Manual No.3011E R6INSTRUCTION MANUALFOR
DUST DENSITOMETERMODEL ISS-101
KV-610014-J

1.

General description
1.1

Introduction
This Dust densitometer model ISS-101 is a relative dust concentration
meter, which utilizes the light scattering method and can be used tocontinuously monitor the dust concentration for an extended period oftime. The analyzer is directly connected to the flume and has a simple
sampling piping system, ensuring easy maintenance.
By supplying the clean air to the optical system, lowering of the sensitivity due tocontamination of the optical system is prevented.
Therefore, the analyzer can measure from the high concentration to low concentration
without effects of load fluctuations and does not require any maintenance for an extended
period of time.
This instruction manual describes how to install, operate, and inspect the Dustdensitometer model ISS-101. Before starting installation of this analyzer, thoroughly readthis instruction manual to fully understand its contents and operate the analyzer in correctmanner.

1

IMPORTANT
1.2

Guarantee of product
The guarantee period of this product is stated in the final document. If thedelivery drawings are not provided, the guarantee period is determined as
one year after delivery.
(1) Conditions
The product shall be stored and installed properly until the trial-run adjustment isstarted. If any defect due to faulty design, defective materials, and/or poor
workmanship is found during the guarantee period, Energy Support corp. shall repair
or replace defective item free of charge.
The proper operating conditions include the following terms.
① The operating conditions and installation conditions specified in this instruction
manual shall be satisfied.
② Excessive mechanical shock and impact shall not be applied to the samplingprobe.
③ The Dust densitometer shall be calibrated and consumable parts shall be
replaced periodically.
④ The confirmation and maintenance of the Dust densitometer operation status
shall be performed correctly.
⑤ The suction and exhaust valves shall be closed not to suck the sample gas until
the warm-up time of the transmitter has elapsed.
⑥ The optical system shall be cleaned and clogging of the probe shall be inspected
and cleaned periodically.
This guarantee does not include defects arising from the following conditions
even during the guarantee period.
･ Defects arising from improper handling (improper operation not stated in this
instruction manual)･ Defects arising from repair, modification, or overhaul cleaning made bypersonnel other than those authorized by Energy Support corp.
･ Defects arising from fire, natural disaster, or improper maintenance (storage ina place where high temperature and high humidity exist, or mold occurs.)
Note: Replacement of consumable and/or similar parts is not included in theguarantee coverage.
(2) Guarantee coverage
This guarantee covers only products manufactured and delivered by Energy Support
corp. Incidental and consequential damages (damage and loss caused by controlled
and recorded results by the product delivered by Energy Support corp. and damage
and loss of the equipment, in which Energy’s product is installed) resulting from
malfunction of the product manufactured by Energy Support corp. are not included.

2

(3) Remarks① It is difficult to remove the slug dust by purging. It is absolutely necessary to
perform the maintenance and replacement work with the probe removed.
② This instrument is a Dust densitometer that utilizes the light scattering method.
When measuring the dust actually, a difference between the indication value on
the Dust densitometer and weight concentration value of the actual dust may be
produced by influences of the color, shape, and grain size of the dust.
Therefore, the customer needs to perform the manual analysis and add thecompensation value from the following weight conversion coefficient to make theindication value on the Dust densitometer matched with the weight concentration
value.
(Actual dust weight concentration value (mg/m 3N)
Weight conversion coefficient =(Average of indication value on the Dust densitometer(mg/m3N))

This compensation is similar to the standard gas calibration of the gas analyzer.

3

Table of contents
1. General description-------------------------------------------------------------------------------------------------------- 1
1.1 Introduction ------------------------------------------------------------------------------------------------------------- 1
1.2 Guarantee of product ------------------------------------------------------------------------------------------------ 2
1.3 Table of contents ------------------------------------------------------------------------------------------------------ 4
1.4 Safety precautions ---------------------------------------------------------------------------------------------------- 6
1.5 Cautions for operation ----------------------------------------------------------------------------------------------- 7
1.6 Overview of Dust densitometer ------------------------------------------------------------------------------------ 8
1.7 Part names and functions ------------------------------------------------------------------------------------------- 9
2. After unpacking ------------------------------------------------------------------------------------------------------------ 11
2.1 Checking of accessories ------------------------------------------------------------------------------------------- 11
2.2 Temporary storage of product------------------------------------------------------------------------------------- 13
3. Installation ------------------------------------------------------------------------------------------------------------------ 14
3.1 Installation conditions ----------------------------------------------------------------------------------------------- 14
3.2 Installation-------------------------------------------------------------------------------------------------------------- 16
3.3 Piping and wiring ----------------------------------------------------------------------------------------------------- 19
3.4 Inspection after installation ---------------------------------------------------------------------------------------- 22
4. Operation ------------------------------------------------------------------------------------------------------------------- 23
4.1

Preparations for operation ----------------------------------------------------------------------------------------- 23

4.2 Key operation --------------------------------------------------------------------------------------------------------- 26
4.3 List of functions ------------------------------------------------------------------------------------------------------- 31
4.4.1 List of system data (user data) ------------------------------------------------------------------------------ 33
4.4.2 List of system data (manufacturer data) ------------------------------------------------------------------ 35
4.5 Starting operation ---------------------------------------------------------------------------------------------------- 37
4.6 Stopping operation --------------------------------------------------------------------------------------------------- 38
4.7 Operation while analyzer is running ----------------------------------------------------------------------------- 39
4.7.1 Measuring range change operation ------------------------------------------------------------------------ 39
4.7.2 Calibration operation ------------------------------------------------------------------------------------------- 40
4.7.3 Purge and bypass operation --------------------------------------------------------------------------------- 47
4.7.4 O2 conversion/weight conversion operation ------------------------------------------------------------- 49
4.7.5 Output signal calculation/hold/output adjustment ------------------------------------------------------ 51

45. Maintenance --------------------------------------------------------------------------------------------------------------- 54
5.1 Cautions for maintenance ---------------------------------------------------------------------------------------- 54
5.2

Maintenance and inspection items ------------------------------------------------------------------------------ 55

5.3

Maintenance and inspection -------------------------------------------------------------------------------------- 56

5.4

Error display ----------------------------------------------------------------------------------------------------------- 66

5.5 Troubleshooting ------------------------------------------------------------------------------------------------------ 68
5.6 Replacement parts --------------------------------------------------------------------------------------------------- 75
5.7 Replacement of parts ----------------------------------------------------------------------------------------------- 77
5.8 About transmitter ----------------------------------------------------------------------------------------------------- 78
6. References ----------------------------------------------------------------------------------------------------------------- 79
6.1 Construction of unit -------------------------------------------------------------------------------------------------- 79
6.2

Outside view and dimensional drawing------------------------------------------------------------------------- 80

6.3 Standard specifications --------------------------------------------------------------------------------------------- 83

5

1.4

IMPORTANT

Safety precautions
WARNING1.

Before starting the wiring work to the terminal block, always
shut-down the power. Failure to do so may cause an electricalshock. Additionally, before starting the maintenance work of electricalparts, always shut-down the power.
2. To prevent an electrical shock accident, connect the grounding cable to thegrounding terminal firmly.
CAUTION1.

To prevent dew condensation, the transmitter main body becomes hot.
Before starting the cleaning and maintenance work of the piping in the opticalsystem, trap, and ejector, always wear heat-resistant gloves.
2. Before attaching and detaching the cap to/from the span port, always wear
heat-resistant gloves since the span port is hot.
3. If the suction and exhaust valves are not closed fully when starting themaintenance work while the furnace is being operated, the sample gas may spout
out.To prevent such troubles, always close the suction and exhaust valves fully.
4. Before installing or removing the Dust densitometer, make sure that the furnace
operation is stopped completely.
If it is strongly required to install or remove the Dust densitometer while the furnace
is being operated, pay special attention to the following cautions.
(1) Since the part close to the mounting seat is hot, always wear heat-resistant
gloves.
(2) If the positive pressure exists inside the furnace, the sample gas may spout
out
from the opening. Never get access to the opening.
(3) Additionally, the dust and soot in the sample gas may also spout out. Always
wear dust-proof glasses to prevent dust and soot from entering your eyes.

6

1.5

IMPORTANT

Cautions for operation

CAUTION
The following cautions must be strictly observed to prevent corrosion
and clogging of dust caused by dew condensation. Always operate
the Dust densitometer correctly while carefully referring to the following
operations.
1. Close the suction and exhaust valves if the HEAT lamp on the controller does not
flash or if the warm-up operation is not performed for 60 min.
2. If the power to the transmitter is shut-down due to power failure, immediately close
the suction and exhaust valves.
3. Perform the heat retention (heat insulation) work on the sample gas flowing pipes
between the furnace wall (guide pipe) and transmitter.
4. The dust concentration inside the furnace becomes high during a period of
approximately 2 hrs. After stopping or starting the furnace operation, causing theoptical system of the Dust densitometer to be contaminated. Therefore, close thesuction and exhaust valves for approximately 2 hrs. after stopping or starting thefurnace operation in order to prevent the dust from entering the analyzer.
5. Open and close the suction and exhaust valves periodically (once a month). If thevalves are not operated for an extended period of time, dust may stick to the valves,causing the valves not to be opened or closed.

7

REFERENCE
1.6

Overview of Dust densitometer[Measuring principle]
This Energy’s Dust densitometer is a light scattering type Dustdensitometer that utilizes the correlation between the dust weight
concentration and scattering intensity.
The light scattering intensity (I) is expressed by the following formula.
I =

2
822

6

m2 – 1m2 + 12(1 + cos2): Scattering angle, : Wavelength, : Grain diameter parameter (2a/), a: Radius ofgrain, R: Distance from grain, m: Index of refraction of light in grain/Index of refraction oflight in medium
When the physical property of the grain (shape, size, composition, color, etc.) is almost
constant, the scattering intensity is parallel to the dust weight concentration.
An infrared ray LED lamp with an emission light waveform of 875 nm is used as lightsource.
When this light is intermittently emitted to the dust passing through the detection area ofthe detector, the scattering light occurs at any angle to the dust.
A light receiving sensor is located at 70 forward to the light axis between the light source
and trap. This sensor receives the infrared ray coming from the light source andconverts it into the electrical signals.
These electrical signals are processed to measure the relative dust concentration at
real-time.
Using the standard grain, scales are put on this Dust densitometer. When measuring theexhaust gas, it is possible to perform the continuous measurement by calculating theweight conversion coefficient based on the measurement in conformity with JIS Z 8808.

8

1.7

Part names and functions
1)

Outside view of Dust densitometer

92)Part names and functions of Dust densitometer

No.

Name

Function

1

Controller

Processes the signals inside the Dust densitometer.

2Power switch

ON/OFF switch for the power to the Dust densitometer

3

HEAT LED

Pilot lamp of the heater for the Dust densitometer.
Lit during temperature rise and flashes during control.

4

MEAS LED

Lit during measurement.

5

MAINTE LED

Lit during measurement.

6

ALARM LED

Lights up if a fault occurs.

7

7-segment LED

Indicates the dust concentration and error No.

8

Alphabetic indicator

Indicates the measuring range and status, such as CAL or
PURGE.

9

Fuse 2A

Fuse for the electronics circuit.

Fuse 7A

Fuse for the heater of the Dust densitometer10

Flow meter of light emission Flow meter for clean air of the light emission part
part

11

Flow meter of light receiving Flow meter for clean air of the light receiving part
part

12

Ejector air valve

Flow regulation valve for driving of the ejector

13

Span port

Span rod is inserted into this port for span calibration.
Cleaning port for cleaning of the suction side

14

EjectorEjector nozzle for suction of the sample gas
When cleaning the exhaust side, remove this ejector and cleanit.

15

Filter membrane

Filter for clean air

16

Light emission part

Infrared LED light source built-in unit

17

Light receiving part

Light sensor and amplifier built-in unit used to detect the
scattering light.

18

Light trap

Absorbs the stray light.

19

Suction/exhaust nozzle

Nozzle used to suck/exhaust the sample gas.

20

Suction/exhaust valve

Valve used to shut-down the sample gas during calibration.

21

Terminal block for power
supply (T1)

Terminal block for power supply to the Dust densitometer22

Terminal block for Dustdensitometer (T2)

Terminal block for signals to the Dust densitometer23

Terminal block for purgesolenoid valve (T3)

Terminal block for driving of the purge solenoid valve for the Dustdensitometer

10

2.

After unpacking
2.1

Checking of accessories

11List of products and accessories
Name

Q’ty

Part No.

Remarks

Dust densitometer modelISS-101

KV-610014-J

1

With case (shelter)

Suction nozzle

KV-620212-L

1

L = Specified length (mm)Exhaust nozzle

KV-620212-L

1

L = Specified length (mm)Span calibration rod

KV-610402-A

1

Optical system jig

KV-650105

1

Cleaning brush

KV-650106

1

T-wrench

KV-650132

1

Span calibration rod storagebag

1

L sizeAccessory storage box

1

B-54

Stop plug

PG3041/8B

1

Used to stop the air inlet of the ejector
nozzle when the ejector is not in use.

Stop plug

PG3161B

1

Supplied with the Dust densitometer
main unit

Allen wrench

1

Width across flats: 3Nut

8For M16

Washer

8

For M16

Spring washer

8

For M16

Flange packing

T1995K10A100RF3T

12

1

2.2

CAUTION

Temporary storage of productThis Dust densitometer must be stored under original packing conditionsin an indoor place (temperature: -5 – 50C, humidity: 90%RH or less) until
the installation work is started.
Do not store the Dust densitometer in an outdoor place (exposed to the rain) or a place
where high temperature or high humidity exists, or mechanical vibration exists. Doing so
may cause the Dust densitometer to malfunction.
When the Dust densitometer is installed, close the door and cure the Dust densitometerso that rain water and dust does not enter the inside through the piping port or wiring port.
In the same manner, cure the probe and transmitter.

13

3. Installation
3.1

IMPORTANT

Installation conditions
This section describes how to carry out the installation, piping, and wiring
work of the Dust densitometer model ISS-101.

If the installation place is selected incorrectly or the installation work is performed
incorrectly, an unexpected trouble may occur later or the performance of the analyzer
cannot be maintained, causing damage to the units. Thoroughly read the following
description to fully understand its contents before staring the installation work.
If it is difficult to install the Dust densitometer under the conditions specified below,
contact Energy Support corp. Before installing the Dust densitometer, determine or
prepare the following items.
① Determine the gas sampling position (Dust densitometer installation position)② Determine the storage panel (purge unit) installation place.

Cautions for installation work ( CAUTION)
1) Before installing or removing the Dust densitometer, make sure that the furnace
operation is stopped completely.
If it is strongly required to install or remove the Dust densitometer while the furnace
is being operated, pay special attention to the following cautions.
(1) Since the part close to the mounting seat is hot, always wear heat-resistant
gloves.
(2) If the positive pressure exists inside the furnace, the sample gas may spout
out from the opening. Never get access to the opening.
(3) Additionally, the dust and soot in the sample gas may also spout out. Always
wear dust-proof glasses to prevent dust and soot from entering your eyes.
2) Make sure that the suction and exhaust valves are closed fully.
If these valves are not closed fully, this may cause dust clogging or corrosion.
3) Attach the flange packing (accessory) so that it does not deviate.
4) Apply the burn prevention agent (mori-coat) to the hexagon bolts and tighten the
hexagon bolts and nuts (accessories) evenly.

14

3.1

IMPORTANT

Installation conditions① Selection of gas sampling position
When selecting the gas sampling position, that is, Dust densitometer
installation position, always take the place satisfying the following
conditions into consideration.
1) Place where the typical dust value can be measured.
2) Place where the dust concentration does not vary rapidly.
3) Place where is close to the manual analysis seat.
4) Place where the gas temperature is 500C or less.
5) Place where the sample gas forms an even laminar air flow.
(It is not appropriate to install the Dust densitometer at a corner where the turbulent
flow occurs easily.)
6) Place where the mechanical vibration and impact are minimized.
7) Place where the maintenance work can be carried out easily.
Keep the maintenance area satisfying the following conditions.
a. Place where is approximately 1000 mm above the center and both sides of themounting seat. (It is necessary to attach and detach the shelter.)b. Place where is located 1000 mm + overall length of the nozzle after themounting seat.
8) Place where the outdoor temperature is –10 - 50C.
② Selection of storage panel (purge unit) installation place
When selecting the storage panel installation place, always take the following
conditions into consideration.
1) Place where the outdoor temperature is 0 - 50C and variation in temperature is
15C or less during daytime.
2) Place where the corrosive gas is minimized.
3) Place where the mechanical vibration and impact are minimized.
4) Place where the Dust densitometer is not exposed to the steam or hot air.
5) Place where the Dust densitometer is not exposed to the direct sunlight.
6) Place where the electro-magnetic induction is minimized.
(Pay special attention to this caution for wiring place.)
7) Place at a distance of 50 m or less from the transmitter.
(To reduce the piping and wiring construction costs and suppress increase inpiping resistance, the above distance shall be made as short as possible.)8) Place where maintenance space to allow opening and closing of the door of thestorage panel can be kept.

15

3.2

Installation1)

Preparations① Wind a seal tape on the screw parts (R 3/4 male-screw) of the suction and exhaust
nozzles.

② Remove four shelter mounting screws from the Dust densitometer. Raise the shelter
to remove it. Apply the burn prevention agent (mori-coat, etc.) to eight M16 bolts
welded to the flange of the Dust densitometer.

16

2)

Procedures① Screw the suction and exhaust nozzles into the flange.

Make the opening of the suction nozzle faced toward the gas
flow and the opening of the exhaust nozzle faced against the gas
flow as shown in the following.
a. Gas flows from the bottom to the top.

b. Gas flows from the top to the bottom.

c. Gas flow from the front side to the far side.

d. Gas flow from the far side to the front side.

To screw-in the suction and exhaust nozzles, first turn the nozzles manually, and thenretighten them with a pipe wrench.
(If the nozzles are not retightened with a pipe wrench, the nozzle may fall down
during operation.)(If the nozzles cannot be positioned as shown in the Fig. above after the nozzles
have been screwed in, adjust the positions by increasing or decreasing the seal tapewinding amount.)17

② Insert the M16 bolt of the Dust densitometer into the mounting seat (guide pipe),
attach the M16 washer, spring washer, and hexagon nut in that order, and thentighten the nut.
(At this time, check that the suction and exhaust valves are closed fully.)

In the above assembly, always attach the flange packing (T1995-10K100RF3T).

CAUTION
Since the weight of the Dust densitometer is approximately 40 kg, always
carry out the installation work by two or more personnel.

③ Carry out the heat retention work of the mounting seat (guide pipe).
Dimensions of guide pipe work (beyond delivery conditions)(Reference)*1 Carry out the heat retention work of the guide pipe.

18

3.3

Piping and wiring
1)

Piping
The air pipes are connected from the Dust densitometer to the purge unit.
The piping ports are located on the bottom surfaces of both the Dust densitometer andpurge unit.

2)

WiringWiring materials□：CVV 2sq×2C○：CVV 2sq×2C (Signal line cables must be shielded.)
If the wiring temperature is 60C or more, the heat-resistant wiring HCVV (-80C) or KGB(-150C) must be used.
The terminal blocks U, V, and E use M5 and other terminal blocks use M4.

19

Terminal pin assignments
The following shows the terminal pin assignments of the Dust densitometer. Always carefully connect
the wires to their specified pins.

CAUTION
The wiring above the TC, TH, contact output 5, U1, V1, and purge solenoid valve
drive terminal has been fixed by the manufacturer. Never touch these wiringlines.

Output signal 1

DC 4-20 mA

Output signal 2

DC 4-20 mA

O2 concentration signal input terminal DC 4-20 mA/0 – 25% O2
Thermocouple for the heat retention heater is connected.
Thermistor for cold-contact compensation of the thermocouple for the heatretention heater is connected.
Remote range contact (L range, M range, and H range) input terminals and bag
filter bypass operation running contact input terminal(These signals use the common terminal as common line and are activated by
non-voltage contact inputs.)

Output 1 Output 2
+
+

O2
+

Output 1 Output 2
-

TC
+
O2
-

TH
+
TC
-

H range L range

TH
-

COM

Contact Contact Contact Contact Contact Contact
output output output output output output
1
2
3
4
5
6

Terminal block T2

Contact Contact Contact Contact Contact Contact
M range Bypass output output output output output output
1
2
3
4
5
6

Select three points of the following four output modes and connect them to contact outputs 1 - 3.
①Turned ON (range echo back) when the High range is selected.
(a-contact)②
Turned ON (range echo back) when the Medium range is selected.
(a-contact)③
Turned ON (range echo back) when the Low range is selected.
(a-contact)④
Turned ON when the maintenance range, manual/auto purge, bypass operation, manual calibration, semi-auto
calibration, auto-zero reset, or purge/auto-zero recovery is selected.
(a-contact)
Contact output 4:
Contact output 5:
Contact output 6:
Contact capacity

Turned ON when bypass operation is selected.
(a-contact)
Turned ON when solenoid valve for auto/manual purge is operated.
(a-contact)
Contact to be turned ON if the power failure or error No. E-01-16, or E-20 alarm occurs is output.
(b-contact)
AC 250V, 5A, DC 30V, 5A

U1
V1

Solenoid valve

U
V
E

Terminal for driving of purge solenoid valve

Terminal block T3

Power supply terminals
for driving of purgesolenoid valve
AC 100V
Power supply terminals
AC 100V
Grounding terminal

Power supply terminal block T1

20

Bundling of wiring cables
The wiring cables are inserted into the wiring ports (4-34) at the lower
portion of the Dust densitometer.
Since the terminal blocks are located above the wiring ports, run the cables tothese points.
The wiring cables are bundled and secured to the cable support and oval wiring port of theterminal block inlet using tie-bands.

Run the cables so that they do not lean against the light receiving unit and light trap.
If any cable leans against such unit, this may hinder the maintenance work of the light trap.

21

3.4

Inspection after installation
1)
2)
3)

Make sure that the Dust densitometer has been installed and the heat retention work
has been completed.
Make sure that the purge piping is 10/8.
Check the insulation resistance between each of the U and V terminals, and the E
terminal with the main power 100V AC turned OFF.
(Check using a DC500V Megger that the insulation resistance is 5 M or more.)

22

4.

Operation

CAUTIONCAUTIONS(1) Before attaching and detaching the cap to/from the span port, always
wear heat-resistant gloves since the span port is hot.
(2) If the cap is removed from the span port, the sample gas may spout out
from the span port. Do not put your face close to the span port.
(3) If the cap of the span port is not tightened completely, the sample gas may leak,causing corrosion. If the cap is removed from the span port, always retighten the capwith the special tool.
(4) The span rod is very important to adjust the sensitivity. Always carefully handle thespan rod so that the glass surface of the span rod is not damaged or the span rod is not
fallen down.
(5) Always close the suction and exhaust valves until a warm-up time of 60 min. haselapsed after the power has been turned ON.

23

4.1

Preparations for operation
When the inspections after installation have been completed, follow the steps below to performthe preparations before operation.
1)

Make sure that both the suction and exhaust valves are closed.

Operation of suction and exhaust valves

IMPORTANT

It is also accepted that only valve window on the right side of the shelter isopened (screws at four locations are removed).

Harf open
The midlle position between
the open and closed states isharf open

24

2)

Detach the cap from the span port.

Attaching/detaching of cap to/from span port

IMPORTANT

Insert the optical system jig into two holes in the span port cap. Turn the jig clockwise totighten the span port cap while turn the jig counterclockwise to loosen it.

CAUTION
Always wear heat-resistant gloves since the span port cap is hot.

3)
4)Open the ejector air valve (valve at the front right potion of the Dust densitometer) fully.
Adjust the pressure set on the pressure reducing valve with the filter (for clean air andejector air main pressure) of the purge unit to 0.15 MPa. (To increase the purge effect,
set as high pressure as possible in a range of 0.2 – 0.6 MPa.)
5) Adjust the flow meter valve so that the flow meters on the light emission and lightreceiving units show 8 liters/min. (8 - 9 liters/min.).
6) If the velocity of the measuring exhaust gas exceeds 5 m/sec., the ejector cannot be used.
At this time, close the ejector air valve fully.

25

4.2 Key operation

The following describes the basic key operating procedures and the displays on the 7-segment
LED and alphabetic indicator.
The operations are described assuming that the upper portion shows the 7-segment LED andlower portion shows the alphabetic indicator.
1)

Turn ON the power switch to put theanalyzer in the warm-up operation.

‐‐‐‐‐
HT PD LD
When the temperature reaches the set level, theindications HT, PD, and LD will disappear.
HT, PD, and LD show the heater, light receiving
sensor, and light emission sensor, respectively.

2)

When the warm-up operation iscompleted, the indicators show theirnormal displays.

0.0
H mg/m3N

26

Measured value
Hi range

3)

Monitor operation
Press the MONI key while the normal display is shown to put the analyzer in themonitor operation.
Normal display
0.0

Press the MONI
key once.

0.05
SENSOR

Light receiving sensor
voltage (V)H mg/m3N

150.0
HEATER

40.0
LED TEMP

Heater temperature(C)

Sensor temperatureof light emission
unit (C)

MONI
40.0
PD TEMP

OFF
02

Sensor temperatureof light receiving
unit (C)

Turned OFF when O2
input value (%O2) is
not input with the O2
conversion selected.

4.00
Output signal 1 (mA)

OUT1

4.00

Output signal 2 (mA)OUT2To sensor
Only the keys, MONI ,▼ , and ▲ are valid in the above operation.

27

4)

System data setting operation
Press the CH key while the normal display is shown to put the analyzer in the setting
operation.
(Bold display shows thatthe indicator is flashing.)
Normal display
Press the CHOFF
key once.
Channel No. flashes.
CH000
0.0
Increase or decrease
H mg/m3N
the value at the
flashing position using
nnnnn
the ▲ or ▼ key.
CH004
Move the flashingposition using the
or
key.
nnnnn
CH
CH004

80.0
CH024

Display a desiredchannel No. to be set
and press the ENT
key once.

ENT
80.0
CH024

80.1
CH024
CH
key is invalid.
80.1

Data starts flashing.
Increase or
decrease the value
at the flashingposition using the▲ or ▼ key.
Move the flashingposition using the
or
key.

CH024

81.1
CH024

Data has been changed.
ENT or CLR

81.1
CH

The keys, CH ,operation.

,

CH024

,

,

Press the [ENT] key tocomplete the settingchange.
Press the [CLR] key tocancel the settingchange.

, ENT , and CLR , are valid in the above

28

5)

System data setting operation (Data ON-OFF switching operation)

Normal display
0.0

Press the CH
key once.

OFF(Bold display shows thatthe indicator is flashing.)
Channel No. flashes.

CH000

H mg/m3N
nnnnn
CH007

Increase or decrease
the value at the
flashing position using
the ▲ or ▼ key.
Move the flashingposition using the
or
key.

nnnnn
CH

CH007

OFF
CH017

Display a desiredchannel No. to be set
and press the ENT
key once.

ENT
OFF
Data starts flashing.

CH017

CH
key is invalid.

ON

Switch between ON
and OFF using the▲ or ▼ key

CH017
ENT
※

0.0
M mg/m3N

REFERENCE※･ To change the range of CH016 – 019, press the ENT key to return to thenormal display. (CH000 - 003 are also included.)･ For manual start channel, such as CH026, 027, 037, and 042, press the
ENT key to start.
･ For ON-OFF selection setting channels other than those described above, press the ENT
key to return to the channel No. flashing state.

29

To switch between OFF and ON, press the ▲ or ▼ key to change to adesired position after the OFF/ON is flashing, and then press the ENT key
to register it.

30

IMPORTANT
4.3 List of functions

Item

Contents

Setting CH No.

Setting of desired
measuring range

One of three measuring ranges, Low, Medium, and High, can be
set. The minimum range (Low) is 0-10. The maximum range(High) is 0 – 100 mg/m3N. In each range setup, set only thespan side to a desired level with the zero side set at 0.

CH121-CH127

Changing of
measuring range
Either remote or local operation can be performed.
remote/local setting

CH120

Changing of
measuring range

In the remote operation, the measuring range is changed by thecontact input (changed by non-voltage contact). In the local
CH16-19
operation, the measuring range is changed by the key operation.

Output signal
calculation function

Two output signal systems, 4-20 mA DC, (set load resistance:
600  or less, insulation output), are provided. The following CH60-63
settings can be made on each system individually.
CH68-71
・Non-conversion output, O2 conversion output, Weight
conversion output, O2 and weight conversion output
Moving average calculation (0 - 60 min. in steps of 1 min.) canbe made on four kinds of dust concentration outputs.
Additionally, the primary delay calculation function can be set
commonly in two systems.
(It is recommended to use the analyzer with an initial setting of 5 CH72
sec.)
Dust concentration value after O2 conversion is output.
(O2 concentration signal: DC 4 – 20 mA, It is necessary tosupply 0-25% O2.)

CH144-146

O2 conversion

Dust concentration value after weight conversion of the manual
analysis dust concentration value is output.
(At this time, it is necessary to input the calculation coefficient.)

CH147

Weight conversion

Output hold can be set individually on each of two output signal
systems.
Output hold function If an alarm occurs, the output is held during maintenance.
The hold value is the value immediately before the alarm occurs
or the set value.

CH74

CH73

CH57-59
CH65-67

Output adjustment
function

The zero and span values of the output signals of two system(4-20 mA) can be adjusted through the key operation.

Calibration function

Manual calibration, semi-auto calibration, and auto zero resetfunctions are provided.
CH24-27
Manual calibration: Value when the key operation is ON istaken as the calibration value. (Both zero and spancalibrations)Semi-auto calibration: When the change in indication becomes
CH40-43
the set value or less after the key operation is ON, the calibration
value is taken automatically. (Both zero and span calibrations)
CH152
Auto zero reset: Zero calibration and purge operation are
synchronized to automatically perform the zero calibration.

31

CH56, 64

Item

Contents

Setting CH No.

Dust concentration
upper limit alarm

If the dust concentration upper limit value is set, the alarm is
output.
CH48, 49
(The alarm is reset naturally. The alarm is output if theconcentration value exceeds the upper limit for 5 sec. or longer.)

Purge function

Auto or manual purge can be performed by optional
synchronization.
(Normally, operate the dialyzer with the auto purge.)

CH32-CH38

Purge function
during bypass
operation

Purge is performed while non-voltage contact is ON, which isturned ON during bypass operation of the bag filter.

CH151

Self-diagnostic
function

Faulty part of the heater and light receiving/emission unit isdetected automatically by the self-diagnostic function. If any
fault is found, relevant error indication and alarm contact are
output.

Value fixed bymanufacturer

Contact input

Remote range change (three points) and bypass operation, thatis, four points in total are provided.
The common terminal is common to all points. The contact is
activated when the contact (ON) is input.

Fixed byhardwareContact output

Three points of four points (range echo back x 3 andmaintenance) are connected to the contact output terminal
blocks 1 - 3.
Contact outputs 4 - 6 are output for bypass operation, purgesolenoid valve, and alarm.
(Contact outputs 4 - 6 are fixed.)

CH136-138

To set CH95 and later, it is necessary to operate the switch on the circuit board (turn ON S1-1).

32

4.4.1 List of system data (user data)
CH No.

Contents

Initialvalue

Data setting range

Remarks000

Non-dust concentration
conversion display

OFF

OFF/ON

001

Dust concentration O2
conversion display

OFF

OFF/ON

002

Dust concentration weight
conversion display

OFF

OFF/ON

003

Dust concentration O2/weight
conversion

OFF

OFF/ON

016

High range selection

ON

OFF/ON

017

Medium range selection

OFF

OFF/ON018

Low range selection

OFF

OFF/ON019

Maintenance range selection

OFF

OFF/ON

024

Span calibration value

100.0

1.0 – 1000025

Calibration mode selection

0

0/1

026

Zero calibration startOFF

OFF/ON

027

Span calibration startOFF

OFF/ON

032

Purge mode selection

1

0/1

033

Auto purge interval

01-00

00-01 – 99-23

034

Purge solenoid valve ON time10

1 – 99Sec.

035

Purge solenoid valve OFF time10

1 – 99Sec.

036

Purge cycle (ON-OFF repetition)3

1 – 99Cycles037

Manual purge startOFF

OFF/ON

038

Purge recovery time1

1 – 99Min.

Displayed by ON-ENT, adust concentration value
display change switch forthe 7-segment LED.
The data setting is valid
only when the O2-weight
conversion is selected.

Local range changeswitch0: Manual calibration
1: Semi-auto calibration

0: Manual purge
1: Auto purge** day - ** hr.

040

Auto zero reset interval

3

1 – 99Auto purge interval(cycle)/Auto zero reset
interval

041

Auto zero reset time3

1 – 99Min.

042

Auto zero reset startOFF

OFF/ON

043

Auto zero reset recovery time1

1 – 99048

Dust concentration upper limit
alarm selection

OFF

OFF/ON

049

Dust concentration upper limit
value

100

1 – 1000056

Output 1 adjustment

OFF

OFF/SPAN/ZERO

057

Output 1 hold mode selection

0

0/1/2/3

33

Min.

0: No hold
1: Maintenance2: Alarm occurs.
3: 1 + 2

CH No.

Contents

Initialvalue

Data setting range

058

Output 1 hold signal selection

0

0/1

059

Output 1 hold set value

0.0

0.0 – 100.0060

Output 1 O2 conversion output

OFF

OFF/ON

061

Output 1 weight conversion
outputOFF

OFF/ON062

Output 1 moving average
selection

OFF

OFF/ON063

Output 1 moving average time00 – 60064

Output 2 adjustment

OFF

OFF/SPAN/ZERO

065

Output 2 hold mode selection

0

0/1/2/3

066

Output 2 hold signal selection

0

0/1

067

Output 2 hold set value

0.0

0.0 – 100.0068

Output 2 O2 conversion output

OFF

OFF/ON069

Output 2 weight conversion
outputOFF

OFF/ON070

Output 2 moving average
selection

OFF

OFF/ON071

Output 2 moving average time00 – 60072

Primary delay calculation time
constant

5

0 – 60073

Weight conversion coefficient

1.00

0.10 – 100.0

074Standard O2 concentrationcompensation value

10.0

0.0 – 25.0

Remarks
0: Previous value is held.
1: Set value is held.
mg

Min.

0: No hold
1: Maintenance2: Alarm occurs.
3: 1 + 2
0: Previous value is held.
1: Set value is held.

Sec.

%O2

CH004 – 015, 020 – 023, 028 – 031, 039, 044 – 047, 050 - 055, 075 – 095 are not used.

34

4.4.2 List of system data (manufacturer data)
To change the setting, it is necessary to operate the switch on the circuit board (turn ONS1-1).
Contents

Initialvalue

Data setting
range

096

Manufacturer data

150－

Do not change this value.

097

Manufacturer data

0.1－

Do not change this value.

098

Manufacturer data0－

Do not change this value.

099

Manufacturer data0－

Do not change this value.

100

Manufacturer dataOFF－

Do not change this value.

104

Manufacturer data

40.0

－

Do not change this value.

105

Manufacturer data

0.0－

Do not change this value.

106

Manufacturer data0－

Do not change this value.

107

Manufacturer data0－

Do not change this value.

112

Manufacturer data

40.0

－

Do not change this value.

113

Manufacturer data

0.0－

Do not change this value.

114

Manufacturer data0－

Do not change this value.

115

Manufacturer data0－

Do not change this value.

120

Range change mode

0

0/1

0: Field key operation
1: Remote contact input

121

High range zero point0－

Do not change this value.

122

High range span point

100

10 – 100

123

Medium zero point

0

－

124

Medium span point

25

10 – 100

125

Low range zero point

0

－

126

Low range span point

10

10 – 100

Set a value in a range of 10 – 100.

127

Maintenance range

0

0/1/2

0: H range, 1: M range. 2: L range

128

Temperature rise time

90

－

Min.

129

Heater temperature lower
limit

80

－

C

130

Heater temperature upper
limit

230

－

C

131

LED temperature lower limit

20.0

－

C

132

LED temperature upper limit

70.0

－

C

133

Optical sensor temperature
lower limit

20.0

－

C

134

Optical sensor temperature
upper limit

70.0

－

C

CH No.

Contents

Initialvalue

Data setting
range

CH No.

35

Remarks

Set a value in a range of 10 – 100.
Do not change this value.
Set a value in a range of 10 – 100.
Do not change this value.

Remarks135

Allowable deviation value
from previous zero calibration
value

－

10.0

mg
0: Not used.
1: H range echo back2: M range echo back
3: L range echo back
4: ON during maintenance

136

Contact output 1 selection

0

0/1/2/3/4

137

Contact output 2 selection

0Same as above

Same as above

138

Contact output 3 selection

0Same as above

Same as above

144

O2 conversion selection

OFF

OFF/ON145

O2 input zero point0－

Do not change this value.

146

O2 input span point25－

Do not change this value.

147

Weight conversion selection

OFF

OFF/ON148

Warning output setting

0

0～7

The details see below.

149

Manufacturer dataON－

Do not change this value.

150

Manufacturer data

ON

－

151

Purge function selection
during bypass operation

OFF

OFF/ON

152

Auto zero reset function
selection

OFF

OFF/ON

153

Manufacturer data2－

Do not change this value.

154

Manufacturer data

1.00

－

Do not change this value.

155

Semi-auto zero calibration
stable range

1.0

－

mg

156

Semi-auto span calibration
stable range

5.0

－

mg

157

Semi-auto calibration limit
time

10

－

Min.

158

Light receiving sensor
voltage at previous zero
calibration－－

Do not change this value.

159

Light receiving sensor
voltage at previous spancalibration－－

Do not change this value.

160

Manufacturer dataON－

Do not change this value.

161

Manufacturer dataON－

Do not change this value.

162

Manufacturer dataON－

Do not change this value.

168 or
Hardware calibration value
later

－

－

Do not change this value.

CH101 – 103, 108 – 111, 116 – 119, 139 – 143, 148, 163 – 167, 174, 175, 182 – 183, 188 - 191 are not
used.

36

Setting of the warning point of contact output by CH148 value
CH148
value

E-17
E-18
E-19

0

1

2

3

4

5

6

7

×
×
×

○
×
×

×
○
×

○
○
×

×
×
○

○
×
○

×
○
○

○
○
○

37

4.5

Starting operation
Start operation

Perform operation preparation steps
1) – 7).

Install the shelter.

Turn ON the power.

Check the system data.

Put the shelter from the top and tighten the mounting
screws at four locations.
Open the valve window on the right side of the shelter.
(Remove four screws.)
Open the front door of the shelter. (Padlock is provided
at two locations.)
When the power switch is turned ON, the temperature of
the heater in the Dust densitometer starts rising. (Ittakes approximately 60 min. to complete the warm-up
operation.)
Always check the data during trial operation.
Recheck the list of functions stated in section 4.3.
Check that desired functions are set correctly using
the list of system data stated in section 4.4.
See section 4.2, key operation.

60 min. have elapsed after the powerhas been turned ON.

Attach the cap to the span port.

Open the suction and exhaust
valves.

Start the measurement.

Return the display to the normal display.

0.0
H mg/m3N

Tighten the cap firmly with the special tool (optical system
jig).
Open the valves with the special tool (T-wrench).
Mount the valve window on the right side of the shelter.

Change the measuring range to a desired range.

38

4.6

Stopping operation
Stopping operation

Close the suction valve.

Adjust the flow meter valve.

Close the ejector air valve fully.

Close the suction valve firmly with the special tool(T-wrench).
Keep the exhaust valve open.
Adjust the flow meter valve so that the flow meters of thelight emission and light receiving units show 8 liters/min.
(8 - 9 liters/min.).
Close the ejector air valve fully.
The stopping operation is then completed.
When the furnace is stopped for an extended period oftime (one month or longer), carry out the following steps.
① lose the main valve for the instrument air to besupplied to the purge unit.
② lose both the suction and exhaust valves.
③ urn OFF the power switch.

39

4.7

Operation while analyzer is running
The following shows the operations to be carried out while the Dust densitometer is running.
－1 Measuring range change operation－2 Calibration operation (manual calibration, semi-auto calibration, and auto-zero reset)－3 Purge and bypass operation－4 O2 and weight conversion operation－5 Output signal calculation, hold, and output adjustment

4.7.1 Measuring range change operation
To change the measuring range, either remote (remote operation) or local(field operation) can be selected. The operation is set by setting the data,that is, CH120 is set at “1” (remote) or “0” (local).
① Changing of remote (remote operation) range･ It is necessary to connect the wires to the H range, M
range, L range, and COM terminals on the terminal
H range L range COM
block.
･ The COM terminal is used as common line. The
M range Bypass
operation is performed by the contact (ON) input.
･
Non-voltage contact is used and the contact is turned
Terminal block
ON when the resistance is approximately 2 k orless.
･ If all range change inputs are ON or OFF at the sametime, the Hi range is then selected.
② Changing of local (field operation) range
Only one data is selected from the system data CH016 - 019.
With key operation, a range, which is set at ON, is selected.
Display on alphabetic indicator
CH016→High range

H mg/m3N

CH017→Medium range

M mg/m3N

CH018→Low range

L mg/m3N

CH019→Maintenance range

MainteFor details, see section 4.2, Key operation.

40

4.7.2 Calibration operation[Zero calibration]
This operation is performed to compensate for drift of the zero level toward the positiveside caused by dust sticking to the trap part or part close to the optical system.
It is possible to perform the manual, semi-auto, or auto zero reset.
[Span calibration]
This operation is performed to compensate for changes in sensitivity caused by dust
sticking to the window or part close to the optical system.
It is possible to perform this calibration in the manual or semi-auto mode.
[Manual calibration]
Closing of the suction and harf open exhaust valves, and attaching of the standard
scattering sample are performed manually.
After the indication value has become stable, turn ON the ZERO/SPAN CALIBRATIONSTART key to load the currently measured value as calibration value.
[Semi-auto calibration]
It is necessary to manually close the suction and harf open exhaust valves, and to attach
the standard scattering sample in the same manner as described for above step, Manual
calibration.
When turning ON the ZERO/SPAN CALIBRATION START key, the measured value is
automatically read as calibration value when the change in indication becomes the set
value or less within a specified period of time.
[Auto-zero reset]
The zero calibration is performed automatically by synchronizing the zero calibration withthe purge operation.
It is not necessary to close the suction and exhaust valves.
There are two kinds of zero rest methods, one is auto zero reset with key operation(purging is started automatically) and the other is that the auto-zero reset is performed bysynchronizing with the auto purge cycle.
In either case, when the set period of auto zero reset time has elapsed, the value
measured at that point is taken as calibration value.

41

① Manual zero calibration･ Positive pressure exists inside
the furnace.

･ Negative pressure exists inside
the furnace.

Fully close the ejector air
valve.

Fully close the ejector air
valve.

Fully close the suction valve
and harf open exhaust valve.

Fully close only the suction
valve.
(Keep the exhaust valve open.)

Detach the cap from the span
port and wait for 2 - 3 min.

Check that the flow meters on
the light emission and lightreceiving units show 8
liters/min.

Fully close the flow meters on
the light emission and lightreceiving units.

Attach the cap to the span
port.

(Always use the special tool.)

Wait until the indication
becomes stable.
If the indication value is 0.0 mg/m3N after the indication
value has become stable, the calibration is not needed.
If the indication value deviates, follow the steps below to
perform the calibration.
Set CH025 (calibration mode) to 0 (manual calibration).

OFF
Display CH026.
CHO26
Change the setting to ON
using the ▲ or ▼ key.

ON
CHO26

Press the ENT key.

0.0
CAL ZERO

When manual calibration iscompleted, the display returns
to the normal display.

0.0
H mg/m3N

To manual span calibration.

42

The message, “CAL ZERO”, is displayed
for approximately 1 sec. after the ENT
key is pressed. After that, the display
returns to the normal display.

② Manual span calibration

IMPORTANTThe span calibration is performed using the span rod having the same
manufacture No. as that of the Dust densitometer.
If the calibration is performed using the span rod having the different No.,
this may cause an error. Never perform the calibration using the span rod
having the different No.
Always carefully store the span rod.

Manual zero calibration is completed.
(Span calibration is started immediately after the zero calibration.)

Detach the cap from the span port.

Insert the span rod into the span
port.

Insert the span rod with the groove on the span
port matched with the span rod positioning mark.

Tighten the cap.

Manually tighten the cap clockwise so that it does
not become loose.

Wait until the indication becomesstable.

After the span rod has been inserted, the indication
value may change rapidly and the range-over or
error E-04 may occur, but this is not a problem.
The indication becomes stable 90% or more withina few minutes. However, it takes about one hourto determine the final indication.

If there is a large difference between the
span value on the span rod and indication
value (5% F.S or more) after the indication
value has become stable, follow the steps
below to perform the calibration.

43

Display CH024.

Check that the span value
shown on the span rod is
input.

80.0
CHO24

If incorrect value is input, change the system data setting.

Display CH027.

OFF
CHO27

Change the setting to ON
using the ▲ or ▼ key.

ON
CHO27

Press the ENT key.

80.0
CAL SPAN

When manual span calibrationis completed, the display
returns to the normal display.

80.0
H mg/m3N

Loosen the span rod
tightening cap.

Remove the span rod.

Attach the cap to the spanport.

The message, “CAL SPAN”, is displayed
for approximately 1 sec. after pressing the
ENT key, and then the display returns to
the normal display.

Turn the tightening cap counterclockwise.
At this time, never turn the nameplate on the span rod.
･ Remove the span rod slowly (so that the
span rod is not damaged).
･ Since the span rod is hot, carefully handle
it and return it to the storage bag
immediately.
(At this time, always use the special tool.)

Adjust the flow rate on theflow meters of the lightemission and light receiving
units to 8 liters/min.
Open the suction and exhaust
valves.

Return the ejector valve to its
previous position.
The manual zero span calibration is then completed.

44

CAUTION③ Semi-auto zero calibration
Perform the same operation steps from Fully open the ejector air valve to Wait until theindication becomes stable. as described for manual zero calibration0

Display CH025.
CHO25
Change CH025 (calibrationmode) to “1”.

Display CH026.

Change the setting to ON
using the ▲ or ▼ key.

Press the ENT key.

1
CHO25
OFF
CHO26
ON
CH026
0.0
CAL ZERO

Semi-auto zero calibration iscompleted.

After the ENT key is pressed, theaveraged value is taken at intervals of
approximately 1 min.
When the indication value becomes stable,
the measured value is taken as calibration
value.

To semi-auto span calibration④ Semi-auto span calibration
Perform the same operation steps from Insert the span rod. to Wait until the indication
becomes stable. and Check the span value. as described for manual span calibration.
0

Display CH027.
CHO27
Change the setting to ON
using the ▲ or ▼ key.

ON
CHO27

Press the ENT key.

80.0
CAL SPAN

Semi-auto span calibration iscompleted.

After the ENT key is pressed, theaveraged value is taken at intervals of
approximately 1 min. When theindication value is stable, the averaged
value is taken as calibration value.

Perform the same operation steps from Remove the span rod. to Return the ejector valve toits previous position. as described for manual calibration.
The semi-auto zero-span calibration is completed.
Note) When starting the span calibration (CH027) in the zero state or the zero calibration (CH026)
in the span state, the calibration error (E-18 or E-19) occurs when starting the next
calibration.
At this time, change the calibration mode selection (CH025) to manual (0) and perform themanual zero-span calibration (P4-19-21).
45

⑤ Auto zero reset
To use the auto zero reset function, it is necessary to change the CH152 setting to ON.
1)Starting of auto zero reset using key operation

Display CH042

OFF
CHO42

Change the setting to ON
using the ▲ or ▼ key.

ON
CHO42

Press the ENT key.

0.0
PURGE

Starting of auto
zero reset

Turn ON CH042 (or start autopurge cycle).

Purge solenoid
valve

ON
OFF

Bypass contact
outputON
OFF

Maintenancecontact output

ONOFF

Purge operation
CH034,035,036(The message, “PURGE”, is displayed on
the alphabetic indicator until the recovery
time elapses.)

Start the zero calibration (immediately before
the auto zero reset time elapses).
▽Auto zero reset time
CH041

Auto zero reset
recovery time
CH043

Auto zero reset time chart
After auto reset recovery time has elapsed.
Normal display

2)0.0
H mg/m3N

Auto zero reset by synchronizing with the auto purge cycle

Display CH032.

Display CH040.

1

Check that the auto purge is selected.

CH032
3
CH040

46

Check the auto zero reset cycle.

Example3)

When the auto zero reset cycle is set at “3”, this means that the auto zero reset is
performed once every 3 days (3 cycles) when the auto purge cycle is set at “1 day”.
The auto zero reset operation is performed in the same manner as described in theabove time chart.
After the system data, such as CH040 - 043 has been changed, reset the power to theanalyzer.
Maintenance contact output during calibration

Time chart of maintenance contact output during manual calibration
CH026 and 027 are turned ON.
ON
OFF

Maintenance contact output

Contact output is turned ON only for approximately 1
sec. after CH026 and 027 are turned ON.
Time chart of maintenance contact output during semi-auto calibration
CH026 and 027 are turned ON.
ON
OFF

Maintenance contact output

Contact output is turned ON only for approximately 1min. – 10 min. (this period may vary depending on
the stable time) after CH026 and 027 are turned ON
until the calibration value is taken.
Time chart of maintenance contact output during auto zero reset
See the time chart of the auto zero reset on the previous page.
(Contact output is turned ON between purge operation and completion of auto zero
reset recovery time.)

During manual/semi-auto calibration
When starting the calibration operation after the maintenance range has
been selected (CH019 is turned ON), the maintenance contact is turned
ON while the maintenance range is ON.
Time chart of maintenance range and contact output
Maintenance range

ON
OFF

Maintenance contact output

ON
OFF

The message, “Mainte”, is displayed on the alphabetic indicator.

47

REFERENCE

4.7.3 Purge and bypass operation[Purge]The purge operation is intended to periodically open or close the solenoid valve for a
specified period of time and introduce a large amount of air to the suction and exhaustsides in order to prevent blocking of the sample gas dust.
[Manual purge]
With key operation, the MANUAL PURGE START switch is turned ON to start the manual
purge.
[Auto purge]
The purge operation is performed at specified intervals after this system has been started.
[Purge during bypass operation]
The purge operation is performed by non-voltage contact signal, which is turned ON
during bypass operation of the bag filter.
･ It is necessary to perform the piping and wiring between the Dust densitometer andpurge unit.
･ The contents of both manual and auto system data settings are performed for a periodof time, which is common to both settings.
CH034
Purge solenoid valve ON (open) time (sec.)
CH035
Purge solenoid valve OFF (close) time (sec.)
CH036
Number of purge cycles (ON-OFF is determined as one cycle.)
CH038
Purge recovery time (min.)① Manual purge
0

Display CH037.
CH037
Change the setting to ON
using the ▲ or ▼ key.

Press the ENT key.

(Change the CH032 setting to “0”(manual purge).)

ON
CH037
0.0
PURGE

48

(The message, “PURGE”, is displayedon the alphabetic indicator until therecovery time elapses.)Turn ON CH037 (or start auto purge cycle).

Purge
ON
solenoid valve OFF
ON OFF ON OFF ON OFF

Maintenance ON
contact output OFF
Purge operation
CH034,035,036

Purge recovery time
CH038

Auto purge cycle
CH033

Time chart of manual/auto purge
After the purge recovery time
elapses.
Display returns to the normal
display.

0.0
H mg/m3N② Auto purge
1

Display CH032.

Check that CH032 is set at “1”.

CH032
Reset the power.
The purge operation is started after the period of time set in CH033 (auto purge cycle) has
elapsed after starting up the system. The auto purge operation is the same as that shownin the above time chart.
After the system data, such as CH032 - 038 has been changed, reset the power to theanalyzer.
The auto purge cycle data of CH033 is displayed in the format like 01day – 00hr.
The minimum data is 00 day-01 hr. while the maximum data is 99 day- 23 hr.
To set the data to a value less than 01 day-00 hr., lower the first digit of the hour data like 00
day-23 hr. using the ▼ key.

49

③ Purge during bypass operation
To start the purge operation during bypass operation, it is necessary to set the CH151
setting to ON.
The purge operation is started by the contact input.

Bypasscontact input

ON
OFF

Bypasscontact output

ON
OFF

Purge
solenoid valve

ON
OFF

Maintenancecontact output

ONOFF
Purge recovery time

CH038

Time chart of bypass operation
The purge solenoid valve is turned ON (opened) between turning ON and OFF of the
bypass contact input.
The message,
The message,time.

BYPASS
PURGE, is displayed on the alphabetic indicator.
, is displayed on the alphabetic indicator during purge recovery

4.7.4 O2 conversion/weight conversion operation[O2 conversion]
The dust concentration value is output after the data has been converted based on thefollowing formula.
Dust concentration after conversion of O2 concentration (mg/m3N)C=

21 – On
21 – Os

x Cs

Cs: Concentration of measuring dust (mg/m3N)
Os: Concentration of oxygen in exhaust gas (%O2) (O2 concentration input signal)
On: Standard oxygen concentration compensation value (%O2)① O2 conversion
To use the O2 conversion function, it is necessary to change the CH144 setting to ON.
Connect the O2 concentration input signals, DC4-20 mA/0-25% O2, to the O2+ and O2terminals on the terminal block.
Set the standard oxygen concentration compensation value (%O2) in CH074.
To display the O2 conversion value, set CH001 to ON.
50

To display the O2 conversion on output-1 and output-2, set CH060 and CH068 to ON.
[Weight conversion]
The scale determined by Energy Support corp. with the standard grain size is put on the
Dust densitometer.
When measuring the dust actually, a difference between the indication value on this Dustdensitometer and weight concentration of the actual dust is produced by influences of thecolor, shape, and grain size of the dust.
Therefore, the customer performs the manual analysis and needs to add thecompensation based on the weight conversion coefficient from the following formula.
Weight conversion
coefficient＝

Actual dust weight concentration value (manual analysis value) mg/m3N(Average value of indication value on Dust densitometer) mg/m 3N① Weight conversion
To use the weight conversion function, it is necessary to change the CH147 setting to ON.
Perform the zero-span calibration.

Perform the manual analysis to obtain the
average value of the dust concentration
indication during that period.

Calculate the weight conversion coefficient.

Set the weight conversion coefficient inCH073.
To display the weight conversion value on the indicator, change the CH002 setting to ON.
To display the weight conversion on output-1 and output-2, set CH061 and CH069 to ON.

Do not change the span value stated on the span rod.

51

4.7.5 Output signal calculation/hold/output adjustment① Output signal calculation
1) The contents of the following calculations can be set individually on each of two output
signal systems.
Check and set the following CH No. data of the system data.

Contents of calculation2)

Output-2

CH060

CH061

CH068

CH069

No conversion

OFF

OFF

OFF

OFF

O2 conversion output

ON

OFF

ON

OFF

Weight conversion output

OFF

ON

OFF

ON

O2 and weight conversion

ON

ON

ON

ON

The moving average (0 – 60 min. in steps of 1 min.) can be set individually on each of
two output signal systems.
Output-1

Output-2

CH062

CH070

Moving average

OFF

OFF

No moving averageONON

Set in CH063.

Set in CH071.

Contents of calculation

Moving average time setting
3)

Output-1

The primary delay calculation can be made commonly in two output signal systems.
A primary delay time constant (0 – 60 sec. in steps of 1 min.) can be set in CH072.
It is recommended to operate the analyzer with the initial setting (5 sec.).

② Output hold1) The output hold mode can be set individually on each of two output signal systems.
Output-1

Output-2

CH057

CH065

No hold

00Hold during maintenance1

1

Hold if alarm occurs.

22

Hold during maintenanceand if alarm occurs.

33

Output hold mode52

No hold: Hold is not performed.
Hold during maintenance:
Hold is performed when the maintenance range,
auto/manual purge, bypass operation, manual/semi-auto
calibration, auto zero reset, or purge/auto zero recovery is
performed.
Hold if alarm occurs: Hold is performed if E-01 – E-16, or E-20 occurs.
* Regardless of the above settings (0, 1, 2, and 3), if E-04 or E-09 occurs, the value
immediately before the error occurs is held.
2)

When “hold” is set, select the hold signal.

Hold signal
Value immediately before holdfunction is activated is held.
Previously set value is held.
3)

Output-1

Output-2

CH058

CH066

0

0

1

1

When the setting is performed so that the previously set value is held, input a holdsetting value.

Hold setting value
Setting value (mg/m3N)

53

Output-1

Output-2

CH059

CH067

0.0～100.0

0.0～100.0

③ Output adjustment
The zero and span values can be adjusted individually in two output signal systems in arange of 4 – 20 mA using key operation.
Adjust the output using the CH Nos. as shown below.

Output adjustment

Operation

Output-1

Output-2

CH056

CH064

Connect an ammeter to the output.

Normal display
0.0(Bold display shows that
OFF the indicator is flashing.)

CH

H mg/m3N

CH000
Select CH056 using the
,
,
, or
key.
OFF
CH056
ENT
OFF
CH056

CH 056

ZErO Change the mode among
OFF, ZEr0, and SPAn
CH056
using theor
key.

SPAn Adjust the value to
20 mA using the ▲CH 056or ▼ key.

ZErO Adjust the value to 4 mAusing the
or
key.
CH056

SPAn

When the value is set, press
the ENT key.

OFF When the value is set,press the ENT key.
CH056
CH

To normal display

54

IMPORTANT

5. Maintenance
5.1

Cautions for maintenance

CAUTION(1) To prevent the dew condensation, the transmitter main body is hot.
Therefore, always wear heat-resistant gloves before starting thecleaning and maintenance work of the piping in the optical system, trap,
and ejector.
(2) Always wear heat-resistant gloves before attaching/detaching the cap to/from the span
port since the span port is hot.
(3) If the suction and exhaust valves are not closed fully when starting the maintenance work
while the furnace is being operated, the sample gas may spout out when opening thevalve during maintenance. Always close the suction and exhaust valves fully.
(4) Before installing or removing the Dust densitometer, make sure that the furnace operationis stopped completely.
If it is strongly required to install or remove the Dust densitometer while the furnace isbeing operated, pay special attention to the following cautions.
1) Since the part close to the mounting seat is hot, always wear heat-resistant gloves.
2) If the positive pressure exists inside the furnace, the sample gas may spout out fromthe opening. Never get access to the opening.
3) Additionally, the dust and soot in the sample gas may also spout out. Always wear
dust-proof glasses to prevent dust and soot from entering your eyes.
(5) If the cap of the span port is not tightened completely, the sample gas may leak, causing
corrosion. If the cap is removed from the span port, always retighten the cap with thespecial tool.
(6) Open and close the suction and exhaust valves periodically (once a month). If the valve
is not opened and closed for an extended period of time, dust may stick to the valve,causing the valve not to be opened or closed.
(7) If the light emission or light receiving unit is fallen down, it may be damaged. Always
carefully handle the units during maintenance.
(8) The dust concentration in the furnace may increase during a period of 2 hrs. after
stopping or starting the furnace operation, causing the optical system of the Dustdensitometer to be contaminated.
Therefore, always close the suction and exhaust valves for approximately 2 hrs. after
stopping or starting the furnace operation to prevent dust from entering the Dustdensitometer.

55

5.2

Maintenance and inspection items

Unit nameDustdensitometer

Inspection locationand inspection item

Inspection criteria and method

Recommended
frequency

Flow meter of lightemission unit
Flow meter of lightreceiving unit

8 liters/min.(8-9 liters/min.)Once/week

Manual (orsemi-manual)
calibration

Perform the span calibration
using the zero and spancalibration rods with the air
supplied.

Once/week –monthAuto zero reset

Check that the auto zero resetis performed once a week.

Once/week

Auto purge

Check that the auto purge isperformed once a day.

Once/dayMembrane filter
element

Replace the filter periodicallyor if the clean air is not flown
at a set flow rate (8 – 9liters/min.)Once/month

Optical system andtrap

Clean the optical system andlight trap if the zero and spancalibration cannot be
performed.

Once/3 – 6monthsEjector and insideof the base metallic
pipe (exhaust side)

Clean the ejector and inside of
the base metallic pipe if thedust is clogged or whencleaning the optical system
and light trap.

Once/ 3 – 6months

Output signal

Check that the output signal
meets the indication value.

Once/year

O-ringReplace the O-ring
periodically.

Once/year

Suction andexhaust valves

Open and close the valvesperiodically. Apply the
lubricant spray periodically.

Flange packing

Replace the flange packing
periodically.

Remarks

Once/month
Once/2 years

Once/year

Replace the packing
when the transmitter isremoved from themounting seat or when
the analyzer isinspected by Energy

Support corp.
SuctionnozzleExhaustnozzleInside of nozzle

Pressure set onpressure reducing
valve with filter

Clean the inside of the nozzle
if dust is clogged or if thefurnace is cleaned periodically.

For ejector and clean air:
0.15 MPa
Purge:

Once/3 – 6monthsOnce/week

0.2 – 0.6 MPa *1

Purge unit
Element forpressure reducing
valve with filter

Replace the element
periodically.

Once/year

Functional check

Check that purge operation
functions correctly.

Once/year56*1 To increase thepurge effect, set
as high pressure
as possible in arange of 0.2 –0. 6
MPa.

5.3

Maintenance and inspection①

Checking of flow meters on light emission and light receiving units･ Check that the center of the float is located at a position
close to 8 – 9 liters/min.
･ Gradually adjust the light emission and light receiving
units alternately.

②

Replacement of membrane filter element
1)
2)
3)
4)
5)
6)
7)
8)

Close the main valve for the instrument air on the purge
unit.
Turn the membrane filter cap (transparent acrylic cap)
counterclockwise to detach it.
Remove the filter element using tweezers.
Wipe off dirt from the body and support metal fitting, andset a new filter element.
If the grease on the O-ring has been dried, apply thegrease.
Turn the filter cap clockwise and tighten it strongly by
hand.
Open the main valve for the instrument air on the purge
unit.
Check the flow rate on the flow meters of the lightemission and light receiving units.

57

③ Cleaning of optical system and light trap

Preparations for cleaning

Close the suction valve.

Adjust the flow meter valve.

Fully close the ejector air valve.

Close the exhaust valve.

Detach the cap from the span port.

Use the special tool (T-wrench).

Adjust the flow meter valve.

Fully close the ejector air valve.

Use the special tool (T-wrench).

Use the special tool (optical system jig).

Turn OFF the power switch.

Turn OFF the power switch (POWER) on the controller.

Remove the shelter.

Remove four shelter mounting screws and gradually raise
the shelter to remove it.

Completion of preparations
for cleaning

58

1)

Disassembly of optical system
Both the light emission and light receiving units have the same structure.

Disassembly of optical system

Disconnect the connector.

Turn the knurled part of the connector and pull out
the connector upward.

Disconnect the nylon tube.

Remove the light receiving/lightemission unit.

Remove the light guide bracket.

Turn the entire unit counterclockwise to remove it.

Insert the special jig (optical system jig) into theholes in the light guide bracket and turn it
counterclockwise to remove it.

Completion of disassembly of
optical system

59

2)

Disassembly of light trap
Both the light emission and light receiving units have the same structure.

Disassembly of light trap

Loosen the hose band screws.

Disconnect the nylon tube.

Loosen the hose band screws with a Phillips
screwdriver.
Fasten the 4 pipe welded to the light trap withlong-nose pliers and raise the nylon tube in the
direction opposite to the light trap to disconnect it.

Remove three hexagon socket headbolts.

Remove three hexagon socket head bolts
completely with the Allen wrench (width acrossflats: 3) supplied with the analyzer.

Remove the light trap.

Since the packing is attached and the light trap issecured to the base jig, fasten the hexagon boss
part (width across flats: 13) of the light trap with aspanner and lay down either left or right part toremove the light trap.

Remove the packing.

Completion of disassembly of trap

Gradually remove the packing from the light trap orbase metal fitting.
(If the hole opening of the packing is scratched andpassed through, replace the packing with a new
one.)

60

3)

Disassembly of light receiving unit/light emission unit
Both the light emission and light receiving units have the same structure.

Disassembly of light receiving/lightemission unit

Before removing thescrews, put marks at theassembly positions
between the bracket forthe optical system and thesensor/LED unit. This
ensures easy reassembly.

Remove the bracket for the opticalsystem.

Remove four M4 small
pan head screws.

Remove the bracket cover for the
optical system.

Remove four M3 small
flat countersunk headscrews.

Remove the O-ring and quartz
window.

The quartz window is sandwiched by two O-rings P21.

Completion of disassembly of lightreceiving/light emission unit

TROUBLE
After the above disassembly has been completed, the inside of the sensor unit
or LED unit can be seen. Always handle it carefully. Do not disassemble
the sensor unit or LED unit further.

61

4)

Cleaning of optical system, trap, and light receiving/light emission unit
Clean both the light emission and light receiving units in the same manner.
Cleaning of inside of base metallic pipe:
a. Remove the light guide bracket and wipe off the dirt sticking to the part close to
the inlet hole inside the pipe (approximately 14).
b. Remove the light trap and wipe off the dirt sticking to the inside of the basemetallic pipe to the light trap.
c. Remove the dirt sticking to parts close to two parts described above through thespan port.

Cleaning of light guide bracket:
d. Remove the dirt sticking to the inlet and inside.

Cleaning of light trap:
e. Remove the dirt sticking to the inside.

TROUBLEAll above parts a to e are painted in black. If any part is scratched largely,
this may affect the indication value. Always clean the parts carefully.
(Blow the compressed air and wire off the dirt with a soft cloth rag.) Neveruse a sharp metallic object.

62

Cleaning of quartz window:

Remove the dirt sticking to both surfaces.
Carefully clean the quartz window with soft gauze or cloth
rag soaked in alcohol.
Cleaning of optical system bracket:
f. Remove the dirt sticking to the inlet and inside.

f

The cleaning work is then completed.
5)

Cautions for reassembly after cleaning

IMPORTANT･ Do not handle the quartz window by contaminated hands.
･ When reassembling the light receiving/light emission unit , make the heatradiation fin faced upward and secure it with fore M3 small pan headscrews.
If the heat radiation fin is not faced upward, remove four small pan head screws andshift the positional relationship between the optical system bracket and the lightreceiving/light emission unit 90 to adjust it.
･ Always attach the O-rings (P18 and P24) to both sides of the light guide bracket.
･ Mount the light trap so that it faces toward the span port of the 4 pipe.
･ After the hexagon socket head bolts for the light trap are tightened manually, retighten
them with the Allen wrench.
･ Insert the nylon tube of the light trap to a position approximately 5 mm away from theroot of the 4 pipe, and secure it with hose bands. (This keeps a space for fastening
the nylon tube with long-nose pliers (5 mm).)

63

6)

④

Starting of analyzer after cleaning and reassembling･ Start the Dust densitometer while referring to section 4.5, Starting operation.
･ Perform the zero-span calibration while referring to section 4.7.2, Calibration operation.

Cleaning of ejector and inside of base metal fitting pipe (exhaust side)
Make the preparations for cleaning in the same manner as described in ③, Cleaning of opticalsystem and trap.
1)

Disassembling procedure of ejector

Disassembly of ejector

Remove the cover with thewarning label (Hot surface).

Remove the screws from both sides.

Disconnect the pipes from theejector.

Remove the Teflon tubes (both sides of the ejector).
Remove the hexagon nuts from the half-union.

Remove the ejector.

Remove four flat countersunk screws securing theejector.

Completion of disassembly ofejector64

2)Cleaning of ejector and inside of base metal fitting pipe (exhaust side)
Cleaning of ejector

a.
b.
c.

Blow the compressed air to the purge air route to remove theblocked materials from the inside of the route.
Blow the compressed air to the ejector air route to remove
the blocked materials from the inside of the route.
Wipe off the ejector nozzle surface with a cloth rag to remove
the contamination.
a

L

R

c

b

Cleaning of inside of base metal fitting pipe (exhaust side)
The base metal fitting pipe is connected from the hole in the base fitting metal, fromwhich the ejector has been removed, to the exhaust nozzle.
To clean the inside of the pipe, prepare the cleaning brush supplied with theanalyzer.
Insert the cleaning brush and open only the exhaust valve. Move the brush backand forth to remove the blocked materials.

CAUTION
Carefully clean the inside of the base metal fitting pipe since thesample gas may spout out.
Pay special attention to burn hazard since the cleaning brush ishot.
3)

Cautions for reassembly after cleaning･ If the packing for the ejector nozzle is scratched, replace it with a new one.
･ Carefully check the L and R mounting positions of the ejector.
･ Tighten the hexagon nuts of the half union so that they are not loose.

4)Starting after cleaning and reassembling･ Start the Dust densitometer while referring to section 4.5, Starting operation.
･ Perform the zero-span calibration while referring to section 4.7.2, Calibration operation.

65

⑤

Replacement of O-ringO-rings are used at the following locations.
O-ring part No.

Q’ty

Remarks

FPM-P18

2 (Light emission and lightreceiving units)

Made of Biton. Application of
the grease is not allowed.

FPM-P24

2 (Light emission and lightreceiving units)

Made of Biton. Application of
the grease is not allowed.

Quartz window

FPM-P212 x 2 (Light emission andlight receiving units)

Made of Biton. Application of
the grease is not allowed.

Span port cap

FPM-P26

1

Made of Biton.

Membrane filter

FPM-V55

1

Made of Biton or nitric rubber.
Application of the grease is notallowed.

LocationLight guidebracket⑥

Suction and exhaust valves･ Open and close the suction and exhaust valves periodically (once/month).
(If the suction and exhaust valves are not opened and closed for an extended period of time,
dust may stick to the valves, causing the valves not to be opened or closed.)･ Apply the lubricant spray during periodic maintenance (when the Dust densitometer isremoved from the furnace).
After the light receiving unit/light emission unit has been removed (seestep (3)-1 in section 5.3), apply the lubricant spray to the suction andexhaust valves while opening or closing the valves.
Before remounting the light receiving unit/light emission unit, turn ON
the power and flow the clean air after approximately 1 hour (valve isclosed and span port cap is opened) to eliminate excessive spray oilcontents.

⑦

Suction and exhaust valves･ For the exhaust nozzle, see the section, Cleaning of inside of base metal pipe (exhaustside).
･ For the suction nozzle, remove the cap from the span port and open the suction valve. The
pipe is connected to the suction nozzle.
Prepare the cleaning brush supplied with the machine.
The inside of the base metal fitting pipe (suction side) on the suction nozzle side is painted inblack (see the section, Cleaning of optical system). Always carefully handle the cleaning
brush when the top of the brush is located between the suction valve and span port. Whenthe top of the brush reaches the suction nozzle, move the brush back and forth to remove theblocked materials.

66

5.4

Error display
If an error occurs, relevant error No. is displayed on the 7-segment LED.
(Contact output 6 and power shut-down are turned ON if any of errors, E-01 – E-16, and E-20
occurs.)Error Nos., E-01 – E-20, are provided. The following table shows the error Nos. and error
contents.

Error No.

Contents

Error occurrence conditions

Retention or natural reset

E-01

ROM error

Memory read/write is impossible.

Error is retained.

E-02

RAM error

Memory read/write is impossible.

Error is retained.

E-03

EEROM error

Memory read/write is impossible.

Error is retained.

Voltage is beyond the measurement
voltage upper/lower limit range.

Error is reset naturally if
this error occurs by theupper limit.
Error is retained if thiserror occurs by the lower
limit.

E-04

Optical sensor
measurement
voltage error

E-05

O2 input error

Input is 2.4 mA or less or 21.6 mA or more.

Error is retained.

E-06

Heater cold contact
error

Cold contact is short-circuited or opened.

Error is retained.

E-07

Heaterthermocouple error

Temperature is -30C or less or 530C or
more.

Error is retained.

E-08

Optical sensor
thermistor error

Thermistor error contact is short-circuitedor opened.

Error is retained.

E-09

LED thermistor error

E-10

Temperature rise
error
(Heater, opticalsensor, LED)

Temperature does not rise within the time
set in CH128.

Error is retained.

E-11

Heater temperaturehigh error

Temperature is higher than that set in
CH130.

Error is retained.

E-12

Heater temperature
low error

Temperature is lower than that set in
CH129.

Error is retained.

E-13

Optical sensor
temperature higherror

Optical sensor temperature is higher thanthat set in CH134.

Error is retained.

E-14

Optical sensor
temperature low
error

Optical sensor temperature is lower thanthat set in CH133.

Error is retained.

E-15

LED temperaturehigh error

LED temperature is higher than that set in
CH132.

Error is retained.

E-16

LED temperature
low error

LED temperature is lower than that set in
CH131.

Error is retained.

E-17

Calibration value deviates more than the
Zero calibration error
value set in CH135 from the previously(Auto zero-reset)
calibrated value.

Error is retained.

Error is retained.

67

Remarks

This error
occurs only
when the O2
conversion isused.

Error No.

Contents

Error occurrence conditions

Retention or natural reset

E-18･ Calibration value deviates more than thevalue set in CH135 from the previously
calibrated value.
･ Calibration does not enter the stable
range set in CH155 within the time set in
CH157 during semi-auto calibration.
Zero calibration error･
When starting the span calibration(Manual andError is retained.
(CH027) in the zero state or whensemi-auto)
starting the zero calibration (CH026) inthe span state, E-18 or E-19 occurs in thenext calibration. If this occurs, change
the calibration mode selection (CH025) tomanual (0) and perform the manualzero-span calibration (P4-19-21).

E-19

Span calibration
error(Manual, semi-auto)･ Calibration does not enter the stable
range set in CH156 within the time set in
CH157 during semi-auto calibration.
･ When starting the span calibration(CH027) in the zero state or when
Error is retained.
starting the zero calibration (CH026) inthe span state, E-18 or E-19 occurs in thenext calibration. If this occurs, change
the calibration mode selection (CH025) tomanual (0) and perform the manualzero-span calibration (P4-19-21).

E-20

Dust concentration
upper limit error

Dust concentration exceeds the upper limit
value set in CH049.

How to reset the error retention state:

Natural reset

Remarks

This error isgiven only
when CH048
is ON.

Turn ON the power again if E-01 – 03 occurs.
Press the CLR and ENT keys if other error occurs.
If the upper limit over error E-04 or E-20 occurs, it isreset naturally.

68

5.5

Troubleshooting①
E-01～03

Turn ON the power
again.

Check the circuit board for
NO faulty part.
Connector is disconnected.
IC is disconnected.

Turn ON thepower again.

YES

Contact theNO manufacturer toreplace the circuitboard.

YES

If the error is resetcorrectly, restart
operation continually.

Disconnection of theconnector is the cause.

②
E-04

Does the error occur
immediately after the
span calibration rod isinserted?

If the voltage of the

Check the voltage of theNO light receiving sensor
using monitor operation.
(SENSOR)Is the voltage –1Vor less?

exceeds 5V, the dust
amount may exceed
100 mmHg.

YES

YES

Contact the manufacturer
to replace the opticalsensor unit.

The error is reset
naturally.

③

NO light receiving sensor

④
E-05

E-06

Is the O2 concentration
signal input 2.4 mA or lessor 21.6 mA or more?

Check if the heater cold
contact (terminal block TH)
is short-circuited or opened.

Adjust the O2 concentration
signal input to the correct
level.
4-20 mA/0-25% O2

Turn ON the power
again or press the
CLR and ENT keys.

NO
If the error is not resetcorrectly, replace the heatercold contact.

69

YES

If the error is resetcorrectly, restart
operation continually.

⑤
E-07

Check if the heater thermocouple(terminal block) is short-circuited or
opened.

Turn ON the power
again or press the
CLR and ENT keys.

YES

If the error is resetcorrectly, restart
operation continually.

NO
If the error is not reset correctly, turn OFF thepower and measure the measuring voltage ofthe thermocouple (between terminals (+) and (-)
of the terminal block TC).
NO
If the measuring voltage of the thermocouple is

25 mV or more (approximately 500C or more),
the thermocouple may have faulty wiring.
Send the analyzer to the manufacturer for
repair.

⑥

E-08, 09, 13,14,15,16

Check if the connector of the lightreceiving unit or light emission unit
is loose.

Turn ON the power
again or press the
CLR and ENT keys.

YES If the error is resetcorrectly, restart
operation continually.

NO
If the error is not reset correctly, replace thelight receiving unit or light emission unit witha new one.

70

⑦
E-10

Using the alphabetic indicator, check
which unit, HT, PD, or LD, does notcomplete the temperature rise.

In case of HT,
see thedescription of
E-11 and 12.

In case of LD, see thedescription of E-15 and 16.

In case of PD,
see thedescription of
E-13 and 14.

⑧

E-11, 12

Turn ON the power
again or press the
CLR and ENT keys.

YES

If the error is resetcorrectly, restart
operation continually.

NO

Relay terminal block in controller
Top

Heater

If the error is not reset correctly, turn OFF
the power and measure the resistance of theheater conductor. See the terminal block(heater) shown to the right.

Fan

○

○

○

○

○

○

○

○

○

○

○

○

To SSR

To powerswitch fuse

BottomIs the resistance ofthe heater within
10 – 30 Ω?

NO

YES

The heater is correct.
Check thethermocouple andcold contact for faulty
part.
See the description of
E-07 and 06.

If the heater may be short-circuited or have faulty
wiring. Send the analyzer to the manufacturer
for repair.

71

⑨
E-17

Is the dust shut-off
by the purge air
during auto zero
reset?

NO

Is the purge mainpressure correct?

Dust is not
shut-off.

Adjust the purge main
NO pressure and performthe auto zero reset
again.

YES

YES
Dust is shut-off by the purge air

Is the auto zero
reset time setting
correct during purge
operation?

NO Since the time is short, theauto zero reset is not
performed.

YES
Zero status rises regardless ofthe time.

Clean the optical system and trap whilereferring to 5.3-(3), and then perform theauto zero reset again.

⑩
E-18, 19

Are the suctionand exhaust
valves closed?

NO Perform the calibration again whilereferring to section 4.7.2, Calibration
operation.

YES
Zero status rises.

Clean the optical system and trap whilereferring to 5.3-(3), and then perform the zeroand span calibration again.

72

Set the time again andperform the auto zero reset
again.

⑪

Indication value is high (higher than the initial indication value).
The main cause is that dust is sticking to the light trap and inside of the base metal
fitting pipe, and the zero level drifts toward the positive side. This symptom may often
occur immediately after starting the measurement of the initial sample or several weeks
after cleaning the piping around the optical system.
If this occurs, perform the zero and span calibration to return the indication value to its
initial value.

Indication value is high.

Do the flow meters of
the light receiving andlight emission units
show 8 liters/min. (8 9 liters/min.)?

NO Adjust the flow rate to 8 liters/min.
(8 - 9 liters/min.).

YES

YES
Is the indication
value high during
zero calibration?

NO

YES
Is the calibration
possible?

Is the indication
value high during
span calibration?

NO

YES
Perform thecalibration.

NO Actual dust
amount is large.

YES
Light trap and/or
inside of the basemetal fitting pipe
may becontaminated.
Remove thecontaminationand perform thecalibration again.

Is thecalibration
possible?
YES
Perform thecalibration.

Is thecalibration
possible?
YES

Span rod may becontaminated or
NO dust may be
sticking to the spanport.
Remove the dust
and perform thecalibration again.

Perform thecalibration.

NO

Light receiving
or light
emission unit,
or circuit board
may be faulty.
Contact the
manufacturer.

Is thecalibration
possible?

YES
Perform thecalibration.

73

Light receiving
or light emission
NO unit, or circuitboard may be
faulty. Contactthemanufacturer.

⑫

Indication value is low (lower than the initial indication value).
The main cause of low indication value is that the optical system (particularly, light guidebracket, quartz bracket, and optical system bracket) is contaminated and the lightemission intensity from the light source to the sensor is lowered and the sensitivity islowered.
If this occurs, perform the zero and span calibration to return the sensitivity to its initialvalue.

Indication value is low.

Do the flow meters of
the light receiving andlight emission units
show 8 liters/min. (8 9 liters/min.)?

NO Adjust the flow rate to 8
liters/min. (8 - 9 liters/min.).

YES

Is the indication
value low during
zero calibration?

Is the indication
value low during
span calibration?

NO

YES
Is thecalibration
possible?
YES
Perform thecalibration.

NO

YES

Light trap and/or
inside of the basemetal fitting pipe
may becontaminated.
Remove thecontaminationand perform thecalibration again.

Span rod may be contaminated or dust
NO may be sticking to the span port.
Remove the dust and perform thecalibration again.

YES
Perform thecalibration.

Is thecalibration
possible?
YES
Perform thecalibration.

Is thecalibration
possible?
YES
Perform thecalibration.

NO Actual dust
amount is small.

YES
Clean the nozzle.

Is thecalibration
possible?

NO

Is the nozzle
clogged?

Light receiving
NO or light emission
unit, or circuitboard may be
faulty. Contactthemanufacturer.

Optical system of the lightemission or light receiving
NO unit (light guide bracket,
quartz window, and opticalsystem bracket) may becontaminated. Remove
the contamination andperform the calibration
again.

Is thecalibration
possible?
YES
Perform thecalibration.

74

Light receiving or
NO light emission unit,
or circuit board may
be faulty. Contact
the manufacturer.

⑬ Drift of indication value is large (5% FS or more/day).

Drift of indication value is large.

Close the suction andexhaust valves. Checkthe drift in the zero state.

Drift is large.

NO

YES
Do the flow meters of
the light receiving andlight emission units
show 8 liters/min. (8 9 liters/min.)?

Is variation inambient
temperature large?
(±10℃ or more)NO

NO Adjust the flow rate to 8
liters/min. (8 - 9 liters/min.).

YES

Is the drift
toward thepositive side?

NO

YES
Variation in ambient
temperature may be large.
Adjust the variation inambient temperature to ±10℃ or less.

YES
Drift may be causedby contamination of
the light trap and basemetal fitting pipe.

Drift may be caused bycontamination of the opticalsystem (light guide bracket,
quartz window, and opticalsystem bracket).

Make the maintenance frequency shorter.
It is recommended to use the following maintenance frequency insection 5.2.
Manual calibration Once/week – month
Auto zero reset
Once/week
Auto purge
Once/day
Clean the optical system and trap once every 3 – 6 months.
If the drift is still large with the above maintenance frequency, makethe maintenance frequency by half.

Light receiving or light emission unit, or circuit board may
be faulty. Ask the manufacturer to repair the faulty unit orsend the faulty unit to the manufacturer for repair.

75

5.6

Replacement parts① Spare parts and consumable parts
Shape

Recommended
replacement frequency

Part name

Part No.

Glass tube fuse

JIS-MF-51NR2A

Spare partFor circuit board power
supply, 2A

Glass tube fuse

JIS-MF-51NR7A

Spare partFor heater, 7A

Membrane filter
element

KS 288424

One month

For membrane filter

Filter element

AF30P-060S

One yearFor pressure reducing
valve with filter

Flange packing

T1995K10A100RF3T

One year(During periodic
inspection or when
the unit isremoved.)For mating flange formounting

Packing for light
trap

KV-610278

One year

Packing for ejector
nozzle

KV-610123-B

One year

FPM-P18

Remarks

For light guide bracket

FPM-P21

For quartz window

O-ringOne year
FPM-P24For light guide bracket

FPM-P26

For span port cap② Other parts
Part nameSuction andexhaust nozzles

Part No.

KV-620212-L

Replacement criteria

Remarks

・If corrosion or damage is large.
・If blocked materials cannot be removed.
・Replace the nozzles every 2 – 3 years during
preventive maintenance.

Length is specified by“L”.

・If a trouble occurs and the heater isshort-circuited or has faulty wiring, or
thermocouple has faulty wiring.

Replacement at site is
not allowed.
Send the defective unit
to the manufacturer for
repair.

Heater andthermocouple－

Span port cap

KV-610118

・If corrosion or damage is large.

Ejector nozzle

KV-610129

・If corrosion or damage is large.

Flow meter

RK200-VB-1/8AI10

・If the drain or contaminated oil enters the air
line.

Membrane filter

KS-283042-A

Ejector air valve(Miniature valve)

VH-6-2

In addition to replacement of the flow
meter, membrane filter, and ejector air
valve, it is necessary to replace the joint
and clean the drain entry part.

76

Part name

Part No.

Replacement criteria

Light guide bracket

KV-610261

・If it is difficult to clean the sticking foreign
matter.
・If corrosion or damage is large.

Light trap

KV-610275

・If it is difficult to clean the sticking foreign
matter.
・If corrosion or damage is large.

Hose band

HB304D7

・If elasticity deteriorates.

Optical system
bracket

KV-610262

・If it is difficult to clean the sticking foreign
matter.
・If corrosion or damage is large.

Optical system
bracket filter

KV-610263

・If damage is found during disassembly of thelight receiving/light emission unit.
・If black painted part is damaged.

Packing for heatinsulation plate

KV-610265

・If damage is found during disassembly of thelight receiving/light emission unit.

Quartz window

NO3410・If damage is found during disassembly of thelight receiving/light emission unit.
・If black painted part is damaged.

Sensor unit－

LED unit－

Light receiving unit－

Light emission unit－

CPU board Assy

KV-680096

TMNL board Assy

KV-680092

Display board Assy

KV-680094

Span calibration rod

KV-610402-A

Remarks

・If a trouble occurs and the light receiving unit
(or only the sensor unit) or the light emission
unit (or only the LED unit) needs to be
replaced.

Replacement at thecustomer’s site is notallowed.
Send the defective unit
to the manufacturer for
repair.

・If a trouble occurs and the circuit board needs
to be replaced.

Replacement at thecustomer’s site is notallowed.
Send the defective unit
to the manufacturer for
repair.

・If the span rod is fallen down and damaged.

Replacement at thecustomer’s site is notallowed.
Send the defective unit
to the manufacturer for
repair.

77

5.7

Replacement of parts

1. The heater, thermocouple, and base metal fitting cannot be replaced at
the customer’s site. It is necessary to send the defective unit to the
manufacturer for repair.
Two kinds of scaling (sensitivity adjustment) are needed after the lightreceiving unit (optical sensor), light emission unit (LED), or CPU board
Assy has been replaced.
1) A set of Dust densitometer is sent to the manufacturer and scaling is performed with thestandard grain.
2) Using the span rod supplied with the analyzer, the sensitivity is adjusted to the level
before shipment from the factory. (This adjustment must be performed by the
manufacturer’s maintenance personnel.)
2. Two kinds of methods are provided to replace the span rod.
1) A set of Dust densitometer is sent to the manufacturer. The scaling and making of the
span rod are performed by the manufacturer.
2) The scaling and making of the span rod are performed using the manufacturer’s
standard span.
After above steps 1 and 2 have been performed, carry out the manual analysis again
to set the weight conversion coefficients again.

Part nameGlass tube fuse

Replacement procedure
How to detach the fuse:
Turn the fuse 1/4 rotation counterclockwise while keeping itpressed.
How to attach the fuse:
After replacing the glass tube fuse, turn the fuse 1/4 rotation
clockwise while keeping it pressed.

Membrane filter element

See section 5.3-(2), Replacement of membrane filter element.

Filter element

Before detaching the case, release the pressure.
Turn the lever at the center clockwise while keeping it lowered to detachthe case.
Turn the baffle counterclockwise to detach it.
Pull down the filter element to detach it,

Flange packing, suctionand exhaust nozzles

See section 3.2, Installation.

Light trap packing, light
trap, and hose clip

See section 5.3-(3), Cleaning of optical system and trap

Packing for ejector
nozzle and ejector
nozzle main unit

See section 5.3-(4), Cleaning of ejector and inside of base metal fitting
pipe (exhaust side).

Span port cap

See section 4.1-2), Attaching and detaching of span port cap.

Light guide bracket

See section 5.3-(3), Cleaning of optical system and trap.

78

Part name
Optical system bracket,
optical system bracket
cover, packing for heatinsulation plate, andquartz window

Replacement procedure

See section 5.3-③, Cleaning of optical system and trap.

5.8 About this productPlease download the Safety Data Sheet (SDS) for IsoWool Bulk (artificial mineral fiber) used inthis product from our homepage.

79

6. References
6.1

Outside view and dimensional drawing

1) Dust densitometer

KV-610014-J

Terminal stand T2
Terminal stand for purge solenoid valve T3
Power terminal stand T1

Main body flange JIS10K100A
Mating flange for mounting JIS10K100A80

2) Suction and exhaust nozzles

KV-620212

Specifications
Material:

SUS316Weight:Approximately 2.3 kg/1000 mm

813) Purge unit

KV-634036-D（E） Purge unit

Specifications
Paint color:
Structure:
Weight:Plate thickness:

Munsell 5Y7/1 (semi-glossy)
Dust-proof, drip-proof, special stand or wall hanging
Approximately 25 kg
1.6 (t)82

6.2

Standard specifications

Model:
Measuring principle:
Power supply:
Measuring range:
Output signal:
Compressed air supply:ISS-101
Forward 70 light scattering method
100V AC  10%, 50/60 Hz, 700 VA
0-10/0-25/0-100 mg/m3N or equivalent
4 – 20 mA DC, (RL  600 insulation) x 2 systems
0.2 – 0.7 MPa (instrument air or equivalent)

Amount of fine particle:
Contaminated oil content:
Size of fine particle grain:
Dew point at atmospheric pressure:

0.1 mg/m3 or less
1 ppm or less10 m or less
-17C or less

When ejector is used: 20 Nliters/min. or less
(When the flow rate is 5 m/sec. or less or the sample point is disturbed, the ejector needs
to be used.)

Purge: 150 Nliters/min. or more
Clean air: 16 Nliters/min.
The clean air is always supplied continuously at 16 Nliters/min. to prevent
contamination of the optical system even though the furnace is stopped.
Note) If there is drain or contaminated oil, the measuring instrument does not
function correctly. Additionally, if the air line is contaminated, it is necessary
to replace the pipes and parts (flow meter and membrane filter, etc.).
Warm-up time:
Approximately 60 min.
Ambient temperature range: -10 - 50C
Mounting posture:
Horizontal mountingNote) Vertical mounting is not allowed.
Mounting flange:
JIS10K100A

Pay special attention to the mounting seat bolt hole positions.

Weight:Paint color:

Approximately 40 kg
Case
SUS304 (except for bottom plate)Bottom plate: Electro deposition black painting
Measuring gas conditions:Temperature: Normal temperature – 500℃
Gas pressure: ±5 KPaWater content: 0 – 55% (No over-saturation is allowed.)(If over-saturation occurs, the light is scattered by water drop. As a result,higher indication value is shown.)
Dust concentration: 0 – 100 mg/m3N
NOx
Max. 500 ppm
Flow rate: Max. 25 m/sec.
SOx:
Max. 150 ppm
HCl:Max. 400 ppm
Accuracy (repeatability):±2% FS (To be measured with the standard scattering rod.)83□ Purge unit
Power supply:

None (Solenoid valve drive signals are connected from the Dustdensitometer.)
Wiring port:

2-φ30

Gas inlet:

Instrument air inlet RC1/4

Gas outlet:

Clean air outlet, ejector air outlet, purge air outlet, RC 1/4

Purge time setting:

By setting the data on the Dust densitometer.

Weight:Approximately 25 kg

Paint color:

Munsell 5Y7/1 (semi-glossy)

84

Adjustment of the speed controller
・This dust densitometer gains the speed controller to do the flow quantity adjustment of the ejector.
・The position of the speed controller, please refer to the chart below.

Ejector air valbe

Speed controller
Lock nut

Needle valve

From the front part of dust densitometer

・When no use ejector air, no need the adjustment. (please apply it in a shipment state)
・The ejector air is set at the time of the shipment to become about 3L/min. (in the case of ejector airpressure 0.2MPa)＜Adjustment method＞①Loosen the lock nut.
②Make a state to fully close the needle valve of the speed controller.
③Please regulate number of revolutions of the needle valve in reference to the following table tomatch the terms of use of the visitor.
④After adjustment, fix the needle valve by the lock nut.
＜Adjustment example＞

Flow quantity（L/min）

When need ejector flow quantity 5L/min in 0.2 MPa, turn valve 3 times from a state to fully close.

Needle valve number of revolutions

Relations of flow quantity and needle valve number of revolutions andthe ejector air pressure85

The contents of this manual are subject to change without notice for improvement.
For inquiries regarding product handling, please contact us or our distributors.
Inquiry form URL：https://www.energys.co.jp/english/inq/all.php
ENERGY SUPPORT CORPORATION
1, Aza Kamikobarii, Inuyama, Aichi 484-8505 Japan