sec In case where auto calibration is carried out at the above setting.
6.4.2 Forced run/stop of auto calibration Auto calibration can be performed just once or forcibly stopped while the calibration is performed. 6.4.2.1 Execution of auto calibration (only once) (1) Display the User mode screen. Move the cursor to “Setting of Auto Calibration” by pressing the or the key, and key. then press the ENT ( ) ENT (2) In the “Setting of Auto Calibration” item selection screen that appears, point the cursor to “Auto Calibration Run” by or key. Press the pressing the key.
6.4.2.2 Forced stop of auto calibration This mode is used to stop the auto calibration forcedly. (1) In the User mode that is displayed, point the cursor to “Setting of Auto Calibration” by pressing the or key. Press the key. ENT ( ) ENT ( ) ENT (2) In the “Setting of Auto Calibration” item selection screen that appears, point the cursor to “Auto Calibration Stop” by pressing the or key. Press the key.
“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 A message, “Zero cal.” blinks at Ch1 and Ch2. Ch NOX ZERO cal. 0-zero100 Ch SO2cal. ZERO 0-100 Ch CO2 Ch CO 0-10 0-100 Ch O2 0-25 • Ch1 span calibration A message, “Span cal.” blinks at Ch1. Ch NOcal. X SPAN 0-100 Ch SO2 Ch CO2 Ch CO Ch O2 0-100 0-10 0-100 0-25 • Ch2 span calibration A message, “Span cal.” blinks at Ch2.
6.5 Setting of auto zero calibration 6.5.1 Autozero 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 calibration component in Item 6.2.4. Before changing the setting of auto zero calibration, set the ON/OFF to OFF. (1) During measurement, press the to display the User mode.
Auto calibration status contact output is closed during auto zero calibration, and is open in other cases. Example Start time Cycle Flow time ON/OFF SUN 12 300 ON 12:00 hour sec In case where auto zero calibration is carried out at the above setting. Sunday 12:00 Cycle Monday 0:00 Monday 12:00 : Auto zero calibration ReplaceZero calibration ment time 300sec 300sec Flow time Gas replacement time after calibration is the same as the flow time.
6.5.2 Forced run/stop of auto zero calibration Auto zero calibration can be performed just once, or auto zero calibration can be forcibly stopped during calibration. 6.5.2.1 Execution of auto zero calibration (just once) (1) Move the cursor to “Setting of Auto Zero Calibration” by pressing the or the key on the user mode screen, and key.
6.5.2.2 Forced stop of auto zero calibration This mode is used to cancel the auto zero calibration forcedly. (1) In the User mode that is displayed, point the cursor to “Setting of Auto Zero Calibration” by pressing the or key. Press the key. ENT ( ) ENT ( ) ENT (2) In the “Setting of Auto Zero Calibration” item selection screen that appears, point the cursor to “Auto Zero Calibration Stop” by pressing the or key. Press the key.
“Auto Zero Calibration” screen Example In case where setting the auto calibration components (see Item 6.2.4) to “Ch1: enable” and “Ch2: enable” Ch • Zero calibration Ch A message, “Zero cal.” blinks at Ch1 and Ch2. ZERO cal. cal. ZERO 0-100 ZERO cal. cal. ZERO 0-100 Ch 0-10 Ch . 0-100 Ch 0-25 0.5 0.3 0.0 0 0.0 2 1.0 2 ppm ppm vol% ppm vol% Caution During auto zero calibration, any key operation is not permitted other than operations such as key lock ON/OFF and “Stop Auto Zero Calibration.
6.6 Peak alarm setting When the peak number of times CO concentration exceeds the upper limit value during measurement exceeds the set number, an alarm is provided. The peak alarm and this setting screen appear only when an option is added. MODE 1. Press the key in the Measurement mode, and the User mode appears. MODE 2. Point the cursor to “Setting of Peak Alarm” by pressing the or key. Press the key. ENT ( ) ENT ( ) ENT ( ) ENT 3.
Setting range Alarm value : 10 to 1000 ppm Alarm count : 1 to 99 times Hysteresis : 0 to 20 % of full scale 5 ppm step (initial value: 500 ppm) (initial value: 5 times) (initial value: 0% of full scale) [% full scale] represents the percentage with the CO range regarded as 100%. 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).
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 • Key Lock • Output Hold • Reset Av. Output • Response time • Average Period • Backlight Timer • Maintenance mode : Current year, month, date, day of the week, hour, and minute setting (The display appears in this order.) Note: The clock backup time is 2 days.
4. 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 or key. To move the using the key. cursor to the right, press the key, that the After setting, press the parameter setting is carried out with the value you set. ENT To close Parameter Setting screen To close the “Parameter Setting” screen or cancel this mode midway, press the ESC key. A previous screen will return.
(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 Remote hold Input Close Open Output hold (4) Screen display during Holding The “on Hold” message blinks on the measuring screen.
(6) You can select the value for hold from the value immediately before entering output hold, “current,” and arbitrary value, “setting.” Follow the procedures shown below to make the setting. 1) Press the ENT key in a state where the cursor is placed next to Hold. ENT 2) “ON” or “OFF” is highlighted. Press the or the key to select ON or OFF. key to return to (1). Press the ENT ( ) ENT key in a state ON/OFF is 3) Press the highlighted, and “Current” or “Setting” is highlighted.
( ) ENT ( ) ENT 5) On the parameter hold screen that appears, move the cursor next to the Ch (component) you want to make the setting by pressing the or the key, key. and then press the ENT 6) The value is highlighted, indicating that the value can be changed. Change the or the key, value by pressing the and then move the cursor to the right by pressing the key. 7) After the value is changed, press the key. Meaning of setting The setting is expressed in % against the range for both ranges.
Average value reset This mode is used to clear all average values O2 correction average and O2 average, and restarts averaging. All average values are reset at a time. The indication value and output value is 0 ppm, vol% or so at the time of the reset input (Refer to the average peripd). Close (hold at least 1.5 sec.) Reset input Open So long as close, resetting lasts. At the edge of changing from closing to opening, the average action restarts.
Example of average action In case the average period was set to 1 hour. Reset Average value Time 1 Time • Sampling occurs every 30 seconds. • Every 30 seconds, the average for last 1 hour (time setting) is output. • At the instant of resetting, zero is assumed for all past values. It means that the average value will not be correct for 1 hour after resetting. Backlight Timer Automatic OFF setting of the backlight of the LCD unit can be made.
6.8 Maintenance mode This mode is used for check of sensor input values, display of error log files or setting of passwords, 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”. (1) Select the Maintenance mode from the Parameter Setting screen to display the Password Setting screen. (2) Enter the password, and the Maintenance Mode item selection screen will be displayed.
• Calibration Log screen Description of Calibration Log screen Past calibration history. Sensor input value, concentration value, and the date when zero/span calibration is performed are logged. The 10 newest calibration data is logged by each component. Move the cursor to Clear Calibration Log and press the ENT key, and the calibration log is cleared completely.
• Moisture interference adjustment screen For details of this item, refer to “Item 7.3.4 Moisture interference adjustment method.” Description of moisture interference adjustment screen In values on the left side of screen, the moisture interference for each component is already offset. The figures at right are interference compensation coefficients. Move the cursor to a desired Ch (compoor the key, and nent) by pressing the key, and the selected value then press the at right is highlighted.
• Output adjustment screen Description of output adjustment screen Analog output adjustment screen. Connect the digital multi meter to the output terminal corresponding to the number of OUT to be adjusted, and adjust the value so that 4mA or 0V is output at zero and 20mA or 1V is output at span. Move the cursor using the , , or the key to the output (OUT No. and zero/ span) to be adjusted, and then press the key. ENT ENT The selected value is highlighted.
• Other parameter Description of each setting screen Password Set : Set the password used to move from the parameter setting screen to the maintenance mode. Arbitrary 4-digit number can be selected. O2 ref. Value : Set the oxygen concentration reference value at the time of oxygen correction calculation. Settable in the range from 00 to 19%. Limit : Set the oxygen concentration limit at the time of oxygen correction calculation. Settable in the range from 01 to 20%.
The measuring range can be arbitrarily selected in the minimum and the maximum range specified at the time of purchase. The range to be used can be selected 1 or 2. (1) Move the cursor to the item to be set by pressing the or the key, and then press the key. ENT ( ) ENT ( ) ENT (2) Move the cursor to the Ch (component) whose or setting is to be changed by pressing the key, and then press the key.
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.” (1) Press the key on the Measurement screen to display the Manual Zero Calibration screen. ZERO (2) Select the Ch (component) to be or key. calibrated by pressing the key, and After selection, press the zero gas will be supplied.
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 NOX, SO2, CO2, CO measurement, use the standard gas with a concentration of 90% or more of the range value.
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7. MAINTENANCE 7.1 Daily check (1) Zero calibration and span calibration 1. Perform zero calibration. For the calibration procedures, refer to “Item 6.9.1 Zero calibration”. 2. Then, perform span calibration. For the calibration procedures, refer to “Item 6.9.2 Span calibration”. 3. Zero calibration and span calibration should be carried out once a week, as required. (2) Flow rate check 1. Sampling gas flow and purge gas flow are as follows: • Sampling gas flow: 0.5 ± 0.
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. (1) Turn off the power switch, stop the sample gas, and allow the zero gas to flow for several minutes to purge the cell interior. Loosen the setscrew (2 pieces) from the top cover and remove it. Top cover (2) Remove the internal gas inlet tube. (3) Loosen both right and left screws for cell holding plate.
Infrared transmission window Bonded together Window holder O ring Sample gas inlet Cell Sample gas outlet Fig.
7.3.2 Cleaning method for sample cell (block cell) (1) Turn off the power switch, stop the sample gas, and allow the zero gas to flow for several minutes to purge the cell interior. Top cover Loosen the setscrew (2 pieces) from the top cover and remove it. (2) Remove the internal gas inlet tube. F10.12E.eps (3) Loosen the 2 detector set bolts. Note) The distribution cell, block cell and detector are fastened by the same bolts.
Cell mounting tool Window fixture O ring holder Outer O ring Inner O ring Infrared transmission window Sample gas outlet Sample gas inlet 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). Fig.
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 serviceman. The adjustment is performed at reassembly after removing the sample cell, etc. for cleaning, etc. (1) Remove the top cover. Allow dry N2 or air to flow through the analyzer unit sample gas inlet until the reading stabilizes.
(3) Carry out the adjustment in the procedure in (4) and subsequent. • Adjust on the primary side of the optical system so that the values for a to d in 1-1 and 1-2 become as close to 0 as possible within ±100 range. • Adjust on the secondary side of the optical system so that the values for e to h in 2-1 and 2-2 become as close to 0 as possible Optical zero adjustment knob within ±100 range. (4) Operate the optical zero adjustment knob to change the value displayed at a (or e ).
(2) Display the moisture interference compensation screen of the analyzer unit (see “6.8 Maintenance mode”). Set the dew point to 28C by using an electronic cooler, and introduce bubbled N2 or air gas to the analyzer (shown on the figure). (3) On the screen, select a desired Ch key, (component) by pressing the adjust the value at right by pressing the or the key so that the value at left falls within ±10 (make it as close to 0 as possible), and then press the key to memorize the value.
7.4 Inspection and maintenance of limited service-life components The analyzer uses limited-life components. The recommended replacement periods are listed in the below table. (1) Limited service-life components are those which wear out or for which failure is presumed within five years under normal operating or storage conditions. Components with more than five years of service life are the exception.
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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 faulty • Motor rotation is faulty or stopped. • Motor rotation detector circuit is faulty. Note) Sector motor is a consumption part. It is recommendable to exchange the motor once two years. Error No.4 Zero calibration is not within. Error No.
In case of Error No. 5 and No. 7 ENT • Pressing ESC delete the error display. ENT ESC Calibrated forcedly Calibration is continued. Unless another calibration error occurs, calibration is carried out to the end, the Measurement screen returns. Ch 9 0.8 1 3.6 0.0 0 0 0.0 0.0 9 Ch Ch Ch Ch Error log file If error occurs, the history is saved in an error log file. The error log file exists in the maintenance mode. Error log screen Date and time when an error occurred.
8.2 Troubleshooting The following table shows how to remedy other troubles, such as faulty readings. Symptom Checking Item • Check if the zero gas is supplied to the Zero calibration fails. Error No. 4, 5, or 8 occurs. analyzer at the specified flow rate. • Check the optical balance. (See Subsection 7.3.3, "Optical zero adjustment method.") • Check the count value on the display panel. (Refer to the sensor input value by maintenance mode.) • Check if the span gas is supplied to the Span calibration fails.
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9. SPECIFICATIONS 9.1 General specifications 1. Standard specifications Measurable gas components and measuring range: Minimum range 0 – 50ppm 0 – 50ppm 0 – 20ppm 0 – 50ppm 0 – 200ppm Maximam range 0 – 5000ppm 0 – 10vol% 0 – 100vol% 0 – 100vol% 0 – 100vol% O2 (built in) 0 – 5vol% 0 – 25vol% O2 (External Zirconia) 0 – 5vol% 0 – 25vol% NO SO2 CO2 CO CH4 • Max. 5 components measurement including O2.
2. Standard Functions Output signal holding: Output signals are held during manual and auto calibrations by activation of holding (turning “ON” its setting). The values to be held are the ones just before start calibration mode or setting value. It is selectable. Indication of instantaneous values will not be held. Remote output holding: Output signal is held at the latest value or setting value by short-circuiting the remote output holding input terminals.
3. Optional function 4. Performance Repeatability : ±0.5% of full scale Linearity : ±1% of full scale Zero drift : ±1% of full scale/week (±2% of full scale/week; range between 0 to 50ppm and 0 to 200ppm) (±2% of full scale/day; smaller than 0 to 50ppm range) Span drift : ±2% of full scale/week (±2% of full scale/day; smaller than 0 to 50ppm range) Response time (for 90% FS response) : Within 60 seconds including replacement time of sampling gas (when gas flow rate is 0.
Span gas ; For other than O 2 measurement, each sample gas having concentration 90 to 100% of its measuring range. For O 2 measurement, O2 gas of 1 to 2 vol%. 6. Installation Requirements • Indoor use. (Select a place where the equipment does not receive direct sunshine, draft/rain or radiation from hot substances. If such a place cannot be found, a roof or cover should be prepared for protection.) • Avoide a place where receives heavy vibration. • Select a place where atmospheric air is clean.
9.
Model and Suffix codes Model IR400 2nd Component 2nd Range (note 2) 3rd Component 1st Range (note 2) 3rd Component 2nd Range (note 2) 4th Component 1st Range (note 2) Suffix code Description Option code Infrared gas analyzer 19-inch rack mounting type with slide rail 0{100 ppm 0{200 ppm 0{250 ppm 0{500 ppm 0{1000 ppm 0{2000 ppm 0{5000 ppm 0{1% 0{2% 0{3% 0{5% 0{10% 0{20% 0{40% 0{50% 0{70% 0{100% Not Available B C D E F G H J K L M P Q R S T U N A B C D E F G H J K L M P Q R S T U N 0{50 ppm 0{100 pp
Model and Suffix codes Infrared gas analyzer 19-inch rack mounting type with slide rail { { { { { { { { { { { { { { { { { 0 100 ppm 0 200 ppm 0 250 ppm 0 500 ppm 0 1000 ppm 0 2000 ppm 0 5000 ppm 0 1% 0 2% 0 3% 0 5% 0 10% 0 20% 0 40% 0 50% 0 70% 0 100% Not available B C D E F G H J K L M P Q R S T U N 4th Component 2nd Range (note 2) { { { 1 2 3 N O2 Analyzer 1st Range (note 2) 0 5% 0 10% 0 25% Not available { { 2 3 N O2 Analyzer 2nd Range (note 2) 0 10% 0 25% Not available { { -4 -1 Output 4
Table 1.
Table 3. Two-component analyzer (NO and CO) Both NO and CO analyzer must meet the range in Table 1; Single component analyzer. Table 4. Two-component analyzer (CO2 and CO) 2nd component (CO), 1st range A B C 1st component (CO2),1st range 0{50ppm 0{100ppm 0{200ppm D 0{250ppm 3 2.5 31 3 2.5 31 3 2.
9.3 External Dimensions Unit : mm Unit:mm 12.7 (22) 123.8 288.9 315.8 466.7 578 Max. M4 (For mounting slide rail) 26.1 38 Power switch Sample gas outlet Rc1/4 or 1/4NPT INFRARED GAS ANALYZER POWER Sample gas inlet Rc1/4 or 1/4NPT (Purge gas inlet Rc1/4 or 1/4NPT) MODE ZERO ESC ENT SPAN 465 483 429 177 169 100.8 7.5 M5 EIA : 101.
Input/Output Terminal Module: K9218SC (Accessory) Unit: mm Mounting hole 6-[4.5 hole 316 150 8 154 164 (140) 5 12 150 Terminal block Terminal block Terminal block Connector 29 (54.5) Screw terminals M3.
EXTERNAL DEMENSIONS of ACCESSORY SLIDE RAIL Model: 305A-24/Accuride International Inc. Closed 63263 Cabinet member 1.52t Closed position flush or under (22.7) Intermediate member Open (9.5) Drawer member 1.27t 609.660.8 577.860.3 565.160.3 45460.3 111.160.3 15.960.5 12.760.3 (24.4) 35.360.3 25.460.3 12.760.3 4.535.3 4.535.3 123.860.3 288.960.3 15.960.5 19.160.3 466.760.3 F06.EPS 606.660.
STANDARD ACCESSORIES Remark: The Zirconia system, due to its principle, may produce a measuring error due to relative concentration versus the com-bustible O2 gas concentration. Also, a corrosive gas (SO2 of 250 ppm or more, etc.) may affect the life of the sensor.
Dedicated relay board (Option code: /R) Part Numbers This relay board receives signals from connector CN3 of the IR400 I/O terminal module and activates the calibration solenoid valve directly. Item Part No. Description Relay board K9218SF • Relay contact : 1 normally closed contact Contact capacity; 250 V AC/2 A (resistive load) Cable For external contact point K9218SG For relay board Qty 1 1 T10.EPS External Dimensions (Unit: mm) 15 Max. Mounting hole ø4.
NO2/NO Converter Power Consumption: Approx. 85 VA Safety conforming standards: EN61010-1 Pollution degree 2 Installation category II Weight: Approx. 1.1 kg (K9350LE) Approx. 1.2 kg (K9350LF) Sample gas requirements: Dust/drain removed, gas temperature at 1508C or less Part number: K9350LE (Non-CE conformity) K9350LF (CE conformity) Mounting: Indoor surface mounting Target Gases: General boiler exhaust gas, atmosphere Catalyst: Amount; 2 cm3 Replacement cycle; Approx. 12 months (at flow rate of 0.
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Customer Maintenance Parts List Model IR400 Infrared Gas Analyzer 1, 2 Item Parts No. Qty. Description 1 K9218SB 1 Fuse (Time Lag Fuse) 2 K9358QL 1 Fuse holder All Rights Reserved, Copyright © 2002, Yokogawa Electric Corporation. Subject to change without notice. CMPL 11G02N01-01E 1/2 1st Edition : Aug.
2 d Pipe Cell 3 3 d Block Cell 5 4 CMPL 11G02M01-01E Item Parts No. Qty. Description 3 K9358SD 2 O-ring 4 K9358SQ 1 O-ring (Out-side) 5 K9358SR 1 O-ring (Out-side) CMPL 11G02N01-01E 2/2 1st Edition : Aug.
Revision Record Manual Title : IR400 Infrared Gas Analyzer Manual Number : IM 11G02N01-01E Edition Date Remark (s) 1s t Oct. 2002 Newly published 2nd Aug. 2006 Fully revised due to style change to S3 P. v., Added "After-Sales Warranty" Section 2.1, "Name and description of main unit": Changed drawing partly Section 3.4, "Piping": Changed drawing partly Section 3.4.7, "Example configuration of gas sampling system": Changed drawing Section 5.
