INFRARED GAS ANALYZER FOR HEAT TREATMENT FURNACES DATA SHEET ZFG OVERVIEW This gas analyzer (ZFG) is capable of measuring the concentrations of CO2, CO and CH4 components in sample gas. Compact and lightweight design is intended, and a maximum of 2 components are simultaneously measurable. A high-sensitivity mass flow sensor is used in the detector unit of infrared method. Due to use of single beam system for measurement, maintenance is easy and an excellent stability is ensured for a long period of time. In addition, a microprocessor is built in and a large sized liquid crystal display is provided for easier operation, higher accuracy and more functions. This analyzer is thus optimum for combustion control of various heat treatment furnaces. FEATURES 1. Compact and lightweight design is intended, and a maximum of 2 components are simultaneously measurable; 2 components selected from among CO2, CO and CH4. 2.A high stability mass flow sensor is used in the detector; The original optics (measurement block) minimizes drift particularly due to contamination of a measuring cell, so an excellent stability is ensured for a long period of time. 3.Subdued interference from other gas components; Interference from other gas components is insignificant, because the detector is a serial dual-layer type transmission detector. 4.Easy maintenance; Because of single-beam system, the measurement block is simple with no need for optical balance adjustment. Therefore, maintenance is easy. 5.Easy to operate; Operation can be carried out smoothly in an interactive way through a large-size liquid crystal display. 6.Abundant functions; • Zero/span can be accurately calibrated just by pressing the calibration keys. • An error will be detected by self-diagnostic function and indicated by error message. • Besides, a rich variety of functions are provided including CP calculation value output, remote range changeover input, range discrimination signal output and output signal holding. SPECIFICATIONS Standard Specifications • Measuring system: Non-dispersive infrared absorption method with single light source and single beam (single beam method) • Measurable gas components and measuring range: CO2 CO CH4 Min. measuring range Max. measuring range 0 to 0.5％ 0 to 100vol% 0 to 0.5％ 0 to 100vol% 0 to 1％ 0 to 10% • Max. 2 components measurable • 2 ranges selectable • Measuring range ratio ≤ 1:5 max • Measured value indication: Digital indication in 4 digits (LCD with back light, Automatic OFF function) • Instantaneous value of each component • Result display for CP calculation (optional) Display language: Japanese or English selectable • Analog output signals: 4 to 20mA DC, 0 to 1V DC, 0 to 10mV DC or 0 to 100mV DC Non-isolated output Analog output corresponds to measured value indication in 1:1. • Allowable load resistance: 4 to 20mA DC 550Ω or less 0 to 1V DC, 0 to 100mV DC, or 0 to 10mV DC, 100kΩ or more EDS3-134a Date Apr. 1, 2011 ZFG • Contact output: 1a relay contact (250V AC/2A, resistive load) Instrument error (standard), range identification signal (optional) All relay contacts are isolated mutually from the internal circuit. • Contact input (optional): No-voltage contact (ON/0V, OFF/5V DC, 5mA flowing at ON) Remote range changeover input, remote hold input Isolated from the internal circuit with photocoupler. Contact inputs are not isolated from one another. • Power supply: Rated voltage 100 to 240V AC Operating voltage 85 to 264V AC Frequency; 50Hz/60Hz Power consumption; 50VA max. • Operation conditions: Ambient temperature; -5 to 45°C Ambient humidity; 95% RH or less, no condensation • Storage conditions: Ambient temperature; -20 to 60°C Ambient humidity; 95% RH or less, no condensation • Dimensions (H × W × D): 211 x 218 x 257 mm • Mounting dimensions: Panel flash-mount type (vertical mounting on panel) • Weight: About 5 kg • Finish color: Off-white (Munsell 10Y7.5/0.5 or equivalent) • Enclosure: Steel casing, for indoor use • Material of gas-contacting parts: Gas inlet/outlet; SUS304, Sample cell; SUS304/neoprene rubber, Infrared-ray transmitting window; CaF 2, Internal tubing; Toaron • Gas inlet/outlet: Rc1/4 or NPT1/4 internal thread (as specified) • Purge gas flow rate: 1 L/min (to be purged as required) • External terminal: Power terminal; M4 screw, Others; M3.5 screw Performance • Repeatability: Within ±0.5% of full scale • Linearity: Max.±1.0% of full scale (max.±2.0% of full scale when range ratio is 1:4 or 1:5) • Zero drift: Within ±2% of full scale/week • Span drift: Within ±2% of full scale/week • Response time (for 90% FS response): Within 10 seconds • Interference from other gas components: Within ±2% • Warm-up time: Approx. 30 minutes 2 Description of functions • Automatic OFF function (standard): After OFF time is set, the LCD backlight automatically turns off when no key is operated. Press any key to turn on. • Output signal holding (standard): By setting an output hold to ON, analog output signal is held in the value just before the manual calibration. • Instrument error contact output (standard): When the main unit is abnormal, contact signal output is provided. • CP calculation (optional): The carbon potential of carburizing furnace and conversion furnace are calculated using furnace temperature (fixed input value) and CO concentration value (fixed or measured value) while referring to CO 2 measured value. Formula; CP = CPS × (PCO)2 K1 × PCO2 CPS ;Saturated carbon concentration (partial pressure) 0.0028t−1.30 (800°C ≤ t < 850°C) 0.0030t−1.47 (850°C ≤ t < 950°C) 0.0034t−1.85 (950°C ≤ t < 1000°C) t ;Furnace temperature (°C) PCO ;CO concentration value (partial pressure) PCO2;CO2 concentration value (partial pressure) K1 ;Constant K1=10 (9.06–15966/T) T ;Rankine temperature (t×9/5+32+460) • Remote output holding (optional): Output signal is held at the latest value or setting value by short-circuiting the remote output holding input terminals. Holding is maintained while the terminals are short-circuited. Indication values will not be held. • Remote range changeover (optional): Range is selected by the contact input signal. Changeover is effective only when remote range setting is turned on. In this case, measuring range cannot be changed manually. When the contact input terminals for each component are short-circuited, the first range is selected, and it is changed over to the second range when the terminals are open. • Range identification signal (optional): The present measuring range is identified by a contact signal. When the contact output terminals for each component are closed, the first range is selected, and it is changed over to the second range when the terminals are open. Standard Requirements for measuring gases 0.5L/min ± 0.2L/min or 1L/min ± 0.5L/min • Temperature: 0 to 40°C • Pressure: 5kPa or less (Gas outlet side should be open to the atmospheric air.) • Dust: 0.3µm or less • Mist: Unallowable • Moisture: Below a level where saturation occurs at room temperature (condensation unallowable). • Corrosive component: HCL 1ppm or less • Standard gas for calibration: Zero gas; Dry N 2 or dry air Span gas; Each sample gas having concentration 90 to 100% of its measuring range (recommended). Unusable at concentrations beyond 100%. • Flow rate: Installation condition • Mount the instrument in a place that is not subject to direct sunlight, weathering nor radiation heat from hightemperature objects. If such a place cannot be found, a roof or cover should be prepared for protection. • Avoid a place where receives heavy vibration. • Select a clean environment. • Discharge the exhaust gas into atmospheric air at a safe location. • Avoid using the analyzer in an explosion-proof area. Standard gas sampling system Flow meter P Clean air Pump Cock P Measuring gas inlet Filter Filter Analyzer Membrane filter Pot Zero gas Span gas Controller Exhaust port To control valve Recorder Note) This is the example of sampling which dose not contain water in the measuring gas. Principle diagram of NDIR type measurement (For CO, CO2, CH4) Quantity of infrared ray that is absorbed by the measuring cell is detected with the mass flow sensor. Infrared light source Gas inlet Gas outlet Detector Motor Measuring cell Chopper Display Mass flow sensor Preamplifier 1mm Mass flow sensor (detection element of the hot-wire wind speed) Output Signal processing and calculation block 3 ZFG CODE SYMBOLS Digit 4 Standard 5 Measurable components 6 7 4 4 5 6 7 8 ZFG F 9 10 11 12 13 14 15 16 Y 1 Specification Gas inlet/outlet connection Output signal 8 9 Modification No. 1st component, 1st range (See the page 5) 10 1st component, 2nd range (See the page 5) 11 2nd component, 1st range (See the page 6) 12 2nd component, 2nd range (See the page 6) 13 Display language 14 Option 15 16 — Adjustment 1st component CO CO2 CH4 CO2 CH4 CO2 Rｃ1/4 NPT1/4 4 to 20ｍA DC 0 to 1V DC 0 to 100ｍV DC 0 to 10ｍV DC 2nd component Without Without Without CO CO CH4 0 to 0.5％ 0 to 1％ 0 to 2％ 0 to 3％ 0 to 5％ 0 to 10％ 0 to 20％ 0 to 25％ 0 to 40％ 0 to 50％ 0 to 70％ 0 to 100％ Others Without 0 to 1％ 0 to 2％ 0 to 3％ 0 to 5％ 0 to 10％ 0 to 20％ 0 to 25％ 0 to 40％ 0 to 50％ 0 to 70％ 0 to 100％ Others Without 0 to 0.5％ 0 to 1％ 0 to 2％ 0 to 3％ 0 to 5％ 0 to 10％ 0 to 20％ 0 to 25％ 0 to 40％ 0 to 50％ 0 to 70％ 0 to 100％ Others Without 0 to 1％ 0 to 2％ 0 to 3％ 0 to 5％ 0 to 10％ 0 to 20％ 0 to 25％ 0 to 40％ 0 to 50％ 0 to 70％ 0 to 100％ Others Japanese English Without With CP calculation value output With Contact input/output With CP calculation value output + Contact input/output — Standard Heat treatment furnaces Steel converter Others F B D E G H J 1 2 1 2 3 4 1 H J K Q L M N V W P X R Z Y J K Q L M N V W P X R Z Y H J K Q L M N V W P X R Z Note) See page 5 and 6 for the possible measuring ranges to be manufactured. ( Y J K Q L M N V W P X R Z 1 2 Y A B C Y A B C Z Table 1 to 3: Single-component analyzer Table 4 to 6: Two-component analyzer ) Correspondence table of the possible measuring ranges Table1: Single-component analyzer <CO2> 2nd range 1st range H J K Q L M N V W P X R 0 to 0.5% 0 to 1% 0 to 2% 0 to 3% 0 to 5% 0 to 10% 0 to 20% 0 to 25% 0 to 40% 0 to 50% 0 to 70% 0 to 100% Y Without J K Q L M N V W P X R 0 to 1% 0 to 2% 0 to 3% 0 to 5% 0 to 10% 0 to 20% 0 to 25% 0 to 40% 0 to 50% 0 to 70% 0 to 100% − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − Table2: Single-component analyzer <CO> 2nd range 1st range H J K Q L M N V W P X R 0 to 0.5% 0 to 1% 0 to 2% 0 to 3% 0 to 5% 0 to 10% 0 to 20% 0 to 25% 0 to 40% 0 to 50% 0 to 70% 0 to 100% Y Without J K Q L M N V W P X R 0 to 1% 0 to 2% 0 to 3% 0 to 5% 0 to 10% 0 to 20% 0 to 25% 0 to 40% 0 to 50% 0 to 70% 0 to 100% − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − Table3: Single-component analyzer <CH4> 2nd range 1st range J K Q L M N V W P X R 0 to 1% 0 to 2% 0 to 3% 0 to 5% 0 to 10% 0 to 20% 0 to 25% 0 to 40% 0 to 50% 0 to 70% 0 to 100% Y Without K Q L M N V W P X R 0 to 2% 0 to 3% 0 to 5% 0 to 10% 0 to 20% 0 to 25% 0 to 40% 0 to 50% 0 to 70% 0 to 100% − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − 5 ZFG Correspondence table of the possible measuring ranges Table4: Two-component analyzer <CO2/CO> 1st component <CO2> 2nd component <CO> 1st range/2nd range 1st range/ 0 to 0.5 0 to 1 0 to 1 0 to 2 0 to 2 0 to 3 0 to 5 0 to 10 0 to 10 0 to 20 0 to 20 0 to 20 0 to 25 0 to 25 0 to 40 0 to 40 0 to 50 0 to 50 0 to 70 0 to 100% 2nd range /1% /2% /3% /3% /5% /5% /10% /20% /25% /25% /40% /50% /40% /50% /50% /70% /70% /100% /100% /Without Code HJ HJ JK JQ KQ KL QL LM MN MV NV NW NP VW VP WP WX PX PR XR 0 to 0.5/1% RY 0 to 1/2% 0 to 1/3% 0 to 2/3% 0 to 2/5% 0 to 3/5% JK JQ KQ KL QL 0 to 5/10% LM − 0 to 10/20% 0 to 10/25% 0 to 20/25% 0 to 20/40% 0 to 20/50% 0 to 25/40% 0 to 25/50% 0 to 40/50% 0 to 40/70% 0 to 50/70% 0 to 50/100% MN MV NV NW NP VW VP WP WX PX PR − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − − 0 to 70/100% 0 to 100%/Without XR RY − − − − − − Table5: Two-component analyzer <CO2/CH4> 1st component <CO2> 1st range/ 2nd range 2nd component <CH4> 0 to 2 /3% 0 to 2 0 to 3 0 to 5 /5% /5% /10% 0 to 10 /20% 0 to 10 /25% 1st range/2nd range 0 to 20 0 to 20 0 to 20 0 to 25 0 to 25 0 to 40 0 to 40 0 to 50 0 to 50 0 to 70 0 to 100% /25% /40% /50% /40% /50% /50% /70% /70% /100% /100% /Without Code JK KQ KL QL LM MN MV NV NW NP VW VP WP WX PX PR XR 0 to 1/2% RY 0 to 1/3% 0 to 2/3% 0 to 2/5% 0 to 3/5% 0 to 5/10% 0 to 10/20% 0 to 10/25% 0 to 20/25% JQ KQ KL QL LM MN MV NV − − − − − − − − − − − − 0 to 20/40% 0 to 20/50% 0 to 25/40% 0 to 25/50% 0 to 40/50% 0 to 40/70% 0 to 50/70% 0 to 50/100% NW NP VW VP WP WX PX PR − − − − − − − − − − − − − − − − − − − − − − − − 0 to 70/100% XR − − − 0 to 100%/Without RY − − − Table6: Two-component analyzer <CH4/CO> 1st component <CH4> 6 2nd component <CO> 0 to 1 0 to 1 /2% /3% 1st range/ 2nd range 0 to 2 /3% 0 to 2 0 to 3 0 to 5 /5% /5% /10% 0 to 10 /20% 0 to 10 /25% 1st range/2nd range 0 to 20 0 to 20 0 to 20 0 to 25 0 to 25 0 to 40 0 to 40 0 to 50 0 to 50 0 to 70 0 to 100% /25% /40% /50% /40% /50% /50% /70% /70% /100% /10% /Without 0 to 1/2% 0 to 1/3% 0 to 2/3% 0 to 2/5% 0 to 3/5% 0 to 5/10% 0 to 10/20% 0 to 10/25% 0 to 20/25% 0 to 20/40% 0 to 20/50% 0 to 25/40% 0 to 25/50% 0 to 40/50% 0 to 40/70% 0 to 50/70% 0 to 50/100% Code JK JQ KQ KL QL LM MN MV NV NW NP VW VP WP WX PX PR JK − − − − JQ − − − − KQ KL QL LM MN MV NV NW NP VW VP WP WX PX PR XR RY 0 to 70/100% 0 to 100%/Without XR RY − − − − OUTLINE DIAGRAM (Unit : mm) Panel 1.6<t< 10 225 218 (140) MODE ESC ZERO ENT Power switch 211 211 GAS ANALYZER SPAN Display Panel mounting bracket Operation part 223 (25) 257 Gas inlet Rc1/4 or NPT1/4 (as specified) Gas outlet Rc1/4 or NPT1/4 (as specified) Made in Japan +2 206 0 +2 0 Purge gas inlet Rc1/4 or NPT1/4 (as specified) VA Fuji Electric Co.,Ltd. 173 OUTLET CH2 R ID + 10 9 20 19 R HOLD + - Fuse (250V / 1A) PURGE PE N L AC V POWER SOURCE FUSE 250VT 1A F - - Panel cut dimensions INLET OUTPUT DC POWER AC100V AC240V 50/60 Hz SER.NO. MFD - CH3 OUTPUT + 6 5 16 15 FAULT - 00000- CH1 R ID + 8 7 18 17 171 CH2 CH2 OUTPUT + - CH1 OUTPUT + 2 1 4 3 12 11 14 13 R RNG CH1 R RNG INFRARED GAS ANALYZER TYPE U SE Power terminal External wiring diagram External terminal M4 screw 204 + 1 11 – 2 12 CH2 Output + 3 13 – 4 14 + 5 15 – 6 16 + 7 17 1 2 3 – 8 18 PE N L + 9 19 + – 10 20 – External terminal M3.5 screw CH3 Output Scope of delivery: Main unit Panel mounting bracket x1 Power fuse x2 (250V AC 1A) Instruction manual; 1 copy Optional items: Gas sampling device Standard gas Receiving instrument, etc Ordering information 1. Type 2.Application and composition of sample gas (in case of nonstandard) CH1 Range identification signal (optional) CH1 Output CH1 Remote range input (optional) CH2 Remote range input (optional) CH2 Range identification signal (optional) Error contact output Power terminal Remote hold input (optional) 100 to 240V AC 50/60Hz 50VA 7 ZFG Caution on Safety *Before using this product, be sure to read its instruction manual in advance. International Sales Div Sales Group Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan http://www.fujielectric.com Phone: 81-3-5435-7280, 7281 Fax: 81-3-5435-7425 http://www.fjielectric.com/products/instruments/ Information in this catalog is subject to change without notice. Printed in Japan