Fuji Electric ZKJ-2 Instruction Manual
Instruction Manual
NDIR TYPE
INFRARED GAS
ANALYZER
TYPE: ZKJ-2
INZ-TN2ZKJ-E
PREFACE
We are grateful for your purchase of Fuji Electric’s Infrared Gas Analyzer, TYPE:ZKJ.
• 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.
• 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.
• After reading the manual, be sure to store it at a place easier to access.
• This instruction manual should be delivered to the end user without fail.
Manufacturer: Fuji Electric Instruments Co., Ltd.
Type: Described in Fuji Electric’s company nameplate on main frame
Date of manufacture: Described in Fuji Electric’s company nameplate on main frame
Product nationality: Japan
Delivered Items
Name Quantity Remarks
Analyzer main frame 1
Input/Output terminal module 1
Connection cable 1
Power cable 1
Fuse 2 250V AC/3A delay type
Cell window mounting tool 1 With mounting block cell
Slide rail 2 Option
Instruction manual 1
Request
• It is prohibited to transfer part or all of this manual without Fuji
Electric’s permission in written format.
• Description in this manual is subject to change without prior
notice for further improvement.
© Fuji Electric Instruments Co., Ltd. 2001
Issued in September, 2001
iINZ-TN2ZKJ-E
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
CAUTION
PROHIBITION
Caution on installation and transport of gas analyzer
DANGER
CAUTION
Wrong handling may cause a dangerous situation, in which
there is a risk of death or heavy injury.
Wrong handling may invite a dangerous situation, in which
there is a possibility of medium-level trouble or slight injury or
only physical damage is predictable.
Items which must not be done are noted.
• 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.
• For installation, observe the rule on it given in the instruction
manual and select a place where the weight of gas analyzer
can be endured.
Installation at an unsuited place may cause turnover or fall and
there is a risk of injury.
• For lifting the gas analyzer, be sure to wear protective gloves.
Bare hands may invite an injury.
• Before transport, fix the casing so that it will not open. Otherwise, the casing may be separated and fall to cause an injury.
• The gas analyzer is heavy. It should be transported carefully
by two or more persons if manually required.
Otherwise, body may be damaged or injured.
• During installation work, care should be taken to keep the unit
free from cable chips or other foreign objects. Otherwise, it
may cause fire, trouble or malfunction of the unit.
ii INZ-TN2ZKJ-E
DANGER
Caution on piping
In piping, the following precautions should be observed.
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.
• Connect pipes correctly referring to the instruction manual.
• Exhaust should be led outdoors so that it will not remain in
the locker and installation room.
• Exhaust from the analyzer should be relieved in the atmospheric air in order that an unnecessary pressure will not be
applied to the analyzer. Otherwise, any pipe in the analyzer
may be disconnected to cause gas leakage.
• For piping, use a pipe and a pressure reducing valve to which
oil and grease are not adhering. If such a material is adhering,
a fire or the like accident may be caused.
Caution on wiring
CAUTION
DANGER
CAUTION
• Wiring work must be performed with the main power set to
OFF to prevent electric shocks.
• Enforce construction of class-D grounding wire by all means.
If the specified grounding construction is neglected, a shock
hazard or fault may be caused.
• Wires should be the proper one meeting the ratings of this
instrument. If using a wire which cannot endure the ratings, a
fire may occur.
• Be sure to use a power supply of correct rating. Connection of
power supply of incorrect rating may cause fire.
Caution on use
• For correct handling of calibration gas or other reference gases,
carefully read their instruction manuals beforehand.
• Before leaving unused for a long time or restarting after left at
such a status for an extended length of time, follow the directions
of each instruction manual because they are different from
normal starting or shutdown. Otherwise, the performance may
be poor and accidents or injuries may be caused.
• Do not operate the analyzer for a long time with its door left
open. Otherwise, dust, foreign matter, etc. may stick on internal
walls, thereby causing faults.
iiiINZ-TN2ZKJ-E
Caution on use
• Do not allow metal, finger or others to touch the input/output
PROHIBITION
Caution on maintenance and check
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.
• Do not allow water to go into the gas analyzer. Otherwise,
hazard shock or fire in the instrument may be caused.
DANGER
CAUTION
• When doors are open during maintenance or inspection, be sure
to purge sufficiently the inside of the gas analyzer as well as the
measuring gas line with nitrogen or air, in order to prevent
poisoning, fire or explosion due to gas leak.
Be sure to observe the following for safe operation avoiding
the shock hazard and injury.
• Remove the watch and other metallic objects before work.
• Do not touch the instrument wet-handed.
• If the fuse is blown, eliminate the cause, and then replace it
with the one of the same capacity and type as before. Otherwise, shock hazard or fault may be caused.
• Do not use a replacement part other than specified by the
instrument maker. Otherwise, adequate performance will not be
provided. Besides, an accident or fault may be caused.
• Replacement parts such as a maintenance part should be disposed of as incombustibles.
Others
• If the cause of any fault cannot be determined despite reference
CAUTION
iv INZ-TN2ZKJ-E
to the instruction manual, be sure to contact your dealer or Fuji
Electric’s technician in charge of adjustment. If the instrument is
disassembled carelessly, you may have a shock hazard or injury.
CONTENTS
PREFACE .....................................................................................................................i
CAUTION ON SAFETY............................................................................................ ii
CONTENTS.................................................................................................................v
1. OVERVIEW..................................................................................................... 1-1
2. NAME AND DESCRIPTION OF EACH UNIT ............................................. 2-1
2.1 Name and description of main unit.....................................................................2-1
2.2 Input/Output terminal module ............................................................................2-2
3. INSTALLATION ............................................................................................. 3-1
3.1 Installation ..........................................................................................................3-2
3.1.1 Installation of analyzer main frame............................................................3-2
3.1.2 Mounting input/output terminal module ....................................................3-3
3.2 Piping..................................................................................................................3-4
3.3 Sampling.............................................................................................................3-7
3.3.1 Conditions of sampling gas ........................................................................3-7
3.3.2 Sampling gas flow ......................................................................................3-7
3.3.3 Preparation of standard gas ........................................................................3-7
3.3.4 Purging of instrument inside ......................................................................3-7
3.3.5 Pressure at sampling gas outlet...................................................................3-8
3.3.6 Example configuration of gas sampling system.........................................3-8
3.4 Wiring.................................................................................................................3-9
3.4.1 Power inlet..................................................................................................3-9
3.4.2 Input/output terminal module.....................................................................3-9
4. OPERATION ...................................................................................................... 4-1
4.1 Preparation for operation ....................................................................................4-1
4.2 Warm-up operation and regular operation..........................................................4-1
5. DESCRIPTION OF DISPLAY AND OPERATION PANELS....................... 5-1
5.1 Name and description of operation panel ...........................................................5-1
5.2 Overview of display and operation panels..........................................................5-2
5.3 Outline of display screen ....................................................................................5-3
5.4 General operation................................................................................................5-6
6. SETTING AND CALIBRATION.................................................................... 6-1
6.1 Changeover of range...........................................................................................6-1
6.2 Calibration Setting..............................................................................................6-2
6.2.1 Setting of calibration concentration............................................................6-2
6.2.2 Setting of manual zero calibration..............................................................6-4
6.2.3 Setting of calibration range ........................................................................6-6
vINZ-TN2ZKJ-E
6.2.4 Setting of auto calibration component........................................................6-8
6.3 Alarm setting ....................................................................................................6-10
6.3.1 Setting of alarm values .............................................................................6-10
6.3.2 Hysteresis setting......................................................................................6-12
6.4 Setting of auto calibration.................................................................................6-13
6.4.1 Auto calibration ........................................................................................6-13
6.4.2 Forced stop of auto calibration.................................................................6-15
6.5 Setting of auto zero calibration.........................................................................6-17
6.5.1 Auto zero calibration ................................................................................6-17
6.5.2 Forced stop of auto zero calibration .........................................................6-19
6.6 Peak alarm setting.............................................................................................6-21
6.7 Parameter setting ..............................................................................................6-23
6.8 Maintenance mode............................................................................................6-27
6.9 Calibration ........................................................................................................6-30
6.9.1 Zero calibration ........................................................................................6-30
6.9.2 Span calibration ........................................................................................6-31
7. MAINTENANCE............................................................................................. 7-1
7.1 Daily check .........................................................................................................7-1
7.2 Daily check and maintenance procedures...........................................................7-1
7.3 Maintenance of analyzer unit..............................................................................7-2
7.3.1 Cleaning method for sample cell (pipe cell)...............................................7-2
7.3.2 Cleaning method for sample cell (block cell).............................................7-4
7.3.3 Optical zero adjustment method (optical balance adjustment)...................7-6
7.3.4 Moisture interference compensation adjustment method...........................7-7
7.3.5 Replacement of fuse on analyzer unit ........................................................7-8
8 TROUBLE SHOOTING FOR ANALYZER....................................................... 8-1
8.1 Error message .....................................................................................................8-1
9. SPECIFICATIONS .......................................................................................... 9-1
9.1 General specifications.........................................................................................9-1
9.2 Code symbols......................................................................................................9-4
9.3 Outline diagram ..................................................................................................9-6
vi INZ-TN2ZKJ-E
1. OVERVIEW
This infrared gas analyzer (type: ZKJ) 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.
Since this instrument incorporates a compact paramagnetic O
nents simultaneously by using the built-in O
sensor (up to 4 components if O2 sensor is excluded).
2
Furthermore, use of a microprocessor or large sized liquid crystal display realizes improvement of operability, accuracy and multi-functions.
This instrument is optimum for measuring combustible gas exhausted from boilers or incinerators, and it
is effective for steel gas analysis (blast furnace, steel converter, thermal treatment furnace, sintering
(Pellet equipment), coke furnace), storage and maturity of vegetable and fruit, biochemistry (microbe),
[fermentation], air pollution [incinerator, exhaust gas desulfurization, denitration], automotive emission
(excluding tester), protection against disasters [detection of explosive gas and toxic gas, combustion gas
analysis of new building material], growth of plants, chemical analysis [petroleum refinery plant, petroleum chemistry plant, gas generation plant], environment [landing concentration, tunnel concentration,
parking lot, building management] and various physical and chemical experiments.
sensor, it allows measuring up to 5 compo-
2
1 - 1INZ-TN2ZKJ-E
2. NAME AND DESCRIPTION OF EACH UNIT
2.1 Name and description of main unit
POWER
DISPLAY
〈Rear panel 〉
Name
q Handle
w Power switch
e Switch for back
light
r Display/operation
panel
t Sampling gas
inlet
y Sampling gas
outlet
Fig. 2-1
Description
Used for withdrawing the main
unit from the panel.
Used for ON/OFF the analyzer.
Used for ON/OFF the back light
of display.
Liquid crysral diaplay and keys
for setting various functions
For connecting to the measuring
gas tube
Connect to the exhaust line. (A
pair of sampling gas inlet/outlet
is provided for each measuring
unit. When ordered with purge,
the piping to measuring unit 2 is
built inside. In this case, the
sample gas outlet for measuring
unit 2 is used for purge gas inlet.)
Name
u Sector motor
i Light source
cover
o Input/output ter-
minal connector
!0 Power inlet
Description
For driving the rotation of sector
Infrared light source is arranged
in the cover.
For connecting to the external
input/output terminal module
For connecting the power cable
2 - 1INZ-TN2ZKJ-E
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
Name
q Mounting hole
w Input/output
terminal block
(TN 1 to TN 5)
Description
Used for mounting input/output terminal module.
φ 4.5, 6 places
Input/output terminal for signals
of analog output, range identification contact, alarm contact output,
etc.
Name
e Calibration
solenoid valve
drive signal
output connector
r Input/output
terminal module
connection cable
t Communication
connector
Provides outputs of solenoid valve
drive signal during auto calibration.
Transistor output
(5V, 50mA, 1 contact)
Used for connecting the analyzer
main unit to the input/output
terminal module.
Connect communication cable.
*Please refer to another manual
(INZ-TN513327-E) about
communication function.
Description
2 - 2 INZ-TN2ZKJ-E
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.
•For lifting the gas analyzer, be sure to wear protective gloves. Bare hands may invite an
injury.
•This unit should be installed in a place which conforms to the conditions noted in the
instruction manual. Otherwise, it may cause electric shocks, fire or malfunction of the unit.
•During installation work, care should be taken to keep the unit free from entry of cable chips
or other foreign objects. Otherwise, it may cause fire, trouble or malfunction of the unit.
3 - 1INZ-TN2ZKJ-E
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
19 inch rack
mounting slide
429
483
177
M6
450 or more
465
101.6
Slide rail
(Supports mass)
rail method
Slide rail
(Supports mass)
Note 1 Check and maintenance of the analyzer main unit may be carried out with the top cover detached.
The guide rail method may be used if a space accessible for maintenance is provided at the top of
the main unit. If maintenance space is not provided specially, it is recommended to use the slide
rail method.
Recommended slide rail: Product No.: 305A-24 manufactured by Accuride International Co.
Note 2 For 19 inch rack mounting, the weight of the analyzer is supported with the bottom of the case
(with the side of the case in case of slide rail method). For mounting dimensions of the slide rail,
see “Item 9.3 External diagram”.
Don’t install the analyzer at a place which is exposed to direct sunlight.
The analyzer should be installed at a place where ambient temperature is within 0 to 40°C, and
temperature fluctuation during use is minimum.
3 - 2 INZ-TN2ZKJ-E
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.
External dimensions Mounting dimensions Mounting method
4.5 mounting hole (x 6 places)
164
316
M4 screw
154
Cut a hole at 6 places.
Drill a 302 x 142 rectangular hole
in the center.
150 150
302
142142
Note) How to ground analyzer main unit and I/O terminal module
To avoid the effect of noises, etc. from external units, it is
recommended to ground them by the procedure described below.
Bring I/O terminal module sheet metal and
panel into continuity at ///// portion.
Terminal
To analyzer rear panel
Screwed to panel
Panel plate
Connection cable
Bring analyzer main unit and panel into continuity
at ///// portion or rail mounting portion.
(No grounding is required at the power terminal).
Mount the analyzer and I/O terminal module on the
same panel.
Ground the panel casing.
Don’t separate the analyzer and I/O terminal module, and be sure to
*
ground them together.
3 - 3INZ-TN2ZKJ-E
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. The instrument provides inaccurate indication due to gas absorption by piping
materials.
• Pipe connection port is Rc1/4 female thread (or NPT1/4). Piping should be cut as short as
possible for a quick response. About 4 mm inner diameter is recommended.
• Entry of dust into the instrument may result in defective operation. Use a clean piping or
coupling.
Connect the gas tube by the following method.
Sampling gas outlet
For measuring
unit 1
Sampling gas inlet
Sampling gas inlet
Sampling gas outlet
(Purge gas inlet)
For measuring
unit 2
Sampling gas inlet: Attach the gas tube to introduce gas to be measured such as one that has
completed dehumidification process and standard gases for zero and span
calibration to this inlet.
Gas flow to be introduced should be constant within the range of 0.5 L/min
±0.2 L/min.
Sampling gas outlet: Exhaust measured gas through the outlet. Attach the tube to exhaust mea-
sured gas outdoors or to the atmosphere.
Purge gas inlet: It is used for purging the inside of the total gas analyzer . When the ana-
lyzer must be purged, refer to Item 3.3.4 Purging of instrument inside.
Use dry gas N
or instrumentation air for purge gas. (flow rate of 1L/min or
2
more should be used and no dust or mist is contained).
3 - 4 INZ-TN2ZKJ-E
Measuring unit 2
Measuring unit 1
Sampling cell
Note)
2 cells may be used
by combination of
range.
OUTLET INLET OUTLET INLET
Sampling gas inlet
Sampling gas outlet
For measuring
unit 1
Sampling gas inlet
Sampling gas outlet
For measuring
unit 2
Built-in
O
2 sensor
Internal piping diagram
Note) When the purge gas inlet is provided, the piping to measuring unit 2 is built inside.
Correspondence of measured components and measuring units
Measuring components
1-component meter for
NO, SO2, CO2, CO and
CH
4
2-component meter for
NO/SO2 and CO2/CO
2-component meter for
NO/CO
3-component meter for
NO/SO2/CO
4-component meter for
NO/SO2/CO2/CO
Measuring unit 1
Each component
NO/SO
2
CO2/CO
NO
NO/SO
2
NO/SO
2
Measuring unit 2
None
None
CO
CO
CO2/CO
Note) When the built-in O2 sensor is provided, it must be con-
nected to the measuring unit 1.
3 - 5INZ-TN2ZKJ-E
Example of connecting each measuring unit
• One pair of gas inlet/outlet
Sampling gas
• Two pair of gas inlet/outlet - (1)
Sampling gas
NO2/NO
converter
Filter
Flow meter
0.5L/min
Filter
Flow meter
0.5L/min
ZKJ
Sampling gas inlet
Sampling gas outlet
Release to atmosphere.
ZKJ
Sampling gas
inlet
Sampling gas
outlet
Exhaust
For
measuring
unit 1
Filter
Note) The NO
2/NO converter is used when NO measurement is used for NOx measurement.
• Two pair of gas inlet/outlet - (2)
Sampling gas
Filter
Flow meter
0.5L/min
Flow meter
0.5L/min
NO
converter
2/NO
Filter
Sampling gas
inlet
Sampling gas
outlet
Sampling gas
inlet
Sampling gas
outlet
Sampling gas
inlet
Sampling gas
outlet
For
measuring
unit 2
Exhaust
Release to atmosphere.
ZKJ
For
measuring
unit 1
For
measuring
unit 2
Exhaust
Release to atmosphere.
Note) The NO
2/NO converter is used when NO measurement is used for NOx measurement.
3 - 6 INZ-TN2ZKJ-E
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. If vapor is contained in the sampling gas, dew point should be
lowered to 0°C by using a dehumidifier.
e If SO
mist is contained in the sampling gas, use a mist filter or cooler to remove SO3 mist.
3
Other mists should be removed by using a mist filter or cooler.
r Corrosive gases such as Cl
2
erable amounts, will shorten the life of instruments.
t Temperature of sampling gas should be within 0 to 50°C. Provide a means that prevents
entry of hot gas directly into the instrument.
3.3.2 Sampling gas flow
Flow of sampling gas should be 0.5L/min ± 0.2L/min.
Avoid flow fluctuation during measurement.
Observe the flow reading by a flowmeter provided as shown in the example of the sampling
system configuration (Item 3.3.6).
3.3.3 Preparation of standard gas
Routine calibration is required by standard gas for keeping this instrument under normal operation
condition (once a week). Prepare a standard gas cylinder for zero calibration and span calibration.
Analyzer without O
measurement
Zero gas
N2 gas
, F2 and HCl, if they are contained in the sampling gas in consid-
Analyzer with built-
2
in O2 sensor
N2 gas
Analyzer with external zirconia O
sensor
Dry air or atmospheric air (Eliminated with CO2 provided)
2
Span gas other
than for O
measurement
Span gas for O
measurement
2
Gas with concentration of 90% or more
of full scale
2
3.3.4 Purging of instrument inside
The inside of instrument need not be purged generally except for the following cases.
q A combustible gas component is contained in sample gas.
w Corrosive gas is contained in the atmospheric air at the installation site.
e The same gas as the sample gas component is contained in the atmospheric air at the installa-
tion site.
In such cases as above, the inside of analyzer should be purged with the air for instrumentation
.
or N
2
Purging flow rate should be about 1L/min.
If dust or mist is contained in purging gas, it should be eliminated completely in advance.
Gas with concentration of 90% or more
of full scale
Gas with concentration of 90% or more
of full scale
Gas with concentration of 90% or
more of full scale
1 to 2% O
2
3 - 7INZ-TN2ZKJ-E
3.3.5 Pressure at sampling gas outlet
Pressure at the sampling gas outlet should be adjusted to atmospheric pressure.
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
q Gas extractor
w
Gas conditioner
e Gas aspirator
r Electronic gas
cooler
t
Solenoid valve
y Membrane filter
Description
Gas extractor with a heating
type stainless steel filter of standard mesh 40µm
For separation of drain, prev ention of drain from being sucked
through secondary filter and
composite operation of constant-pressure bubbler
For aspiration of sample gas
Dries the moisture in sample
gas to a dew point of approx.
2°C.
Used for introducing calibration
gas.
PTFE filter used to eliminate
fine dust particles and permit
monitoring of dust adhering
condition on the front panel of
the gas analyzer.
Name
u Flowmeter
i Standard gas
o Zirconia O2 sensor
!0 NO2/NO converter
Description
Adjusts and monitors the flow
rate of sample gas.
Reference gas used for calibrating zero and span of the analyzer. Total 6 cylinders requir ed
for zero gas air, span gas NO,
SO2, CO, CO2 and O2.
External zirconia oxygen
sensor used for measuring the
oxygen concentration (0 to
25%) in sample gas.
(This is not necessary in case
when O2 sensor is built-in.)
Added to NOx analyzer.
A special catalyst material for
efficient conversion of NO
gas to NO is used.
2
3 - 8 INZ-TN2ZKJ-E
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
• Avoid installing this instrument near an electrical unit (high frequency furnace or electric welder)
that generates much electrical noise. If using the instrument near such a noise generating unit is
unavoidable, use a different power line to avoid noise.
Main unit
power supply
• Mount a noise suppressor such as varister (ENA211-2 by
Varistor or
spark killer
Fuji Elctric) or spark killer (S1202 by OKAYA) to the
noise generating unit when noise is generated from relays
or solenoid valves.
Mount the suppressor near the noise generating source,
or it will have no effect.
Install (connect)
near the source.
Noise
generating
source
3.4.2 Input/output terminal module
This analyzer should be connected to the input/output terminal module by supplied exclusive
cable.
Plug this cable connector into the receptacle at the rear panel of the analyzer and the receptacle on
the PC board of the input/output module.
Analyzer
Exclusive cable
(1 meter long)
Input/output
terminal module
3 - 9INZ-TN2ZKJ-E
(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 or less
• 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. It is recommended to isolate
signals individually to prevent interference from unnecessary signals or to prevent external
interference.
(2) O
sensor input: terminal block 2 q – w
2
Input signal:
External zirconia O
External O
analyzer: 0 to 1 VDC (DC input resistor of 1MΩ or more)
2
• It is used when the external zirconia O
• To connect to the output of the external Zirconia analyzer or external O
analyzer: Zirconia O2 sensor signal (Fuji ZFK7 output)
2
analyzer or external O2 analyzer is specified as order.
2
analyzer prepared
2
separately.
• In case of an external O
analyzer, input a signal of 0 to 1 VDC with respect to O2 full scale
2
of the analyzer.
• In case of built-in O
sensor input is not isolated. It is recommended to isolate when an external O2 analyzer is
O
2
analyzer, do not use the terminals.
2
installed apart from this analyzer.
(3) Contact input (DI): terminal block 2 !1 to @0, terminal block 3 t to !0
• It is for a contact input at no voltage. An input is provided when switching to short circuit
(on) or open (off).
• No voltage is applied to the terminals.
(4) Contact output (DO): terminal block 3 !1 to @0, terminal block 4 and terminal block 5
• Contact rating:250VAC/2A, load resistance
• An output is for a relay contact output. An output is provided when switching to conductive
(on) or open (off).
Wiring of analog output signal, O
sensor input and contact input should be fixed separately
2
from the wiring of power supply and contact output.
Note) To avoid the effect of noise generated from external units, be sure to ground the
analyzer main unit. Continue between the I/O module mounting plate and the panel
and connect the panel casing to the same ground as the analyzer.
3 - 10 INZ-TN2ZKJ-E
Terminal block 1
<TN1>
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
(M3.5 screw)
CH9 output
(CH9_OUT)
CH10 output
(CH10_OUT)
CH8 output
(CH8_OUT)
CH7 output
(CH7_OUT)
CH6 output
(CH6_OUT)
CH1 output
(CH1_OUT)
CH2 output
(CH2_OUT)
CH3 output
(CH3_OUT)
CH4 output
(CH4_OUT)
CH5 output
(CH5_OUT)
+
–
+
–
+
–
+
–
+
–
+
–
+
–
+
–
+
–
+
–
+
–
Terminal block 2
<TN2>
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
(M3.5 screw)
CH4 remote range
changeover input
(R_RNG_CH4)
CH5 remote range
changeover input
(R_RNG_CH5)
CH3 remote range
changeover input
(R_RNG_CH3)
CH2 remote range
changeover input
(R_RNG_CH2)
CH1 remote range
changeover input
(R_RNG_CH1)
CH12 output
(CH12_OUT)
CH11 output
(CH11_OUT)
Unassigned
Unassigned
O
2
sensor input
(O
2
_IN)
Note 1
Terminal block 3
<TN3>
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
(M3.5 screw)
CH4 range identification
contact output (RNG_IDCH4)
CH5 range identification
contact output (RNG_IDCH5)
CH3 range identification
contact output (RNG_IDCH3)
CH2 range identification
contact output (RNG_IDCH2)
CH1 range identification
contact output (RNG_IDCH1)
Auto calibration
remote start
input (R_CAL)
Average value reset
input (RESET)
Remote hold input
(R_HOLD)
Unassigned
Unassigned
Terminal block 5
<TN5>
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
(M3.5 screw)
Unassigned
Power disconnection
alarm output
(POWER_OFF)
CH5 alarm output
(ALM_CH5)
CH4 alarm output
(ALM_CH4)
CH3 alarm output
(ALM_CH3)
CH2 alarm output
(ALM_CH2)
CH1 alarm output
(ALM_CH1)
Unassigned
Terminal block 4
<TN4>
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
(M3.5 screw)
Unassigned
Unassigned
Unassigned
Auto calibration status/
maintenance status contact
output (ACAL/MNT)
Calibration error
contact output
(CAL_ALM)
Unassigned
Unassigned
Note 1 : For external O
2
sensor input.
Instrument error
contact output
(FAULT)
Pump ON/OFF
contact output (PUMP)
Peak count alarm
output (PEAK_ALM)
Connector
<CN3>
Solenoid valve drive signal output for calibration
(Transister output)
<D-sub 9P>
Contact output for
zero calibration
Contact output for
sample gas selection
Contact output for CH1
span calibration
Contact output for CH2
span calibration
Contact output for CH3
span calibration
Contact output for CH4
span calibration
Contact output for CH5
span calibration
5V DC relay drive power
1
2
3
4
5
6
7
8
9
(5) List of terminal blocks
3 - 11INZ-TN2ZKJ-E
(6) Description on terminal block
Terminal block 1
<TN1>
CH5 output
(CH5_OUT)
CH4 output
(CH4_OUT)
CH3 output
(CH3_OUT)
CH2 output
(CH2_OUT)
CH1 output
(CH1_OUT)
1
–
+
2
3
–
+
4
5
–
+
6
7
–
+
8
9
–
+
10
(M3.5 screw)
12
13
14
15
16
17
18
19
20
CH10 output
–
+
(CH10_OUT)
CH9 output
–
+
(CH9_OUT)
CH8 output
–
+
(CH8_OUT)
CH7 output
–
+
(CH7_OUT)
CH6 output
–
+
(CH6_OUT)
11
Terminal block 2
<TN2>
2 sensor input
O
(O
CH12 output
(CH12_OUT)
CH11 output
(CH11_OUT)
Unassigned
Unassigned
Note 1
2_IN)
1
–
+
2
3
4
5
6
7
8
9
10
(M3.5 screw)
CH5 remote range
11
changeover input
(R_RNG_CH5)
12
CH4 remote range
13
changeover input
14
(R_RNG_CH4)
CH3 remote range
15
changeover input
(R_RNG_CH3)
16
CH2 remote range
17
changeover input
(R_RNG_CH2)
18
CH1 remote range
19
changeover input
(R_RNG_CH1)
20
Note 1: For external O2 sensor input.
Terminal block 2 <TN2>
Terminal block for analog output (non-isolated
output)
Between 1–2: CH5 output
Between 3–4: CH4 output
Between 5–6: CH3output
Between 7–8: CH2 output
Between 9–10: CH1 output
Between 11–12: CH10 output
Between 13–14: CH9 output
Between 15–16: CH8 output
Between 17–18: CH7 output
Between 19–20: CH6 output
Terminal block 2 <TN2>
Between 1–2: O
sensor input
2
(For input of Fuji’s zirconia
oxygen sensor and externally
oxygen sensor. Must not be used
unless external O
sensor is
2
provided.)
Between 3–4: CH12 output
Between 5–6: CH11 output
Between 7–10 For internal connection. Must
not be wired. (Must not be used
as junction terminal).
Between 11–12: CH5 remote range changeover
input
Between 13–14: CH4 remote range changeover
input
Between 15–16: CH3 remote range changeover
input
Between 17–18: CH2 remote range changeover
input
Between 19–20: CH1 remote range changeover
input
Action of remote range changeover
High range is selected when
open. Low range is selected
when short-circuited. For details
of action, see “Item 6.7 Parameter
Setting, Remote Range”.
3 - 12 INZ-TN2ZKJ-E
Unassigned
Unassigned
Remote hold input
(R_HOLD)
Average value reset
input (RESET)
Auto calibration
remote start
input (R_CAL)
Terminal block 3
<TN3>
11
1
12
2
13
3
14
4
15
5
16
6
17
7
18
8
19
9
20
10
(M3.5 screw)
CH5 range identification
contact output (RNG_IDCH5)
CH4 range identification
contact output (RNG_IDCH4)
CH3 range identification
contact output (RNG_IDCH3)
CH2 range identification
contact output (RNG_IDCH2)
CH1 range identification
contact output (RNG_IDCH1)
Terminal block 3 <TN3>
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.
For details, refer to “Item 6.7
Parameter setting, Output Hold”.
Between 7–8: Average value reset input. short-
circuitting the contact input (for
at 1.5 sec min.) resets O
and O
corrected average simulta-
2
average
2
neously. Opening it restarts the
average value.
For details, refer to “Item 6.7
Parameter setting, Average Value
Resetting”
Between 9–10: Automatic calibration remote
start input
After shorting for 1.5 sec. or
more, automatic calibration is
started by the opening input
whether the automatic calibration
setting is ON/OFF.
For details, refer to “Item 6.4
Setting of auto calibration”
Between 11–12: CH5 range identification contact
output
Between 13–14: CH4 range identification contact
output
Between 15–16 CH3 range identification contact
output
Between 17–18: CH2 range identification contact
output
Between 19–20: CH1 range identification contact
output
Action of range identification signal
Range identification contact is
conductive at low range and open
at high range.
3 - 13INZ-TN2ZKJ-E
Terminal block 4
Peak count alarm
output (PEAK_ALM)
Auto calibration status/
maintenance status contact
output (ACAL/MNT)
Pump ON/OFF
contact output (PUMP)
Calibration error
contact output
(CAL_ALM)
Instrument error
contact output
(FAULT)
<TN4>
11
1
12
2
13
3
14
4
15
5
16
6
17
7
18
8
19
9
20
10
(M3.5 screw)
Unassigned
Unassigned
Unassigned
Unassigned
Unassigned
Terminal 4 <TN4>
Between 1–2: Peak count alarm contact output
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”.
Between 3–4: Contact output of auto calibration
status and maintenance contact
When the auto calibration is
carried out and remote hold is
ON, it is conductive. Remains
open otherwise.
Between 5–6: Pump ON/OFF contact output
Used when turning ON/OFF the
pump. It is open during auto and
manual calibration status and
conductive during measurement.
Between 7–8: Calibration error contact output
It is conductive when an error
occurs during zero calibration or
span calibration. It is normally
open.
Between 9–10: It is conductive when an error
occurs to the analyzer unit. It is
normally open.
Between 11–20: For internal connection, wiring is
not allowed. (Do not use it as
junction terminal).
3 - 14 INZ-TN2ZKJ-E
Unassigned
CH3 alarm output
(ALM_CH3)
CH2 alarm output
(ALM_CH2)
CH1 alarm output
(ALM_CH1)
Terminal block 5
<TN5>
11
1
12
2
13
3
14
4
15
5
16
6
17
7
18
8
19
9
20
10
(M3.5 screw)
Unassigned
Power disconnection
alarm output
(POWER_OFF)
CH5 alarm output
(ALM_CH5)
CH4 alarm output
(ALM_CH4)
Terminal 5 <TN5>
Between 2, 3 and 4:
CH3 alarm output
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.
Between 5, 6 and 7:
CH2 alarm output
When the output exceeds the set value,
it is conductive between 5 and 6, and
open between 6 and 7. Otherwise, it is
open between 5 and 6, and conductive
between 6 and 7.
Between 8, 9 and 10:
CH1 alarm output
When the output exceeds the set value,
it is conductive between 8 and 9, and
open between 9 and 10. Otherwise, it
is open between 8 and 9.
Between 12, 13 and14:
Analyzer unit power OFF output
When the analyzer unit is turned ON,
it is conductive between 12 and 13,
and open between 13 and 14. When
the analyzer unit is turned OFF, it is
open between 12 and 13, and conductive between 13 and 14.
Between 15, 16 and 17:
CH5 alarm output
When the output exceeds the set value,
it is conductive between 15 and 16,
and open between 16 and 17. Otherwise, it is open between 15 and 16,
and conductive between 16 and 17.
Between 18, 19 and 20:
CH4 alarm output
When the output exceeds the set value,
it is conductive between 18 and 19,
and open between 19 and 20. Otherwise, it is open between 18 and 19,
and conductive between 19 and 20.
For detailed action of the alarm
contact, refer to “Item 6.3 Alarm
setting”.
3 - 15INZ-TN2ZKJ-E
Connector <CN3>
Solenoid valve drive signal output for calibration
Connector
<CN3>
(Transister output)
Contact output for
sample gas selection
Contact output for
zero calibration
Contact output for CH1
span calibration
Contact output for CH2
span calibration
1
2
3
4
5
<D-sub 9P>
Contact output for CH3
6
span calibration
Contact output for CH4
7
span calibration
Contact output for CH5
8
span calibration
5V DC relay drive power
9
Connector <CN3> provides outputs in combination with calibration action during auto calibration
and manual calibration.
An output is from a transistor (ratings: 5V/50mA).
A transistor is turned ON before starting each calibration.
Sample selection output is ON during measurement and OFF during calibration.
If calibration is not performed, the other transistors are OFF.
In case of auto calibration, sequential output is ON/OFF according to the setting.
Refer to “Item 6.4 Setting of auto calibration”.
Note) No. 9 pin is for solenoid valve ON/OFF relay drive power (5V DC/0.5A, max).
Use No. 9 with reference to the diagram.
Example of using solenoid valve drive signal output for calibration
<Electrical system>
SV4
CH1
span
Contact relay
Relay board
CH2
span
5V
I/O terminal module
<Gas sampling system>
Electronic
gas cooler
9
1
3
4
5
SV2SV1
Cable
CN3
Membrane filter
SV3
Zero
Standard gas for calibration
SV1
SV2
SV3
SV4
Solenoid valve
drive power
SV1 to SV4: solenoid valves
Refer to “Item 3.3.6 Example configuration
of gas sampling system”.
Relay board (TK7H2949C4) and exclusive cable (D-sub 9p straight cable: 1.5 meters)
are available on request.
3 - 16 INZ-TN2ZKJ-E
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