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Model ZS8 Flameproof Zirconia Oxygen Analyzer

1. lt 1 gt lt 2 gt lt 3 gt lt 4 gt Model and Suffix Codes Reference gas Calibration Steam Ejector inlet outlet gas inlet inlet outlet inlet outlet IM 11M7A3 01E lt 1 General gt 1 1 3 Flameproof High temperature Detector ZS8D H J L 010 2 L N HL Model for Electric Heater Providing Heat Insulation Unit mm SYS S3 Ejector SSN inlet Approx 280 A gt lt 1 gt Reference lt 3 gt Ejector I gas outlet outlet 9155 4 fo I 130 AM 1 Y CHL 1 T A 83 meets z rox yl pp C me I Fr 24 Ha ie Approx 93 A gt Approx Insertion 1 100 uU Approx 250 gt Es length I RP 405 Approx 150 Section A A lt 2 gt Calibration gas inlet Check valve J Two G3 4 IS 5K 65 FF flange openings for wiring or equivalent F1 8E ai 1 2 3 Model and Suffix Codes Reference gas Calibration Ejector Weight kg inlet outlet gas inlet i
2. EERE EEE OO 0 25 CAL Mode changed to calibration Note P ease set C4 Note 1 If 00 0 min is set in C 4 this 1 message is displayed prohibiting calibration WARM UP ON is displayed while warming up gt Span cal Y N Zero cal Y N a jJ B Di P J Please confirm span gas 20 90 O2 To O on the next page Y Displayed only 5 sec span g 600ml a as min Y Displayed only 5 sec Span valve open EE a Flow of span gas at 600 ml min Y i L To on the next page I TI YES S lt Did calibration time expire YES YES Is output stabilized C Span point is calibrated C j Normally calibrated NO Note 2 The following messages are displayed depending on the calibrated results Span cal good Span valve close Y Span cal error Try again Y N Stability error Try again Y N n cal e a rror y again Y N ye To Note 2 Y N Zero cal l J lt gt Continued on the next page F8 5E ai IM 11M7A3 01E 8 6 lt 8 Calibration gt Continued from the previous page Span cal good Span valve close Please confirm zero gas 01 00 02 y Displayed only 5 sec Introd
3. A Detector F08 ai Weight kg ZS8P H L1 050 0 JJ ZS8P H L1 150 0 JJ JIS 10K 100 FF SUS304 or equivalent 19 dia 8 holes Approx 10 kg ZS8P H L1 050 0 KJ 150 0 KJ JPI CLASS 150 4 RF SUS304 or equivalent 19 dia 8 holes Approx 050 0 AA ZS8P H L1 150 0 AA ANSI CLASS 150 4 RF SUS304 or equivalent 19 dia 8 holes Approx ZS8P H L1 050 0 EA ZS8P H L1 150 0 EA DIN PN10 DN100 A SUS304 or equivalent 19 dia 8 holes IM 11M7A3 01E 1 1 6 lt 1 General gt 1 2 5 Flameproof Converter ZS8C 1 Specifications Display Section Measured value display section 4 digit LED Talk and response display 40 character dot matrix LCD with backlight Display Content LED Oxygen concentration vol error code display LCD Measured value group A 1st level Analog bar output range alarm setpoints simultaneous display max min oxygen values average value period setting possible cell emf mV clock year month day hour minute Measured value group B 2nd level Span correction rate record zero correction rate record cell response time sec cell resistance Q cell condition estimated cell life span heater on time rate Setpoint group C calibration related Calibration gas concentration 0 calibration mode one touch semi automatic automatic stabilization time calibration time calibration cy
4. Wiring port 6 G3 4 With flame arrester Purge air inlet nominal 50A F3 4E ai Figure 3 4 Converter Purging 3 6 4 Piping for Air Purge in Converter If specified the air purge joint is already connected to the bottom of the converter upon shipment Make piping using a copper tube or the like with an OD of 6 mm ID of 4 mm or nominal size 1 4 inch between the air supply and the air purge joint 3 6 2 Air Supply for Air Purging Implement air purging using clean dry air For example use instrument air as the air supply Air consumption is about 1 l min when the supply air pressure is 50 kPa Flowrate l min Supply pressure kPa F3 5E ai Figure 3 5 Flow Characteristics of Joint on Air Supply Side IM 11M7A3 01E 4 11 lt 4 Wiring gt reels sa LL LL T39 MIH ISNA UH ISNI Joj ejeq A8SZ 48 04U09 eunjeJeduie e uy sjejeAuoo 0 AjUO seidde siu JEU 910N Yndjno si eA eA oy ejeAnoe oj JEMOd ie Jojoefe ay 10 BAJEA piouejos euj 104 0 pueg sjeuiuuei OL p 90N Ind1no si seA eA eu ejeAre o JEMOd anleA piouojos ueds y 10 6 pue sjeuruue pue eA eA prousjos oJez au 1016 pueGg sjeunue o g 90N 9 Jo jeuiuuie 0 10199jep eui Jo pjalys ejqeo HLH PUUD Z AON ZH 09 08 OV OPZ OZZ SLL OOL A ddns jewod s9aAUOO 30N Jamo peus OND uondo Jejeay 91119913 V piousjos 1081UOJ j Tire 103 ejuo plouajos SA eNn Od
5. sss 8 5 8 3 Methods of Operating Valves in the ZA8F Flow Setting Unit 8 7 8 3 1 Preparation before Calibration errnnrrrnnrrnnnrrnrnrnnrnnnnrnnnnnnnnnnennn 8 7 8 3 2 Operating the Span Gas Flow Setting Valve s 8 7 8 3 3 Operating the Zero Gas Flow Setting Valve sssss 8 7 8 3 4 Treatment after Calibration ssssssssseeee 8 7 Inspection and Maintenance esce ener 9 1 9 1 Inspection and Maintenance of the Detector 9 1 9 1 1 Precautions for Inspecting the Detector ssessssss 9 1 9 1 2 Checking the Flow of Sucked Sample Gases ss 9 1 9 1 3 Calibration of Indication ssesssssssseeeenenns 9 2 9 1 4 Checking the Flow Setting Unit During Normal Operation 9 2 9 1 5 Cleaning the Sensor Assembly seen 9 2 9 1 6 Cleaning the Calibration Gas Tube ees 9 4 9 1 7 Replacing the Sensor Assembly sss 9 4 9 1 8 Cleaning the High Temperature Probe Adapter 9 6 9 2 Inspection and Maintenance of the Converter 9 7 9 2 1 Replacing Fuses rrnnnrnnnvnnnvnnnvnnnrnnnvnnnvnnnrnnnvnrnvensrersvessrersressressreesnnn 9 7 9 2 2 Replac
6. For detector heat insulation provided by electric heaters Panel English Japanese Wall mounting With wall mounting bracket With pipe mounting bracket Air purge connection 1 ANPT F Rc1 4 1 Asteam heater 0 must be specified when heavy oil fuel gas and heavy oil fuel mixture is used or clew point temperature of exhaust gas is about 130 C Notes 1 Always use the specified external cable lead in apparatuses given in the table below 2 The number of mountable external cable lead in apparatuses is as follows Cable gland up to 7 3 As standard three cable glands G9601AE for the external cable lead in apparatuses are mounted on the cable inlet ports for the power supply and output signal On the remaining four ports blind plugs are mounted 4 If any signal other than the power supply and output signal is required additionally prepare the following parts as necessary External Cable Lead in Apparatus Name Part No Description Remarks CABLE GLAND G9601AE Cable O D 210 to 213 5 Cable gland IM 11M7A3 01E lt 1 General gt 1 1 9 3 External Dimensions Unit mm O e O O Four 10 mm dia openings AB eo S O TOMO
7. Flange joint connection brio JIS 10K 100 FF SUS304 Ir JPI Class 150 4 RF SUS304 ANSI Class 150 4 RF SUS304 Im DIN PN10 DN100 A SUS304 Ejector inlet joint C Heat insulation jacket Tag plate bun pan ius Rc1 4 specified for JIS and JPI flanges E 1 4NPT specified for ANSI and DIN flanges IJP For probe adaptors Stainless steel tag plate 1 Ifthe temperature inside the furnace is 800 C or more select B 2 Select whether to discharge mixed gases the sample gas sucked in by the ejector plus the ejector air outside the furnace or to recirculate them in the furnace 3 The probe adaptor is equipped with an auxiliary ejector assembly as standard IM 11M7A3 01E lt 1 General gt 1 15 3 External Dimensions Auxiliary ejector Gasket 1 5 mm in thickness Unit mm Air ejector mounting port Rc1 2 180 e gt nn Ey 80 r1 roi EF Po pn dB m go EX cQ BL r JE VUA Y HI i Approx 215 3 81 H i NN hu REST TI Y 1 8 1 E i EN DIAM HW L LIP ERA NN Insertion Model and Suffix Codes Insertion Length Probe for high temperature use 52 or more SiC lt 1 gt Flange mm
8. IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 11 A 5 Output Current Output Measurement Range The current output value mA of the output signal and the measurement range vol O are displayed Displ f th tput de 99 A5 OUTPUT 10 4m ADC measurement range RANGE 000 025 02 example Note The relationship between the output values of the current mA DC and the oxygen concentration vol O is as shown below 1 For a linear output signal of 0 to 20 mA DC Output current mA 20 x Px RangeH 2 For a linear output signal of 4 to 20 mA DC Output current mA 7 16 x Px RangeH 4 3 For a logarithmic output signal of 0 to 20 mA DC Output current mA 20 x 1 log RangeH 0 1 log Px 0 1 4 For a logarithmic output signal of 4 to 20 mA DC Output current mA 16 x 1 log RangeH 0 1 log Px 0 1 4 where Px Oxygen concentration vol O RangeH Maximum value of measurement range vol O The figure below indicates the relationship between each range and the logarithmic output signal 4 to 20 mA DC Eo Range0 1to5 0 1t010 0 1to25 0 1to 100 Mehrheit PPP 0 1 05 1 5 10 50 100 Px vol O F7 2E ai A 6 Time The time is displayed by the clock function of the converter year month day hour minute If correction of this time is required enter the correct time in Function No F 0 Display of time A6 PRESENT TIME Example 90 05 26 13 00 A 7 Air Ratio
9. 100mm Ih EE A space of 52 mm or more in diameter and long enough ML 1 for the length of the probe Never mount the probe Flange Install the rating se with its tip higher than flange the same as the base that for the probe l adaptor The allowable margin for probe tilt is within 5 An SiC probe shall be mounted vertically Horizontal mounting is used with a SUS probe F2 2E ai Figure 2 2 Examples of Probe Insertion Hole Construction Detector Installation In the detector zirconia ceramic is used as the sensor Be careful not to subject it to strong shock such as from being dropped when the detector is installed The same caution applies to a high temperature SiC probe adaptor Provide a gasket on the tie in flange surface to prevent gas leakage It is required that the gasket material be heat resistant and corrosion resistant conforming to the properties of the measuring gas Table 2 2 shows the parts which are necessary for installing a high temperature probe adaptor Table 2 2 Parts Necessary for Installing High Temperature Probe Adaptor ua Part Quantity Remarks JIS 10K 100 FF Bolts M16 x 80 8 The gasket should be heat resistant and Nuts M16 8 corrosion resistant Washer for M16 16 Gasket 1 JPI CLASS150 4 RF Bolts 5 8 11UNC x 80 8 The gasket should be heat resistant and Nuts 5 8 11UNC 8 corrosion resistant Washer for 5 8 11UNC 16 Gasket 1 DIN PN10 DN10
10. 2 42 Converter Mounting The converter can be mounted either to a pipe nominal 50A or on a wall The converter can also be mounted at an angle but as a rule vertical mounting is recommended Carry out converter mounting in the following procedure Pipe Mounting 1 Provide a pipe nominal 50A OD of 60 5 mm for mounting the converter vertically with sufficient strength 2 Mount the converter to a pipe Fix the converter rigidly in the procedure shown in Figure 2 9 Converter Threads Mounting pipe nominal 50A bow EUN Bracket x Washers a Bolts e Mounting Procedure 1 Screw four bolts into the bracket 2 Sandwich the mounting pipe by screwing four bolts into the threads through the bracket 3 Fully tighten the bolts Bolts F2 4E ai Figure 2 9 Pipe Mounting IM 11M7A3 01E lt 2 Installation gt 2 1 9 2 5 2 9 1 Wall Mounting 1 Drill four mounting holes on the wall as shown in Figure 2 10 Uf Unit mm 4 99 holes or 4 M8 screws 7 112 zz F2 5E ai Figure 2 10 Machining of Mounting Holes 2 Mount the converter Securely fix the converter with four screws Note For wall mounting install the wall mounting bracket on the back of the converter F2 6E ai Figure 2 11 Wall Mounting Installation of Flow Setting Unit This is necessary when the ZA8F flow setting unit is to be used Installation Site Install the flow setting unit by selecting a lo
11. Jan 2011 CMPL 11M7A3 03E Subject change without notice Printed in Japan D Parts No K9291FB K9291FA Y9814NU K9291FE K9291FF son G9601AE G9330DQ oun CMPL 11M7A3 03E ow asa Description Bracket pipe mounting only Bracket wall mounting only Screw Flame Arrestor Assembly Rc1 4 Flame Arrestor Assembly 1 4NPT Cable Gland Assembly Plug Jan 2011 Subject change without notice Printed in Japan Customer ZS8P H EXA oxy Flameproof Maintenance Zirconia Oxygen Analyzer Parts List Probe Adaptor Style S2 Item Parts No Qty Description 1 K9292TP 1 Probe SiC L 0 5m K9292TQ 1 Probe SiC L 0 7m E7046AL 1 Probe SiC L 1 0m E7046BB 1 Probe SiC L 1 5m K9292TV 1 Probe SUS 3108 L 0 5m K9292TW 1 Probe SUS 3108 L 0 7m E7046AP 1 Probe SUS 3108 L 1 0m E7046AQ 1 Probe SUS 3108 L 1 5m 2 K9292TA 1 Case for JIS 10K 100 FF equivalent K9292TB 1 Case for ANSI CLASS150 4 RF equivalent K9292TC 1 Case for DIN PN10 DN100 A equivalent K9292TD 1 Case for JPI CLASS150 4 RF equivalent 3 K9292UJ 1 Gasket 4 Y9660RU 4 Bolt 5 Y9121BU 4 Nut 6 Y9120WU 8 Washer 7 K9292WA 1 Sub Ejector Rc1 4 K9292WB 1 Sub Ejector 1 4NPT 8 E7046FQ 1 Gasket 9 E7046FN 1 Plate 10 Y9825NU 4 Screw 11 Y9800WU 8 Washer 12 Y9801BU 4 Nut 13 K929
12. Hour 27 28 29 30 31 32 33 34 35 36 E 0 0 Al 10101 Slash Comma P gt P gt pP gt p gt gt Alarm code 00 No alarm HH High high alarm H High alarm L Low alarm LL Low low alarm TH Input temperature alarm Error code mmmmmmmmm 00 No error 01 Cell failure 02 Cell temperature error low 03 Cell temperature error high 04 A D converter error 05 Zero calibration error 06 Span calibration error 07 Stabilization time over 08 Memory failure IM 11M7A3 01E lt 4 Wiring gt 4 17 Data Format for DR Command Communication 2 Transmission 37 38 39 40 41 42 43 44 45 46 format data W EID T lO 1 0 96 Comma Unit Oxygen concentration value O 2 10 0 010 0 O 10 0 009 99 Wet concentration dry concentration WE Wet concentration DY Dry concentration 47 48 49 50 51 52 53 54 55 56 A V 1 012111 10101 Comma Unit Oxygen concentration value 000 00 to 100 00 Average oxygen concentration 57 58 59 60 61 62 63 64 65 66 A T 0 21 4 H Space Comma Unit hour Calculation time 000 to 999 Calculation of average oxygen concentration 67 68 69 70 71 72 73 74 75 76 MIX1012151 10101 Comma Unit Oxygen
13. IM 11M7A3 01E lt 9 Inspection and Maintenance gt 9 3 Note e As a rule this work must be carried out in a state where both working place and inside of the furnace are safe against explosion Especially if the pressure in the flue is positive care must be exercised e Donotreuse a gaskets K9292UJ K9292DL to seal the detector 1 Removal of the detector Loosen the four M8 Allen bolts fixing the detector and remove them The flange J positioning is carried out by the two OD 8 mm spring pins 2 Removal of the flame arrester block F There is a M5 thread hole at the center of the flame arrester block F Screw any M5 bolt into this hole and pull it out by pulling the bolt toward you As the OD 6 mm ID 4 mm stainless steel pipe is provided for the block draw this pipe out also 3 Cleaning If the surface of the sensor is dry and attachment can be easily removed you can use an air gun to clean it off If it cannot be removed use boiling water or suitable solvent etc to clean it 4 Cleaning of other parts Clean the mating surface of the flange holes through which gas flows and the ejector by using an air gun or boiling water Mounting flange Housing Filter Probe Gasket Gasket K9292DL Detector K9292UJ Flame arrester f Sensor parts Suction pipe M8 Bolt F9 1E ai 5 Checking the probe Check the filter at the tip of the probe at the frequency of once every three mont
14. Use the number increase key number decrease key entry key etc Which keys you use depend on the present state you are in i e the operation mode and the position of the cursor e Selecting Function No D 0 when already in Function No C 1 Display of Function No C 1 C1 CAL GAS CONC 02 ZERO ES T1 99 The displayed data are registered and the cursor moves to the upper C 1 CAL GAS CONC 02 left ZERO 2001 00 Display of Function No D 1 A D changes from D 1 OUTPUT RANGE 2 025 02 eo eo o The cursor moves over to the No D 1 OUTPUT RANGE 000 025 9602 Display of Function No D 0 the no decreases DO OUTPUT RANGE 1 000 050 96 02 IM 11M7A3 01E 7 4 lt 7 Operating Keys and Display of Converter gt 6 Entering the setting data Selection of setting details Use the number increase key number decrease key cursor key entry key etc Which keys you use depend on the present state you are in i e the operation mode and the position of the cursor e Selecting hold HLD in Function No D 2 when already in Function No D 0 Display of Function No D 0 DO OUTPUT RANGE 1 000 050 02 The displayed data are registered SiNi and the cursor moves to the upper DO OUTPUT RANGE 1 left 000 050 02 Display of Function No D 0 The cursor moves over to the No DO OUTPUT RANGE 1 000 050 02 2 Press this key twice D 1 Display of Function No D 2 Note comes up if you press this D ouTPUT
15. 2 HiHi alarm 3 Hi alarm 4 LoLo alarm 5 Lo alarm 6 Entry 7 Range switching answerback 8 Warm up 9 Reduction of calibration gas pressure repeat output of contact input 10 Calibration 11 Blow back If any combination is applicable during default the contact points will operate Contact point 1 NC normally energized 1 Abnormal Contact point 2 NO normally de energized 6 Entry 10 Calibration 8 Warm up Contact point 3 NO normally de energized 3 Hi alarm 5 Lo alarm Contact Output for Solenoid Valve Solid State Relay Triac output 2 points Contact capacity 250 V AC 1A Leakage current at SSR OFF 3 mA or less Contact output for ejector air stop solenoid valve Contact capacity 250 V AC 1 A load resistance n the case of a probe with electric heaters if the heater temperature falls below 10 C against setting temperature for some reason or if the power goes off the ejector stops Serial communications with an RS 422 A interface Self diagnosis Abnormal cell abnormal cell temperature low high abnormal analog circuit abnormal calibration abnormal ROM RAM power failure Contact Input optional 2 points isolated Contact input or voltage input ON OFF Contact input 200 O or less 100 kQ or more Voltage input 1to 1 VDC 4 5 to 2 5 V DC or more The following functions are programmable for each contact input 1 Reduction of calibration gas pressure Ca
16. 6 2 Stationary OperatlOn itineri interit i ep eR E ER init 6 20 6 2 1 Collection of Control Data esisiini iniaa 6 20 6 2 2 Troubleshootlng us iiic iconic ence eec eant ecce 6 20 6 2 3 Checking Operating Conditions seeee 6 21 6 2 4 Stopping and Restarting Operations ssssssssssss 6 22 Operating Keys and Display of Converter 7 1 7 1 Operating KEYS cc 7 1 7 1 1 Types and Functions of Operating Keys sssesesss 7 1 7 1 2 Examples of Applications of the Operating Keys 7 2 IM 11M7A3 01E 10 IM 11M7A3 01E lt CONTENTS gt 7 2 Readout Displays eerie aana Aa Aaaa aaa earan 7 6 7 2 1 Status Display eia tin HER EIU aliens 7 6 7 2 2 Data Display rnt e RR ERR EA EM KU REMAIN EHE 7 6 7 2 3 Message Display sse 7 6 Calibration Oc P n 8 1 8 1 i C pm 8 1 8 1 1 Principles of Zirconia Oxygen Analyzer sees 8 1 8 1 2 Calibration Gas ii RR EEUR EE URE EUR ETRAS 8 2 8 1 3 Lo 10 0121 0151 110 ME 8 2 8 1 4 Characteristic Data from a Sensor Measured During Calibration 8 3 8 2 Calibration Procedures oot nhan kikka aent akse Kne ak 8 4 8 2 1 Operation Flowchart of Semi Automatic and Automatic 65 10 10 g JE ENE 8 4 8 2 2 Operation Flowchart
17. Check the heat insulation conditions See Section 6 1 2 3 Check the status of set valves See Section 6 1 3 4 Supply power to the converter See Section 6 1 4 See Sections 6 1 5 and 6 1 6 To set data enter the password 16 5 Warm up amp set the data 6 Calibrate See Section 6 1 9 Y Note Also check for normal operation of alarm output Stationary operation etc before starting up stationary operation if possible i Inspection of Piping and Wiring Conditions In referring to Chapters 3 and 4 inspect the piping and wiring to see that they are correctly installed Checking the Heat Insulation Conditions For heat insulation with steam check that steam is supplied to the copper pipe for heat insulation with steam which is connected to the flame arrester and that the flame arrester is sufficiently heated Also check that the flame arrester and the detector s main ejector are sufficiently heat insulated with insulating materials Note Set the steam pressure so that the heat insulation temperature is the dew point of sulfuric acid for the measuring gas 10 C 200 Sulfuric acid dew point C Sulfur content in fuel F6 1E ai Figure 6 1 Sulfuric Content in Fuel and Sulfuric Acid Dew Point for reference IM 11M7A3 01E 6 2 lt 6 Operation gt 6 1 3 6 1 4 Checking of Set Valves Inspect the valves as follows depending on your system 1 Ifa needle valve is mounted at the cali
18. Ejector Installation Install the main ejector for the detector and the high temperature auxiliary ejector in the position shown in Figure 3 3 Both main and auxiliary ejectors can be installed in any direction at 90 angles If soot accumulates on the bottom of the probe and corrodes it it is recommended that the ejector be installed pointing downward for purging 2 Piping A CAUTION The temperature of gas from outlet of ejector is high temperature about 200 C Release it to safe place please It would arouse furns and furmiry accident a Install the pressure gauges and supply the air adjusting the needle valves as near the ejector as possible However if the temperature of the pressure gauge mounting location exceeds 40 C install them in a location at 40 C or less away from the ejector b Use copper tubes or stainless steel tubes of OD 6 mm ID 4 mm for piping Take some measures such as winding the ejector s air supply tube around the detector itself near the sensor if the ambient temperature is low so that the tube does not become clogged due to condensation by the cooled ejector see Figure 2 5 IM 11M7A3 01E lt 2 Installation gt 2 2 5 2 2 6 2 3 c Ejector outlet piping For the detector with a high temperature probe adaptor the measuring gas cannot be returned to the furnace Both the main ejector for the detector and the auxiliary ejector for the probe adaptor are influenced by back pressure s
19. Failure of components which are out of scope of warranty stated in instruction manual Failure of components which are out of scope of warranty stated in instruction manual Failure caused by usage of software hardware or auxiliary equipment which Yokogawa did not supply Failure due to improper or insufficient maintenance by user Failure due to misoperation misuse or modification which Yokogawa does not authorize Failure due to power supply voltage frequency being outside specifications or abnormal Failure caused by any usage out of scope of recommended usage Any damage from fire earthquake a storm and flood lightning disturbance riot warfare radiation and other natural changes B Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application B Yokogawa will not bear responsibility when the user configures the product into systems or resells the product B Maintenance service and supplying repair parts will be covered for five years after the production ends For repair this product please contact the nearest sales office described in this instruction manual IM 11M7A3 01E Model ZS8 Flameproof lt CONTENTS gt i Zirconia Oxygen Analyzer CONTENTS IM 11M7A3 01E 3rd Edition PREFACE ee i Flode iii Precautions for Flameproof Instruments ess
20. The current air ratio obrained by calculation is displayed If you use this air ratio data for estimating the combustion efficiency etc check that there is no air leaking in beforehand and that the measured value has not been affected by any interference gas CH CO H etc Air ratio m is calculated by the following formula m 1 21 Oxygen concentration x 21 Display of air ratio A 7 EXCESS AIR RATIO example 03 59 A 7 is the last message in the measured value group A If you want to display messages in measured value group B press the cursor key IM 11M7A3 01E 7 12 lt 7 Operating Keys and Display of Converter gt B 0 Span Point Correction Ratio Record The span point correction ratio obtained every time the span point is calibrated is displayed You can determine the degree of deterioration in the cell sensor from this value You can display the data record for the previous 10 times including the latest data To display each datum on the screen call up the next screen by pressing the message HELP key You can have the span point correction ratio as follows The correctable range of the span point is 0418 corresponding to a voltage at a span point of about x15 mV 81 92 Zero origin Calibration curve before correction Cell voltage mV 7 Corrected theoretical calibration curve t Span origin 21 0 p1 p2 0 51 Span gas Zero gas concentration concentration
21. gt Ww 4 Tl I U I O gt c m Be Display when an error occurs Example 7 O lt w T DZ O c 02 w r Zz I ES A O gt nZz c r 4 Ao O C UJ m U z o 4 Z lt UO O gt or r o A F gt IIn m oO T Mr r za r 4 O A z o gt I IU m o JE O O 4 e Error Code E 8 Display when an error MEMORY FAILURE ion occurs Example 6 ROM RAM H CUST RPR IMPOSSIBLE CONT YKGW SVCE DEPT A 1 Maximum or Minimum O Concentration The maximum and minimum values of measured oxygen concentrations are stored and updated according to the time intervals set in Function No F 2 In Function No A 1 the latest values are displayed By subsequently pressing HELP the auxiliary message display key generated data and time of those values are displayed Display of maximum and minimum O A 1 M concentrations M example 02 AX 3 2 N 48 02 H 19 15 IM 11M7A3 01E 7 10 lt 7 Operating Keys and Display of Converter gt A 2 Mean O Concentration The mean value of the measured oxygen concentration is stored and updated according to the time intervals set in Function No F 1 In Function No A 2 the latest value is displayed Display of mean O A2 AVERAGE 024hour concentration example 016 92 O 2 A 3 Cell Voltage Cell Sensor voltage is an index for noting the deterioration of the sensor In Function No A 3 the cell voltage
22. 0 01 8 43 11 27 0 77 No 4 det 83 0 10 5 0 5 04 35 20 0 1 43032 40604 10 3 1 55 1 18 0 02 8 18 10 93 0 72 J 3 Net calorific value of fuel in A J 1 Moisture content in exhaust gas e Gas fuels J 2 Theoretical air qty Ty J 4 X value Fy Fuel Chemical components Heat value Sud properties Specific by weight kJ Nm Theoretical Combustion gas qty N m m X weight combustion value kg Nm CO H CO CH CH O N High Low N m m CO H O N Total Type rc E 0 544 90 505 26 259 39 01 80 20428 18209 4 455 0 45 Blest furnace gas 1 369 25 0 2 0 200 530 3391 3349 0 603 0 45 Natural gas 0 796 20 884 32 1 6 42 37883 34074 9 015 0 98 Propane 2 030 C H 9096 C H 10 102055 93976 24 63 3 10 Butane 2 530 C H 10 C H 90 125496 115868 30 37 3 90 Gases Molecular Formula Oxygen 1 43 O Nitrogen 1 25 N Hydrogen 0 09 H 12767 10758 2 390 Carbon monoxide 1 25 CO 12642 12642 2 390 1 0 Carbon dioxide 1 96 CO Methane 0 72 CH 39750 35820 9 570 1 0 Ethane 1 34 C H 69638 63744 16 74 2 0 3 0 13 2 182 1 60 Ethylene 1 25 C H 62991 59060 14 35 2 0 2 0 1 4 154 148 Propane 1 97 C H 99070 91255 23 91 3 0 4 0 189 25 9 229 Butane 2 59 CH 128452 118623 31 09 4 0 5 0 246 336 2 98 J 3 Net calorific value of fuel in A un J 1 Moisture content in exhaust gas
23. 300 ml min for both the reference amp NA 1 to 7 days setting unit calibration gases for correctly measured and calibrated values Cell voltage To know the extent of deterioration of the sensor cell Compare 1 to 2 weeks Function No A 3 the displayed value with theoretical one and To determine the intervals between replacement of calibration gas Pressure in the calibration i zero gas cylinders Specify min pressure and check for highter 1 to 2 weeks gas oylinder pressure Set value of oxygen conc To obtain a correct calibrated value Check for complete setting of Upon Padi dins replacement for calibration gas zero oxygen conc in the calibration gas zero in use et Digital circuit error power To determine the intervals between replacement of purge gas 1 to 2 weeks failure cylinders Determine min pressure and check for highter pressure Air supply pressure Tor For correct measurements check that the air supply pressure set main and auxiliary i 1 to 2 weeks in Section 6 1 8 does not change ejectors Steam supply pressure For heat insulation by steam check that the supply pressure is 1 to 2 weeks IM 11M7A3 01E 6 22 lt 6 Operation gt 6 2 4 Stopping and Restarting Operations lt Operation stoppage gt Before stopping operations it is important for you not to make the detector sensor inoperable If you stop the operation of the zirconia oxygen analyzer at the s
24. Bar graph When you press the measurement mode select key an analog bar graph is first displayed On the top line is displayed the analog bar graph showing the oxygen concentration of the measurement span On the bottom line are displayed the minimum and maximum values of the measurement range and arrows indicating the lower limit alarm set value Lo and the upper limit alarm set value Hi When an error occurs a message is also displayed If there are multiple messages H is displayed at the bottom right part of the display Thus in this case display auxileary messages using HELP key to confirm the contents 1 The minimum unit on the analog bar graph corresponds to 2 5 created by dividing the 100 of measurement span by 40 There is one displayed value after being smoothed 2 Displayable alarm set values indexes are those only for the lower and upper limits The extreme upper and extreme lower limits if any are not displayed In addition if the lower or upper alarm set value is set in excess of the measurement range it is not displayed either 3 Ifthe alarm set value indication index overlaps the display unit of the minimum or maximum value in the measurement range it is not displayed 4 Ifthe analog bar graph indicates the hold value preset or preceding value HOLD is displayed in the lower line Display of analog BHEHNHENHEHNHEHHEHHEHNHENENENMIIIIIIUIrDLI bargraph Example 1 0 1 r 25 L H Note1 Th
25. Converter lt Main fuse gt 1 Before replacing the fuse turn off the converter s power supply 2 Loosen the fuse from its holder by turning the holder cap counterclockwise Then remove the fuse with its cap from the holder 3 Be sure that the new fuse is rated at steam heater 3A and detector heater 12A Insert it into the fuse cap and then place it in the fuse holder To complete the replacement turn the cap clockwise until it stops IM 11M7A3 01E
26. Correctable range 0 18 PE Figure 8 3 Calculation of a Calibration Curve and Correction Factor in a 1 Point Calibration Using a Span Gas 8 1 4 Characteristic Data from a Sensor Measured During Calibration During calibration the following data for monitoring the conditions of the sensor are collected as well as calibration data However if calibration is not properly executed error occures in automatic or semi automatic calibration these data are not collected in the current calibration 1 Record of span correction factor You can monitor values acquired from the past 10 calibrations using Function No B 0 2 Record of zero correction factor You can monitor values acquired from the past 10 calibrations using Function No B 1 3 Response time You can monitor the response time provided that a 2 point calibration has been performed These values can be monitered using Function No B 2 IM 11M7A3 01E lt 8 Calibration gt 8 2 Internal resistance of a cell Internal resistance gradually increases as the cell sensor deteriorates You can monitor the value measured during the latest calibration using Function No B 3 Robustness of a cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed in a number on 5 levels You can monitor cell robustness using Function No B 4 Calibration Procedures In this Section the procedures for operating semi automatic automatic an
27. Figure 9 4 Removal of Fuse F1 and F2 When converter for 100 V series power 3 After checking that the new fuse has the specified rating 3 15 A place this new fuse cartridge glass tube fuse in the holder Insert the fuse into the cap and then both into the holder Turn the cap 90 clockwise while pushing it at the same time with a flat blade screwdriver lt Replacing the fuses F3 F4 to protect the electric circuit in a converter gt 1 Turn OFF the main switch of the converter to maintain safety while replacing the fuse 2 Remove the fuse Fuses F3 F4 are cartridge socket types in which 2 prongs of the fuse are inserted into the socket on the printed circuit board If you cannot remove fuses F3 F4 easily with your hand use a tool such as long nose or needle nose pliers 3 Check the new fuse for the specified rating 0 5 A before installing it Hold the body of the fuse gently with a pair of pliers and fully insert the 2 prongs into the socket on the printed circuit board Be careful not to bend the prongs during installation otherwise the fuse may be damaged Fuse F3 F4 0 5 A cartridge socket type Needle nose plier F9 8E ai Figure 9 5 Removal of Fuse F3 and F4 Replacing the Message Display Unit The dot matrix LCD incorporated in the message display unit has a high performance and durability for long time operation However after long time use the performance deteriorates gradually and unavoidably i
28. HOLD key only once 0 0 N 1 HLD 2 P HLD Press this key twice The Display of Function No D 0 cursor moves over to 1 D2 OUTPUT HOLD 0 0 N 1 HLD 2 P HLD Ni Registered Note Presently set item is displayed by the ENTER number of left side in the lower line 7 Entering the setting data Input of data values Use the number increase key number decrease key cursor key entry key etc Which keys you use depend on the present state you are in i e the operation mode and the position of the cursor e When span gas concentration is to be changed from 21 00 vol O to 20 00 vol 0 in Function No C Display of Function No C 0 Press the key 4 times to move 0 uo Fuss s 3 2 rds M z Lene the cursor to the 1 from the C CO CAL GAS CONC 02 7 SPAN 021 00 The 1 is changed to 0 to come up CO CAL GAS CONC O2 with the figure 20 00 SPAN 020 00 The displayed data are registered GE and the cursor moves to the upper C0 CAL GAS CONC 02 left PAN 020 00 If the entered value exceeds the settable range such a SET RANGE EXCEEDED display is presented and than the input state display returns again Check the setting range in Table 7 1 and enter a correct value again 8 Changeover from the setting mode to the measurement mode Use the measurement mode select key e When changing over from Function No D 0 Display of Function No D 0 DO OUTPUT RANGE 1 000 050 02 2 9 The mode is
29. IM 11M7A3 01E lt 6 Operation gt 6 1 5 Calculation Formulae If you use a fuel not described in Table 6 2 calculate the set values for Function Nos J 1 to J 4 using the following formulae e Liquid fuels Moisture content in exhaust gas 1 100 1 24 9 h w m kg Theoretical air quantity 12 38 10000 x H 1 36 m kg Net calorific value H X value 3 37 10000 x H 2 55 m kg Where H Net calorific value of fuel h Hydrogen in fuel 96 by weight w Moisture content in fuel by weight H Same as H e Gasfuels Moisture content in exhaust gas 1 100 h 72 2 C hy w m m Theoretical air quantity 11 2 x H 10000 m m Net calorific value H X value 1 05 10000 x H m m Where H Net calorific value of fuel h Hydrogen in fuel by weight w Moisture content in fuel 9o by weight H Same as H e Solid fuels Moisture content in exhaust gas 1 100 1 24 9h w m kg Theoretical air quantity 1 01 H 1000 0 56 m kg Net calorific value H H 5 9 9h w kcal kg X value 1 11 0 106 1000 x H m m Where w Total moisture content during use 96 by weight h Hydrogen content by weight Mean hydrogen content of domestic coa moisture ash free is 5 796 Therefore h is approximated by the following formula h 5 7 x 100 w a 100 x 100 w 100 w Where a Ash content 96 w Moisture content based on industrial analyses constant humidity
30. Installation gt IM 11M7A3 01E Procedure 3 Procedure 4 Fit the heat insulating material Body Undo the magic tape on body heat insulate material cover the heat insulate electric heater from side of detector terminal box and take care of make flexible pipe from electronic hearter go through the surface of heat insulate material make the pipe from ejector go out from the hole in two side of heat insulate material po Sa Fit the heat insulating material on the detector Stick the magic tape of plate heat insulate material on the side of heat insulate material Body And then stick the magic tape on the side of terminal box of heat insulate material Body to the detector wrap the flexible pipe up with magic tape on the side of plate heat insulate stick it tightly and fix it by rope at last These are all procedures Please confirm your fitting by the photo above lt 2 Installation gt 2 1 1 Inthe case of steam hearter ae EL Procedure 1 Wrap and fix the heat insulate material Wrap the copper pipe on the flame arrester of detector with ring like heat insulate material Fix the ring like heat insulate on the copper pipe tightly by magic tape Please refer to photo by procedure 5 that the installation of jacket is finished Procedure2 Fitthe heat insulating material Plate Undo the magic tape on plate heat insulate material then insert it between the upside of flange of detector probe and
31. JIS 10K 100 FF SUS304 or equivalent Approx 13 ZS8D L J A 050 1 N LI Rc1 4 1 4NPT JPI CLASS 150 4 RF SUS304 or equivalent Rc1 4 1 4NPT ZS8D L J A 150 1 N ANSI CLASS 150 4 RF SUS304 or equivalent ZS8D L J A 050 1 N Rc1 4 1 4NPT ZS8D L J A 150 1 N IM 11M7A3 01E DIN PN10 DN100 A SUS304 or equivalent Approx lt 1 General gt 1 1 1 Flameproof General purpose Detector ZS8D L J A 0O 2 O0 0 O00 Model for Electric Heater Providing Heat Insulation Unit mm Insertion length Jen 405 Approx Approx 250 DET ee Section A A Outlet to return suctioned gas to the furnace Rc 1 8 lt 4 gt Mounting flange Suction gas return port lt 2 gt Calibration gas inlet Check valve Section B B lt 1 gt Reference gas Inlet Outlet lt 2 gt Calibration gas Inlet 3 Ejector Inlet Outlet F1 6E ai Two G3 4 openings for wiring 4 Flange Joint Model and Suffix Codes J Rc1 4 Weight A 1 4NPT A B C
32. Note If a replaced fuse blows out immediately a problem may exist in the circuit Completely go over the circuit to find out why the fuse blew Main fuses two 9517VK 3A for steam heater S9503VK 124A for detector heater d sol R 3 ZAR LR EE LEE VAASKD ER a w hd Sr 2 F1 F2 3 15A fuse F1 and F2 for detector heater 0 5A amplifier fuses F3 and F4 Part no A1113EF Part no L9021EF provided on the back of the cover F9 6E ai Figure 9 3 Locations of Fuses for Converter Main fuse 1 Before replacing the fuse turn off the converter s power supply 2 Loosen the fuse from its holder by turning the holder cap counterclockwise Then remove the fuse with its cap from the holder Be sure that the new fuse is rated at 3 15A Insert it into the fuse cap and then place it in the fuse holder To complete the replacement turn the cap clockwise until it stops 3 IM 11M7A3 01E 9 2 2 lt 9 Inspection and Maintenance gt lt Replacement of Detector Heater Fuses F1 F2 gt Replace the fuses for the detector heater in the following manner 1 Turn OFF the power to the converter for safe replacement work 2 Remove the fuses from the fuse holders Turn the fuse holder cap 90 counterclockwise using a flat blade screwdriver that just fits the holder cap slot In this state the fuse can be pulled out together with the cap Cap Flat blode Screwdriver inm Socket Fuse
33. O O O O O ZS8P H Probe adaptor O O O ZA8F Flow setting unit O O O Ejector assembly O O oO Part No K9292VA VB WA WB Calibration gas unit case Part No E7044KF O O A CAUTION There are two types of general purpose detectors one which vents to the outside of a furnace the mixed gases of a sample gas suctioned in by the ejector and ejector air and another which returns mixed gases to the furnace High temperature detectors all vent to the outside of a furnace Vent the mixed gas of a sample gas and ejector air to a place where no safety problems will occur the venting flowrate should be 40 to 50 l min A general purpose detectors may be a return to the furnace type A return pipe is provided as standard However be cautious in returning gas to a furnace because air is blown into the furnace The normal flow rate of Netwrining gas is approximately 3 l min to 5 l min IM 11M7A3 01E lt PREFACE gt This manual takes the following configuration A brief description of each chapter and the chapters to be referred to for installation operation and maintenance are given Chapter configuration of the manual and items to be referred to Chapter Configuration of This Manual and Items to be Referred to For reference to parts list damaged are illustrated for each unit Chapter Brief description Instal Opera Mainte lation tion nance General
34. Setting Digit Nos 2 to 14 Section of contact signal to be used to use 1 Don t use 0 Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No Digit No 1 2 3 4 5 6 7 8 9 10 11 14 Relay Operation Relay operation is selected whether it is normally energized or deenergized 0 Normally energized NE 1 Normally deenergized NDE Error Occurrence Relay operates when an error code E 1 to E 8 occurs High high alarm HH Relay operates when the high high limit setpoint set with function No E 0 is reached Note 2 High Alarm H Relay operates when the high limit setpoint set with function No E 0 is reached Note 2 Low Alarm L Relay operates when the low limit setpoint set with function No E 1 is reached Note 2 Low low Alarm LL Relay operates when the low low limit setpoint set with function No E 1 is reached Note 2 Entry E Relay operates when the setting mode is set In Calibration C Relay operates when calibration action is selected Renge selection Answerback R Relay operates when the selection command is input in a state where the range selection command R is set in function No G 3 or No 14 In Warming up W Relay operates when the detector is warmed up Calibration Gas Pressure Reduction G Relay operates when the pressure reduction ala
35. The measured value is higher than the true value 2 The measured value is lower than the true value 3 The measured value sometimes show abnormal values IM 11M7A3 01E 10 10 lt 10 Troubleshooting gt 10 3 1 Measured Value Higher Than True Value lt Causes and Measures gt If the converter s indicated value is higher than the true value the following probable causes may be found Check the following 1 IM 11M7A3 01E The ejector pressure is set improperly If the ejector pressure is set as indicated below the converter s indicated value is higher than the true value or the air concentration is indicated 1 For general use converters Even though the furnace s internal pressure is negative a higher ejector suction pressure on the positive side than that pressure is set 2 For high temperature detectors with probe adaptors Even though the furnace internal pressure is negative the suction pressure of the probe adaptor side ejector hereinafter referred to as auxiliary ejector is higher than that pressure which is set Or a higher suction pressure of the detector side ejector hereinafter referred to as a main ejector than the furnace internal pressure is set See Section 6 1 8 for ejector supply pressure setting If there is a pressure leak in the detector or probe adaptor flange The following probable causes may be found 1 The calibration gas inlet pipings or joint sections are leaky 2 The flan
36. Various Values of Fuels e Liquid fuels J 2 Theoretical air qty UY J 4 X value UY Fuel an Chemical components Heat value Combustion gas qty P Specific Theoretical 3 properties weight by weight kJ kg combustion N m kg oe Type kl c h of Nn s w Ash High Low NY co Ho so N Total Kerosene erm 857 140 0 5 0 0 0 0 46465 43535 114 1 59 1 56 0 00 9 02 12 17 0 96 Light oil RE us 856 132 1 2 00 0 0 45879 43032 112 1 59 1 47 0 00 8 87 11 93 0 91 No 1 0 857 85 9 12 0 0 7 0 5 0 5 0 3 0 05 45544 42739 10 9 1 60 1 34 0 00 8 61 11 55 0 89 A Heavy oil 0 88 class 1 0 83 No 2 9 89 846 11 8 07 0 5 20 0 3 0 05 45125 42320 10 8 1 58 1 32 0 01 8 53 11 44 0 86 B Heavy oil mE 84 5 11 3 0 4 04 30 04 0 05 43827 41274 10 7 158 127 0 02 844 11 31 0 77 class2 0 93 No l ums 86 1 10 9 05 0 4 1 5 05 0 1 43953 41441 10 7 1 61 1 22 0 01 8 43 11 27 0 79 No2 poss 84 4 10 7 0 5 04 3 5 0 5 0 1 43116 40646 10 5 1 58 120 0 02 832 11 12 0 72 C Heavy oil 0 96 class 3 0 92 No 3 1 00 88 1 10 9 0 5 0 4 1 5 06 0 1 43660 41190 10 7 1 61 1 22
37. ambient temperature is 60 C or more use heat resistant wires IM 11M7A3 01E 4 1 4 Mounting of Cable Gland implementation of conduit work lt 4 Wiring gt 4 5 Mount a specified cable gland external wire lead in utensil in a converter cable inlet port except for Unit mm Converter TL Q gt EE i 14 N fi eee y EI Lock nut urbe d EI Washer Ne Packin if SS Select one from the table below depending on the Approx 76 5 RI table OD S A Allen set screw M4 N Y Compression nut Union coupling T2 Cable i 20 c y Ed y IR G Basic packing shape D Table 4 3 Cable Gland Dimensions Cable gland dimensions ee Hexagon part Cable OD Packing actual Identification Size Width across Width across measured mark TI T2 flats corners value F G G PF G PF mm mm mm mm 10 to 211 G9601AE 011 1 to 212 012 1 to 13 5 013 5 13 50 IM 11M7A3 01E 4 6 lt 4 Wiring gt 4 2 Wiring for Detector Signal This wiring is made so that the converter receives the cell output thermocouple output and cold junction compensating signal from the detector Lay the wiring cable so that each signal wire resistance including each return wire is 100Q or less Also lay the cable away from the power cables Inthe case of stea
38. at the oxygen concentration presently measured is displayed The sensor is judged to be normal if the measured value agrees with the theoretical value at the same oxygen concentration The following equation can obtain the theoretical value of cell voltage E when the sensor is controlled at 750 C E 50 74 log Px Pa mV Where Px O concentration in the measurement gas Pa O concentration in the comparison gas 21 vol O Table 7 2 shows the relationship between the oxygen concentration and cell voltage Table 7 2 Oxygen Concentration vol 0 Vs Cell Voltage mV Cell Temperature 750 C oa ez 05 oa J os os or os Display of cell A 3 CELIL EMF 018 3mV voltage example A 4 Cell Temperature Thermocouple Voltage Cell temperature is measured using a type K chromel alumel thermocouple The cold junction of this thermocouple is located at the terminal end of the detector The temperature at this cold junction is measured with a transistor In Function No A 4 displayed is a voltage affected by the temperature at the cold junction terminal If the cell temperature is higher than 780 C error E 3 is effected while error E 2 is displayed at 730 C or less Note When the cell temperature is to be determined based on the displayed voltage compensate for voltage error due to the temperature at the cold junction Displ f cell iini A4 CELL TEMP 0750 C thermocouple voltage TC K EMF 030 4mv example
39. begins when you press the entry key Stored maximum and minimum values are updated by comparing them with the new data periodically When the set time expires the stored values are reset and new maximum and minimum value storage begins all over again Readout on the message F 2 MAX 1 MIN INTERVAL display Ex 8 h 6 r F 3 Setting the temperature unit C This instrument allows you to set the temperature unit to be displayed in Function Nos A 4 and B 5 in section 7 2 3 Readout on the message F 3 TEMP UNIT SET display Ex 0 0 C Do not set the functions of Nos F 4 and F 5 G 0 G 1 G 2 Contact outputs 1 2 3 This instrument can freely output any contact signal selected out of 13 specified types You select this together with the assignment of the relay contact operation normally energized or deenergized in Function Nos G 0 G 1 and G 2 In the default state the operation of the relay contact in Function No G 0 is normally energized while that in No G 1 is normally energized In this state the contact signals in entry in calibration and in warm up are output At that time the operation of the relay in Function No G 2 is normally deenergized and outputs the contact signals high limit alarm and low limit alarm IM 11M7A3 01E 6 10 Readout on the message display Ex lt 6 Operation gt 2 3 45 6 7 8 9 10 11 12 13 14 Digit No 1 Relay Operation
40. greater than 800kPa If such pressure cannot be obtained use heat insulation with an electric heater For gas combustion where ion components are not included heat insulation at about 130 C is sufficient even at a steam pressure of 200 to 300kPa For the zirconia oxygen analyzer 10096 nitrogen cannot be used as the zero gas Generally approximately a 1 vol oxygen nitrogen gas balance mixture is used The setting of the ejector supply air pressure depends on the furnace pressure IM 11M7A3 01E 1 6 lt 1 General gt 1 2 1 2 1 Specifications General Specifications Measurement Target Oxygen concentration in combustion exhaust gases and mixed gases excluding flammable gases Measurement System Zirconia system Flameproof Construction Detector Exd II BT3X Max surface temperature of 200 C Converter Exd II BT6 Max surface temperature of 85 C Used condition of Flameproof Converter a Before opening the cover remove power and make sure of non hazardous atmospheres b When the ambient temperature of the converter exceeds 50 C use wire resistant to 70 C or greater for external wiring Detector a Before opening the cover remove power and allow the detector to stand at least 40 minutes b When the ambient temperature of the detector exceeds 30 C use wire resistant to 70 C or greater for external wiring c The detector cannot be used except in mixed gases composing air or m
41. is recommended that nickel plated bare crimp on terminal lugs be used in high temperature locations detector terminal board screws are for M3 5 and M4 screws 4 1 2 Care During Wiring 1 IM 11M7A3 01E Turn off all power supplies and make wiring by removing the detector and converter covers Among the bolts for mounting the converter cover the one on the bottom left is longer than the others In ordinary maintenance remove all other bolts except this bolt and carry out work rotating the cover around this bolt This may prevent an accident from dropping the cover Terminal arrangements for the detector and the converter are as shown in Figures 4 1 and 4 2 Perform terminal connections based on the connection diagram of Figure 4 11 Use wires by selecting sheath materials depending on the ambient temperature near the wiring path to the detector Also determine wire size diameter for wiring between the detector and converter so that the conductor resistance including that of the return wire is 100 or less When a multi conductor cable is to be used select that with a finished OD matching the electric wire lead in utensils used This is described in section 4 2 Wiring for Detector Signal and later For installation where the ambient temperature exceeds 80 C be sure to use heat resistant covering wires for wiring In addition also use a heat resistant flexible conduit between the detector and relaying connection box or between con
42. its temperature above the dew point of the measuring gas Be sure to maintain the surface temperature of the steam heater below 200 C in accordance with the explosion protection standards Detector s Main Ejector Use a heater electric or steam to heat the main ejector to maintain its temperature above the dew point of the measuring gas Be sure to maintain the surface temperature of the heater below 200 C in accordance with the explosion protection standards Wrap an ejector air pipe around the heater portion of the detector in order to prevent clogging in the ejector See Figure 2 5 Gas Suction Pipe of Detector Probe As for general purpose detectors use heat insulating material for the mating flange portion to maintain the temperature of the gas suction pipe of the detector probe above the dew point of the measuring gas If necessary use a steam heater for example to heat the gas suction pipe to maintain its temperature as specified Probe Adapter Maintain the heat of the probe adapter to keep its temperature above the dew point of the measuring gas Although the probe adapter is not a flameproof instrument be sure to maintain its surface temperature below 200 C when using it in combination with the flameproof detector The surface temperature of the probe adapter should be measured on the surface of blind flange on the opposite side of the probe Methods to Change the Surface Temperature If the surface temperature does not
43. maintenance Note 1 Note 2 For the sulfuric acid dew point see the separate table One example of heating and insulating sections A to D is to wrap glass wool around the heating and insulation section and then apply a waterproof aluminum tape to secure it Figure 2 6 Sulfuric acid dew point C Figure 2 7 Work Example of Heating and Insulating General Purpose Flameproof Detector Example of Heating and Insulation by Electric Heater Sulfur content in fuel Cited reference L K Rendle and R D Sulfur Content in Fuel and Sulfuric Acid Dew Point for reference IM 11M7A3 01E 2 1 8 lt 2 Installation gt 2 4 Installation of Converter 2 4 1 Installation Site Install the converter by selecting a location where 1 the explosion protection standards are satisfied 2 the indicated oxygen concentrations and messages are legible and key operation is easy avoiding exposure to direct sunlight 3 inspection and maintenance are easy 4 the ambient temperature is not too high max 55 C and the temperature varies little recommended to vary no more than 15 C a day 5 the humidity is moderate 40 to 75 RH is recommended and no corrosive gases are present Note If there is a corrosive gas carry out air purging The air purge tube joints are optionally attached only when required 6 there is little vibration 7 the detector is installed relatively nearby
44. power failure This error also occurs when the converter digital circuits fail such as time up of the watchdog timer normally reset in a fixed period In either case if the error occurs display in the data display disappears Next measures when the error occurs due to the digital circuit operation failure will be described lt Causes gt 1 Low supply voltages exceeding the specifications are applied or the effect of noise is given to digital circuits 2 Digital circuit failure IM 11M7A3 01E lt 10 Troubleshooting gt 1 0 9 lt Locating the Cause of Failure and Taking Measures gt Turn off the power to the converter Check for a blown fuse in the electric circuitry Also check that the supply voltage is the rated voltage Then turn on the power Check that the converter is operating normally If the error occurs again repair is necessary Contact Yokogawa 10 2 Where the Output Response Is Too Slow If the suction flowrate of a sample gas decreases check to see that the detector s main ejector is not clogged When the probe adaptor is used also check that the auxiliary ejector is not clogged 10 2 1 Checking the Main Ejector for Clogging 1 Remove the main ejector from the detector 2 Remove the ejector nozzle from the air supply side There is a threaded M5 size opening for withdrawing the nozzle So use an appropriate screw to remove the nozzle 3 After removing the nozzle check that the ejector
45. practical sensor shows a slight deviation from the theoretical value This is the reason why calibration is required It s performed to obtain a calibration curve for correcting a deviation from a theoretical cell electromotive force IM 11M7A3 01E lt 8 Calibration gt Cell voltage mV mm ad es I 1 I l 1 1 I I 1 lu 1 I I 1 1 I I I 1 lu I 1 I lu i l I I 1 lu l I I I 1 1 I I 1 l l I mod l l 1 i ee opal ake EG SER EE FOG GOE vr Le rursus eee Ie ae gp RE se Ke 4r Pete e e D HEGE l I l 1 bg 100 q 4 p4 k bb i Ld Rub doi Aix eee 4 7 4 b b 1 i lira NE 1 Ly ror rt 80 4 r A Neo psig 4 rie aro gJ p1 r t 1 i LEO p NE L 1 1 SS ee ener L1 gb qn dh bl lll 1 1 Ty 1 0g TI t re NE I 1 Ly ror Li 60 1 r r r 4 T p4d P6 tt 1 1 Vae sd si ri 1 1 Ly ror rt p 4 h eee dieu co T 4 r r4 rE LiL 1 1 bs so i 40d r 2a BEE AE EE 1 Ly ror NE 1 Linra Li 4 4t pr r 44 1 Ly ror ri 1 V p qoa 1g 201 r den pc ee EE pa r tt 21 0 O 0 mV n 7 Span origin of calibration 0 00 o rM 1 rt 1 rt Be a der Aone eg C xu ED aA a e l li jH pesee a le ee quidque a EEan 1 rt en ee ee 4 l l EE E S E EEEE tee aI XXE REIR 1 1 1 1 NE 0 1 0 5 1 5 10 21 0 50 100 Oxygen concentration vol O F8 1E ai Figure 8 1 Oxygen Con
46. required for operation are stored in EEPROM in the converter Temporary data as set forth individually are stored in the RAM The temporary data read in the RAM are preserved through the backup of an electric double layer capacitor for a short time even if the main power supply fails After that however the data in the RAM is lost while the stored data in the converter changes to a default state IM 11M7A3 01E lt 6 Operation gt 6 3 Also upon shipment the data read and loaded into the converter are in the default state Thus upon commencement of operation set the data to match each operation Table 6 1 shows the setting items and their default values Refer to it when setting data In addition to enter the password 16 or key operations when data is set see Chapter 8 Table 6 1 Settable Items and Their Defaults Group No Setting range or default details Default LCD display Setting Calibration C 0 Span gas concentration 4 5 to 100 vol O 21 00 O 21 0 C 1 Zero gas concentration 0 3 to 100 vol O 1 00 O 1 00 C 2 Mode One touch TCH Semi Auto SEM Auto AT TCH 2 TCH C 3 Stabilizing time 0 to 10 minutes 3 0 min 3 0 minutes C 4 Calibration time 0 to 10 minutes 3 0 min 3 0 minutes C 5 Calibration interval 0 to 255 day or 0 to 23 hours 1day 1day C 6 Calibration
47. shield unconnected in the converter c The heater cable may use a two conductor cable without shield if it is wired through a conduit separate from the signal cable lt 4 Wiring gt Unit mm reg pes F4 2E ai 7j Cold Junction n o o E 5 2 e 23 i o l l F4 1E ai LO ONENEARONNENEN El Ql OOOO OO ES C9 C9 G9 69 69 69 69 69 69 C9 C9 C9 C9 C9 C9 C9 CO M3 5 8 3mm C9 69 69 69 69 69 69 69 69 69 C9 C9 C9 C9 C9 C9 C9 RW 2 e eus R 0 amp Q g o Q COCOON NO PG Ol NZ o S 5 S c 2 o O THMS _ CELL T CO OC JO Analog Output 4 20 mA DC Detector Terminal Arrangement Gal EIGE ENG A Figure 4 1 IM 11M7A3 01E Converter Terminal Arrangement Figure 4 2 4 4 lt 4 Wiring gt 4 1 3 Cables Use a CVV PVC insulated and sheathed control cable JIS C3401 and others for the cables and lay it if necessary in steel conduits to protect it from external damage For screw parts be sure to coat non curing seal materials and also apply a waterproof treatment Forwiring a cable with the lead in procedure using flameproof packing be sure to use the external cable lead in utensils specified by Yokogawa Part numbers in Yokogawa for these external cable lead in ut
48. the operation is normal If the operation is normal it is considered that the error may be caused by temporary failure of power System such as voltage drop or influence of noise If the cause is clear and the error may possibly occur with the same cause take suitable measures to prevent re occurrence If the error occurs again it may be caused with the converter electric circuits such as CPU card In this case it is not so easy to find the failed part and to restore If the error occurs again contact Yokogawa Confirm that power system is not in failure by checking the supply voltage and others to make sure of it 10 1 6 Causes of E 5 Calibration Value Error Zero and Procedure for Restoration This error occurs when the zero point correction factor see Subsection 8 1 3 exceeds the range 100 30 in the automatic and semi automatic calibrations lt Causes gt 1 The oxygen concentration of zero gas and the value set with function No C 1 do not agree or the span gas is accidentally used as the zero gas 2 The zero gas does not flow by the specified quantity about 600 ml min 3 The sensor cell is damaged and the cell emf contains an error lt Locating the Cause of Failure and Taking Measures gt 1 To make sure carry out the calibration once more Before calibration examine the following If they are not in normal state correct them Doesthe value set in the function No C 1 agree with the zero gas ox
49. value ZERO Displayed during calibration the present zero point calibration value is not effected E 6 Calibration value SPAN Displayed during calibration the present span calibration value is not effected E 7 Start power stability time Displayed during calibration the present calibration value is over not effected E 8 ROM RAM error Goes into fail mode automatically turning OFF the power supply to the detector heater OO00 Digital circuit error power Goes into fail mode automatically turning OFF the power Display failure supply to the detector heater erased Displayed upon restart after remedying the power failure Data values default Note E 5 E 6 or E 7 is displayed alternately with the O concentration Checking Operating Conditions In order to maintain normal operating conditions determine which items are to be inspected periodically and check them regularly for errors Items recommended for periodic inspections are as follows for your reference For maintaining or recovering performance see Chapter 9 Table 6 5 Example of Items for Periodic Inspection Inspection item Complete closing of Purpose amp detail of inspection To prevent condensation which may break sensor Inspection interval kept at the pressure required calibration gas inlet Check for a complete closing of needle valve ed Set flow rate of flow Check that flow is about
50. wool or the like to enhance the heat insulation effect Installation of Flameproof High temperature Detector Installation Site Install the flameproof high temperature detector in a location where 1 2 3 4 the explosion protection standards are satisfied there is easy access to the detector and safe work is ensured in checking and maintenance the ambient temperature is below 60 C and the terminal box is not subject to radiant heat there is no vibration Probe Insertion Hole The ZS8D H flameproof high temperature detector is used in combination with the ZS8P H high temperature probe adaptor If this high temperature detector is to be used provide the probe insertion hole for the high temperature probe adaptor When constructing the probe insertion hole take the following into consideration 1 2 If the high temperature probe adaptor is made of silicon carbide SiC construct the hole so that the probe is placed vertically tilting within 5 degrees If the high temperature stainless steel probe adaptor is to be installed horizontally the probe tip should not be higher than the flange center Figure 2 2 shows examples of constructing the probe insertion hole IM 11M7A3 01E lt 2 Installation gt 2 2 3 Flange Install the rating flange the same as that for Aspace SE mmor gt more in diameter and the probe adaptor long enough for the length of the probe
51. 0 A Bolts M16 x 80 8 The gasket should be heat resistant and Nuts M16 8 corrosion resistant Washer for M16 16 The following is a point to be taken into consideration in installation work 1 Install the high temperature detector considering the attitude of the detector In particular if it is to be installed horizontally be careful that the detector probe tip is not pointed upward it is recommended that detector be installed vertically unless otherwise restricted by the location 2 When mounting the high temperature probe adaptor be sure to insert a gasket between the flange surfaces to prevent gas leakage Special care should be taken for air tightness if there is negative pressure in the furnace to prevent air leakage into the furnace 3 When installing the detector with an attitude other than vertical do it so that the cable inlet port is pointed downward IM 11M7A3 01E lt 2 Installation gt 2 5 2 2 4 Install the detector so that the probe tip is pointed downward For SiC probes mount it within 5 degrees of the vertical F2 3E ai Figure 2 3 Installing the High temperature Detector Ejector Installation For a high temperature detector two ejectors main ejector attached as standard auxiliary ejector optional are required Only venting out of the furnace is applied for the measuring gas suctioned by the ejector in the case of a high temperature probe adaptor 1
52. 1 E NE gt i 0 20 40 60 80 Supply pressure kPa F3 5E ai Figure 3 5 Flow Characteristics of Joint on Air Supply Side IM 11M7A3 01E lt 4 Wiring gt 4 1 4 This chapter describes procedures for wiring to be provided for the Model ZS8C Flameproof Converter WARNING 4 1 1 Never turn on the power before wiring work is completed construction work conforming to the explosion protection standards is over and the converter cover is mounted Otherwise there is the danger of ignition or an explosion depending on the atmosphere around the instrument 2 There is the danger of electrical shock if the terminals are touched Safety Precaution for External Wiring A CAUTION For external wiring always use the specified external cable lead in utensils Otherwise the wiring may not conform to the explosion protection standards and may introduce the danger of an explosion by the ignition of gases around the equipment and units Wiring Precautions For external wiring use cables for flameproof packing use Determine each conductor s diameter in the cables between the detector and the converter so that the conductor resistance including that of returning wire is 100 or less Securely ground dead exposed metal parts conforming to JIS class 3 grounding grounding resistance of 1000 or less For details see USERS GUIDELINES for Electrical Installation for Explosive Gas Atmospheres in General Industry i
53. 1 to 8 Space Command 2 Transmitted data 1 2 3 4 5 6 7 8 9 10 RJC 11 OF hg 0 r tr 0 calibratable 1 calibration abort L o Same as received data 4 Not calibratable Comma 2 CR Change Range Function Analog output range selection signal Note The ZS8C converter contact input signal has priority Data structure 1 Received data 1 2 3 4 5 6 7 8 CIR 11 11 S te L Delimiter 1 Output range 1 2 Output range 2 Comma ZS8C converter channel number 1 to 8 Space Command 2 Transmitted data 12 34 56 7 8 CIR ieli RT Same as received data IM 11M7A3 01E lt 4 Wiring gt 4 15 3 DT Data Trigger Function The latest measured data and the date amp time are taken into the communication memory inside the ZS8C converter Data structure 1 Received data 1 2 3 4 5 6 DJT 1 Sr 4 DOO ag ca Delimiter ZS8C converter channel number 1 to 8 Note 1 Space Command Note 1 For channel number 0 measured data are taken simultaneously in all the converters Note 2 Data retained with the DT command are transmitted to the computer by the DR command Note 3 Ifa DT 0 C L command is transmitted from the computer to the converter allow an interval of one second or longer until the next command for example a DR
54. 220V 240V AC Y C 2mm or more 2 wire shielded cable Interior of ar eneck valve furnace Reference gas D flow meter o i 300 ml min 20 Air set Reference 4 Instrument gas Needle valve A sir krone un Calibration M SN gas 3 Calibration gas unit mm Calibration gas om valve t ur oe eg sk flow meter ji 7600 mlimin 10 PX F1 iSa regulator i 1Calibration gas Needle yaly pressure regulator Zero gas 5777 Span gas Flow setting unit ZA8F G7013XF i cylinder cylinder i GMN G7001Z6 F1 4E ai Figure 3 1 System Piping for heat insulation by steam The main points of piping for this system are as follows Ifthe ambient temperature of the detector is 60 C or more use heat resistant pipes and joints Also use instrument air clean without dust moisture or oil mist Mounta check valve to the calibration gas inlet of the detector Connect the piping to the check valve Ifa high temperature detector for venting sample gas to the outside of the furnace is used and the pressure of the gas to be measured is 500 Pa or more Install suitable restrictions like needle valves on the probe adaptor sample gas outlet and the main ejector gas outlet In this case set the amount of discharge from the needle valve to 300 to 500 ml min Note This is a measure taken to suppress the sample gas temperature to 800 C or less If the measuring ga
55. 2DL 1 Gasket Subject to change without notice 4th Edition Oct 2010 YK Yokogawa Electric Corporation Customer Fr EXA oxy i irconia Oxygen Analyzer Maintenance Auxiliary Ejector Parts List K9292VA K9292VB K9292WA K9292WB 2 i l For Probe Adaptor Use bersed K9292WC K9292WD For Detector Use K9292VE K9292VF Item Parts No Qty Description 1 K9292VA 1 Main Ejector Connection Rc1 4 For Detector Use K9292VB 1 Main Ejector Connection 1 4NPT For Detector Use K9292WA 1 Auxilliary Ejector Connection Rc1 4 For Probe Adaptor Use K9292WB 1 Auxilliary Ejector Connection 1 4NPT For Probe Adaptor Use 2 L9852CB 1 Needle Valve Connection Rc1 4 G7016XH 1 Needle Valve Connection 1 4NPT 3 E7046EK 1 Pressure Gauge Connection Rc1 4 E7046EV 1 Pressure Gauge Connection 1 4NPT 4 K9292VE 1 Ejector Assembly Connection Rc1 4 For Detector Use K9292VF 1 Ejector Assembly Connection 1 4NPT For Detector Use K9292WC 1 Ejector Assembly Connection Rc1 4 For Probe Adaptor Use K9292WD 1 Ejector Assembly Connection 1 4NPT For Probe Adaptor Use YOKOGAWA vest rennet Coat 0108 vrogenaEucnccaponatn CMPL TIMTAS ME n i 2nd Edition Apr 2001 YK Yokogawa Electric Corporation Revision Record e Manual Title Manual Number EXA OXY Direct In Situ Flameproof Zirconia Oxygen Analyzer IM 11M7A3 01E Edition Date Remark s 1st Apr 1996 Newly published 2nd Mar 1997 Some error corrected 3rd Sep 2010 IM st
56. 3 3 3 4 3 5 Unit mm Reference With sealing plug gas inlet 3 G3 4 holes for wiring Calibration gas inlet F3 2E ai Figure 3 2 Connection of Check Valve to the Calibration Gas Inlet Reference Gas Piping Thereference gas piping is provided between the air supply instrument air and the flow setting unit and between the flow setting unit and the detector Inthe piping between the air supply and the flow setting unit insert an air set close to the flow setting unit Prepare a flowmeter and a control valve for reference air so that the specified flowrate of 300ml min 20 can normally be obtained Useastainless steel pipe with an OD of 6 mm ID of 4 mm or nominal 1 4 inch for the piping between the flow setting unit and the detector Piping to the reference air outlet is not necessary refer to Section 2 1 4 Piping to Probe Adaptor If the measuring gas pressure is negative the gas must be forcibly suctioned Connect the piping parts for this purpose to the probe adaptor when the high temperature detector is used Connect an auxiliary ejector in the procedure shown in Figure 3 3 when the measuring gas pressure is negative Mount the pressure gauge as near the auxiliary ejector as possible However if the ambient temperature is high place the piping in a location at 40 C or less Auxiliary ejector assembly Main ejector assembly Flameproof high temperature N detector F3
57. 3E ai Figure 3 3 Connection of Ejector IM 11M7A3 01E 3 4 lt 3 Piping gt 3 6 Purge Gas Piping If there are corrosive gases in the atmosphere or if the ambient temperature at the converter installed location is high purge the inside of the converter with air Connect a copper or stainless steel pipe to the purge air inlet Set the supply air to about 50 kPa If purging is to be carried out remove the gasket between the cable gland and the converter in one port to make an outlet for the purge air Unit mm 28 5 28 5 28 5 28 5 28 5 28 5 lt gt lt gt lt gt lt gt gt lt ss NE Aw Wiring port 6 G3 4 With flame arrester Purge air inlet nominal 50A F3 4E ai Figure 3 4 Converter Purging 3 6 4 Piping for Air Purge in Converter If specified the air purge joint is already connected to the bottom of the converter upon shipment Make piping using a copper tube or the like with an OD of 6 mm ID of 4 mm or nominal size 1 4 inch between the air supply and the air purge joint 3 6 2 Air Supply for Air Purging Implement air purging using clean dry air For example use instrument air as the air supply Air consumption is about 1 l min when the supply air pressure is 50 kPa 1 4 1 2 Flowrate l min 0 8 o o o PX EE Ee E a aa ES ES ES HUE TT E as NER NET Ed E S EN CET EE MS SA 4 Y 1 L
58. 6 so enter this number To do so use the number increase decrease key cursor movement key and the entry key IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 3 e Entering the password for setting checking temporary data Display of password entering message PASS WORD K gt qvo times PASS WORD NH Cursor moves to PASS WORD 1 on the right side Press Enter after Display of Function No C 0 Cv Suhl 16 is displayes CO CAL GAS CONC 02 SPAN 021 00 The first Function No in the setting mode is displayed 4 Selection of Function No selection of number The number increase key number decrease key and the cursor key are used e Display of Function No C 0 Display of Function No C 0 CO CAL GAS CONC 02 SPAN 021 00 Cursor moves over to the next number CO CAL GAS CONC 02 SPAN 021 00 Display of Function No C 1 Number is changed from 0 to 1 C1 CAL GAS CONC 02 ZERO 2001 0 0 I Dy D H No increases No decreases Note 1 C2 oo e r A4 UJ Am e ona mz zo Z NZ 0 40 om Data entering status is effected displays an analog bar graph Note 1 Ifthe entry key ENTER is pressed when the cursor resids in a function No position note that 0 AT automatic calibration is automatically set as the calibration mode 5 Selection of Function No selection of group symbol
59. 8D L J A L1 1 N L1 U 1E T Model for Steam Heater Providing Heat Insulation 4 Ejector inlet Ejector 4 Ejector outlet LL c Outlet to return suctioned gas to the furnace Rc 1 8 Section A A Suction gas return port Copper tube for heat insulation by steam 3 Steam inlet TR lt 3 gt Steam outlet Section B B Note that the steam inlet and outlet positions may be changed Joint Model and Suffix Codes J Rc1 4 Carborundum filter A 1 4NPT Section C C Unit mm id Insertion length EV 405 NE B B Ejector lt 5 gt Mounting y y flange lt 1 gt Reference gas outlet 1 ter Approx 83 PT Approx 93 A gt T lt 1 gt Reference i i With sealing pl gas inlet ng pg es 1 Reference gas Inlet Outlet 2 Calibration gas Inlet 3 Steam Inlet Outlet 4 Ejector Inlet Outlet IR Fe lt 2 gt Calibration gas inlet valve Two G3 4 openings for wiring 303 F1 5E ai 5 Flange Weight A kg B C ZS8D L J A 050 1 N D Rc1 4 1 4NPT ZS8D L J A 150 1 N O
60. A communication interface is used up to 8 converters can be connected to one computer Channel numbers are used to distinguish them from converters so set channel numbers which are different from the converter numbers Readout on the message HO COMM MODE Er 0 0 FREE 1 When 1 is assigned HO 0 HAN IM 11M7A3 01E 6 12 lt 6 Operation gt H 1 Baud rate data communication rate assignment You assign here operating digital communications For a data communication rate of 9600 bps or 4800 bps enter 0 or 1 respectively For 2400 bps select 2 from the keyboard Readout on the message H 1 BAUD RATE bp S display Ex 1 0 96 1 48 2 24 Note DISP Key H 1 BAUD RATE 0 9600 Bits sec J 0 Types of fuels You can select a type of fuel for obtaining the concentration of oxygen in a dry gas Select and assign in Function No J 0 what fuel you are using from the following 5 types 0 Heavy oil A A 1 Heavy oil B B 2 Heavy oil C C 3 Gas G 4 Coal X If your oil in use is heavy oil C move the cursor to 2 with the keys Readout on the message J 0 FUEL GRAD AR 2 0 A 1 B 2 C J 1 Moisture content in exhaust gas You can set the amount of moisture contained in the combustion exhaust gas of the fuel used in the measurement process in terms of N m kg or m m in proportion to the unit volume of the fuel Look up the setting value from Table 6 2 If there are no relevant description
61. Approx 54 2 inch JIS 50 A mounting pipe option code p 28 5 28 5 28 5 28 5 205205 186 5 LY i Six G3 4 openings for wiring with flame arrester Seven G3 4 openings for wiring without flame arrester Purge air inlet optional with flame arrester AP1 Rc 1 4 AP2 1 4 NPT Option code Wall mounting bracket m a code W Weight Approx 20 kg Four 9 mm dia openings use M8 screws for wall mounting a Ls E E A Y M 112 O EG 5 p F1 10E 210 Wall mounting dimensions IM 11M7A3 01E 1 20 lt 1 General gt 1 2 6 Options 1 Check Valve K9292DN K9292DS This is used to prevent entry of the process gas into the calibration gas line It is incorporated in the product as standard If it is necessary to have one as a spare part select it according to the specifications Connection Material Supply Pressure Weight Rc1 4 or 1 ANPT F R1 4 or 1 4NPT M connectable SUS304 Between 150 kPa to 350 kPa Approx 40 g Unit mm K9292DN Rc1 4 A R1 4 B K9292DS 1 4NPT A 1 4NPT B Approx 19 A Approx 54 F11 1 EPS 2 Auxiliary Ejector Assembly K9292VA K9292VB for detector K9292WA K9292WB for probe adaptor Assemblies for both the detector and probe adaptor are availab
62. Calibration To operate the ZA8F flow setting unit prepare for calibration as follows 1 Check for a complete closing of the zero gas flow setting valve in the unit and open the regulator valve for the zero gas cylinder until the secondary pressure is 50 to 100 kPa 2 Check that the oxygen concentration of the zero gas in the cylinder is set in the converter Operating the Span Gas Flow Setting Valve The following description is given assuming that instrument air the same as the comparison gas is used as the span gas 1 When the message DID YOU OPEN SPAN VALVE Y is displayed in the readout of the converter during calibration open the span gas flow setting valve of the flow setting unit and adjust the flow rate to 600 60 ml min Turn the valve regulator slowly counterclockwise after loosening the lock nut To check the flow rate monitor the calibration as with a flow meter 2 After adjusting the flow rate press the interactive key YES of the converter Because of the time set in Function No C 4 when this key is pressed span point calibration is executed When the message SPAN CALIBRATION FINISHED is displayed close the span gas flow setting valve to stop the span gas air flow Be sure to tighten the lock nut to prevent any leakage of span gas into the sensor during measurement because the valve may become loose during measurement Operating the Zero Gas Flow Setting Valve Operation of the zero gas flow setting v
63. Calibration start time You can set the date and time at which the first automatic calibration is to start If it is 4 30 pm July 15 1995 for example set the date by entering 95 07 15 16 30 Readout on the message C 6 CAL START TIME display Ex 95 07 15 16 30 C 7 Skip Calibration is normally performed for both zero and span points However either of them may be omitted but both zero and span points should be calibrated once In this section the assignment of this omission is described If you do not want to omit them any longer select 0 For omitting span or zero point select 1 or 2 respectively These assignments are effective for semi automatic and automatic calibrations You cannot omit them in one touch calibration Readout on the message CH SKIP display Ex 0 0 NONE 1 SPN 2 ZR IM 11M7A3 01E lt 6 Operation gt D 0 Output range 1 You can set the range of oxygen concentration to correspond to the analog output signal 4 to 20 mA or 0 to 20 mA DC You can set a free range from 0 to 25 vol O Also a partial range is selectable provided the minimum value in the range is 6 vol O under the condition that the ratio of maximum minimum is 1 3 1 or greater Note If the output mode is set to Logarithm in function No D 4 the minimum value of the output range is always 0 1 regardless of this setting Readout on the message DO OUTPUT RANGE 1 display Ex 000 050 02 CAUTIO
64. HEATER DUTY ON time ratio E example 037 5 B 7 Dry O Concentration Moisture Content When data corresponding to Function Nos J 0 to J 7 are set the captioned values are calculated based on the data while displaying the dry O concentration vol O and the moisture content 76 H O in the exhaust gas as follows Display of the dry O concentration B7 DRY 02 0097 51 O 2 moisture content SET H20 010 5 90H20 example The readouts of all the messages in measured value group B have been described on the preceding pages IM 11M7A3 01E lt 8 Calibration gt 8 1 8 8 1 8 1 1 Calibration In this Chapter the method for calibrating a zirconia oxygen analyzer is described General Principles of Zirconia Oxygen Analyzer Before detailing calibration the principles of measuring with a zirconia oxygen analyzer will be described A solid electrolyte such as zirconia allows the conductivity of oxygen ions in a high temperature state Therefore when a zirconia plated element with platinum electrodes on both sides is heated up in contact with gases having different partial oxygen pressures on each side the element shows the action of the concentration cell In other words the electrode in contact with a gas with a higher partial oxygen pressure acts as a negative electrode As the gas comes in contact with the zirconia element in this negative electrode oxygen molecules in the gas acquire electrons and bec
65. Jone Fa ZS8C Provided by heaters Flameproof converter Stop valve i Air set 6 4 to 20mA DC Detector output wiring 1 25mm or more 8 wire shielded cable Interior of furnace e oa Aer 0 LLL LLL LLL LLL LL LLL LLL LL Bo qg NM Detector heater power wiring 2mm or more 4 wire shielded cable Contact input ae PE Heat insulation Q Check valve 2 K9292DN et K9292DS Reference gas flow meter 220V 240V AC A 300 ml min 20 i i OG 5 Airset G7003XF K9473XK Reference i gas i pk er 2 Instrument Calibration gas uni i Needle valve air o c REL Calibration i ny Ni 9 gasta ME Needle valve Calibration gas unit Calibration gas Calibration gas E pressure flow meter py m NT 9 I regulator i 600 ml min 10 Calibration gas i Needle valve I pressure i ANM Span gas a er regulat Flow setting unit ZA8F G7ot3xr Zero gas cylinder cylinder 1 G7014XF G7001ZC F1 1E ai 1 Conduits 1 When installing conduits use flexible conduits so that the probe removed 2 Use a shielded cable for the signal cable and ground the shield together with the probe ground 3 Provide separate conduits for the signal and heater lines 4 The maximum outside diameter of the cable suited for the cable gland used for the instrument is 13 5mm in case that the thread at the conduit side i
66. L RM SET P 002 395 ELD os o E 2 Contact operation of alarm output When measured values return to a stationary range after leaving the alarm range it is sometimes desirable for existing alarm output to be reset conditionally instead of being reset immediately You can set such conditions i e operation delay and hysteresis The operation delay once set here is effective even after measured values shift from the stationary range to the alarm range Set the operation delay in seconds and the hysteresis in the oxygen concentration vol O respectively For instance to set an operation delay of 5 seconds and a hysteresis in the oxygen concentration of 2 0 vol O enter 005 and 2 0 on the keyboard Note The operation delay set here is applied to all contact signals selected with function numbers G 0 to G 2 Readout on the message E 2 RL DELAY 0 05 2 0 ec display Ex RL HYS O2 o La The alarm output for the example above becomes as follows 5 5 7 5 vol 0 2p Alarm output is not reset i SR del y 5s because the hysteresis does not exceed the set value even though the set operation delay time is exceeded Operation delay 5s Time F6 2E ai IM 11M7A3 01E lt 6 Operation gt 6 9 F 0 Adjustment of date and time Set the clock in this instrument to the present date and time If the present date time is April 26 2006 6 45 pm for instance enter 06 04 26 18 45 an
67. L1 Output signal 1 CN5 for RL1 l Relay RL2 Output signal 2 CN6 for RL2 I Relay RL3 Output signal 3 CN7 for RL3 elay RL3 Output signal 3 Break Make contact contact Setting jumper connector Mounting position of jumper CN5 CN6 or CN7 connectors CN5 CN6 or CN7 F6 5E ai Figure 6 4 Setting Position of Jumper Connector and Setting Method Supplying Pressure to Ejector 1 After the proper temperature is reached the LED indicates the gas concentration about 21 of span when the instrument air is flowing Supply air to the main ejector 30 minutes after the power is applied to the converter Set the ejector supply pressure so that a pressure of 300 to 500 ml min is suctioned in accordance with the characteristic curves Ifthe furnace pressure is around atmospheric pressure set the supply pressure of 20 kPa 2000 p Furnace Pressures E 190 o 980Pa 1960Pa 9 e 4900Pa 1000 Atmospheric Pressure m 4900Pa 5 1960Pa E A 980Pa a 9500 0 10 30 50 70 90 110 Supply Pressure kPa EHE Figure 6 5 Supply Pressure to Suction Flowrate Characteristics in Main Ejector for Detector 2 When the probe adaptor is used supply air to the auxiliary ejector The probe adaptor inner pressure is the same as the furnace pressure independent of the auxiliary ejector suction pressure For the supply pressure to the auxiliary ejector for t
68. N When the instrument is used in explosion proof atmospheres it cannot measure the oxygen concentration where the maximum measured value exceeds 21 vol O D 1 Output range 2 Output range 2 can be output only when the converter has the functions of contact input or digital communication by the range change command Similar to output range 1 set the oxygen concentration range correspondent to the analog output signal 4 to 20 mA DC or 0 to 20 mA DC Any range from 0 to 25 vol O can be set If the minimum value of a range is 6 vol O or more a partial range can be set under conditions where the ratio of the maximum value to the minimum value is 1 3 to 1 or more If selecting a partial range of 10 to 25 vol 0 set 010 025 In addition if the range selection command is to be made with a contact input select Change in measurement range in function Nos G 3 or G 4 However if the command is made via digital communications do not select Change in measurement range If selected a command via digital communications cannot be received Readout on the message D 1 OUTPUT RANGE 2 display Ex 010 025 02 CAUTION When the instrument is used in explosion proof atmospheres it cannot measure the oxygen concentration where the maximum measured value exceeds 21 vol O D 2 Output signal hold You assign whether or not analog output signals are in a mode other than measurement mode as for example maintenanc
69. Oxygen concentration vol O F73E ai Zero point correction factor B A x 100 96 Correctable range 10013096 Span point correction factor C A x 100 Correctable range 0418 Figure 7 1 Calculation of the Zero Point Correction Ratio and the Span Point Correction Ratio sires dodo diae BO SPAN 0 2001 5 point correction ratio 89 04 30 09 30 H record 1 example B 1 Zero Point Correction Ratio Record The zero point correction ratio obtained every time the zero point is calibrated is displayed You can determine the degree of cell sensor deterioration from this value You can display the data record for the previous 10 times including the latest data To display each data display screen call up the next screen by pressing the message HELP key You can get the zero point correction ratio by the method in Figure 7 1 The correctable range for the zero point is 100 30 098 7 Display of the zero B 1 ZERO 0 130 09 30 H point correction ratio record 1 example 89 04 B 2 Response Time Response time displayed in Function No B 2 can be obtained during calibration by the method in Figure 7 2 Note If the zero point or the span point is skipped it is not executed In one touch calibration mode also not executed IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 13 Maximum 5 min 10 of the corrected calibration curve MC Time Sus Span Calibration start Cali
70. SUS310S 0 to 800 C SiC 800 to 1400 C Detectors need sufficient heat insulation For combustion including ion components ensure heat insulation greater than dew point of sulfuric acid about 160 C In this case the steam pressure should be greater than 800kPa If such pressure cannot be obtained use heat insulation with an electric heater For gas combustion where ion components are not included heat insulation at about 130 C is sufficient even at a steam pressure of 200 to 300kPa For the zirconia oxygen analyzer 100 nitrogen cannot be used as the zero gas Generally approximately a 1 vol oxygen nitrogen gas balance mixture is used The setting of the ejector supply air pressure depends on the furnace pressure lt 1 General gt 1 5 4 Example of Steam Trace Heat Insulation for the ZS8D H flameproof detector Heat insulation Pressure gauge 98kPa 4 Conduit 1 Q Stop valve Air set Q Auxiliary ejector air Hazardous Non hazardous Steam outlet Pressure gauge 20kPa 4 Hare location location Steam inlet converter Stop valve Air set Main ejector air H ey Detector output wiring 1 25mm or more 6 wire shielded cable 4 to 20mA DC output High F TUHI A mi 9IL Contact output temperature V HHA He Bl 22 22222222 2 AA sss probe Detector heater power wiring adaptor 2 2mm or more 2 wire shielded
71. System component units for the EXA OXY zirconia A o oxygen analyzer and system configuration are shown Installation Installation procedures for each unit are described A Piping Piping procedures are explained for four standard A system configurations 4 Wiring Wiring procedures are given for each system such as power supply wiring output signal wiring etc Components and Names and major functions of components of main 5 their functions units in the manual are illustrated 6 Operation Basic procedures are presented to put the EXA OXY A analyzer into the operation status Operating keys and Converter key operations and items related to the A display of converter display are detailed 8 Calibration Calibration procedures carried out as necessary are A described 9 Inspection and Inspection items to maintain the EXA OXY analyzer maintenance performance and procedures for replacing O deteriorated parts and components are described 10 Troubleshooting Countermeasures when the system fails and or disposition for failure are shown Customer maintenance Parts that can be freely replaced by the user if A O Thoroughly read the instructions and do work after fully understanding the contents O Before actual work first read the description or refer to it if necessary A Itis recommended that you read the description IM 11M7A3 01E lt PREFACE gt V Precautions for Flameproof Instrume
72. User s Manual Model ZS8 Flameproof Zirconia Oxygen Analyzer EXA oxy IM 11M7A3 01E vigilantplant YOKOGAWA 9 IM 11M7A3 01E 4th Edition Yokogawa Electric Corporation lt PREFACE gt i PREFACE This instruction manual describes the handling of the flameproof zirconia oxygen analyzer To ensure safe operation and maximum performance of flameproof zirconia oxygen analyzer read this manual carefully before using it Items to which attention needs to be paid with regard to the handling of the flameproof zirconia oxygen analyzer are shown in this manual in the form of 4A WARNING and CAUTION These items must be read before it is put in operation 4A WARNING Items involving serious accidents due to incorrect handling of flameproof zirconia oxygen analyzer CAUTION Items involving injury damage to device or physical damage WARNING e Power source Before the power for the unit is turned ON make sure that the power voltage conforms to the power supply voltage Earthing Before turning ON the power for the unit be sure to earth the unit to prevent electric shocks Necessity of earthing Neither cut off the internal or external earth cable of the unit nor disconnect the earth terminal otherwise it causes a hazard to human body e Defect in function If protective functions such as earthing fuse etc seem to be defective do not operate the unit Before operating the unit check to make sure tha
73. ace the contact fthere is any corroded or discolored area in the metal O ring groove in which the contact is embedded sand the groove with sandpaper or use a metal brush and then sand further with a higher grade of sandpaper no 1500 or so or use an appropriate metal brush to eliminate any sharp protrusions on the groove The contact s resistance should be minimized IM 11M7A3 01E 1 lt 9 Inspection and Maintenance gt 9 5 Identifying parts to be replaced In order not to lose or damage disassembled parts identify the parts to be replaced from among all the parts in the sensor assembly Normally replace the sensor metal O ring and contact together at the same time If required also replace the U shaped pipe bolts filter and associated spring washers N HS as Sensor cell Filter Filter holder Contact Bolts EM QN NE U shaped pipe j F9 4E ai Figure 9 2 Exploded View of Sensor Assembly Removal procedures Remove the four bolts and associated washers from the tip of the detector probe Remove the U shaped pipe support together with the U shaped pipe Remove filter also Pull the sensor assembly toward you while turning it clockwise Also remove the metal O ring between the assembly and the probe Remove filter also When replacing the assembly be careful not to scratch or dent the tip of the probe with which the metal O ring comes in contact the surface with which the sens
74. air 0 1 to 1 0 l min Dust proof and rainproof construction SPCC Cold rolled steel sheet Baked epoxy resin Dark green Munsell 2 0 GY 3 1 0 5 or equivalent Clean air supply of measured gas pressure plus approx 50 kPa G measured gas pressure plus approx 150 kPa maximum pressure rating is 300 kPa when a check valve is used pressure at inlet of the auto calibration unit Air Consumption Approx 1 5 l min Weight Approx 2 3 kg Model and Suffix Codes Suffix code Description Flow setting unit Rc1 4 1 ANPT F with adaptor Style code Style C 1 23 lt 1 General gt External Dimensions 180 6 holes je gt i 140 Unit mm Y K 7 i v REFERENCE CHECK REFERENCE SPAN ZERO 1 1 1 235 8 2 inch mounting pipe 222 8 E c Y Calibration gas outlet ui c Span gas inlet Zero gas inlet Reference gas outlet 32 z 2 Piping connection port A Model Piping connection port A y PE ou ZA8F J C 5 Rc1 4 ZA8F A C 5 1 4NPT 70 Weight Approx 2 3kg EE CA ie ment air inlet CHECK REF OUT OUT Flow Flow meter meter x4 x4 ZERO GAS IN SPAN AIR IN GAS IN n Instrument air Approx 1 5 l min Air set Air pressure without check val
75. alve during zero point calibration is as follows 1 When the message DID YOU OPEN ZERO VALVE Y is displayed in the readout of the converter during calibration open the zero gas flow setting valve of the flow setting unit and adjust the flow rate to 600 ml min To rotate the valve shaft loosen the lock nut and slowly turn it counterclockwise To check the flow rate monitor the calibration gas flow meter 2 After adjusting the flow rate press the interactive key YES of the converter Because of the time set in Function No C 4 when this key is pressed zero point calibration is executed When the message ZERO CALIBRATION FINISHED is displayed close the zero gas flow setting valve to stop the zero gas flow Be sure to tighten the lock nut to prevent the any leakage of the zero gas into the sensor because the valve may become loose during measurement Treatment after Calibration No special treatment of the instrument is needed after the completing the calibration However it is recommended that the regulator valve for the zero gas cylinder be closed if calibration will not be necessary so frequently in the future IM 11M7A3 01E lt 9 Inspection and Maintenance gt 9 1 9 Inspection and Maintenance In this Chapter inspection and maintenance for keeping or recovering the measuring performances of the EXA OXY Flameproof zirconia oxygen analyzer is described 4A WARNING 9 1 9 1 1 9 1 2 Before opening the cove
76. ame time as the boiler or furnace etc condensation forms in the sensor and dust adheres to it If you restart operations with the sensor in this state as it heats up to 750 C it causes dust to accumulate which significantly deteriorates its performance In an extreme case with a lot of condensation the analyzer may break To prevent such an occurrence you have to take the following steps to stop the equipment 1 Keep the power supply to the analyzer ON as long as possible If this is impossible remove the detector 2 If both of the above are impossible keep air flowing into the calibration gas piping at a rate of about 1000 ml min Stop supplying air to the main and auxiliary ejectors A CAUTION The flame arrester section electric or steam heat insulation section and the detector surface are extremely hot immediately after turning off the power If the detector is removed or maintenance is required never touch these sections immediately after turning off the power The probe adaptor is also extremely hot immediately after stopping the auxiliary ejector Special care must also be taken as given above lt Operation restart gt If none of the above precautions for stopping operations can be done supply air into the calibration gas piping for 5 to 10 minutes at a rate of about 600 60 ml min After stopping operations for a long period of time set the necessary data again see Table 6 1 Ejector air supply pressure Check t
77. ameproof Steam outlet converter Steam inlet Stop valve Air set Ejector air e Interior of Detector output wiring n furnace 1 25mm or more 6 wire shielded cable _ Detector heater power wiring 2mm or more 2 wire shielded cable Heat insulation Q Check valve K9292DN aa ge K9292DS eterence gas i Ad 100V 115V flow meter 220v 240VAC YY 300 ml min 20 Air set Reference i Al G7003XF K9473XK Instrument F Calibration gas unit gas Needle valve air POTATO aS ut i Calibration i By Na 9 A 2 3 4 IM 11M7A3 01E gas 3 Needle valve Calibration gas unit Caliration gas Calibration gas pressure regulator flow meter py f NA o i 600 ml min m A i 1 Calbration gas i i eedle valve 1 i la ao os pressure regulator oer Span gas Flow setting unit ZA8F G7013XF Zero gas cylinder cylinder aor i G7001ZC F1 3E ai Conduits 1 When installing conduits use flexible conduits so that the probe removed 2 Use a shielded cable for the signal cable and ground the shield together with the probe ground 3 Provide separate conduits for the signal and heater lines 4 The maximum outside diameter of the cable suited for the cable gland used for the instrument is 13 5mm in case that the thread at the conduit side is G3 4 The probe material SUS310S or SiC should be selected according to the specified measurement gas temperature
78. ary Ejector for Clogging 10 9 10 2 3 Checking the Tip Filter SiC for Clogging ssssesss 10 9 1024 OS iai ettet e aee Pe e e reds 10 9 10 3 Measures When Measured Value Shows an Error 10 9 10 3 1 Measured Value Higher Than True Value ssssss 10 10 10 3 2 Measured Value Lower Than True Value susss 10 11 10 3 3 Measured Value Sometimes Show Abnormal Values 10 11 Customer Maintenance Parts List CMPL 11M7A3 01E Customer Maintenance Parts List CMPL 11M7A3 03E Customer Maintenance Parts List CMPL 11M7A3 04E Customer Maintenance Parts List CMPL 11M7A3 11E Revision RECON M i IM 11M7A3 01E lt 1 General gt 1 1 1 1 1 General The Z88 flameproof zirconia oxygen analyzer can be used for monitoring and controlling oxygen concentrations in combustion gases in heating furnaces or boilers in petroleum refining petrochemical and city gas production industries The analyzer mainly consists of a detector and a converter The ZS8 flameproof detector includes general purpose detectors that can be used for measuring gases at up to 800 C and high temperature detectors tha
79. ate when the error occur E 1 Sensor failure cell The analyzer goes to the fail mode and power to the detector heater is automatically turned off E 2 Sensor temperature The analyzer goes to the fail mode and power to the detector heater is error Low automatically turned off E 3 Sensor temperature The analyzer goes to the fail mode and power to the detector heater is error High automatically turned off E 4 A D analog circuit The analyzer goes to the fail mode and power to the detector heater is failure automatically turned off E 5 Calibration value error Displayed in calibration The current zero point calibrated value is not Zero employed E 6 Calibration value error Displayed in calibration The current span calibrated value is not Span employed E 7 EMF stabilization Displayed in calibration The current calibrated value is not employed time over E 8 ROM or RAM failure The analyzer goes to the fail mode and power to the detector heater is automatically turned off OOOO Digital circuit failure The analyzer goes to the fail mode and power to the detector heater is Display Power interruption automatically turned off disappears occurs Displayed in turning power on again after power off Data value default Errors displayed with error code E 5 E 6 or E 7 are those generated in carrying out automatic or semi automatic calibration If these errors occur that error code and oxygen concent
80. base H High heat value of fuel kJ kg H Low heat value of fuel kJ kg H Same as H IM 11M7A3 01E 6 16 lt 6 Operation gt 40 Wet bulb 30 temperature AN I I SSS FSR STR STE SSS 0 2 4 6 mS 12 a 16 18 20 22 24 26 28 30 32 34 36 38 40 Dry bulb temperature C Figure 6 3 Absolute Humidity of Air 0 004 0 002 0 000 IM 11M7A3 01E Absolute humidity kg kg F6 4E ai lt 6 Operation gt 6 1 7 6 1 7 Set of Relay Contacts for Contact Output A CAUTION Never open the cover of the converter before turning off the power source Contact status Normally Open or Normally Closed of the contact outputs selecting applications with function No G 0 G 1 or G 2 is determined by the selected relay operation normally energized or de energized and types of relay contact make contact or break contact Note NO of the contact status means the contact operating status where the contact is closed when a contact signal is output NC is its inversion Make contact in the types of relay contact means the contact which is closed when the relay coil is energized Table 6 3 Contact States Classified with Relay Operation and Types of Contact Contact Status Relay Operation Type of Relay Contacts When Contact Normal Power OFF Signal is Output Condition Break contact shortcircuiting jumpers 1 and 2 Closed Open Closed Nommely eneren Make contact shortcircuitin
81. be at a right angle to the measuring gas flow or with the probe tip located on the downstream side 3 Ifthe vent gas is to be returned to the inside of the furnace using a general purpose detector devise the mounting flange pipe so that its inner surface is placed outer than the ejector air return port position because the return port radius is 41 mm Also place the filter root position 30 mm or more away from the inner surface of the furnace wall If itis less than this distance if may be affected with the ejector s return air 4 Adjustment of deflector mounting direction Adjust the position of the filter protector deflector of the probe tip so that it is a right angle to the gas flow as shown in Figure 2 1 for both general purpose and high temperature detectors The deflector direction can be readily changed by loosening the lock nut on the probe tip Figure 2 1 shows an example of probe insertion hole construction work IM 11M7A3 01E lt 2 Installation gt 2 1 3 2 1 4 Locknut Vertical Range of possible insertion hole construction ttt 100mm Flange Gas flow Deflector Install the rating Deflector adjustment flange the same as that for the detector Horizontal Note Diameter of 60mm or more 100mm Note 95mm dia or more for return to inside of furnace JIS flange ANSI flange F2 1E ai Figure 2 1 Example of Probe Insertion Hole Construction Work Dete
82. bly for probe adaptors Rc1 4 with a pressure gauge and needle valve K9292WD Ejector joint for probe adaptor 1 4NPT K9292WC Ejector joint for probe adaptor Rc1 4 External Dimensions Pressure Gauge Assembly Ejector Joint Unit mm 3 Pressure Meter Ejector joint K9292WC Needle valve K9292WD 943 for probe is adaptor Approx 67 Height when fully opened Fein To be constructed JA by the customer t lt 2 gt lt 1 gt Ejector joint K9292VE K9292VF Auxiliary Ejector Assembly K9292VA K9292VB K9292WA K9292WB Parts number for detector F1 12E ai Specification K9292VA For Detector use Rc1 4 K9292VB For Detector use 1 ANPT K9292WA For Probe adaptor use Rc1 4 Pipe O D 26 K9292WB Note 1 For Probe adaptor use 1 ANPT Pipe O D 21 4 The connector of auxiliary ejector assembly is a dedicated connecter with nozzle function IM 11M7A3 01E 1 22 lt 1 General gt 3 IM 11M7A3 01E Flow Setting Unit ZA8F Specifications Used when instrument air is provided This unit controls flow rates of calibration gas and reference gas and consists of flowmeter and flow rate control valve Flowmeter Construction Case Material Painting Tube Connections Rc1 4 or 1 ANPT F Reference Air pressure Calibration gas 0 1 to 1 0 l min Reference
83. bration completion F7 4E ai Response time is calculated after the corrected calibration curve is obtained With a starting point where a voltage corresponding to 1096 of the corrected calibration curve span is found the time that it takes for the voltage to reach the 90 mark of a 100 voltage corresponding to the oxygen concentration of a calibration gas zero gas set in the converter is calculated In other words the response time for the above is in the range from 10 to 90 Figure 7 2 Calculation of response time Display of response B2 CELL RESPONSE LE 10 90 003 sec B 3 Resistance in the Cell new cell sensor has an internal resistance of less than 2000 The resistance increases as the cell deteriorates Therefore the internal resistance of a cell is an index for indicating the degree of sensor deterioration In Function No B 3 the value obtained at the most recent calibration is displayed i bed Mr B3 CELL RESISTANCE l example 00175 Q B 4 Robustness of the Cell The robustness of the cell an index for estimating the remaining life of the cell sensor is classified by a number from 5 good to 1 poor This robustness is determined after comprehensively evaluating various data monitored during calibration e g the response time the internal resistance of the cell and the calibration coefficient However when the zero point or span is skipped no response time is measurable Thus cell robustness is obtained
84. bration gas automatic or semi automatic calibration e 4 Check calibration operation Execute calibration lt Checking the set calibration data gt Sequentially display the data from Codes C 0 to C 7 on the message display of the converter and check for errors in the set data e g the selected calibration method and the concentration of calibration gas lt Checking the calibration operation gt Carry out calibration and check for normal operation Begin calibration by pressing the key CAL on the converter For the operation procedures of one touch calibration see Chapter 8 If you have trouble when you monitor serial operations to the end of calibration immediately remedy the problem by for example changing set data etc Note If the error code E 5 or E 6 is shown in the data display make the correction according to Chapter 10 lt Executing calibration gt If you changed set data previously in checking the calibration operation you have to calibrate once again by checking for normal operation Before beginning automatic calibration check that the correct time is set in the converter and after stationary operation see section 6 2 begins set the time for the first execution 6 1 10 Checking Functional Operations 6 2 6 2 1 6 2 2 If you have some ongoing instrument operations which need to be checked before beginning stationary operation check these operations according to the method su
85. bration gas inlet of the detector completely open this valve beforehand 2 When instrument air is used as the reference gas set the secondary pressure of the air so that the air pressure becomes 70 to 100 kPa In addition to set the opening rotate the shaft of the reference gas flow adjust valve REFERENCE in the flow setting unit so that the flow rate changes to about 0 3 l min Flow rate increases by rotating the valve screw counterclockwise Before rotating the screw loosen the lock nut After the completion of the setting be sure to tighten the lock nut again Note Ne setting of the calibration gas flow will be performed later Keep the relevant needle valve in the flow setting unit fully close Supplying Power to Converter Check that the supplied voltage meets the specifications of your converter see 2 4 and then turn on the power to the converter In addition turn ON the main switch on the converter on the left side of the external wire terminals At that time the converter will begin to operate However measurement will not take effect for about 10 minutes because the sensor of the detector will not have reached the specified temperature All of the set parameters etc will also be in a default state so enter data as required see 6 1 5 The display will be as shown in Figure 6 2 immediately after the power is turned ON Set the calibration gas concentration measuring ranges and other required items while the sensor s h
86. cable Contact input ZA Interior of Check valve furnace X K9292DN Reference gas 100V 115V K9292DS flow meter i 220V 240V AC d A 300 Mimin 2207 Air set 67003XF K9473XK a Reference E PD Instrument ONT gas Needle valve air Calibration gas mm Calibration P sky M Na 9 Calibration gas Needle valve Calibration gas unit Calibration gas flow meter 3 i SN o pressure i 1600 ml min 10 py E regulator Needle valve Calibration gas Gub eens pressure regulator gt er gas 777 Span gas Flow setting unit ZA8F G7013XF cylinder cylinder OE i G7001ZC Fae 4 2 3 4 Conduits 1 When installing conduits use flexible conduits so that the probe removed 2 Use a shielded cable for the signal cable and ground the shield together with the probe ground 3 Provide separate conduits for the signal and heater lines 4 The maximum outside diameter of the cable suited for the cable gland used for the instrument is 13 5mm in case that the thread at the conduit side is G3 4 The probe material SUS310S or SiC should be selected according to the specified measurement gas temperature SUS310S 0 to 800 C SiC 800 to 1400 C Detectors need sufficient heat insulation For combustion including ion components ensure heat insulation greater than dew point of sulfuric acid about 160 C In this case the steam pressure should be
87. cation where 1 2 3 4 5 there is access for inspection and maintenance the locations of the detector and converter mounting are nearby the ambient temperature is not too high up to 55 C and temperature fluctuations are small and nan nN Oa there are no corrosive gases there is little vibration IM 11M7A3 01E 2 20 lt 2 Installation gt 2 5 2 Flow Setting Unit Mounting The flow setting unit can be mounted on a pipe nominal 50A or on the wall As the flow setting unit incorporates a flowmeter be sure to mount the unit vertically so that no error occurs Mount the unit in the following procedure Pipe Mounting 1 Provide a vertical mounting pipe nominal 50A OD of 60 5 mm with sufficient strength 2 Mountthe flow setting unit to the pipe Securely fix the mounting bracket to the pipe by fully tightening the U bolt nuts F2 7E ai Figure 2 12 Pipe Mounting Status Wall Mounting 1 Drill the mounting holes to the wall as shown in Figure 2 12 N 4 96 5 holes or M6 screws F2 8E ai Figure 2 13 Drilling of Mounting Holes Unit mm 2 Mountthe flow setting unit Remove the pipe mounting parts from the mounting bracket and securely fix the unit to the wall F3403 EPS Figure 2 14 Wall Mounting Status IM 11M7A3 01E lt 2 Installation gt 2 21 2 6 Installation of Calibration Gas Unit Case The calibration gas unit case is a case for storing the G7001ZC zero ga
88. ccording to Function No J 1 through J 7 Readout on the message D6 WET SELECT DRY CE E 0 0 WET 1 D 2 RY IM 11M7A3 01E 6 8 lt 6 Operation gt E 0 Setting of extreme high limit high limit alarms You can set the level s of contact output signals for the extreme high limit and or high limit alarms If for instance you want to have an alarm set at an oxygen high limit of 6 5 vol O but deactivate the extreme high limit alarm enter 000 0 for the extreme high limit alarm HH and 006 5 for the high limit alarm HI You can set these settings related to contact output with Function Nos G 0 through G 2 Note For alarm value display see 7 2 2 Function No A 0 Analog Bargraph Display O 2 Readout on the message E 0 A display Ex H 7 5 ARM SET PT 000 0 H1 Osx 0 E 1 Setting of extreme low limit low limit alarms You can set the level s of contact output signals for the extreme low limit and or low limit alarms If for instance you want to have an alarm set at an oxygen extreme low limit of 2 5 and activate a low limit alarm of 4 9 enter 002 5 for the extreme low limit alarm LL and 004 9 for the low limit alarm LO You can set these settings related to contact output with Function Nos G 0 through G 2 Note For alarm value display see 7 2 2 Function No A 0 Analog Bar graph Display I gt I Om Readout on the message E 1 AL display Ex L
89. ce air outlet you can connect a short pipe 100 mm maximum with a minimum of 6 mm ID to the outlet IM 11M7A3 01E lt 2 Installation gt 2 3 2 1 5 Heat Insulation A CAUTION For explosion protection standards the lagging surface temperature must be 200 C or less 2 2 2 2 1 2 2 2 The path of the gas flow in the probe must be heat insulated above the dew point to prevent clogging due to condensation a Heat insulate the flame arresters at both the measuring gas inlet and outlet using an electric heater Make the heat insulation temperature above the dew point and at 195 C or less The electric heater or steam trace copper tubing can be supplied optionally Heat insulate the mating flange section so that the inside of the measuring gas suction pipe does not drop below the dew point using steam tracing Also heat insulate the air ejector so that it is above the dew point As the strength of the measuring gas suction is weak about 300 ml min supply an air flowrate of about 3 l min there will be no problem in heat insulation by using lagging only except when the ambient temperature is extremely low Prevent rain water from entering the air ejector In addition the problem of supply air piping clogging is better solved by heating the piping by winding it around the detector heater section before connecting it to the ejector Coverthe heat insulating section by steam trace or the electric heater with ceramic
90. centration in a Measurement Gas vs Cell Voltage 21 0 O Equivalent Calibration Gas Agas with a known oxygen concentration is used for calibration Normal calibration is performed using 2 different gases a zero gas of low oxygen concentration and a span gas of high oxygen concentration In some cases only one or the other gas may be used for calibration However even if only one of the gases is normally used calibration using both gases should be done at least once The zero gas normally used has an oxygen concentration of 0 95 to 1 0 vol O with a balance of nitrogen gas N The span gas widely used is clean air e g instrument air Compensation The deviation of a measured value from the theoretical cell electromotive force is checked by the method in Figure 8 2 or 8 3 Figure 8 2 shows a 2 point calibration using 2 gases zero and span Cell electromotive forces for a span gas with an oxygen concentration p1 and a zero gas with an oxygen concentration p2 are measured while determining a calibration curve passing between these 2 points The oxygen concentration of the measurement gas is determined from this calibration curve In addition the calibration curve corrected by calibration is compared with the theoretical calibration curve for determining the zero point correction ratio represented by B A x 100 on the basis of A B and C shown in Figure 8 2 and the span point correction ratio of C A x 100 If the zero point co
91. changed over to the measurement mode and the analog bar graph is displayed BHEHNHNHNHNEHNEHHENU IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 5 9 Changing displayed data Use the number increase key to change the function number Use the cursor key to change to another function group or to move to the next screen e When changing from Function No A 0 Display of Function No A 0 The no changes every BHEHNHEHHEHNHEHEHNHI time the key is pressed The number will return to 0 if the key is pressed again after reaching 7 in group A The display changes from Group A to Group B BO SPAN 0 099 89 04 26 14 30 H When there are 2 or more component screens the second or next screen can be displayd by pressing the cursor key 10 Calibration start or suspension instructions Use the calibration start or suspension key For more details on the calibration keys see Chapter 8 e When a calibration start instruction issued in the semi automatic calibration mode is suspended during mid activity Display of Function No A 0 BHEHNHNHENHNHENENNEIIIIUDODnLUDrD 0 1 25 CAL CALIBRATION Y SS HELP SE eee ooooooooo 0 1 25 Ir CALIBRATION Y 2 The mode changes from the measurement mode to the calibration mode Upon pressing the key the solenoid valve in the calibration gas line is closed After the stability time a
92. cle calibration start time Setpoint group D output related Output range 1 2 0 presence or absence of output hold preset value analog output smoothing constant Setpoint group E alarm HH alarm H alarm LL alarm and L alarm setpoints contact output delay sec hysteresis 9o span Status message group Self diagnosis calibration warm up stabilization abnormal content Talk and response message group Calibration operation indicator component check indicator password entry indicator Help message Information supplementary to display content Analog Output Signal 4 to 20 mA DC max load resistance 5500 Input output isolation Range any settings between 0 to 5 through 0 to 25 vol 0 switching between 2 ranges by external contact input possible optional partial range possible span zero rate 2 1 3 Output dumping 0 to 255 seconds Dumping released during abrupt output change releasing range 0 to 3 0 vol Hold non hold selection preset value setting possible at hold Contact output signal 3 points contact capacity 30 V DC 2A 250 V AC 2A resistive load Fail safe condition normally energized normally de energized selectable NO NC selectable using jumper pin Delay function 0 to 255 sec and hysteresis function 0 to 25vol O can be set for Hi Lo alarm IM 11M7A3 01E lt 1 General gt 1 1 7 The following functions are programmable for each contact output 1 Abnormal self diagnosis
93. command is sent Receiving When cod format setting DT 1 RF When Nene reading Transmitting format DT 1 R 4 DR Data Read Function This command can make the ZS8C converter transmit data amp time and measured data Data structure 1 Received data 1 2 3 4 5 6 DIR 1 94 tF ST TE Delimiter ZS8C converter channel number 1 to 8 Space Command 2 Transmitted data 1 2 3 4 5 9 Tee 226 227 228 DR 0 1 Data Sr te L Data see page 4 17 and later for the format Comma ZS8C converter channel number 1 to 8 Space Command Receiving When format setting Nong When e reading DR TRE Note Answer back signals for commands other than the DT 0 C L command may be sent by placing them after the undefined code for two characters depending on the signal circuit switching state IM 11M7A3 01E 4 16 lt 4 Wiring gt Data Format for DR Command Communication Transmission 1 Transmission format data 7 8 9 10 11 12 13 14 15 16 B OI 0 7 14 5 J Apostrophe 17 18 Slash 19 20 21 Slash Comma Day Month 22 23 24 Year 25 26 5 Colon Status code S 1 Measurement mode S 2 Maintenance mode Minute
94. concentration value 000 00 to 100 00 Maximum oxygen 77 78 79 80 81 82 83 84 85 86 concentration MII 1012151 10101 Comma Unit Oxygen concentration value 000 00 to 100 00 Minimum oxygen concentration IM 11M7A3 01E 4 18 lt 4 Wiring gt Data Format for DR Command Communication 3 Transmission 87 88 89 90 91 92 93 94 95 96 format data E LB LZ rS 5 M Comma Unit mV Electromotive force value 000 0 to 200 0 Positive or negative sign Cell emf 97 98 99 100 101 102 103 104 105 106 T 0 7 Sp ace Comma Unit C C Temperature value 0000 to 1000 107 108 109 110 111 112 113 114 Cell temperature 115 116 R e Comma Unit Calibration coefficient value 000 0 to 100 0 n Positive or negative sign 117 118 119 120 121 122 123 124 Span calibration coefficient 125 126 R M Comma Space Unit Calibration coefficient value 000 0 to 130 0 Zero calibration coefficient 127 128 129 130 131 132 133 134 135 136 RIO Space Comma Cell resistance value ohm 00000 to 99999 Cell resistance IM 11M7A3 01E lt 4 W
95. contact output is 30 V DC 2A or 250 V AC 2A Connect the loads indicator lamps annunciators or others so as to satisfy these values Contact Input Wiring The converter can respond to a maximum of two contact input signals received These contact input signals can be selected from five types of signals e g the range selection command or calibration gas under pressure alarm When using these contact inputs do the wiring as illustrated below Converter Tarminal board F4 16E ai Figure 4 15 Contact Input Wiring IM 11M7A3 01E 4 22 lt 4 Wiring gt 4 8 1 Cable Specifications Use a 2 conductor cable for one point contact input or 4 conductor cable for two point contact inputs with an OD of 10 to 13 5 mm for this wiring 4 8 2 Wiring Procedure 1 The terminal screws of the converter are of M4 size ISO 4 mm Treat the cable end using crimp on terminal lugs conforming to this screw size 2 The on off levels of this contact are identified by resistances or voltages Use a device to be connected which satisfies the conditions shown in Table 4 4 Table 4 4 Identification of Contact Input On Off Levels ON OFF Resistance value contact 200 ohm or less 100 kohm or more Voltage value 1to1VDC 4 5 to 25 V DC 4 9 Wiring for Solenoid Valve Because there is power to supply the contact of solenoid valve for auto calibration Zero Span and Stopping of ejector Note the external power is unnec
96. crew them in along with the washers First tighten the four bolts uniformly by hand and then use a torque wrench to tighten all areas of the metal O ring uniformly that is to make sure the sensor flange is perfectly horizontal to the O ring s working face in the probe This is done by tightening first one bolt and then its opposing bolt each 1 8 turn and then one of the other bolts followed by its opposing bolt each also 1 8 turn This continues in rotating fashion until they are all fully tightened with the torque wrench preset to approximately 5 9 N m If they are not uniformly tightened the sensor or heater may be damaged Replacement of the sensor assembly is now complete Install the detector and restart operation Calibrate the instrument before making a measurement A CAUTION Optional Inconel bolts have a high coefficient of expansion If excess torque is applied while the bolts are being tightened abnormal strain or bolt breakage may result So tighten the bolts following the instructions given above 9 1 8 Cleaning the High Temperature Probe Adapter A CAUTION Do NOT subject the probe of the High temperature Probe Adapter ZS8P H B to shock This probe uses silicon carbide SiC which may become damaged if it is subjected to a strong shock or thermal shock The high temperature detector is structured so that the gas to be measured is directed toward the detector with the high temperature probe adapter Therefore if the pr
97. ctor poor contact at the terminal connections disconnection shortcircuiting etc Failure of the heater in the detector disconnection etc Blown heater temperature fuse in the detector lt Locating the Failure and Taking Measures gt Turn off the power to the converter Is there any breakage or poor contact in wiring to the converter terminals Is there any breakage or poor contact in wiring to the detector terminals Does the detector heater fail Is the temperature fuse blown Does the thermocouple in the detector fail error occurs during warm up Restore the damaged parts Restore the damaged parts Problems other than a blown temperature fuse cannot be recovered As it cannot be restored replace the detector with a new one As it cannot be restored replace the detector with a new one Does the cold junction compensating Is the error displayed Replace the cold junction compensating sensor e Temporarily operate the converter by turning its power switch The electronic circuit in the converter may possibly be failed Contact Yokogawa Yes End Set the temporary cts Items marked with should be checked when the e Examine fuses Fl and F2 for the detector heater whether or not they are blown and then check wiring connections to t
98. ctor Installation In the detector zirconia ceramic is used as a sensor Be careful not to subject the sensor to strong shock such as from being dropped when the detector is installed Prepare and use a gasket on the tie in flange surface to prevent gas leakage It is required that the gasket material be heat resistant and corrosion resistant conforming to the properties of the measuring gas Table 2 1 shows the parts which are necessary for installing the detector Table 2 1 Parts Necessary for Installing the Detector Mounting flange Part Quantity Remarks rating The gasket should be heat resistant and Gasket 1 corrosion resistant JIS 10K 100 FF Bolts M16 x 80 Nuts M16 8 Washer for M16 16 Gasket 1 The gasket should be heat resistant and corrosion resistant JPI CLASS150 4 RF Bolts 5 8 11UNC x 80 Nuts 5 8 11UNC Washer for 5 8 11UNC 16 The gasket should be heat resistant and Gasket 1 corrosion resistant DIN PN10 DN100 A Bolts M16 x 80 Nuts M16 Washer for M16 16 The following is a point to be taken into consideration in installation work Flameproof Detector If the detector is to be mounted horizontally point the cable inlet port downward Reference Air Outlet Do not block the reference air outlet Otherwise the terminal box inner pressure increases and an indication error may occur To prevent rain water from entering through the referen
99. currence of an alarm etc are indicated by lit up lights Lamp MEAS Lights up in the measurement mode MAINT Lights up in the calibration mode or setting mode This light also glows when an error occurs with the instrument stopping measurement operations ALM Lights up when an alarm is issued according to the details set in Function Nos G 0 to G 2 The operation mode changes from the measurement mode to the maintenance mode depending on the type of alarm FAIL Lights up when an error occurs while stopping the Status display measurement operations of the instrument 7 2 2 Data Display This display incorporates a large 4 digit LED Items displayed here are the warm up state warm up symbol ON and the current temperature of the sensor measured oxygen concentration vol O and the error code Normally just the measured oxygen concentration is displayed e Example of warm up state display U LU LJ LJ Alternately displayed f u c Current temperature of sensor in C e Example of measured oxygen concentration display Note 1 Measured value is displayed Thus aven if 1 oxygen concentration in dry gas is selected in function No D 6 indication in the data display is the oxygen consentration in wet gas e Example of error occurrence display Note 2 An error display E 5 E 6 or E 7 generated in calibration is indicated olternately with oxygen c
100. d one touch calibrations are described using flowcharts 8 2 1 IM 11M7A3 01E TTT TTT yyy oo I 0 25 Note 1 Ca ibration Y N Lr CAL J contact signal MY Operation Flowchart of Semi Automatic and Automatic Calibrations Also instructable through an external The mode changes to a Note 3 semi automatic I Setting of C 7 0 y Setting of C 7 2 C Span gas solenoid valve open NE On span cal Y ov Span point calibration Vos C Span gas solenoid valve close On EN Zero gas solenoid valve open TE zero cal i I C Zero point calibration Y Y C Zero gas solenoid valve close ME Displayed only during the time set in C 3 calibration Automatic calibration starts Note 1 WARM UP ON is displayed while warming up J EAN Hr 3 Note 2 The calibration procedure above finishes at which time the mode automatically returns to the measurement mode Note 3 After the calibration ends Note 2 Calibration Y N is displayed If the analog bargraph display is to be displayed function No A 0 lt J J press the measurement mode selection key DISP F8 4E ai lt 8 Calibration gt 8 5 8 2 2 Operation Flowchart
101. d press the ENTER key to activate the date and time Readout on the message F 0 C 0 LOCK ENTRY display Ex 6 04 26 18 45 F 1 Mean O concentration calculation time You can set the time for collecting measured data in order to calculate the mean oxygen concentration indicated when you access Function No A 2 Measured data are collected and summarized in 60 second intervals while averages are calculated every time a datum is collected And after the set time expires the calculated mean value is reset and the operation of calculating a new mean value begins all over again If you want to update accumulated data every 24 hours set this function at 024 Accumulation of data begins from the time you press the entry key Note The calculation of the mean value is activated every time a datum is collected So the longer the calculation time is extended the more data which are used in averaging are collected If you use mean data periodically you should take notice of this Readout on the message F 1 AVERAGE INTERVAL display Ex 02 F 2 Time interval for monitoring maximum minimum O The converter stores the maximum and minimum values of measured oxygen concentrations within a set time period You can see these values on the message display by accessing Function No A 1 You can set the time period for storing these maximum and minimum values If you want to store them for a week enter 168 hr The storage of data
102. duits and in particular consider rainproofness in the case of outdoor installation Be sure to connect wire ends to predetermined terminals using crimp on terminal lugs Note If the ambient temperature of the location where the detector is installed exceeds 60 C do not use terminal lugs with an insulation sleeve or insulation resin tape The use of these may cause a poor contact of the terminals due to toxic gas produced through burning of the resin In high temperature locations it is recommended that nickel plated bare crimp on terminals be used for detector terminal board M3 5 or M4 screws Use of conduit is recommended for wiring Both the detector and the converter have wiring holes of G3 4 Connect cables using the specified cable glands In addition in wiring work around the detector use flexible conduits so that the detector probe can be pulled out without disconnecting the wiring between the detector and the relaying terminal box or between the conduits Exercise care so that noise does not mix into the signal wires a Separate the signal cable from the power cable and ground wire Thus if wiring to the detector and converter is to use conduits pass the signal cable and the heater cable through separate conduits b Use a shielded cable for the signal cable Connect the shield to the screw with the ground mark of the detector In this case exercise care so that the shield does not touch the heater terminals Leave the
103. dust be careful because an increase in the suction flowrate is likely to cause clogging in the ejector If the pressure in the furnace is positive increasing the aperture of the needle valve for the discharge outlet of the measuring gas increases the suction amount of measuring gas For the position of the needle valve see section 5 1 2 If the above measures do not raise the surface temperature of the probe adapter ejector or mating flange above the dew point of measuring gas heat them with heat sources such as a steam heater 2 3 4 Fitting a Thermal Insulating Jacket Option Note Wrap the ejector air pipe around the heater portion of the detector Be sure to insulate the exposed pipe and ejector air pipe that are not insulated by the thermal insulating jacket option Be sure to insulate the ejector outlet pipe too IM 11M7A3 01E lt 2 Installation gt 2 9 A Heat insulation of detector Please install the jacket as below Inthe case of electric heater Procedure 1 Before install the jacket Appearance Procedure2 Fitthe heat insulate material Plate Make the flange side of detector probe on top The side of electric heater for heat insulation undo the magic tape on plate heat insulate material and let the magic tape on side face to the terminal box of detector than insert it to the plate heat insulate material Next As photo above stick the magic tape tightly IM 11M7A3 01E 2 10 lt 2
104. e giving ambiguous readouts etc If the readout on the display becomes indistinct replace the matrix LCD To replace the LCD remove it together with the entire unit If an error in your message display unit cannot be adjudged as to whether it is due to failure in the dot matrix LCD or a different cause contact YOKOGAWA IM 11M7A3 01E lt 10 Troubleshooting gt 1 0 1 10 Troubleshooting This chapter describes the checking and restoring methods when the ZS8C converter self diagnosis function detected errors or other troubles occur A WARNING Before opening the cover of the ZS8C converter remove power and make sure of non hazardous atmospheres The text plate says Open circuit at non hazardous location before removing cover since the internal energy of the ZS8C converter decreases under the specified value The definition of the non hazardous area is followed by the description in the Users Guide to Installing Flameproof Electrical Apparatus at Plants issued by the Technology Institution of Industrial safety Japan As a non hazardous area is considered a place where no occurrence of explosive gas atmospheres is guaranteed by the foreperson and confirmed by a written document Therefore if non hazardous area is secured it is allowed to open the cover in the field Before opening the cover of the ZS8D detector remove power and allow the detector to stand at least 40 minutes CAUTION a The probe adapto
105. e calibration value is completely read also in minutes If itis 5 minutes for example enter 05 0 When you calibrate a system where no solenoid IM 11M7A3 01E lt 6 Operation gt 6 5 valve is used for the calibration gas you have to operate a valve to get rid of the gas in the meantime and so on Take this into account when setting the data Upon the completion of the calibration time interval you will see the message Span or Zero cal good on the display Readout on the message C 4 CAL IBRAT ION TIME display Ex 05 0minutes C 5 Calibration interval You can set the interval from the time of starting a calibration to the time of starting the next calibration in automatic calibration Set in days or hours the calibration frequency differs according to your process conditions However it is normally recommended that intervals of 1 to 3 months 30 to 90 days be used If a calibration interval of 60 days is to be set select 0 from the settable item selection messages thereby displaying the day setting message and set 60 days by entering O60 If you want to set 12 hours for example select 1 from the settable item selection messages and after the time setting request message is shown enter 12 hours with 12 Readout on the message C 5 CAL INTERVAL display Ex When 0 is selected from C5 CAL INTERVAL 0 060 day 9 When 1 is selected from C5 CAL INTERVAL 1 12 hr C 6
106. e case of a Flameproof instrument mechanical aspects such as the gaps and path lengths of joints and mating surfaces and mechanical strength of enclosures are critical factors in explosion protection Exercise great care not to damage the joints and mating surfaces and to protect enclosures from shock b If damage is incurred by any area of a part critical to the maintenance of flameproof performance for example threads joints or mating surfaces inspection windows connecting section between transmitter and terminal box shrouds or clamps external wiring connection ports etc contact Yokogawa Note Never rethread a threaded connection or refinish or touch up the finish on a joint or mating surface Doing so is extremely dangerous as the flameproof explosion protection will be compromised c Unless otherwise specified electrical circuits and mechanisms inside the enclosure may be repaired by component replacement as this will not directly affect flameproof explosion protection however the instrument should always be restored to its original condition Only Yokogawa specified parts should be used for repair d Before returning a repaired instrument to service always reinspect all parts necessary for the preservation of flameproof explosion protection Verify that all screws bolts nuts and threaded connections are properly tightened 3 Prohibition of Specification Changes and Modifications Users are prohibited from makin
107. e gas In addition change of moisture content in exhaust gas after combustion is also considered as a cause of error However normally this error is negligible Calibration gas zero gas is mixed into the detector due to leakage If the zero gas is mixed into the detector due to leakage for the reason of failure of the valve provided in the calibration gas tubing system the measured value shows a value a little lower than normal Check valves in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed state Measured Value Sometimes Show Abnormal Values lt Causes and Measures gt 1 2 Noise is mixed into the converter from the detector output wiring Take measures so that noise is not mixed into the converter e g by shielding the wiring The converter is affected with noises from the power supply Insert the line filter in the power line IM 11M7A3 01E Customer ZSeD EA oxy Flameproof Maintenance Zirconia Oxygen Analyzer Parts List Detecter Standard type 2 11 12 15 6 5 4 3 7 10 9 8 8 gt 0 Q 890 E 920 3 BE o o DD O Q amp Item Parts No Qty Description 1 K9292CX 1 Cold Junction Assembly 2 K9292DE 1 Filter Assembly 3 E7042BR 1 Plate 4 E7042BQ 1 Pipe 5 E7042DW 4 Washer M5 SUS304 stainless steel 6 G7109YC 4 Bolt M5x12 SUS316 stainless steel 7 E7042UD 1 Cell Assembly with Japanese introduction sh
108. e is used or clew point temperature of exhaust gas is about 130 C By selecting either 1 or 2 the steam heater or electric heater is installed For high temperature detector only discharge outside furnace is applied 2 Select whether to discharge mixed gases the sample gas sucked in by the ejector plus the ejector air outside the furnace or to recirculate them in the furnace If 1 is selected a gas return pipe is provided 3 The flameproof detector is equipped with a check valve and auxiliary ejector assembly as standard 4 Heat insulation jacket must be ordered It is essential to use owning hood in where installed in surrounding rain Notes 1 Always use the specified external cable lead in apparatuses given in the table below 2 The number of mountable external cable lead in apparatuses is as follows Cable gland 1 or 2 3 As standard two cable glands G9601AJ for the external cable lead in apparatuses are mounted on the cable inlet ports for the power supply and output signal On the remaining port the blind plug for heat insulation provided by steam heaters or flexible tube for heat insulation provided by electric heaters is mounted External Cable Lead in Apparatuses Name Part No Description Remarks CABLE GLAND G9601AJ Cable O D 10 to 13 5 Cable gland IM 11M7A3 01E 1 10 lt 1 General gt 3 External Dimensions Flameproof General purpose Detector ZS
109. e mode in which calibration or data setting is performed Assign O 1 or 2 for directly outputting the measured value without holding it outputting the measured value after having held it until immediately before entering a mode other than the measurement mode or outputting the preset value respectively When 2 is selected a message for setting a preset value is then displayed so enter your value from the keyboard Preset values are in O vol units If for example you desire 0 corresponding to 4 mA DC in the case of 4 to 20 mA select 000 IM 11M7A3 01E lt 6 Operation gt 6 7 Note The output signal in a state other than normal operation such as in data setting mode or during warming up shows the value either for holding the preceding value or for preset holding where 2 is set even if 0 is set If the preset value is not set in the preset hold mode the preceding value holds Readout on the message D2 OUTPUT HOLD LD 2 display Ex 2 O N XH P HLD When 2 is assigned D2 OUTPUT HOLD 2 PRESET HOLD 000 D 3 Types of output signals You assign the analog output signals conforming to the specifications of the receiving meter in use Enter 0 for 4 to 20 mA DC AO to 20 mA current output cannot be set Readout on the message D 3 CURRENT OUTPUT display Ex 0 0 4 20mA 1 0 20mA D 4 Output signal characteristics The relationship between the 4 to 20 mA DC analog output sig
110. e second decimal place and enter 00 77 Readout on the message J 4 VALUE OF 00 7 m 3 X display Ex Ik g m3 J 5 Absolute humidity of atmosphere You can set the absolute humidity of the atmosphere used in igniting moisture kg dry air kg If the absolute humidity is 0 021 kg kg enter 0 021 For your reference a graph for determining absolute humidity by the temperature indications of a psychrometer is shown in Figure 6 3 It is a little inferior in accuracy If the exact humidity is required determine the value by referring to References such as JIS B8222 Heat Balancing of Boilers for Land Use Readout on the message J 5 ABS 0 0 HMD OF A IR display Ex 210 kg kg J 6 Temperature of exhaust gas You can set the temperature of the exhaust gas in the actual combustion process C If the temperature of the exhaust gas is 450 C enter 0450 Readout on the message J 6 FUEL GAS TEMP display Ex 0 4 5 0 o C J 7 Temperature of atmosphere You can set the temperature of the atmosphere taken in for igniting C Measure the temperature of the atmosphere at a place as close to the air intake port as possible If the temperature is minus 1 C for instance enter 001 You can alternately display plus and minus signs by pressing the increase key display Ex Readout on the message J 7 AMB AIR TEMP 0 1 7 0 C IM 11M7A3 01E 6 1 4 lt 6 Operation gt Table 6 2
111. e surface temperature of the detector must be kept below 200 C in accordance with the explosion protection standards The ambient temperature significantly changes over the course of the year and the operating condition changes as the load changes Therefore if factors that change the surface temperature change be sure to check that the surface temperature is not above 200 C If the surface temperature is above 200 C reduce it to below 200 C by the methods described later see section 2 3 3 Portions Requiring Heat Insulation and Temperature to be Maintained 1 Detector Sensor Portion s Flame Arrestor With regards to the heater for the frame arrestor you can select either en electric heater or steam heater by specifying the model code The maximum controllable temperature of the electric heater is about 130 C Accordingly the electric heater can be used for gas burning or other applications for which the oxygen dew point is 130 C or less IM 11M7A3 01E lt 2 Installation gt 2 7 2 3 3 a Heat Insulation by Electric Heater 2 3 4 Use heat insulating material to maintain the temperature of the frame arrestor portion above the dew point of the measuring gas Set the surface temperature of the electric heater to 160 C or less in order to prevent the thermal fuse built in the electric heater from meting down Heat Insulation by Steam Heater Use a steam heater to heat the frame arrestor portion to maintain
112. e value corresponding to the output current is shown in the analog bargraph Therefore when 1 is selected with function No D 4 logarithmic indication of the current is displayed Ehen 1 is selected with function No D 6 oxygen concentration in dry gas is displayed Note2 If a HOLD value is displayed HOLD is also displayed Example 2 BERRE OO000000000000 In HOLD state 0 1 HOLD 25 IM 11M7A3 01E 7 8 lt 7 Operating Keys and Display of Converter gt In addition if an error occurs during displaying a bargraph it changes to the following error message display e Error Code E 1 Display when an error FAILURE CAUSE occurs Example 1 OR WRG CONVDET When more than one error occurs H is displayed Sequentially transfer the display using the auxiliary message H display key POOR or NC in OUTLNE CELL BRKN or DMGD H Ar Do O Cx wm I gt m go o I Oz On 1 zz OR sZ E gt m e Error Code E 2 4 m v 4 O O r O l O gt C o Display when an error occurs Example 2 z O O I Oo vv I A z I om I Az 4 7m C o odo D O O IH IO 4r DO on a4 ao OA r 4 Z m ollwo O ZD J No Zz gt UJ Z I Z ow Ir og OZzZI O e Error Code E 3 Display when an error occurs Example 3 Ul Nul rtoll U 4r zr gsr zm ar Zollo 2aul 0 Don O DZ Ilo vu O ca o Eu CA
113. eater temperature increases Indication of warm up Current temperature of sensor C Alternately LULL displayed f u e Note The message display indicates the message for the next operation Example SET PRESENT TIME ENTER TO CODE FO Figure 6 2 Readout Upon Turning ON Power and During Warm Up Data Display Note Approximately an hour after the power is applied supply ejector air for measurement gas suction After warming up the detector even in measurement mode if the piping temperature is lower than a sulfuric acid dew point the gas flow line may clog During Warming up The warm up period before measurement can begin i e until the detector sensor reaches the specified temperature is about 10 minutes from the time the power is turned ON Since measuring operations are suspended during this time you can take this opportunity to set the data The analog output signal during the warm up period reads an O value of 076 However this indicates a default When Function No D 2 is adjusted to PRESET the preset value is set After completion of the warm up period the data display indicates the measured oxygen concentration Data Setting To set data enter the password 16 With the EXA OXY Explosion proof Zirconia Oxygen Analyzer you can have the most suitable operation and measurement functions for your individual processes by setting the various data Basic data e g parameters
114. econd or more Blowback start ON command contact input OFF 1 to 11 seconds start timing Time Interval set to function No C 4 _ ON OFF Blowback signal About ten seconds contact output By pressing the HELP key ON the operation can be stopped in mid stream OFF F6 3E ai 1 Blowback can be stopped with the HELP key 2 Blowback is not started during calibration because the calibration start commands AUTO SEMI AUTO ONR TOUCH and calibrating action have priority 3 The blowback signal time does not include the stabilizing time set for function No C 3 4 The analog output at the blowback operation becomes the mode specified for function No D 2 Non Hold Hold or Preset Hold Readout on the message display Ex G 4 Contact input 2 In Function No G 4 select the contact input signal from the following 3 types 0 Calibration gas under pressure alarm G 1 Instructions for change in measurement range R 2 Instructions for start of calibration C If the measurement range change instruction is assigned move the cursor with the keys to 2 Readout on the message G 4 RY 2 CONT INPUT ae 2 26 T R 2 H 0 Communication mode The communication mode should be specified only when digital communications are achieved When 1 is specified the message Set ZA8C converter channel number CH appears So enter channel numbers 1 through 8 for the individual converters Note When an RS 422
115. ed through the calibration gas inlet and the analog output signal begins to change Flameproof Detector ZS8D 1 Specifications Sampling Method Ejector air Air ejector method Supply pressure 20 kPa flow rate at 4 l min or less At atmospheric pressures inside the furnace As sample gas exhaust methods recirculate in furnace and discharge outside furnace are available Specify the method using our model code according to specifications when ordered For high temperature detector only discharge outside furnace is available Sample Gas Temperature ZS8D L ZS8D H Sample Gas Pressure Gas Flow Velocity Dust Amount Heat Insulation 0 to 800 C general purpose detector Probe material SUS310S 800 to 1400 C high temperature detector Probe material SiC For this type probe adaptor ZS8P H is required The ZS8D H high temperature detector can be selected if a general purpose detector cannot be installed owing to limited installation space 5 to 5 kPa for the ZS8D L general purpose detector 1 5 to 5 kPa for the ZS8D H high temperature detector 30 m s or less 500 mg Nm or less Select either heat insulation provided by electric heaters or by steam Heat insulation provided by steam Pressure Normal 800 kPa maximum 1 MPa At temperatures above the dew point of sulfuric acid below 160 C and for gas combustion there are no sulfuric components so heat insulation can be attained a
116. eet 8 E7042BS 1 Contact 9 K9470BJ 1 Metal O Ring 10 E7042AY 1 Filter Assembly 11 Y9508RU 2 Bolt 12 K9292VA 1 Ejector Rc1 4 K9292VB 1 Ejector 1 4NPT 13 K9292DN 1 Check Valve Rc1 4 K9292DS 1 Check Velve 1 4NPT 14 K9292BA 1 Flame Arrestor Calibration gas Reference air Inlet Rc1 4 K9292BB 1 Flame Arrestor Calibration gas Reference air Inlet 1 4NPT 15 K9292BU 1 Flame Arrestor Reference air outlet Rc1 4 K9292BY 1 Flame Arrestor Reference air outlet 1 4NPT 3rd Edition Apr 2001 YK Yokogawa Electric Corporation Customer ZS8C EXA oxy Flameproof Maintenance Zirconia Oxygen Analyzer Parts List Converter Item Parts No Qty Description 1 K9291XA 1 Packing 2 Y9635ZU 12 Bolt M12x35 SUS f 4th Edition Jan 2011 YK Yokogawa Electric Corporation Item ason CMPL 11M7A3 03E Parts No Y9406LS L9801BF K9291DP L9813VJ K9291PA Description Screw Washer LCD Assembly Clamp Display Assembly Jan 2011 Subject change without notice Printed in Japan Gunner j ST ae x Item Parts No Qty Description 1 K9291QA 1 CPU Assembly for ZS8C J 5 O0 J O O K9291QF 1 CPU Assembly for Z88C J 8 D J D D K9291QL 1 CPU Assembly for ZS8C J 3 or 4 O J O O K9291QB 1 CPU Assembly for ZS8C J 5 0 E O O K9291QG 1 CPU Assembly for ZS8C J 8 0 E O O K9291QM 1 CPU Assembly for ZS8C J 3 or 4 O E O O 2 K9291YA 1 Controller ZS8C J O 1 0 O O only 3 K9291YD 1 Noise Filter ZS8C J 3 or 4 0 0 0 0 only
117. ell or remove it from the probe for checking be sure to replace the metal O ring Otherwise the furnace gas may leak and then the leaking corrosive gas will cause the built in heater or thermocouple to go open circuit or the detector may corrode Before opening or closing the terminal box first remove dust sand or the like from the terminal box cover Checking the Flow of Sucked Sample Gases The flow of sample gases to be sucked through the filter at the tip of the probe is set to about 300 to 500 ml min However the reduction of suction flow due to the clogging of the filter capillary tube or ejector will cause deterioration of response or deviation of indication Check the suction flow according to the following procedure at the frequency of once a week at the beginning and determine the period based on the result of the data 1 Let the calibration gas when comparing the oxygen concentration of a zero gas and span gas with that of sample gases whichever with larger concentration deviation of 1 5 l min to 3 l min flow through the calibration gas line When using the ZA8F flow setting gas unit the flow rate exceeds the scale of the flowmeter However it does not affect the flowmeter Note When the ZA8F is used the flame arrester at the tip of the detector inlet restricts the rate of flow to the cell to about 2 5 l min supply pressure of 70kPa even if the flowmeter needle valve is fully opened Continue to allow the sa
118. ening sealant be applied to the threads for waterproofing The flameproof gland packing should be securely tightened to prevent the passage of explosive gases or flame fronts 5 Maintenance of Flameproof Instruments When opening the cover for maintenance the warning added on page i must be observed 1 Maintenance with Power ON Maintenance of flameproof instruments with power on should be avoided unless there is no alternative However if maintenance with power on cannot be avoided a gas detector should first be used to verify that an explosive atmosphere is not present before the instrument cover is opened If itis not possible to verify that explosive gases are not present the scope of maintenance should be limited to the following a Visual inspection Visually inspect the flameproof instrument metal conduit cables etc for physical damage and corrosion and other mechanical and structural defects b Key operation Adjustment should be made only to the extent that it can be done from the outside without opening the instrument cover Great care must be taken not to cause mechanical sparks with tools IM 11M7A3 01E lt PREFACE gt vii 2 Repairs If a flameproof instrument requires repair turn off the power and carry the instrument to a nonhazardous area Observe the following points during repair a Make only such electrical and mechanical repairs as will restore the equipment to its original condition In th
119. ensils are as shown below depending on conduit connection screw size Table 4 1 External Cable Lead in Utensils Name CABLE GLAND Part name G9601AE Specifications Cable with OD of 10 to 13 5 mm Description Cable gland screw G3 4 on the conduit side Asthe cable to be used select a cable with an OD matching the wire lead in utensils to be used and select packing with an ID closest to the cable s OD Table 4 2 Recommended Cables Type of wiring Typsialicanles Wire cress Conditions Construction Material section Detector signal output For steam heaters CVVS 1 25 mm or 10 ohm or 6 conductor shielded wire more less For electric heaters 8 conductor shielded wire Detector heater power For steam heaters CVVS 2 0mm or 3 ohm or 2 conductor shielded wire more less For electric heaters 4 conductor shielded wire Power supply 2 or 3 conductor wire one conductor CVV 2 0 mm or is to be grounded more Analog output signal 2 conductor shielded wire CVVS 0 5 mm or more Digital communication 3 pair twisted pair shielded wire or CVVS 0 3 mm or signal 6 conductor shielded wire more Contact output 2 or 4 conductor shielded wire CVV 0 75 mm or more Solenoid valve driving 4 conductor shielded wire CVV 0 75 mm or power more Contact input 2 or 4 conductor shielded wire CVV 0 75 mm or more Grounding CVV 1 6 mm or 100 ohm or more less If the
120. ent mode Changing displayed data e Calibration start or suspension instructions Displaying the data values in the calibration mode 1 Changeover from the measurement mode to the setting mode Used as the setting mode selection key entry key e Exanoke for changing over from the display of Function No A 2 to the setting mode Display of Function No A 2 Measurement mode A2 AVERAGE 024 hour MEAS lights up on the display 011 525502 Setting mode Inquiry display example NES MAINT lights up on the display MAINTENANCE MODE Reply to the inquiry by pressing ENTRY MODE lt Y N gt the interactive key yes or no For more details see the following example 2 Reply to inquiry Use an interactive key YES or NO key e Example of replying to the message when changing to the setting mode Message display for changing to the setting mode Status after the reply MAINTENANCE MODE tothe inquiry diers ENTRY MODE lt Y N gt according to the message details I D Message display for entering the password When password input I J PASS WORD 27 message is displayed enter 16 For the more detailed procedure see 3 Display of Function No A 0 analog bar graph EHEEEEEEEEEEGOOOOOOOI F Measurement mode is effected 3 Entering the password 16 To assign a function in the setting mode you have to enter the password The password is 1
121. erter side Resistance value is normal if it indicates 10 O or less e Turn on the power switch to put the analyzer in operating properly Inside of the converter or detector is suspected of failure C End Set temporary cat Contact Yokogawa F10 1E ai Causes of E 2 Sensor Temperature Error Low and Procedure for This error occurs when the sensor temperature after warm up in steady state operation is lower than Fuse F1 and or F2 for the detector heater in the converter is blown Failure in wiring between the converter and the detector poor contact of terminal connections Failure of Sensor for cold junction compensation at the detector terminal board poor contact in Failure of thermocouple in the detector disconnection shortcircuiting in wiring inside the Failure of the heater inside the detector disconnection etc 10 1 3 Restoration 720 C lt Causes gt 1 2 disconnection shortcircuiting etc 3 terminal connections or failure 4 detector 5 6 Blown heater temperature fuse in the detector 7 Electronic circuit failure inside the converter IM 11M7A3 01E 10 4 lt 10 Troubleshooting gt lt Locating the Failure and Taking Measures gt Turn off the power to the converter Yes Restore the damaged parts Is there any breakage or poor contact in wiring to the converter terminals Is there a
122. es ener V After Sales Warranty sessi esses esee ee ene enne nennen nnn nnne nnns nnn nn nennt viii 1 t M 1 1 1 1 System Configuration rssrnnnvnnnvnnnvnnnvnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 1 1 1 1 1 Examples of System Configuration esssssess 1 2 1 2 SpecifiCatiOns eret ien intu Gnnecsnadznnncen Gnasnsnntzapeduncaceatnedsanetentedinans Suanetinteia de 1 6 1 2 1 General Specifications sese 1 6 1 2 2 Characteristics cr rtr vismannen 1 7 1 2 3 Flameproof Detector ZS8D senes 1 7 1 2 4 High Temperature Probe Adaptor ZS8P H sssssse 1 14 1 2 5 Flameproof Converter ZS8C sss 1 16 1 2 6 OPUONS am 1 20 2 nrc pp eser e reer en ee 2 1 2 1 Installation of Flameproof General purpose Detector 2 1 2 1 1 Installation Site ciet eret eerie ee Eee ub e tenes 2 1 2 1 2 Probe Insertion Hole 2 cccccccesceceeeeeeeeeeeeeeeeeeceeeneeseaeeseaeesseeesees 2 1 2 1 3 Detector Installation sssssssssssssseeeeeeenenns 2 2 2 1 4 Reference Air Outlet ssssssssssssssseeeeenentnes 2 2 2 1 5 Heat Insulation essssssssssseseeeeereeneee nennen 2 3 2 2 Installation of Flameproof Hi
123. escribes the ZS8C converter communication specifications as well as wiring procedure 4 6 1 Wiring of RS 422 A Communication Cable RS 422 A communications can be carried out by connecting up to eight converters to one computer In the ZS8C converter communication I O signals are not isolated If the computer is located away from the converter the communication cable length is 15 m or more as a guideline and thus their ground potentials cannot be equalized use a computer with an I O signal isolating interface Figure 4 12 shows the terminal connections for an RS 422 A communication cable Notices in Implementing Wiring 1 Lay communication cables away from cables which may become noise sources In addition lay the adjacent cables so that they are not parallel with each other 2 Ifa computer is to be connected to more than one converter implement ground wiring so that the ground potentials of each converter are equal If the ground potentials of each converter may differ do the wiring using sufficiently thick conductors Converter fn nsa Computer F4 13E ai Note Connect the converter terminals R to the computer terminal T and converter terminals T to the computer terminal R R shows the terminating resistance R 100Q 1 2 W match it with the cable s impedance Figure 4 12 Connections for RS 422 A Communications Specifications for and Maximum Length of Communication Cable For an RS 422 A commu
124. essary Please joint the solenoid valve to contact in suitable capacity Contact capacity of solenoid for calibration 250 VAC 1 A SSR output leakage current When power is off below 3 mA Contact capacity of solenoid for stopping of ejector 250 V AC 1A Resistance load Note In case of electric heat insulating of detector if the temperature come to less or equal 155 C Or when the power is off the ejector would be stopped IM 11M7A3 01E lt 5 Components and Their Functions gt 5 1 5 Components and Their Functions This chapter describes the components of main units composing the EXA OXY flameproof zirconia oxygen analyzer and their functions 5 1 Detector 5 1 1 General purpose Detector construction Terminal box This is of on rainproof Probe Sensor mounting This part is inserted into section a furnace Its length can be selected Flange from 0 5 0 7 1 0 or 1 5 m This is used for fixing the detector Either JIS standard or ANSI standard flanges can be selected Calibration Sensor cell gas tube Filter Filter retainer Contact Connects the positive pole of the sensor electrically to the circuit Washer Bolts to the terminals in the LT O ring metallic terminal box S U shaped pipe S T ed F5 1E ai Figure 5 1 Components of Sensor Mounting Section and Their Functions IM 11M7A3 01E 5 2 5 Components and Their Functions 5 1 2 High te
125. fall within the specified range use the following methods to change the surface temperature so that it falls within the specified range When the surface temperature exceeds 200 C gt 1 If insulating material is used reduce the thickness of the insulating material or remove it altogether However the surface temperature may fall below the dew point of the measuring gas in locations where raindrops fall on the surface or the surface is subjected to a strong wind In such a case provide a rain protection cover Reduce the suction flowrate of the measuring gas of the probe adapter If the pressure in the furnace is negative reduce the supply pressure to the ejector to reduce the suction flowrate of the measuring gas For the setting of the suction flowrate see section 6 1 8 Supplying Pressure to Ejector If the suction flowrate is reduced air is sucked from the ejector as a result of changes in the pressure in the furnace resulting in an indication error Be sure to check to make sure air is not sucked in If the pressure in the furnace is positive reduce the aperture of the needle valve for the discharge outlet of measuring gas to reduce the suction amount of measuring gas For the position of the needle valve see section 5 1 2 If the surface temperature exceeds 200 C due to heat radiating from the furnace wall or other heat sources provide a blocking plate or heat insulating material between the furnace wall and pr
126. for Detector Heater Power Wiring for Sensor Heater Power In the case of steam heater This wiring is for supplying power to the heater to heat the sensor in the detector from the converter Detector Converter 2 conductor shielded wire F4 6E ai Figure 4 5 Wiring for Detector Heater Power Wiring for Detector Heater Power In the case of electric heater This wiring is for supplying power to the heater for detector heat insulation above the dew point Detector Converter 4 conductor shielded wire F4 7E ai Figure 4 6 Heater Power Supply Wiring for Detector Heat Insulation Cable Specifications Use a shielded cable of 10 to 13 5 mm OD for this wiring as a rule Connection to Detector Connect the cable to the detector taking the following into account 1 The cable inlet port of the detector is a thread of G3 4 Use the specified electric wire lead in utensils As the detector may be removed for maintenance allow a sufficient margin for the cable length 2 The terminal screws are of M3 5 and M4 type ISO 3 5 mm and 4 mm Treat the cable end using crimp on terminal lugs Mi If the ambient temperature of the detector installed location exceeds 60 C use bare crimp on terminal lugs Connection to Converter Connect the cable to the converter taking the following into account The terminal screws of the converter are of M4 type ISO 4 mm Treat the cable end using crimp on type terminal lugs conforming to
127. from the other evaluation items Display of cell B4 SEL L ROBUSTNESS 5 robustness example LIFE gt 12 MONTH B 5 Temperature at the Cold Junction on a Thermocouple The temperature at the cold junction terminal measured with a transistor is displayed The highest permissible temperature of the terminal depends on detectors the temperature of the general detector is 80 C and that of the high temperature detector is 150 C If these temperatures are exceeded they must be lowered by shielding the detector terminal box from radiation heat etc Display of the temperature at the cold B 5 CJ TEMP 0026 C junction on a thermocouple example IM 11M7A3 01E 7 14 lt 7 Operating Keys and Display of Converter gt B 6 Heater ON Time Ratio The sensor in the detector is heated up to and maintained at a temperature of 750 C by the heater The higher the temperature of the measurement gas is the less the ON time of the heater becomes However if this time becomes too short the temperature of the measurement gas might exceed the limit temperature of 600 C which is not good for the detector The heater ON time ratio is an index for monitoring an abnormal temperature rise in the measurement gas However its critical temperature rise varies depending on the conditions in individual processes Therefore no definite specifications are given herein A general guideline though is about 20 to 3096 Display of the heater B6 CEL
128. g jumpers 2 and 3 Open Closed Open Break contact shortcircuiting Normally jumpers 1 and 2 Open Closed Closed de energized Make contact shortcircuiting jumpers 2 and 3 Closed Open Open On shipment the relays are set as shown below Function No G 0 Contact output 1 Contact status NO Normally energized Break contact Function No G 1 Contact output 2 Contact status NO Normally de energized Make contact Function No G 2 Contact output 3 Contact status NO Normally de energized Make contact If the type of contact is necessary to be changed do it in the following procedure The relay operation can be set to function No G 0 No G 1 or No G 2 with key operation At that time carry out the changing work after the converter was moved to nonhazardous area such as a control room 1 Remove the converter cover and the printed circuit board cover The CPU Assy printed circuit board Assy appears as shown in Figure 6 4 2 Setthe corresponding jumper connector CN5 CN6 or CN7 position on the CPU Assy again and change the type of contact For obtaining a make contact set the jumper connector to pins 2 and 3 while for obtaining a break contact set the jumper connector to pins 1 and 2 When the Set work has been done restore the PCB cover and turn on the power switch IM 11M7A3 01E 6 18 6 1 8 lt 6 Operation gt Printed circuit board PCB Relay R
129. g any modifications to specifications or physical configuration such as adding or changing the configuration of external wiring ports 6 Flameproof Packing Gland Selection A CAUTION The flameproof packing glands used at the external wiring connection ports of Flameproof instruments conforming to IEC standards are certified in combination with the flameproof instruments Therefore only those flameproof packing glands specified by Yokogawa should be used IM 11M7A3 01E viii PREFACE After Sales Warranty B Do not modify the product B Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the customer site is located outside of the service area a fee for dispatching the maintenance engineer will be charged to the customer B During the warranty period for repair under warranty carry or send the product to the local sales representative or service office Yokogawa will replace or repair any damaged parts and return the product to you Before returning a product for repair under warranty provide us with the model name and serial number and a description of the problem Any diagrams or data explaining the problem would also be appreciated Ifwe replace the product with a new one we won t provide you with a repair report B In the following cases customer will be charged repair fee regardless of warranty period
130. ge joint sections are leaky The measuring gas pressure becomes higher The measured oxygen concentration value X vol O is expressed as shown below when the measuring gas pressure is higher than that in calibration by Ap mm H O X Y 1 Ap 10336 where Y Measured oxygen concentration value at the same pressure as in calibration vol O Where an increment of the measured value by pressure change cannot be neglected measures must be taken Investigate the following points to perform improvement available in each process Is improvement in facility s aspect available so that pressure change does not occur e Is performing calibration available under the averaging measuring gas pressure internal pressure of a furnace Moisture content in a reference gas changes increase greatly If air at the detector installation site is used for the reference gas large change of moisture in the air may cause an error in measured oxygen concentration value vol 0 When this error is not ignored use a gas in which moisture content is constant such as instrument air in almost dry condition as a reference gas In addition change of moisture content in exhaust gas after combustion is also considered as a cause of error However normally this error is negligible Calibration gas span gas is mixing into the detector due to leakage If the span gas is mixing into the detector due to leakage for the reason of failure of the valve
131. gh temperature Detector 2 3 2 2 1 Installation Site eisini iiai 2 3 2 2 2 Probe Insertion Hole errnnnnnnnrnnnnrnnnnvnnrnnnnnnnnnnnnnnrnnnnrnnnnnnnnennnnnnennn 2 3 2 2 3 Detector Installationen innana 2 4 2 2 4 Ejector Installation usen E icr P E ica 2 5 2 2 5 HeatnSulatiOn niente tenue Ple errant 2 6 2 2 6 Blocking Radiant Heat seeee 2 6 2 3 Heat InsulatiOni reiten hann ERR ERR AE ERN aa Aaaa Kaa SER ENREERRRSEKR REPRE RE 2 6 2 3 1 Surface Temperature of Detector sss 2 6 2 3 2 Portions Requiring Heat Insulation and Temperature to be Maintained ssssssssssssssseseeneeeeeeeee eene 2 6 2 3 3 Methods to Change the Surface Temperature 2 7 IM 11M7A3 01E 4 IM 11M7A3 01E lt CONTENTS gt 2 3 4 Fitting a Thermal Insulating Jacket Option ss 2 8 2 3 5 Heating and Insulation Range when Not Using a Heat Insulating Jacket iniit Gall Gait oni Eni nd n n ns 2 15 2 4 Installation of Converter esee 2 18 2 4 1 Installatiorni Site iioii em eem eee E ace en 2 18 2 4 2 Converter Mounting sessenta onn tenente tentent 2 18 2 5 Installation of Flow Setting Unit eere 2 19 2 5 1 Installation Site iic e een Leere eL La d ed 2 19 2 52 Flow Setting Unit Mounting enn 2 20 2 6 Installation of Calib
132. h function No B 1 Permissible range of the zero point correction factor is 100 30 Examine the sensor cell internal resistance displayed with function No B 3 Anew sensor shows the value of 200 O or less While the dissipated sensor approaching to the end of the life indicates the value of 3 to 10 kO Examine the sensor integrity data five grade evaluation of 5 to 1 displayed with function No B 4 A sensor in good state shows 5 IM 11M7A3 01E lt 10 Troubleshooting gt 1 0 7 10 1 7 Causes of E 6 Calibration Value Error Span and Procedure for Restoration This error occurs when the span point correction factor see Subsection 8 1 3 exceeds the range 0 18 in the automatic and semi automatic calibrations lt Causes gt 1 The oxygen concentration of span gas and the value set with function No C 0 do not agree or the zero gas is accidentally used as the span gas 2 The span gas does not flow by the specified quantity 600 60 ml min 3 The sensor cell is damaged and the cell emf contains an error lt Locating the Cause of Failure and Taking Measures gt 1 To make sure carry out the calibration once more Before calibration examine the following If they are not in normal state correct them Does the value set in the function No C 0 agree with the span gas oxygen concentration Doesthe calibration gas tubing have measures to no span gas leakage 2 If the error does not occ
133. hat it is set to the specified supply pressure Steam supply pressure Supply sufficient steam pressure for heat insulation IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 1 7 7 1 7 1 1 Operating Keys and Display of Converter In this Chapter the operating keys on the operation panel of the converter and the indication on the display unit are described Operating Keys O O Css De pe DISP ENTER O O F7 1E ai Types and Functions of Operating Keys There are 9 seat keys on the operation panel of the converter You can select an operation mode measurement mode or maintenance mode register temporary data display various measurements or calculated data using these 9 keys To operate the keys press the center of each key Note Operation mode 1 Measurement mode Maintenance Calibration mode in which calibration is activated mode E Setting mode in which set data is checked or entered Fail mode in which a fail error occurs Table 7 1 Types Functions and Applications of Operating Keys Key Name Functions applications YES Interactive key yes Used for replying yes to an inquiry Y N Interactive key no Used for replying no to an inquiry Y N Sub message display key Used for displaying sub messages HELP Calibration stop key Used for suspending calibration Used for issuing start instructions in one touch or semi automatic CAL Calibratio
134. hazardous area is followed by the description in the Users Guide to Installing Flameproof Electrical Apparatus at Plants issued by the Technology Institution of Industrial Safety Japan As a non hazardous area is considered a place where no occurrence of explosive gas atmospheres is guaranteed by the foreperson and confirmed by a written document Therefore if non hazardous area is secured it is allowed to open the cover in the field Before opening the cover of the ZS8D detector remove power and allow the detector to stand at least 40 minutes When the ambient temperature of the detector exceeds 30 C use wire resistant to 70 C or greater for external wiring The detector cannot be used except in mixed gases composing air or mixed gas with oxygen concentration lower than air or combustible gas or vapor A CAUTION IM 11M7A3 01E Choose a suitable location for installation The unit should be installed in a place of normal temperature and humidity where there is less change in temperature and the unit is not exposes to strong radian heat and direct sunlight Since the unit is designed for indoor use choose a place free from direct wind rain or use a suitable case cover Do not use the unit in a place with vibration Cleaning of instrument Do not use benzine or thinner for cleaning as it deforms or cracks the unit Use in good atmosphere The unit should be used in a clean place free from corrosive or combustible gas Caution t
135. he uu Nipple Rc1 4 or 1 4NPT market peat Zero gas cylinder Item recommended by Yokogawa G7001ZC Pressure regulator Item recommended by Yokogawa G7013XF or G7014XF TNR On the Piping joint Rc1 4 or 1 4NPT market Flameproot Air set Item recommended by Yokogawa G7003XF or K9473XK isle l Reference o emperature gas pipin EN nthe detector gas piping Piping joint Rc1 4 or 1 4NPT market Auxiliary ejector Item recommended by Yokogawa K9292WA or K9292WB Regular tee On the Sample piping joint Rc1 4 or 1 4NPT market gas suction Needle valve Rc1 4 or 1 4NPT On the piping market Different Rc1 2 Rc1 4 Rc1 2 1 4NPT On the diameter nipple market The parts marked should be used if necessary 3 8 Calibration Gas Piping This piping should be provided between the zero gas cylinder and the flow setting unit and between the flow setting unit and the detector Install the cylinder where it is exposed to direct sunlight as little as possible e g accommodated in the calibration gas unit case Also mount the pressure regulator for the cylinder recommended by Yokogawa to the cylinder Attach a check valve to the calibration gas inlet of the detector as shown in Figure 3 2 the detector is shipped with the check valve attached Use a stainless steel pipe with an OD of 6 mm ID of 4 mm or nominal 1 4 inch for the piping between the flow setting unit and the detector IM 11M7A3 01E lt 3 Piping gt
136. he converter terminals 5 6 7 8 16 and 17 If the repeater terminal box is used also check the connections inside the box e Examine wiring connections to the detector terminals 3 4 5 6 7 and 8 Check if the terminal and cable conductors are not corroded Also check that wiring is not shortcircuited between the converter and the detector e Remove wiring to converter terminals 16 and 17 and measure resistance between these leadwires If it is 90 Q or lower it is normal e Remove wiring to the converter terminals 5 and 6 and measure resistance between these leadwires If it is 15 Q or lower it is normal In addition lead resistances between the converter and detector are normal if they are 10 O or less e Examine that the voltage across wiring terminals 7 and 8 inside the converter to which the cold junction compensating sensor is connected is about 0 4 to 0 7 V DC varies with ambient temperatures F10 3E ai Causes of E 4 A D Analog Circuit Failure and Procedure for Restoration This error occurs when the electric circuit of the converter does not operate normally lt Causes gt 1 2 The analog circuits of the converter contains a failure The supply voltage significantly drops 15 or more of the rating IM 11M7A3 01E 10 6 lt 10 Troubleshooting gt lt Locating the Failures and Measures gt Turn the power to the converter off and then back on Then check whether or not
137. he probe adaptor set the supply pressure so that a suction flowrate of about 20 to 30 l min is attained However if the probe adaptor s surface temperature exceeds 200 C or if dust causes the ejector to clog reduce the suction flowrate IM 11M7A3 01E lt 6 Operation gt 6 1 9 T E v E 3 Furnace Pressure ir OPa c S 196Pa 392Pa 588Pa 980Pa 0 20 40 60 80 100 120 140 160 Supply Pressure kPa F6 7E ai Figure 6 6 Supply Pressure to Suction Flowrate Characteristics in Auxiliary Ejector for Probe Adaptor Calibration The calibration of this instrument is carried out by matching either the zero gas or the span gas or either the oxygen concentration of the zero gas or of the span gas with the measured value of the relevant calibration gas The reference oxygen concentration at that time is already read into the memory in the converter The converter detects the deviation of the measured result from this value and automatically corrects it The following 3 methods of calibration are available further calibrations can be carried out periodically or occasionally and the calibration gas for these later calibrations can be automatically or manually introduced You can select any of these methods by registering it in the converter 1 Automatic calibration A calibration operation begins when you set the calibration start time and the calibration f
138. heat insulate in probe adapter is used by jacket as bellow Procedure 1 Wrap the heat insulate jacket For inside Warp the frame adapter with inside heat insulate jacket IM 11M7A3 01E 2 14 lt 2 Installation gt dad Procedure 2 Fix the heat insulate jacket For inside Wrap the Frame adapter tightly with wrapped jacket and fix it by magic tape Please make the ejector out from the heat insulate jacket Procedure 3 Fit the heat insulate jacket For outside Please undo the magic tape of outside heat insulate jacket make the mounting flange out from the jacket as photo above then put the probe adapter With inside heat insulate jacket in it Make the pipe from ejector go out from the hole in two side of heat insulate jacket IM 11M7A3 01E lt 2 Installation gt 2 1 5 Procedure 4 Fix the outside heat insulate jacket Finish the fitting of heat insulate jacket by locking all the side magic tape Please confirm your fitting by the photo above If the condition temperature is below the dew point please keep heat insulate by steam or electric heater If the heat insulate material Ceramic wool etc is not used by jacket please ensure fully in heat insulate section Flame arrester section and ejector section Please set the waterproof on the heat insulate section also 2 3 5 Heating and Insulation Range when Not Using a Heat Insulating Jacket Heating and insulation work for the flange and i
139. hen closely wrap the auxiliary ejector s air pipe around them Inside the furnace Note 1 For the sulfuric acid dew point see the separate table Note 2 One example of heating and insulating sections A to F is to wrap glass wool around the heating and insulation section and then apply a waterproof aluminum tape to secure it Measuring gas Figure 2 5 Work Example of Heating and Insulating Flameproof High Temperature Detector Example of Heating and Insulation by Steam Heater IM 11M7A3 01E Pre heating section s pipe for ejector air needs to be heated and insulated PO SS NSSSSSSSSSSOSNN Ns N o V N N N N N N Oo sia ESSE Measuring gas SSN WS Inside the furnace Outside the furnace Ejector air pre heating section Wrap a pre heating pipe firmly around the wall surface of the mating flange Instrument air WES lt 2 Installation gt 2 17 Carry out heating and insulation work to maintain the temperature of the ejector above the oxygen dew point Note 1 The ejector s outlet pipe needs to be heated and insulated am This flange may be a SSN Note 2 removed for maintenance When carrying out heating and insulation work separate the heating and insulation section on the side of the flange into sections A to D to enable the flange to be removed for
140. hs at the beginning of operation and determine the period based on the result of checking Also when checking suction flow of sample gases if reduction of suction flow is recognized check the filter If clogging is found clean it or replace the entire filter assembly Filter assembly Filter Deflector Bolt F9 2E ai IM 11M7A3 01E 9 4 lt 9 Inspection and Maintenance gt 9 1 6 Cleaning the Calibration Gas Tube The calibration gas supplied through the calibration gas inlet of the terminal box into the detector flows through the tube and comes out at the tip of the probe The tube might become clogged with dust from the measurement gas If you become aware of clogging such as when a higher pressure is required to achieve a specified flow rate clean the calibration gas tube To clean the tube follow these steps 1 Remove the detector from the installation assembly 2 Following Section 9 1 7 later in this manual remove the four bolts and associated spring washers that tighten the sensor assembly and the pipe support as well as the U shaped pipe 3 Usearod2 to 2 5 mm in diameter to clean the calibration gas tube inside the probe In doing this keep air flowing from the calibration gas inlet at about 600 ml min and insert the rod into the tube 3 mm inside diameter However be careful not to insert the rod deeper than 40 cm for a general purpose detector or 15 cm for a high temperature detector 4 Clean the U
141. ibration mode presently set is expressed with the number displayed under the function number For more details on the operation of each mode see 6 1 7 Calibration Readout on the message C2 CALIBRATION MODE display ERU 2 0 AT 1 SEMI2 TCH Number of mode presently set C 3 Stabilizing time You can set a waiting period for the time from the completion of the calibration to the beginning of measurements again in minute units Set an interval for the time between stopping the flow of the calibration gas and completing the replacement of the calibration gas around the detector sensor with measurement gas If it is 3 minutes 30 seconds for example enter 03 5 The operation mode switched to the maintenance mode MAINT during calibration operations will return to the measurement mode MEAS Readout on the message C BB STABILIZING TIME display Ex 03 5minutes C 4 Calibration time You can set a time at which the converter reads the oxygen concentration of a calibration gas span gas or zero gas In automatic or semi automatic calibration mode set a time in minutes from which the converter outputs solenoid valve driving signals power supply which causes the calibration gas to flow out In one touch calibration set a permissible maximum interval for the time between when you enter a positive answer by pressing the key YES in reply to the message Span or Zero valve open Y shown in the message display and when th
142. ibration requirement check that the reference air flow and the calibration gas flow supplied to the detector are normal Reference air flow 300 60 ml min Calibration gas flow 600 60 ml min checked during calibration 2 Calibration Gas Cylinder s Primary and Secondary Pressure When the primary pressure falls below 980 kPa replace the calibration gas cylinder Set the calibration gas so that the secondary pressure will be between 67kPa and 196kPa 3 Checking the Filter Every Three Months Check the filter at the tip of the probe every three months at the initial stages of operation From this decide an appropriate cycle for checking the filter In a case where the suction flow of the sample gas decreases check the filter for clogging If a clogged filter is found clean or replace it 9 1 5 Cleaning the Sensor Assembly N CAUTION If the sensor assembly is so detached allow enough time for the detector to cool down from its high temperature If exhaust flue gas is sucked for a long period dust in the flue sticks to the tube wall of suction path which prevents gas flow and reduces suction flow Especially if temperature of the gas suction root is reduced than the sulfuric acid dew point of the flue gas because of some causes condensation will occur and dust can easily adheres For reduction of suction flow disassembling and cleaning of the sensor assembly are necessary Carry them out according to the procedure described below
143. id Valve esee 4 22 Components and Their Functions rrrrxnnnnvnnnnnnnnnnnnnnnvnnnennnnnnnnnennnnevennnn 5 1 5 1 Dt COON is seis A T EETA 5 1 5 1 1 General purpose Detector c cccceceeeeceeeeeeeeeeeeeeeeeeeeeseneesenneenees 5 1 5 1 2 High temperature Detector with a high temperature probe adaptor sssssss 5 2 5 2 Converter vu 5 3 5 3 Flow Setting Unit imisrneeresnssenssvenevnsnsnsnsnsnsnnnennnsnnnsnnnennnennnsnnnsnsnennnennndn neve sne 5 4 OPNA 6 1 6 1 TT en wn ahha ne ann ween apna pnd enna ied ane aa enn ted anne seaman gn 6 1 6 1 1 Inspection of Piping and Wiring Conditions sssse 6 1 6 1 2 Checking the Heat Insulation Conditions sess 6 1 6 1 3 Checking of Set Valves sssssssssseeeeeeenenenenes 6 2 6 1 4 Supplying Power to Converter sssseeeeene 6 2 6 1 5 During Wartningetp cess ela elec crt rtt ttes re ani g 6 2 6 1 6 Data Setting To set data enter the password 16 6 2 6 1 7 Set of Relay Contacts for Contact Output rrrnrrrnrrnrnrnnrnrnnrnnnrn 6 17 6 1 8 Supplying Pressure to Ejector mnrrnrnrnrnrnnnrnnnrnnnrnnnvnnnrnnnrnrnrernreen 6 18 6 1 9 Calibration ssssssssseeneeneeneene nennen 6 19 6 1 10 Checking Functional Operations sseeee 6 20
144. ing the Message Display Unit 9 8 Bj eum eet ete Ree teed 10 1 10 1 Disposal When an Error Code Is Displayed 10 1 10 1 1 Types of Error Codes eene 10 1 10 1 2 Causes of E 1 Sensor Cell Failure and Procedure for Mciiere M E 10 2 10 1 3 Causes of E 2 Sensor Temperature Error Low and Procedure for Restoration sss 10 3 10 1 4 Causes of E 3 Sensor Temperature Error High and Procedure for Restoration cesse 10 4 lt CONTENTS gt v 10 1 5 Causes of E 4 A D Analog Circuit Failure and Procedure for Restoration 10 5 10 1 6 Causes of E 5 Calibration Value Error Zero and Procedure for Restoration sss 10 6 10 1 7 Causes of E 6 Calibration Value Error Span and Procedure for Restoration sess 10 7 10 1 8 Causes of E 7 EMF Stabilization Time Over and Procedure for Restoration sss 10 7 10 1 9 Causes of E 8 ROM and RAM Failure and Procedure for Restoration sss 10 8 10 1 10 Causes of Display Disappearance Data Display and Procedure for Restoration sss 10 8 10 2 Where the Output Response Is Too Slow esses 10 9 10 2 1 Checking the Main Ejector for Clogging sssssesss 10 9 10 2 2 Checking the Auxili
145. ion gas unit g Needle valve ai er Calibration S p T4 9 gas 3 INeedlevalve Calibration gas unit iCalibration gasf Calibration gas i ipressure 1 flow meter i i Ny o regulator i 600 ml min 10 Needle valve Calibration gas i i LL Span gas Flow setting unit ZA8F G7013XF Zero gas cylinder cylinder G7014XF 7 i G7001ZC F1 2E ai 4 Conduits 1 When installing conduits use flexible conduits so that the probe removed 2 Use a shielded cable for the signal cable and ground the shield together with the probe ground 3 Provide separate conduits for the signal and heater lines 4 The maximum outside diameter of the cable suited for the cable gland used for the instrument is 13 5mm in case that the thread at the conduit side is G3 4 2 The probe material SUS310S or SiC should be selected according to the specified measurement gas temperature SUS310S 0 to 800 C SiC 800 to 1400 C 3 For the zirconia oxygen analyzer 100 nitrogen cannot be used as the zero gas Generally approximately a 1 vol oxygen nitrogen gas balance mixture is used 4 The setting of the ejector supply air pressure depends on the furnace pressure IM 11M7A3 01E lt 1 General gt 3 Example of Steam Trace Heat Insulation for the ZS8D L flameproof detector ZS8D Hazardous Non hazardous Flameproof detector Conduit 1 ZS8C location location 2 Pressure gauge 20kPa 4 Fl
146. iring gt 4 19 Data Format for DR Command Communication 4 Transmission format data 137 138 139 430 141 142 143 144 145 146 R P 9 0 5 Space Comma Unit Seconds Response time 000 to 999 Cell response time 147 148 149 150 151 152 153 154 155 156 SB FO 14 2 Slash Space Comma Cell life guideline 000 to 012 Cell life ranking 0 to 5 Sensor cell life 157 158 159 160 161 162 163 164 165 166 T P 5 5 3 9 s These data cannot be used 167 168 169 170 171 172 173 174 175 176 o e 2 o o M A L Comma Space Unit mA Current value 00 0 to 20 0 Output current IM 11M7A3 01E 4 20 lt 4 Wiring gt Data Format for DR Command Communication 5 Transmission 177 178 179 180 181 182 183 184 185 186 format data RIA o olo ololo Slash Comma Span side 0 to 100 Zero side 0 to 100 Range 1 Slash Comma Span side 0 to 100 Zero side 0 to 100 Range 2 197 198 199 200 201 202 203 204 205 206 VO LO fro DT LEE Ld l Comma Slash Slash Hour Day Date of Month ate of span Y calibration s
147. is in the measuring status MAINT Shows when maintenance is carried out This is indicated when calibration or data setting is being carried out ALM Indicates when an alarm occurs FAIL Indicates when the converter is not functioning normally Main fuse Operation keys Used when selecting the contents to be displayed in the message display or setting data Outline of operation The operating procedure is summarized However it is necessary to read the instruction manual to optimize the analyzer status 2 z Li Ld L4 L L bJ E E MOALZALZLLPILIITIM Detector heater fuse Amplifier fuse Under the cover F5 3E ai Figure 5 3 Components of the Converter and Their Functions IM 11M7A3 01E 5 4 lt 5 Components and Their Functions gt 5 3 Flow Setting Unit Reference gas flow Span gas flow Zero gas flow setting valve setting valve setting valve REFERENCE SPAN Reference gas flowmeter Calibration gas VOKOGAWA flowmeter Awas ZA8F Flow Setting Unit F5 4E ai Figure 5 4 Components of Flow Setting Unit and Their Functions IM 11M7A3 01E lt 6 Operation gt 6 1 6 6 1 6 1 2 Operation In this Chapter the basic operation methods for the EXA OXY Explosion proof Zirconia Oxygen Analyzer are described Startup The general procedures for starting up are as follows 1 Inspect the piping amp wiring conditions See Section 6 1 1 2
148. ited to individual processes It is recommended that you check safety functions e g the process gas error alarm for normal operation beforehand Stationary Operation Collection of Control Data You can display maximum minimum O concentration of function No A 1 or mean O concentration of A 2 on the message display However you cannot use it as an output signal If you have to control them read the value at a time as constant as possible for recording Troubleshooting If an error occurs 1 A FAIL lamp on the converter status display lights us 2 An error code appears in the data display area and 3 Error messages appear in the message display area IM 11M7A3 01E lt 6 Operation gt 6 21 6 2 3 Every time an error occurs immediately correct it according to the instructions in Chapter 10 The following error codes are operable Table 6 4 Error Codes Details and Status Error code Error detail Error status E 1 Sensor cell error Goes into fail mode automatically turning OFF the power supply to the detector heater E 2 Sensor temp LOW Goes into fail mode automatically turning OFF the power supply to the detector heater E 3 Sensor temp HIGH Goes into fail mode automatically turning OFF the power supply to the detector heater E 4 A D Analog circuit error Goes into fail mode automatically turning OFF the power supply to the detector heater E 5 Calibration
149. ixed gas with oxygen concentration lower than air or combustible gas or vapor Measurement Range Display 0 to 100 vol 6O 3 digit digital display Output 0 to 5 vol 0 to 0 to 25 vol O Although the measuring range can be set up to 0 to 25 vol 0 a sample gas with the oxygen concentration of over 21 vol O cannot be measured in terms of the flameproof standard Warm up Time Approx 30 minutes Maximum Distance Between Probe and Converter Conductor two way resistance must be 100 or less 300 m or less with 1 25 mm conductors Power Supply 100 115 220 240 V AC 10 15 50 60 Hz Power Consumption Analyzer 80 VA for ordinary use maximum of 270 VA Electric heaters providing heat insulation approximately 200 VA for ordinary use maximum of approximately 400 VA IM 11M7A3 01E lt 1 General gt 1 7 1 2 2 1 2 3 Characteristics Repeatability Linearity Drift Response Time 0 5 of span 0 to 5 vol 0 or more and up to 0 to 25 vol O range 176 of span 0 to 5 vol 0 or more and up to 0 to 25 vol 0 range Sample gas pressure within 4 9 kPa The following conditions must be satisfied Use oxygen of known concentration with in the measuring range as the zero and span calibration gases Excluding standard gas tolerance Excluding the cases where the reference air is by natural convection 2 0 of span month both zero and span 9096 response within 5 seconds measured when gas is f
150. kg ZS8D L J A 050 2 Approx 14 Rc1 4 JIS 10K 100 FF SUS304 1 ANPT or equivalent ZS8D L J A 150 2 ZS8D L J A 050 2 L Rc1 4 JPI CLASS 150 4 1 4NPT RFSUS304 or equivalent ZS8D L J A 150 2 L ZS8D L J A 050 2 L Rc1 4 ANSI CLASS 150 4 1 4NPT RFSUS304 or equivalent ZS8D L J A 150 2 L ZS8D L J A 050 2 I Rc1 4 DIN PN10 DN100 A 1 4NPT SUS304 or equivalent ZS8D L J A 150 2 I IM 11M7A3 01E 1 1 2 lt 1 General gt Flameproof High temperature Detector ZS8D H J L 010 1 N N HL Model for Steam Heater Providing Heat Insulation B B Unit mm yy y 4 Ejector inlet _ jecior ne Ejector Insertion ap Ejector h 4 Ejector outlet length I Approx 150 __ 155 130 Approx 83 Y E 93 A ui Section A A Mr p 405 sl lt 1 gt Reference T gas inlet Sealing plug lt 3 gt Steam inlet i cra ed l d E ze m Br Approx 0150 Two G3 4 openings Flange Check valve _ for wiring JIS 5K 65FF lt 3 gt Steam outlet lt 2 gt Calibration gas inlet or equivalent Section B B F1 7E ai ae
151. le If it is necessary to have one as a spare part select it according to the specifications Ejector Joint K9292VE K9292VF for detector K9292WC K9292WD for probe adaptor Ejector Air Pressure Air Consumption Connection Material Tube Connection 20 kPa for detector 98 kPa for probe adaptor 4 l min for detector 40 l min for probe adaptor Rc1 4 or 1 4NPT F SUS304 6 4 or 1 4 inch copper or stainless steel tubing Pressure Gauge Assembly Pressure Gauge Type JIS B7505 A1 5U3 8X75 Material in Contact with Gas SUS316 Case Material Scale Tube Connections IM 11M7A3 01E Aluminum alloy painted in black 0 to 50 kPa K9292VA VB for detector 0 to 200 kPa K9292WA WB for probe adaptors Rc1 4 or 1 4NPT SUS304 1 21 lt 1 General gt 1 Instrument air inlet Needle Valve Connection Material Rc1 4 or 1 4NPT F SUS316 Note Pipes and connectors other than the above are not supplied Part No Part No Part No K9292VB Auxiliary ejector assembly for detector 1 4NPT with a pressure gauge and needle valve K9292VA Auxiliary ejector assembly for detector Rc1 4 with a pressure gauge and needle valve K9292VF Ejector joint for auxiliary ejectors 1 4 NPT K9292VE Ejector joint for main ejectors Rc1 4 K9292WB uad ejector assembly for probe adaptors 1 4 NPT with a pressure gauge and needle K9292WA Auxiliary ejector assem
152. le from the power supply to the converter terminals Carry out wiring work taking the following points into account 1 Use a two conductor shielded cable with an OD of 10 to 13 5 mm for this wiring 2 The terminal screws of the converter are of M4 type ISO 4 mm Treat the cable end using crimp type terminal lugs conforming to this screw size 3 If the power line is grounded with either one of its wires connect the grounded wire to the L2 terminal terminal number 34 4 5 2 Ground Wiring The ground terminal must be grounded Ground the ground terminal according to the standard of JIS class D ground wiring ground resistance of 1000 or less or better Ground the detector at the terminal screw with the mark at the lower part of the exterior of the detector case ground screw is M5 ISO 5 mm size Ground the converter at the terminal screw with the mark at the lower part of the converter case or the ground terminal screw with the mark at the lower part of the rear face of the converter ground screw is M5 ISO 5mm size Use a 600 V grade PVC insulated wire for grounding IM 11M7A3 01E 4 10 4 Wiring lfasignal has polarity exercise care not to mistake the polarity Connect the ungrounded side wire of the power cable to the specified converter terminal After wiring is completed check that there is no mistake and loosening in the wiring between the detector and converter and then mount
153. lead resistances between the converter and detector are normal if they are 10 Q or less e Remove wiring to the converter terminals 5 and 6 and measure resistance between these leadwires If itis 15 O or lower it is normal In addition lead resistances between the converter and detector are normal if they are 10 Q or less e Examine that the cold junction compensating sensor leadwires connected to wiring terminals 7 and 8 in the detector are not disconnected If the cold junction compensating sensor is normal the voltage across terminals 7 and 8 is about 0 4 to 0 7 V varies with ambient temperatures F10 2E ai and Procedure for This error occurs when the converter detects that the sensor temperature is higher than 780 C It also occurs if the converter detects failure of the heater circuit and temperature measuring and controlling circuit during warm up lt Causes gt If the error code is displayed in steady state operation the following is considered as the causes 1 Cold junction compensating sensor failure at the detector terminal board 2 Failure of thermocouple in the detector 3 Failure of electronic circuits in the converter Next if the error code is displayed during warm up the following is considered as the causes IM 11M7A3 01E lt 10 Troubleshooting gt 10 5 Fuses F1 and or F2 in the converter for the detector heater are blown Wiring failure between the converter and the dete
154. libration Calibration method One touch automatic semi automatic optional All are operated by a talk and response procedure with the LCD panel With automatic semi automatic either zero or span can be skipped Calibration gas concentration setting range 0 3 to 25 vol O minimum setting unit 0 01 vol O Use the standard zero and span gases which are gas mixtures of nitrogen and about 10 oxygen for an 80 to 100 scale IM 11M7A3 01E 1 1 8 lt 1 General gt Ambient Temperature 20 to 55 C Power Supply 100 115 220 240 V AC 10 15 50 60 Hz Construction JIS C0920 waterproof NEMA3 or equivalent when the openings for conduits are completely sealed Power Connection Inlet Seven G3 4 holes Air purge Rc1 4 or 1 4NPT F connection optional Approx 1 l min at 50 kPa Note that the number of the power connection inlets becomes six when purging Installation Wall or pipe mounting Case Aluminum alloy Paint Colors 0 6GY3 1 2 0 for instrument front cover and 2 5Y8 4 1 2 instrument case Paint Baked epoxy resin Weight Approx 19 kg 100 to 115 V AC Approx 20 5 kg 220 to 240 V AC 2 Model and Suffix Codes Suffix code Description Converter Flameproof Exd II BT6 Max surface temperature 85 C standard Power supply 220V AC 50 60Hz 240V AC 50 60Hz 100V AC 50 60Hz 115V AC 50 60Hz Auxiliary heater For detector heat insulation provided by steam heaters thermostat for probe C
155. ll internal resistance displayed with function No B 3 Anew sensor shows the value of 200 Q or less While the dissipated sensor approaching to the end of the life indicates the value of 3 to 10 kQ Examine the sensor integrity data five grade evaluation of 5 to 1 displayed with function No B 4 A sensor in good state shows 5 10 1 8 Causes of E 7 EMF Stabilization Time Over and Procedure for Restoration This error occurs when the sensor cell emf is not stabilized even if the calibration time is over because the sensor part of the detector is not filled with calibration gas zero and span gases at the one touch calibration IM 11M7A3 01E 10 8 lt 10 Troubleshooting gt lt Causes gt 1 Flow of the calibration gas is small specified flow 600 60 ml min 2 Measuring gas flows toward the tip of the detector probe 3 Sensor cell response is deteriorated lt Locating the Cause of Failure and Taking Measures gt 1 Examine the setting time with function No C 4 whether or not it is suitable If not suitable modify the setpoint and perform recalibration again Carry out recalibration after confirming that the tubings does not leak and flowing calibration gas by the specified rate about 600 ml min 2 When calibration is normally carried out continue the steady state operation If the error occurs again replace the sensor assembly after checking that whether or not the error corresponds
156. m heater Detector Converter 6 conductor shielded wire F4 4E ai Figure 4 3 Wiring for Detector Signal In the case of steam heater Inthe case of electric heater Detector Converter 8 conductor shielded wire F4 5E ai Figure 4 4 Wiring for Detector Signal In the case of electric heater 4 2 1 Cable Specifications Use a shielded cable of 10 to 13 5 mm OD for this wiring as a rule For details see Table 4 1 Recommended Cables 4 2 2 Connection to Detector Connect the cable to the detector taking the following into account 1 The cable inlet port of the detector is a hole G3 4 mm in diameter Use the specified electric wire lead in utensils As the detector may be removed for maintenance allow a sufficient margin for the cable length 2 Connect the cable shield to the ground terminal Note The cable shield is grounded on the converter side if 600 V grade silicone rubber insulated glass fiber braided wires are used 4 2 3 Connection to Converter Connect the cable to the converter taking the following into account 1 The terminal screws of the converter are of M4 type ISO 4 mm Treat the cable end using crimp on type terminal lugs conforming to this screw size 2 Avoid double connection to the converter of a ground wire already connected to the detector For grounding see also Section 4 5 IM 11M7A3 01E lt 4 Wiring gt 4 7 4 3 4 3 1 4 3 2 4 3 3 4 3 4 4 3 5 Wiring
157. mperature Detector with a high temperature probe adaptor Needle valve Main ejector Needle valve Auxiliary ejector Sample gas outlet port When the pressure of a measurement gas is negative the auxiliary ejector assembly must be connected If the temperature does not decrease to 200degC or less under high temperature and high pressure conditions connect a restriction e g needle valve Mounting flange Either JIS standard or Din or ANSI standard flange can be selected High temperature detector Can be installed in a location whose ambient temperature is 60degC or less Its construction is the same as that of the standard detector Probe There are two types of materials available stainless steel JIS SUS3108 or silicon Gert E dr size carbide SiC The length is e probe length is either 0 5 0 7 1 0 1 5 m If an 15cm SiC probe is used mount it vertically F5 2E ai Figure 5 2 Components of High temperature Detector and Their Functions IM 11M7A3 01E lt 5 Components and Their Functions gt 5 2 Converter Message display Messages for states interactions and complementary descrip tion can be displayed Data display Measured oxygen concentration value is displayed If an error occurs an error code is displayed Status display The present status such as the operating status is indicated by indicator lamps MEAS Shows that the converter
158. mple gas to flow for several minutes after the indication has stabilized at the oxygen concentration of the calibration gas IM 11M7A3 01E lt 9 Inspection and Maintenance gt 3 Take time until the indication begins to change since the flow of the calibration gas is stopped If it is within one minute the suction flow of the sample gases is will be correctly attained 4 Other checks a Pressure and flow rate of the flow setting unit When using the flow setting unit check the supply pressure to it Supply pressure 67 kPa to 196 kPa Check the reference air flow and calibration gas flow to be supplied to the detector Especially in automatic calibration Reference air flow 300 60 ml min Calibration gas flow 600 60 ml min check at calibration b Primary and secondary pressures of a gas cylinder Replace the gas cylinder when the primary pressure is 980 kPa or less Set the secondary pressure from 67 kPa or more to 196 kPa or less 9 1 3 Calibration of Indication The period of calibration of indication is different depending on measurement conditions At the beginning of operation carry out calibration at the frequency of once a week and determine the period based on those data 9 1 4 Checking the Flow Setting Unit During Normal Operation 1 Supply Pressure and Flowrate When the flow setting unit is used check to see that the supply pressure to the unit is normal Supply pressure 67 kPa to 196 kPa For an automatic cal
159. n start key calibration Measurement mode Used for returning the mode from the setting mode etc to an analog bar select key Calibration display measurement mode data display key Used for monitoring various data during calibration Entry key Used for registering data in setting mode Setting mode select key Used for changing from the measurement mode to the setting mode Used for moving the cursor to the number or letter to be changed or JAMBE Furore registered Message COS key Used for the display continuation of a message on 2 or more Number increase key Used for increasing a number on the cursor Used for changing from one No forward key Function No to the next Number decrease key Used for decreasing a number on the cursor No backward key Used for returning to one Function No from another IM 11M7A3 01E 7 2 lt 7 Operating Keys and Display of Converter gt 7 1 2 Examples of Applications of the Operating Keys This section describes how to operate the keys with the following examples of operations For displays see 7 2 Changeover from the measurement mode to the setting mode Reply to inquiry Entering the password Selection of Function No Selection of number 5 Selection of Function No Selection of group symbol Entering the setting data Selection of setting details Entering the setting data Input of data values Changeover from the setting mode to the measurem
160. nal and oxygen concentration is normally linear However you can modify it to logarithmic You can set either For a linear or logarithmic relationship assign O or 1 respectively Note For the relationship between the output current and oxygen concentration when selecting log see the description of function No A 5 mentioned in subsection 7 2 3 Readout on the message D4 OUTPUT SCALE display Ex 0 0 Linear 1 i Log D 5 Output smoothing constant If the oxygen concentration of the measurement gas changes suddenly and you use these measured values directly to control operations problems e g frequent turning ON OFF of operations might occur To avoid such situations you introduce a modified time constant into the operation in order to smooth out the signal variations You can set a time constant of up to 255 seconds so enter a suitable value from the keyboard If it is 30 seconds enter 030 Readout on the message D5 SIGNAL DAMPING display Ex 030 sec D 6 Moisture base in measurement gas Combustion gases contain moisture created by burning hydrogen in the fuel If this moisture is removed the oxygen concentration after removal might be higher than before You can select whether the oxygen concentration in a wet gas is measured directly or compensated to a dry gas value before use For wet or dry conditions assign 0 or 1 respectively You can set the moisture content required for the calculation a
161. nication cable use a three twisted pair cable or a 6 conductor 22 AWG or thicker shielded cable with an OD of 10 to 13 5 mm so that the cable impedance is 100Q and cable capacitance is 50 pF m or less It is recommended that the cable length be within 15 m to balance the ground potentials However if a computer with an I O signal isolating interface is used the cable length may be extended up to 500 m In this case do the ground system wiring in the procedure shown in Figure 4 13 As the end treatment for the cable wires attach crimp on terminal lugs conforming to M4 screws to the ends of the wires which are connected to converter terminals The length of the conductors exposed over which the cable shield is stripped should be as short as possible IM 11M7A3 01E 4 13 lt 4 Wiring gt Three twisted pair shlelded cable The shield must be grounded on either the computer side or the converter side Rx Computer 18 19 20 21 9 32 TX If the ground potentials of each converter may differ do the wiring using sufficiently thick conductors Figure 4 13 Connection for RS 422 A Communications when using an I O signal isolating computer 4 6 2 ZS8C Converter Communication RS 422 A Specifications Communication Specifications Classification Item Description Specifications Signal level Conforming to EIA RS 422 A standards I O signal no
162. nlet outlet ZS8D H J L 010 2 L1 N HJ Approx 11 8 ZS8D H J L 010 2 L1 N HA 1 ANPT 1 ANPT 1 4NPT IM 11M7A3 01E 1 1 4 lt 1 General gt 1 2 4 High Temperature Probe Adaptor ZS8P H 1 Specifications The ZS8P H probe adaptor is required for the ZS8D H high temperature probe Sample Gas Temperature Sample Gas Pressure Insertion Length Material in Contact with Gas Installation Flange Probe mounting angle Case Material Weight 2 Model and Suffix Codes Model Suffix code Description code 0 to 800 C when SUS310S probe is used 800 to 1400 C when SiC probe is used 1 5 to 5 kPa 0 5 m 0 7 m 1 0m 1 5m SiC or SUS 310S SUS304 flange SUS304 Flange mounting FF or RF type JIS 10K 100 FF SUS304 JPI Class 150 4 RF SUS304 ANSI Class 150 4 RF no serration SUS304 and DIN PN10 DN100 A SUS304 Vertically down within 5 SUS3108 probe can be mounted horizontally SUS304 Aluminum alloy With insertion length of 0 5 m approx 10 to 12 kg JIS JPI ANSI DIN 0 7 m approx 10 5 to 12 5 kg JIS JPI ANSI DIN 1 m approx 11 to 13 kg JIS ANSI 1 5 m approx 12 to 14 kg JIS ANSI Style S2 Option verse High Temperature probe adaptor sig dite thie SUS310S 0 to 800 C een SiC 800 to 1400 C 1 Puce d ees 0 5m Ker dew Sai 0 7m TERETERE 1 0m n 1 5m Sample gas exhaust method pieds Discharge outside furnace
163. nstallation of heat insulating material are carried out by customer Ejector air outlet Outside the furnace Inside the furnace Select an electric heater or steam heater to heat and insulate the frame arrestor section Steam inlet outlet Rc 1 4 When using an electric heater When using a steam heater Figure 2 4 Heating and Insulating Gas Flow Path Section IM 11M7A3 01E 2 1 6 lt 2 Installation gt Be sure to heat and insulate the steam pipe Heat and insulate the ejector to maintain its temperature above the oxygen dew point Note 1 The pipe for ejector air needs to be heated and insulated after it has been pre heated Detector s ejector air pre heating section Wrap the detector s ejector air pipe firmly around the steam pipe The ejector s outlet pipe needs to be heated and insulated N N N N N N N N N N N N N SN gt FITTE KssN RSSSSSSN N N a jeg il HH aug z J G4 NE 2 DIS gt ES This flange may be removed for maintenance When carrying out heating and insulation work separate the heating and insulation section on the side of the flange into sections A to F to enable the flange to be removed for maintenance Note 2 Instrument air Auxiliary ejector s air pre heating section Wrap a steam pipe around the probe adapter and t
164. nts 1 General Instruments with Flameproof construction hereafter referred to as flameproof instruments are tested and certified by the public authority in accordance with the Labor Safety and Health Laws of Japan A certified instrument is provided with a certification label and a nameplate that states specifications required for explosion protection performance All installations of certified instruments should be executed in compliance with the nameplate specifications For details see USERS GUIDELINES for Electrical Installation for Explosive Gas Atmospheres in General Industry issued by the Research Institute of Industrial Safety of the Ministry of Labor in Japan 1994 2 Flameproof Instruments Instruments that can be termed flameproof must satisfy the following conditions They must have been tested and certified by an official body in accordance with the Industrial Safety and Health Act and must carry a certification label on them They must be used in accordance with the specifications stated on the nameplate The following operating conditions must be observed 1 ZS8D Detector a Before opening the cover remove power and allow the detector to stand at least 40 minutes b When the ambient temperature of the detector exceeds 30 C use wire resistant to 70 C or greater for external wiring c The detector cannot be used except in mixed gases composing air or mixed gas with oxygen concentration lower than air
165. ny breakage or poor contact in wiring to the detector terminals Problems other than Yes blown temperature fuse As it cannot be restored replace the detector with a new one Does the detector heater fail Is the temperature fuse blown As it cannot be restored replace the detector with a new one Does the thermocouple in the detector fail Does the cold junction compensating sensor fail Yes Replace the cold junction compensating sensor e Temporarily operate the converter by turning its power switch The electronic circuit in the converter may possibly be failed Contact Yokogawa Era Set the temporary cata 10 1 4 Causes of E 3 Sensor Temperature Error High Restoration Yes Is the error displayed e Examine fuses F1 and F2 for the detector heater whether or not they are blown and then check wiring connections to the converter terminals 5 6 7 8 16 and 17 If the repeater terminal box is used also check the connections inside the box e Examine wiring connections to the detector terminals 3 4 5 6 7 and 8 Check if the terminal and cable conductors are not corroded Also check that wiring is not shortcircuited between the converter and the detector e Remove wiring to the converter terminals 16 and 17 and measure resistance between these leadwires If it is 90 Q or lower it is normal In addition
166. o do not connect any piping through the ejector outlet However to prevent rain water from entering the ejector you can connect a 1 4 inch 10 5mm O D pipe with a maximum length of 300 mm bent slightly d Ifthere is positive pressure at the sampling point above 500 Pa and also release to the atmosphere is possible main and auxiliary ejectors are not necessary In this case In this case mount the needle valve on the auxiliary ejector mounting port and adjust it so that the temperature near the probe adaptor is 200 C Also directly connect a suitable needle valve which can adjust the vent gas quantity to the main ejector mounting port Adjust the needle valve So that it will vent a gas quantity of 300 to 500 ml min This is because abnormal overheating of the detector cell section due to much sample gas exhaust should be prevented Heat Insulation See section 2 3 Heat Insulation Blocking Radiant Heat If the surface temperature of the flame arrester portion of the detector is likely to exceed 200 C due to heat radiating from the furnace wall or other heat sources block the radiant heat with a blocking plate or take other measures Heat Insulation A CAUTION 2 3 1 2 3 2 For explosion protection standards the lagging surface temperature must be kept to 200 C or less strictly To prevent the block by dew in the gas flowing pipe on probe keep the temperature higher than dew point Surface Temperature of Detector Th
167. o electric shocks The earth cable must be earthed to prevent electric shocks Key operation Do not operate the keys on the front of the instrument with a sharp end object lt PREFACE gt iii Introduction The EXA OXY Model Z58 Flameproof Oxygen Analyzer is used for combustion status monitoring or control in processes which require combustion control in every field There are several types of EXA OXY detectors and the auxiliary equipment needed for optimum measurement are also available Also devices for automating calibration are available As stated above since many kinds of equipment and devices are available for this EXA OXY analyzer select the appropriate devices and construct the optimum measuring system when this model is to be used This manual describes the installation operation inspection and maintenance of almost all of the equipment related to EXA OXY systems Read the instructions thoroughly before you handle the equipment but you may skip sections on equipment which is not included in your system The types of equipment described in this manual and the contents for each one are as shown below Types of Equipment Described in This Manual and Contents for Each One Items Described in the Manual Model Product Name Specifi Instal Opera Mainte i A CMPL cations lation tion nance ZS8D L General purpose detector O O O O O ZS8D H High temperature detector O O O O O ZS8C Converter
168. obe adapter and detector to block the radiant heat IM 11M7A3 01E 4 lt 2 Installation gt If temperature rises significantly due to heat transfer keep the mounting flange of the probe adapter and detector as far away as possible from the furnace wall When the surface temperature falls below the dew point of measuring gas 1 If the probe adapter and detector are not thermally insulated insulate them See section 2 3 If they are thermally insulated enhance the thermal insulation effect by for example increasing the thickness of the heat insulating material A thermal insulating jacket is available as an option to thermally insulate the detector and probe adapter When installing the detector and probe adapter in locations where raindrops fall on their surface or their surface is subjected to a strong wind the surface temperature is likely to fall below the dew point of the measuring gas so be sure to provide a rain protection cover Keep the surface temperature of the electric heater below 160 C and that of the probe adapter below 200 C to prevent the thermal fuse built in the electric heater from melting down Increase the suction amount of the probe adapter If the pressure in the furnace is negative an increase in the supply pressure to the ejector increases the suction flowrate of measuring gas For the setting of the suction flowrate see section 6 1 8 Supplying Pressure to Ejector If there is a lot of
169. obe or the sample gas outlet clogs a precise measurement is no longer possible because of no gas flow If you use the high temperature detector you have to inspect it periodically and if any part of it is significantly clogged with dust clean it Dust found sticking to the probe should be blown off If any dust still remains after the blowing clean it with a metal rod etc inserted In addition if dust is found on the auxiliary ejector or needle valve choke at the sample gas outlet remove these parts from the high temperature probe adapter and then clean them To remove dust blow air on them or rinse them with water IM 11M7A3 01E lt 9 Inspection and Maintenance gt 9 2 Inspection and Maintenance of the Converter You need not inspect or perform maintenance work on the converter daily or periodically If the converter fails to work properly it might come from power failure or other causes in most cases However burned out fuses or ambiguous readouts on the message display after long time use are sometimes caused by deterioration of the related parts 9 2 1 Replacing Fuses The converter incorporates a total of 6 fuses 2 for the detector heater and 2 for the electric circuit in the converter except 2 main fuses for whole protection If any fuse burns out replace it in the following manner However it is recommended that the fuses for the detector heater F1 F2 be replaced every 2 years even if they are not burned out
170. ome ions Moving in the zirconia element they eventually arrive at the positive electrode on the opposite side There the electrons are released and the ions return to oxygen molecules This reaction is indicated as follows Negative electrode O 4e 20 Positive electrode 20 5O 4e The electromotive force E mV between the 2 electrodes generated by the reaction is governed by Nernst s equation as follows gi uan PX De 1 nF PA Where R Gas constant T Absolute temperature n 4 F the Faraday constant Px Oxygen concentration in the gas in contact with the negative zirconia electrode 96 PA Oxygen concentration in the gas in contact with the positive zirconia electrode 96 Assuming the zirconia element is heated up to 750 C then the equation 1 becomes 50 74 log gus 2 With this analyzer the sensor zirconia element is heated up to 750 C so the relationship of equation 2 remains valid At that time a relationship as in Figure 8 1 is effected between the oxygen concentration of the measurement gas in contact with the positive electrode and the electromotive force of the sensor 7 cell where a comparison gas of air is used on the negative electrode side Measurement principles of a zirconia oxygen analyzer have been described above However the relationship between oxygen concentration and the electromotive force of a cell is only a theoretical one Usually a
171. onsentration display eo e 7 2 3 Message Display The message display incorporates the dot matrix LCD of 40 characters 20 characters x 2 lines This readout displays the following messages To display the message of a value setting group you have to enter the specified password The password is the 2 digit number 16 1 Measurement value group A Function Nos A 0 A 7 2 Measurement value group B Function Nos B 0 B 8 3 Value setting group C Function Nos C 0 C 7 4 Value setting group D Function Nos D 0 D 6 IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 7 5 6 7 Value setting group E Function Nos E 0 E 2 8 Value setting group F Function Nos F 0 F 5 Value setting group G Function Nos G 0 G 4 9 Value setting group J Function Nos J 0 J 7 Value setting group H Function Nos H 0 H 1 10 Status message group 1 11 Interactive message group 12 Sub message group Among other message groups the value setting group has already been described in 6 1 6 For the status interactive and sub message groups to be displayed automatically the relevant descriptions will be given when required e g Calibration in Chapter 8 Therefore the following description describes only the messages in the measurement value groups 1 and 2 Displaying measurement value group messages A 0 Display of an Analog
172. or combustible gas or vapor 2 Converter a Before opening the cover remove power and make sure of non hazardous atmospheres The warning added on page i must be observed b When the ambient temperature of the converter exceeds 50 C use wire resistant to 70 C or greater for external wiring 3 Flameproof Instrument Installation 1 Installation Area Flameproof instruments may be installed in hazardous areas where the specified gases are present They should not be installed in Division 0 areas Note Hazardous areas are distinguished based on the frequency and duration of the occasions when explosive atmospheres are encountered IEC standard 79 10 classification of hazardous areas Areas where explosive atmospheres are continuously present or persist for long periods are classified as Division 0 Areas where there is a risk that an explosive atmosphere will be encountered during normal operation of the equipment and facilities are classified as Division 1 Areas where there is no risk that an explosive atmosphere will be encountered during normal operation of the equipment and facilities and where an explosive atmosphere will persist for only a short period even if encountered are classified as Division 2 2 Environmental Conditions The standard environmental condition for flameproof instrument installation is an ambient temperature range of 20 to 40 C If the equipment is installed where there is a risk that it may be exposed
173. or flange also comes in contact Otherwise the measurement gas will not be sealed Use tweezers to pull the contact out of the groove in the tip of the probe Clean the sensor assembly especially the metal O ring contact surface to remove any contaminants adhering to that part If you can use any of the parts from among those removed also clean them up to remove any contaminants adhering to them Once the metal O ring has been used it can not be reused So be sure to replace it Part assembly procedure First install the contact Being careful not to cause irregularities in the pitch of the coil spirals i e not to bend the coil out of shape place it in the ringed groove properly so that it forms a solid contact Groove in which the contact E7042BS is placed F9 5E ai Figure 9 3 Installing the Contact IM 11M7A3 01E lt 9 Inspection and Maintenance gt 2 Next make sure that the O ring groove on the flange surface of the sensor is clean Install the metal O ring in that O ring groove and then insert the sensor in the probe while turning it clockwise After inserting it until the metal O ring comes in contact with the probe s O ring contact surface properly align the U shaped pipe insertion holes with the bolt openings Attach the U shaped pipe to its support with filter then fully insert the U shaped pipe and its support into the probe Coat the threads of the four bolts with antiseize grease and then s
174. outlet hole defuser or gas suction portion is not clogged If clogging is found clean it or that portion to remove the blockage Reverse the procedure for replacement 10 2 2 Checking the Auxiliary Ejector for Clogging 1 Remove the auxiliary ejector from the probe adaptor 2 Remove the nozzle from the air supply side For the nozzle replacement be sure to install the nozzle correctly 3 After removing the nozzle check that the ejector T shaped joint is not clogged If clogging is found clean it to remove clogged areas Reverse the procedure for replacement 10 23 Checking the Tip Filter SiC for Clogging If the ejector is not clogged check the probe s tip filter for clogging If clogging is found clean or replace it For filter replacement see the applicable instruction manuals see Section 9 1 5 in this manual 10 2 4 Others If there is no clogging in the ejector or SiC filter the sensor may be defective or the flame arrester may be clogged Check the flame arrester or replace the cell 10 3 Measures When Measured Value Shows an Error The causes that the measured value shows an abnormal value is not always due to instrument failures There are rather many cases where the causes are those that measuring gas itself is in abnormal state or external causes exist which disturb the instrument operation In this section causes of and measures against the cases where measured values show the following phenomena 1
175. ower eere 4 7 4 3 1 Wiring for Sensor Heater Power In the case of steam heater 4 7 4 3 2 Wiring for Detector Heater Power In the case of electric heater 4 7 4 3 3 Cable Specifications assornir uninin a 4 7 4 3 4 Connection to Detector sse 4 7 4 3 5 Connection to Converter esses enean detenta ns 4 7 4 4 Wiring for Analog Output 1er ritenute niente Lene n Dan nean se 4 8 4 4 1 Cable Specifications sss 4 8 4 4 2 Wiring Procedure ir idt es 4 8 lt CONTENTS gt iii 4 5 Power and Ground Wiring eee 4 9 4 5 1 Power WING accordii arianna ee EPA EEG ERE 4 9 4 5 2 Ground Wirlng 3 2 pet e E n e E e e e EE ai 4 9 4 6 Digital Communication Wiring eere enne 4 12 4 6 1 Wiring of RS 422 A Communication Cable 4 12 4 6 2 ZS8C Converter Communication RS 422 A Specifications 4 13 4 7 Contact Output Wiring ecc cerc reiecit erret eerte ntn rnb innt h inni nmn inns 4 21 4 7 1 Cable Specifications 2 irte aai 4 21 4 7 2 Wiring Procedure ssssseseeeneenennennen nnns 4 21 4 8 Contact Input Wiring eerie 4 21 4 8 1 Cable Specifications ssssssssssssseseeeeee 4 22 4 8 2 Wiring Procedure sesseseneenenenenneenenenenenns 4 22 4 9 Wiring for Soleno
176. pipe of outlet of steam pipe At last close the inserting section tightly by magic tape IM 11M7A3 01E 2 12 lt 2 Installation gt Procedure 3 Fit the heat insulating material Body Undo the magic tape on body heat insulate material cover the copper pipe of steam by heat insulate electric material from side of detector terminal box Please take care of Make the pipe from ejector go out from the hole in two side of heat insulate material Procedure 4 Fix the heat insulating material Body Confirm that the pipe of ejector and pipe for heat insulate steam go out from the heat insulate material stick the all magic tape of body IM 11M7A3 01E lt 2 Installation gt 2 1 3 Procedure 5 Fix the heat insulating material on the detector Stick the magic tape of plate heat insulate material on the side of heat insulate material Body And then wrap the detector up with magic tape of the side of terminal box stick it tightly and fix it by rope at last These are all procedure Please confirm your fitting by the photo above The heat insulate effect would be weakened if heat insulate section is got wet Please set the waterproof on the heat insulate section If the heat insulate material Ceramic wool etc is not used by jacket please ensure fully in heat insulate section Flame arrester section and ejector section Please set the waterproof on the heat insulate section also B The heat insulate in probe adapter The
177. provided in the calibration gas tubing system the measured value shows a value a little higher than normal Check valves in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed state lt 10 Troubleshooting gt 1 0 1 1 10 3 2 10 3 3 6 The reference gas is mixing into the measuring gas and vice versa Since the difference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller the measured value shows a higher value An error which does not appear as the error E 1 may occur in the sensor Visually inspect the sensor If any crack is recognized replace it with a new sensor assembly Note Data such as cell integrity displayed with function No B 4 should also be used for deciding sensor quality Measured Value Lower Than True Value lt Causes and Measures gt 1 2 The measuring gas pressure becomes lower Where an increment of the measured value by pressure change cannot be neglected take measures referring to Subsection 9 1 1 1 Moisture content in a reference gas changes decrease greatly If air at the detector installation site is used for the reference gas large change of moisture in the air may cause an error in measured oxygen concentration value vol 0 When this error is not ignored use a gas in which moisture content is constant such as instrument air in almost dry condition as a referenc
178. r and detector tip are extremely hot Do not touch these portions Otherwise you may get burned b When the sensor is to be replaced first allow it to cool sufficiently If you attempt to replace the sensor while it is still hot the sensor may be damaged because its mechanical strength is weak while it is at hot state c As a flame arrester the detector flange surface is very important for explosion protection Do not scratch the flange surface nor tighten the flanges with foreign matter between them Also handle the converter flange surface with care for explosion protection 10 1 Disposal When an Error Code Is Displayed 10 1 1 Types of Error Codes There are nine types of error that can be detected with the self diagnosis function of ZS8C converter When these errors occur except for digital circuit failures the corresponding error codes are displayed in the data display In the message display error messages are also displayed In addition if more than one error occurs simultaneously the letter H is also displayed in the message display In this case by selecting the displayed message using the auxiliary message display key HELP individual error that occurred can be confirmed Error codes and their contents are shown in Table 10 1 IM 11M7A3 01E 10 2 lt 10 Troubleshooting gt Table 10 1 Error Codes Their Contents and States When Each Error Occurs Error code Error contents St
179. r of the ZS8C converter remove power and make sure of non hazardous atmospheres The text plate says Open circuit at non hazardous location before removing cover since the internal energy of the ZS8C converter decreases under the specified value The definition of the non hazardous area is followed by the description in the Users Guide to Installing Flameproof Electrical Apparatus at Plants issued by the Technology Institution of Industrial safety Japan As a non hazardous area is considered a place where no occurrence of explosive gas atmospheres is guaranteed by the foreperson and confirmed by a written document Therefore if non hazardous area is secured it is allowed to open the cover in the field Before opening the cover of the ZS8D detector remove power and allow the detector to stand at least 40 minutes Inspection and Maintenance of the Detector Precautions for Inspecting the Detector 1 4 Be careful not to touch any hot parts The sensor at the tip of the detector probe is heated up to 750 C during operation If an operation is carried out immediately before inspection be careful not to touch the probe with your finger tips Do not drop or bump or cause any great impact on the sensor assembly The sensor is made of ceramic zirconia If the detector is dropped or hit with something the sensor might be damaged and no longer work Do not reuse a metal O ring to seal the cell assembly If you replace the c
180. ration Gas Unit Case eren 2 21 2 6 1 Installation Sil ror t n rt n re one 2 21 2 6 2 MoUuiilliig on rh Rn dns 2 21 lot 3 1 3 1 System m 3 1 3 2 Parts Required for Piping rrsvvrnnnvnnnnvnnnnvnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnen 3 2 3 3 Calibration Gas Piping eere 3 2 3 4 Reference Gas Piping esee nennen tnnt tnnt nns 3 3 3 5 Piping to Probe Adaptor rrnnnvnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 3 3 3 6 Purge Gas Piping mem a anA ANARA EAER 3 4 3 6 1 Piping for Air Purge in Converter seee 3 4 3 6 2 Air Supply for Air Purgirig oiii iit tic tte ted 3 4 L gt mee EEE EEE 4 1 4 1 Safety Precaution for External Wiring eene 4 1 4 1 1 Wiring Precautions oerte certc tcc 4 1 4 1 2 Care During Wiring seseeenenennmen 4 2 4 1 3 Cables P de 4 4 4 1 4 Mounting of Cable Gland eenean teet 4 5 4 2 Wiring for Detector Signal ener 4 6 4 2 1 Cable Specifications sesssssssssssssseeeeeeeeenes 4 6 4 2 2 Connection to Detector cessent enne 4 6 4 2 3 Connection to Converter sss 4 6 4 3 Wiring for Detector Heater P
181. ration value are alternately displayed in the data display The error is released when the analyzer returns to the measurement mode and at the same time the error code display disappears The error message display is cleared by pressing the measurement mode select key DISP Note Re calibration after an error occurred should be performed after examining that setpoints and piping conditions are not improper Errors displayed with error code E l E 2 E 3 E 4 or E 8 including digital circuit failure occur generally caused by equipment failures If these errors occur the converter stops the supply of power to the detector heater and holds the output signal at the value immediately before the error occurrence preset value if 2 is set with function No D 2 When these errors occur turn off the converter power and practice restoration The error code display is released after the equipment is restored and operates normally 10 1 2 lt Causes gt 1 disconnection etc IM 11M7A3 01E Causes of E 1 Sensor Cell Failure and Procedure for Restoration Failure in wiring between the converter and the detector poor contact of terminal connections Sensor cell assembly failure damage deterioration Failure in the sensor cell assembly mounting part poor continuity between the sensor electrode and the contact etc Wiring system failure inside the detector disconnection etc lt 10 Tro
182. requency and then press the key or enter an external contact signal to begin All operations related to calibration e g calibration time opening closing of the solenoid valve and sequence are automatically activated based on the data set in the converter Automatic calibration is applicable to a system corresponding to System 3 or 4 2 Semi automatic calibration In this mode calibration begins only when the converter is operated with the keys or receives starting instructions from a contact signal through an external circuit The other details are the same as those for automatic calibration This mode is applicable also to a system corresponding to System 3 or 4 3 One touch calibration In this mode operate keys to send the calibration gas or for other procedures depending on the readout on the message display on the converter after you have given the calibration start instructions in the same way as for semi automatic calibration Other calibration operations are automatically processed by the converter One touch calibration is applicable to a system corresponding to System 1 or 2 You can begin calibration as described above For more details on calibration see Chapter 8 IM 11M7A3 01E 6 20 lt 6 Operation gt Calibration The following description mainly explains how to prepare for calibration Preparation for calibration 1 Check the set calibration data Adjust opening in the valve for cali
183. rm is input in a state where the calibration gas pressure reduction alarm G is set in function No G 3 or G 4 Always set 0 zero for Digit No 12 Solenoid Valve Assembly Drive P Relay operates when the process gas failure alarm is input in the state where the process gas failure alarm input P is set with function No G 3 Note 3 Blowback B Relay operates when blowback state command is input in the state where the blowback state command B is set with function No G 3 Note 1 Note 1 When a function is to be used it is specified by setting the corresponding digit to 1 The default status is those G 0 0 G 1 1 0 G 2 1 0 oo Note 2 The relay is energized corresponding to the operation delay and hysteresis valve set in function No E 2 Note 3 Solenoid valve assembly drive is a function for driving a solenoid valve which supplies purge gas to the detector when gases not yet burned are mixed into the measuring gas This function can also be applied to the cases where a sensor breakage accident due to condensed water should be prevented by purging the calibration gas tubing at the restart of operation On shipment relay contacts for contact output relays are set as shown below Function No G 0 Contact output 1 relay contacts Break contact closed when de energized Function No G 1 Contact output 2 relay contacts Make contact Function No G 2 Contact outp
184. rox 14 to 16 kg with an insertion length of 1 m for JIS JPI ANSI DIN applications Approx 15 to 17 kg with an insertion length of 1 5 m for JIS JPI ANSI DIN applications lt 1 General gt 1 9 2 Model and Suffix Codes Model Suffix code Description General purpose detector 0 to 800 C High temperature detector 800 to 1400 C Flameproof Exd II BT3X Maximum surface temperature 200 C standard Probe material SUS310S Specify for general purpose detector SUS304 Specify for high temperature detector Insertion length 0 1 m Specify for high temperature detector 0 5 m SUS310S 0 to 800 C 0 7 m SUS310S 0 to 800 C 1 0 m SUS310S 0 to 800 C 1 5 m SUS310S 0 to 800 C Heat insulation model Steam heater 1 Electric heater Power supply electric For heat insulation provided by steam heaters heater providing heat 220V AC 50 60Hz insulation 240V AC 50 60Hz 100V AC 50 60Hz 115V AC 50 60Hz Exhaust method 2 Specify for high temperature detector Discharge outside furnace Recirculate in furnace Flange joint connection JIS 5K 65 FF specify for high temperature detector JIS 10K 100 FF JPI Class 150 4 RF ANSI Class 150 4 RF DIN PN10 DN100 A Calibration gas reference gas Rc1 4 and ejector inlet joints 3 1 4NPT F For steam heaters For electric heaters 1 Asteam heater 1 must be specified when heavy oil fuel gas and heavy oil fuel mixtur
185. rrection ratio exceeds a range of 100 30 or the span point correction ratio becomes larger than 0 18 calibration of the sensor becomes impossible IM 11M7A3 01E lt 8 Calibration gt 8 3 y Zero origin Cell voltage Corrected mV calibration curve Ad VON Theoretical calibration curve Span origin 21 0 p1 p2 0 51 Span gas zero gas concentration concentration Oxygen concentration vol O Zero point correction factor B A x 100 Correctable range 100 x 30 Span point correction factor C A x 100 Correctable range 0 18 F82E ai Figure 8 2 Calculation of a Calibration Curve and Correction Factor in a 2 Point Calibration Using Zero and Span Gases Figure 8 3 shows a 1 point calibration using only a span gas In this case only the cell electromotive force for a span gas with an oxygen concentration p1 is measured The cell electromotive force for the zero gas is carried over from a previous measurement to obtain the calibration curve The principles of calibration using only a span gas also applies to the 1 point calibration method using a zero gas only 81 92 Cell ez voltage mV Corrected calibration curve 7 Zero origin Previous zero gas data s Span origin 21 0 pi 0 51 Span gas concentration Oxygen concentration vol 0 Zero point correction factor B A x 100 Correctable range 100 30 Span point correction factor C A x 100
186. s G3 4 2 The probe material SUS310S or SiC should be selected according to the specified measurement gas temperature SUS310S 0 to 800 C SiC 800 to 1400 C 3 For the zirconia oxygen analyzer 100 nitrogen cannot be used as the zero gas Generally approximately a 1 vol oxygen nitrogen gas balance mixture is used 4 The setting of the ejector supply air pressure depends on the furnace pressure IM 11M7A3 01E lt 1 General gt 2 Example of Heat Insulation with Electric Heater for the ZS8D H flameproof high temperature detector Auxiliary ejector air Pressure gauge 98kPa 4 Stop valve Air set Non hazardous Conduit 1 Wiring for heat insulation Provided by heaters Main ejector air amp 9 Pressure gauge 20kPa 4 Stop valve Air set Heat insulation Detector output wiring BG ZS8C location Flameproot Hazardous location 4 to 20mA DC output High 1 25mm or more 8 wire shielded cable Contact output temperature DHA He Bl _______________________ cM cu NE RT probe Detector heater power wiring Contact i t adaptor 2 2mm or more 4 wire shielded cable t ON ACE pats x Check valve Interior of furnace K9292DN Reference gas 100V 115V K9292DS flow meter i 220V 240V AC f 300 mnd Air set G7003XF K9473XK a Reference L gt gt Instrument Calibrat
187. s cylinder The Installation procedure for the case when used is as follows 2 6 1 Installation Site Install the calibration gas unit case by selecting a location according to the following considerations Convenience in replacement of the cylinder Easy access for inspection Proximity to the detector and converter as well as the flow setting unit Little vibration Ambient temperature of 40 C or less 2 6 2 Mounting Mount the calibration gas unit case to a pipe nominal 50A in the following procedure 1 Provide a vertical mounting pipe nominal 50A OD of 60 5 mm with sufficient strength 2 Mountthe calibration gas unit case to the pipe Securely fix the mounting bracket to the pipe by fully tightening the four U bolt nuts Mounting pipe nominal 50A OD of 60 5mm F2 10E ai Figure 2 15 Pipe Mounting Status IM 11M7A3 01E 3 1 lt 3 Piping gt 3 3 1 Piping System Piping is described for the system configuration shown in Figure 3 1 Pressure gauge 98kPa 4 Auxiliary ejector air Stop valve Air set Steam outlet Steam inlet Heat Main ejector air Pressure gauge 20kPa 4 Stop valve Air set Non hazardous location Hazardous location insulation Detector output wiring 1 25mm or more 6 wire shielded cable Detector heater power wiring C 4 to 20mA DC output p Contact_ output s Contact input 577 100V 115V
188. s for your fuel calculate the value using the formula shown on pages 6 18 If the moisture content is 1 27 N m kg for example enter 01 27 Readout on the message J 1 H20 IN FUEL display Ex 01 27 m3 kg m3 J 2 Theoretical air quantity You can set the theoretical air quantity required for the fuel used in the measurement process to ignite N m kg or m m Look up the setting value from Table 6 2 If there are no relevant descriptions for your fuel calculate the value using the formula shown on Pages 6 18 If the theoretical air quantity is 10 7 N m kg enter 10 70 Readout on the message J 2 THEOR IT I SENER 10 70 m3 3 gt CO ID IM 11M7A3 01E lt 6 Operation gt 6 1 3 J 3 Net calorific value You can set the net calorific value of the fuel used in the measurement process in kJ kg or kJ m Look up the setting value from Table 6 2 If there are no relevant descriptions for your fuel calculate the value using the formula shown on Pages 6 18 If the net calorific value is 41274 kJ kg enter 41274 Readout on the message JB NET CALO PLN 41274 kJ I J 4 X value X a b H The X value N m kg or m m is the coefficient provided with each fuel Look up the x value of the fuel used from Table 6 2 If there are no relevant descriptions for your fuel calculate the value using the formula shown on Pages 6 18 If the X value is 0 773 m kg for instance round off the value to th
189. s is high in temperature and also in pressure the sample may reach the detector before its temperature decreases below 800 C On the other hand it is also not preferable for the condensate to be generated in the high temperature probe adaptor because the sample gas temperature becomes too low If condensate may be generated by a remarkable drop in the ambient temperature in winter protect the high temperature probe adaptor with lagging Use copper or stainless steel pipes OD of about 6 mm ID of 4 mm for the piping However use stainless steel pipes if the piping is in a location where the ambient temperature exceeds 60 C or a corrosive atmosphere exists IM 11M7A3 01E 3 2 lt 3 Piping gt 3 2 Parts Required for Piping Check that the parts listed in Table 3 1 are ready Table 3 1 Major Parts for Piping Detector Type of gt eed piping Parts required Description Check valve Item recommended by Yokogawa K9292DN or K9292DS On the uu Nipple Rc1 4 or 1 4NPT market Fed Zero gas cylinder Item recommended by Yokogawa G7001ZC Flameproof Pressure regulator Item recommended by Yokogawa G7013XF or G7014XF detector DEM On the Piping joint Rc1 4 or 1 4NPT market Air set Item recommended by Yokogawa G7003XF or K9473XK Reference Onih as pipin i oe nthe gas pIpINg Piping joint Rc1 4 or 1 4NPT ant Check valve Item recommended by Yokogawa E7042VR or E7042VV On t
190. s set in Function No C 4 elapses the mode On ZERO CAL Y ELP changes back to the measurement mode BEHHEHNHENBHNHNENBUUIUUIDUDUUDOLD If changing another display in the 0 1 h 25 measurement mode to an analog bar graph press DISP key 11 Displaying the data values in the calibration mode You can display the readout from Function No A 0 You can also display the set data in Function No C 0 and subsequent functions However no data is settable e Whencalibration commences in the semi automatic calibration mode and the data is displayed Display of Function No A 0 BERBER RB Calibration mode CAL is effected 1 rv 2S The readout changes to the data display CAL The readout again indicates calibration is under way If calibration was already completed calibration begins again CALIBRATION Y BEHHHEHNHHENENBENUUUUUUUULUD 0 IM 11M7A3 01E 7 6 lt 7 Operating Keys and Display of Converter gt 7 2 Readout Displays There are 3 kinds of readouts a status display data display and message display on the operation panel of the converter In the status readout the operation mode and the error alarm if any are displayed In the data readout the measured oxygen concentration and the details of any error which has occurred are displayed In the message readout various measured data set data and messages are displayed 7 2 1 Status Display The related operation mode and the oc
191. shaped pipe The pipe can be rinsed with water However it should be dried out thoroughly before reassembly b Restore all components you removed for cleaning Follow Section 9 1 7 to restore all components in their original positions Be sure to replace the O ring s with new ones Exploded view of components pg Rod i with outside diameter Ped amp y of 2 to 2 5 mm gas tube a ue ES s g lt F9 3E ai Figure 9 1 Cleaning of Calibration Gas Tube 9 1 7 Replacing the Sensor Assembly The performance of the sensor cell deteriorates as its surface becomes soiled during operation Therefore you have to replace the sensor when its life expectancy expires for example when it can no longer satisfy a zero gas ratio of 100 30 or a span gas ratio of 0 18 In addition the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement If the sensor becomes no longer operable for example due to breakage investigate the cause and remedy the problem as much as possible to prevent recurrence N CAUTION Ifthe sensor assembly is to be replaced allow enough time for the detector to cool down from its high temperature Otherwise you may get burned If the cell assembly is to be replaced be sure to replace the metal O ring and the contact together Additionally even in a case where the cell is not replaced if the contact becomes deformed and cannot make complete contact with the cell repl
192. ssued by the Research Institute of Industrial Safety of the Ministry of Labor in Japan 1994 Generally carry out wiring work taking care with the following points 1 Do the electrical wiring so as to avoid laying the cable together with the power cables for large capacity transformers motors or other power supplying cables 2 Be sure to apply waterproof treatment for screws it is recommended for waterproof treatment that silicone resin group non curing sealing agents be used 3 Do not use the same duct for the signal cables and power cables in order to prevent noise Also use shielded cables when wiring is carried out where wiring is likely to be affected by noise 4 If wiring is to be carried out in a location where the ambient temperature is high or low use wires or cables matching the location 5 Ifthe analyzer is to be used in an atmosphere containing harmful gases or liquids or oil or solvents use wires or cables that use a material resistant to these 6 tis recommended that the end of wires used for wiring in the converter be end treated using crimp on terminal lugs with an insulation sleeve for M4 screw IM 11M7A3 01E lt 4 Wiring gt If the ambient temperature of the detector installed location exceeds 60 C do not use crimp on terminal lugs with an insulation sleeve or insulation tape This may cause poor contact at the terminals because resin is parched at high temperatures and toxic gases are generated It
193. start time Month Day Hour Minute C 7 Skip None 0 Span 1 Zero 2 0 NONE 0 NONE Analog D 0 Range 1 0 to 25 vol O 0t010 0 000 010 O output p t Range 2 0 to 25 vol O 01025960 000 025 O D 2 Hold None N HLD P HLD HOLD 1 HLD D 3 Selection 4 to 20 mA or 0 to 20 mA 4 to 20 mA DC 0 4 20 mA D 4 Output characteristic selection Linear Log Linear 0 Linear D 5 Smoothing constant 0 to 255 sec 0 sec 000 sec D 6 Wet gas O Dry gas O Wet gas O O WET Alarm E 0 Extreme Upper limit Upper limit 0 to 100 0 O Both 0 none HH 0 HI 0 E 1 Extreme Lower limit Lower limit 0 to 100 0 O Both 0 none LL 0 LO 0 E 2 Contact delay sec Hysteresis O 3 sec 0 1 O 3sec 0 1 O Time F 0 Hour meter setting Day Hour Minute sie yA F 1 O concentration averaging time 1 to 255 hour 1 hour 1hr unit F 2 Max Min O averaging time 1 to 255 hour 24 hour 24 hr Mal gning F 3 Temperature unit specification C C 0 C F 4 F 5 Contact G 0 Contact output 1 NE F output G 1 Contact output 2 See 6 1 7 NDE E C W G 2 Contact output 3 NDE H L Contact G 3 Contact input 1 P process gas error alarm i R 1 R input ek NN G4 Contact inputa pm NR 2 2s C Instructions for start of calibration Communication H O Communication mode freewheel handshake handshake handshake H 1 Baud rate 9600 b s 4800 b s 2400 b s 4800bps 1 48 Fuel J 0 Types of fuels oe J 1 Moi
194. sture content in exhaust gas 0 to 5 m kg m J 2 Theoretical air quantity 1 to 20 m kg m J 3 Net calorific value 0 to 62790 kJ kg m J 4 X value X a b H J 5 Absolute humidity of atmosphere 0 to 1 kg kg J 6 Temperature of exhaust gas 0 to 2000 C J 7 Temperature of atmosphere 50 to 60 C IM 11M7A3 01E lt 6 Operation gt lt Details about Selecting Set Data gt C 0 Span gas concentration You can set the oxygen concentration for your span gas used for calibration If the air at the detector installation site is taken in or the instrument air is used as a span gas set the value at 21 vol O i e nearly the same oxygen concentration of clean air by entering 021 00 If the air at the installation site is to be taken in but is obviously polluted check the actual oxygen concentration using a portable oxygen analyzer etc Readout on the message CQ CAL GAS CONC 02 display Example SPAN 2021 00 C 1 Zero gas concentration You can set the oxygen concentration for the zero gas used for calibration Set it for the gas charged in the cylinder you are using at present If the concentration is 1 vol O for example then enter 001 00 Readout on the message C 1 CAL GAS CONC 90 O 2 display Example ZERO 001 00 C 2 Calibration mode Select your mode from AUTO AT SEMI AUTO SEMI and ONE TOUCH TCH Set the cursor to the corresponding number The cal
195. t Baked epoxy resin Paint Color Jade green Munsell 7 5BG 4 1 5 Mounting Two inch pipe mounting Weight Approx 3 6 kg External dimensions Calibration Gas Unit Unit mm Regulator EE d G7014XF Zero gas cylinder G7001ZC a o b F 2 inch pipe 0 D 60 5 e 2 DR oblique line is an opening portion bi asE di Note The zero gas cylinder and the regulator valve are not included in the E7044KF case assembly G7001ZC Zero gas Cylinder 485 325 0140 Note Export of such high pressure filled gas cylinders to most countries is prohibited or restricted IM 11M7A3 01E 1 26 lt 1 General gt Cylinder Pressure Regulator Secondary Primary pressure pressure Unit mm gauge gauge l N x ator handle Ea 5 lt aN safety valve Edipe Approx 82 L Approx 163 Approx 174 F1 16E ai Part No Inlet Outlet G7013XF W22 14 threads Rc1 4 G7014XF W22 14 threads 1 4 NPT F Weight Approx 1kg IM 11M7A3 01E lt 2 Installation gt 2 1 2 2 1 Installation This analyzer is an instrument of flameproof construction and has been certified by a public agency based on the Industrial Safety and Health Law of Japan For the wiring and piping work in the case of installing this analyzer in a hazardous area do the work in accordance
196. t a steam pressure of 200 to 300 kPa Specify when heavy oil or heavy oil and gas fuel is used IM 11M7A3 01E 1 8 lt 1 General gt Heat insulation provided by electric heaters Specify only when gas fuel is used Power consumption 200 VA for ordinary use Reference Gas Calibration Gas Insertion Length Surface Temperature maximum of 400 VA Temperature 130 C Gas fuel Instrument air 300 ml min 20 Instrument air and standard gas 600 ml min 10 0 5 0 7 1 0 1 5m 200 C or less Material in Contact with Gas Installation Flange Case Material Weight IM 11M7A3 01E Probe SUS310S or SUS304 Zirconia SUS304 flange SUS316 tube Flange mounting Probe mounting angle e ZS8D L For SUS3108 between the horizontal and vertically down positions e ZS8D H For SUS3108 between the horizontal and vertically down positions For SiC Vertically down within 5 Joint Rc1 4 or 1 4NPT F ZS8D L JIS 10K 100 FF SUS304 JPI Class 150 4 RF SUS304 ANSI Class 150 4 RF no serration SUS304 DIN PN 10 DN100 A SUS304 ZS8D H JIS 5K 65 FF SUS304 Material in contact with gas SUS316 Terminal box Aluminum Others SUS304 Approx 10 3 kg with an insertion length of 0 15 m JIS high temperature use Approx 13 to 15 kg with an insertion length of 0 5 m for JIS JPI ANSI DIN applications Approx 12 to 15 kg with an insertion length of 0 7 m for JIS JPI ANSI DLN applications App
197. t can be applied to measuring gases at 800 C or more These detectors are both direct insertion detector This allows the detectors to be mounted on flue walls or the like to measure internal gases directly The converter has good operability and is provided with many functions measurement and computing functions and maintenance functions such as self diagnosis as standard In addition digital communication functions can be added For calibration one touch calibration can be performed with key operation of the converter by using the ZA8F flow setting unit and making zero and span gases flow As stated above since the ZS8 flameproof zirconia oxygen analyzer is provided with a number of functions and many auxiliary units the optimum system can be constructed by selecting the units matching an application System Configuration The ZS8 oxygen analyzer is composed of the following units 1 ZS8D flameproof detector 2 ZS8C flameproof converter 3 ZAB8F flow setting unit 4 Calibration gas unit consists of a zero gas cylinder pressure regulator and case assembly However note that the units to be used differ depending on the specifications IM 11M7A3 01E 1 2 lt 1 General gt 1 1 1 Examples of System Configuration 1 Example of Heat Insulation with Electric Heater for the ZS8D L flameproof detector ZS8D Hazardous Non hazardous Flameproof detector Conduit 1 7 location location 2 Wiring for heat insulation Pressure
198. t isolated Communication system Start stop system Half duplex RS 422 A Four wire multi drop connection Computer converter 1 N N 1 to 8 Communication distance RS 422 A Up to 500m between an I O signal isolated computer and ZS8C converter Communication rate 2400 4800 or 9600 bps switching Transmission procedure No procedure or handshaking switching No procedure available only for data transmission transmission period 10 seconds Data length 8 bits Parity None Start bit 1 Stop bit 1 Communication code ASCII code Contents Reception 1 Zero and span calibration request calibration abort request 2 Analog output range selection signal Transmission Time O concentration wet and dry cell emf cell temperature error code alarm code status number calibration coefficient cell resistance response time cell life O average O averaging time maximum and minimum O concentration output current and date and time of calibration start IM 11M7A3 01E 4 14 lt 4 Wiring gt Command Interpretation 1 RC Request Calibration Function Zero and span calibration start request signal or calibration abort signal Note Set the ZS8C converter calibration mode to Auto or Semi auto Data structure 1 Received data 1 2 34 5 6 7 8 RIC 11 L0 oR Delimiter 0 calibration start 1 calibration stop Comma ZS8C converter channel number
199. t the protective functions are not defective Fuse To prevent fire accidents be sure to use the specified type of fuse Do not attempt to use other types of fuses Care should be taken not to short the fuse holder When it becomes necessary to replace fuse turn OFF the power switch and disconnect the unit from the main power source Donottouch the inside The unit has high voltage circuits Do not touch the inside of the unit when the power is ON Do not replace or repair the unit by yourself Contact our service man or authorized engineer External connection The unit must be earthed before connecting it to measuring object or external control circuit Prohibition of modification or mounting of additional parts in unit Do not attempt to modify or mount additional parts in the unit otherwise it affects the safe operation or damages the unit Media No IM 11M7A3 01E 4th Edition Jul 2011 IM 11M7A3 01E All Rights Reserved Copyright 1996 Yokogawa Electric Corporation lt PREFACE gt WARNING Before opening the cover of the ZS8C converter remove power and make sure of non hazardous atmospheres When the ambient temperature of the converter exceeds 50 C use wire resistant to 70 C or greater for external wiring t The text plate says Open circuit at non hazardous location before removing cover since the internal energy of the ZS8C converter decreases under the specified value The definition of the non
200. tart Sar a See Note below Apostrophe 207 208 209 210 211 212 213 214 215 216 1 0 0 0 ie Colon Space Comma E Time of span calibration start See Note below Note If span calibration is set to omission for function no 7 these indicate the date and time of the zero calibration start respectively 217 218 219 220 221 222 223 224 225 226 BIOIDITIO 0 70 Space Comma Unit Oxygen concentration value Measured value just before starting calibration IM 11M7A3 01E lt 4 Wiring gt 4 21 4 7 4 7 1 4 7 2 4 8 Contact Output Wiring The converter can output a maximum of three contact signals These contact outputs can be used for 13 applications see Subsection 6 1 8 freely selecting up to three required items e g low limit alarm or high limit alarm When using these contact outputs do the wiring as illustrated below Converter Terminal board Annunciator and others 1 out put 2 out put 3 out put F4 15E ai Figure 4 14 Contact Output Wiring Cable Specifications Use a cable with an OD of 10 to 13 5 mm The number of cores in cable depends on the number of contacts used for this wiring Wiring Procedure 1 Theterminal screws of the converter are of M4 size ISO 4 mm Treat the cable end using crimp on terminal lugs conforming to this screw size 2 The contact rating of relays for
201. the cover Ground terminal screw M5 F4 10E ai Figure 4 9 Position of the Detector Ground Terminal Ground terminal screw M5 F4 11E ai Figure 4 10 Position of the Converter Ground Terminal IM 11M7A3 01E 4 11 lt 4 Wiring gt egz v4 Indjno 29j0ju09 eunjejedujej e YIM sJeyeAuoo oj UO Sal dde siu JEU e1oN SI AJEA OU SJEANDE 0 JEMOd Jie Jojoefe BU 10 BA EA PIOUAJOS BU JO 69 pue amp SjeuiuJe OL p 90N jndjno si sajen ay ajerjoe oj Jamod SA eA prouejos ueds ay 10 GE pue f seuru pue BAJEA plousjos 0487 OU 10 GE pue EE sjeulws oL e1oN 10 eunue 0 Joj ejep eu Jo pjelus ejqeo x 1H 19euuo Z ejoN ZH 09 05 OV A Ove 0ZZ SLL 001 Aiddns je od Jeyeauog 30N metae bep RC CIC M CER MC Cd a qu E UD NC CN CN PG THOhMIM 38D UH ISN 109918G 857 JEMOd Peus ano uondo Jejeou oujo 3 NLA JEX pouaos 1ndino T ue 10299 peo sien OG VU 02 7 E X plousjos yndino 9 d oavu ozy ueds Bojeuy fez indino Gorey SNA l5 _ E X piou jos c TH oJ Z ndul r2 eioN peuo indu peuog uoneoiu NWWOD lenas T g 5 D iL J8penU0 OBSZ Wiring Diagram IM 11M7A3 01E 4 12 lt 4 Wiring gt 4 6 Digital Communication Wiring If communications via an RS 422 A interface is intended connect the converter to the personal computer which you are using This section also d
202. this screw size IM 11M7A3 01E 4 8 lt 4 Wiring gt 4 4 Wiring for Analog Output This wiring is for transmitting a 4 to 20 mA DC output signal to an instrument e g a recorder Maintain a load resistance of 5500 or less Converter Receiving Instrument F4 8E ai Figure 4 7 Analog Output Wiring 4 4 1 Cable Specifications Use a two conductor shielded cable with an OD of 10 to 13 5 mm for this wiring 4 4 2 Wiring Procedure 1 Theterminal screws of the converter are of M4 type ISO 4 mm Treat the cable end using crimp on type terminal lugs conforming to this screw size As a rule ground the cable shield on the side of the instrument connected to the converter 2 Do not mistake the polarity of the wiring that is positive and negative IM 11M7A3 01E lt 4 Wiring gt 4 9 4 5 Power and Ground Wiring A CAUTION Confirm the power supply specifications and supply proper power If an improper power supply is used burn out may occur or operation may be disabled These are for supplying driving power and for grounding the converter Converter Detector G L1 L2 32 33 34 Connecting procedure to the converter case ground terminal Grounding Grounding 4 Converter case Z Crimp type terminal Power supply 100 115V AC 50 60 Hz or lug for ground wire 220 240V AC 50 60 Hz Spring washer Ground terminal F4 9E ai Figure 4 8 Power and Ground wiring 4 5 1 Power Wiring Connect the cab
203. to radiant heat from plant equipment direct sunlight etc take steps to heat insulate the equipment IM 11M7A3 01E vi lt PREFACE gt 4 External Wiring for Flameproof Instruments External wiring for flameproof instruments must employ cable wiring Securely ground all non live metal parts For details see USERS GUIDELINES for Electrical Installation for Explosive Gas Atmospheres in General Industry issued by the Research Institute of Industrial Safety of the Ministry of Labor in Japan 1994 It is recommended to use cable glands for wiring Use PVC insulated and sheathed control cable CVV JIS C 3401 or equivalent Where protection from external physical damage is required the cable must be enclosed in steel conduit Connections between such cables or between such cables and wiring routed through flameproof metal conduit must be enclosed in a flameproof junction box per item 2 to prevent any explosive gases from entering and flame fronts from moving in cables For instruments in which cables are to be brought in through flameproof packings use the flameproof packing glands specified for use with the instruments and select the flameproof packings whose internal diameters are appropriate for the cable external diameters Ifa flameproof packing gland is used screw it into the connection port so that a minimum of five threads are fully engaged and fasten securely with a lock nut It is mandatory that a nonhard
204. to the following Dustsignificantly sticks to the detector probe tip If dust sticks clean it see 9 1 5 9 1 6 If the error occurs in calibration even after the sensor assembly is replaced influence of measuring gas flow is considered as the cause Make the measuring gas not flow toward the detector probe tip by changing the mounting position of the detector or in other means 10 1 9 Causes of E 8 ROM and RAM Failure and Procedure for Restoration This error occurs when ROM contents reading and or writing memory to RAM are not possible lt Causes gt 1 ROM and RAM pins are not fully inserted into the socket 2 High supply voltages exceeding the specifications are applied or the effect of noise is given to ROM and RAM 3 ROM and or RAM failed 4 Failure occurred in digital circuits on the CPU board and others lt Locating the Cause of Failure and Taking Measures gt Turn off the power to the converter Check that the supply voltage is the rated voltage Then turn on the power Check that the converter is operating normally If the error also occurs repair is necessary Contact Yokogawa 10 1 10 Causes of Display Disappearance Data Display and Procedure for Restoration Operation of the converter digital circuits is being self checked with the watchdog timer WDT or clock monitor This error occurs when power is turned on again after power supply to the converter electrical circuit is interrupted due to
205. ubleshooting gt 1 0 3 lt Locating the Failure and Taking Measures gt Turn off the power to the converter Is there any breakage or poor contact in wiring to the converter terminals Is there any breakage or poor contact in wiring to the detector terminals Is the sensor extremely dirty or corrosive or damaged Is there any place of disconnection or poor continuity in wiring between the converter and Is an error displayed Restore the damaged parts Restore the damaged parts Replace the sensor assembly Yes Replace the wiring cables Temporarily operate the analyzer by mounting the spare sensor assembly The analyzer operates e Examine the wiring connection to the converter terminals 3 and 4 If the repeater terminal box is used also check wiring connection there e Examine the wiring connection to the detector terminals CELL Also check that terminals and cable conductors are not corroded e Remove the sensor assembly from the detector and check presence of corrosion that may cause poor contact in continuity between the electrode and contact The sensor assembly whose failure is not found may be used again e Remove the wiring conductors from the detector terminals CELL amp OG and short the conductors removed Measure the resistance of this conductor on the conv
206. uce Zero gas Flow rate 600ml min Y Displayed only 5 sec Zero valve open Y I Flow of zero gas at 600 w gt ToO ml min Mud YES On zero cal lt x Did calibration time expire YES YES Is output stabilized 3 3 u Zero point calibration Note 3 The following messages are displayed depending on the calibrated results Zero cal good Zero valve close Y Zero cal error Try again Y N Stability error Try again Y N YES Normally calibrated l error in Y N gt 1f To 8 0 o Oo AN x x x x Note 3 Zero valve close Stabilizing time Q Y Displayed only during the time set in C 3 The one touch calibration procedure above finishes Span cal Y N Select the function No A 0 display by pressing the measurement mode select key EM IM 11M7A3 01E lt 8 Calibration gt 8 7 8 3 8 3 1 8 3 2 8 3 3 8 3 4 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F flow setting unit is used as a calibration device for a system conforming to Section 1 1 1 Examples of System Configuration Calibration in such a system is to be operated as in a one touch System So you have to operate the valve of the flow setting unit upon each calibration starting and stopping the calibration gas flow and adjusting the flow rate Preparation before
207. ur in re calibration it is considered as the cause of the error in the first calibration that the calibrating conditions were not proper In this case no particular restoration is necessary Restart the steady state operation If the error also occur in re calibration it is considered as the cause of error occurrence that the sensor deteriorates or is damaged Confirm that the error corresponds to one or more of the following phenomena and replace it with a new sensor see Section 10 1 4 When span gas is passed the sensor cell emf indicated with function No A 3 greatly differs from the theoretical value in that oxygen concentration When three kinds of gas zero gas span gas and the gas having approximately middle oxygen concentration between the above two are measured correlation cannot be found in these measured data for oxygen concentration In addition check the sensor deterioration or damage which caused the error occurrence whether or not it abruptly occurs by the following phenomena If abrupt occurrence may be suspected check the check valve located at the inlet of detector calibration gases whether or not the valve has failed Check valve failure causes condensed water in the calibration gas tubing which is the cause of sensor breakage Examine historical data of the span point correction factor displayed with function No B 0 Permissible range of the span point correction factor is 0 18 Examine the sensor ce
208. ut 3 relay contacts Make contact The contact type can be changed by re setting the jumper connector positions on the PCB If Break contact open when energized is necessary change it referring to subsection 6 1 7 G 3 Contact point input 1 The instrument can accept a total of 2 contact inputs assigned in Functions Nos G 3 and G 4 You select them from the following 5 types in Function G 3 0 Calibration gas under pressure alarm G Instructions for change in measurement range R Instructions for start of calibration C 1 2 3 Process gas error alarm P 4 Instructions for start of blow back B see Note 2 IM 11M7A3 01E lt 6 Operation gt 6 1 1 If the process gas error alarm is selected move the cursor to 3 with the keys If this error alarm is assigned the power circuit supplying the detector with power from the converter is turned OFF when the contact signal is received At the same time the contact signal for driving the solenoid assembly is output Note 2 The Blowback start command is valid when blowback is specified for function No G 0 or G 1 or G 2 Take the blowback start command contact input for more than one second When the converter receives the blowback start command it outputs a contact signal which turns ON and OFF about every ten seconds for an interval the same as the calibration time set for function No C 4 starting at 1 to 11 seconds after receiving the command One s
209. ve measured gas pressure approx 50 kPaG with check valve measured gas pressure approx 150 kPaG F13 14 EPS 4 AirSet G7003XF K9473XK Specifications Primary Pressure Max 1 MPaG Secondary Pressure 0 to 200 kPa G Rc1 4 or 1 4NPT F Zn alloy Connection Material IM 11M7A3 01E 1 24 lt 1 General gt Part No a Fart No G7003XF K9473XK Description Primary Pressure Max 1 MPa G Max 1 MPa G Secondary Pressure 0 to 200 kPa G 0 to 200 kPa G Connection Rc1 4 1 ANPT with adaptor Material Zn alloy Zn alloy External dimensions Unit mm Panel Horizontal 4 mounting Panel Vertical Lu mounting Secondary pressure Max 210 G7003XF Rc1 4 K9473XK 1 4NPT connector Approx 122 weight 1 0 kg Air Set G7003XF K9473XK F1 14E ai 5 Calibration Gas Unit This unit consists of a zero gas cylinder pressure regulator and case assembly Zero Gas Cylinder G7001ZC Capacity Filled Pressure Gas Composition 3 41 9 8 to 12 MPa G 0 95 to 1 0 vol O N balance Cylinder Pressure Regulator G7013XF G7014XF Pressure Gauge Primary Secondary Connection Inlet Outlet Body Material IM 11M7A3 01E 0 to 14 8 MPaG 0 to 0 4 MPa G W22 14 threads right hand screw Rc1 4 or 1 ANPT F Brass lt 1 General gt 1 25 Case Assembly E7044KF Case Material SPCC Case Pain
210. vu ot e Piouoios Pno ueds Bojeuy SAICA X plousjos 0197 qndur ndul 910N pejuog c2 198jU02 uoneoiu NWLWOD Jeues JEMSAUOO 28SZ Wiring Diagram Figure 4 11 IM 11M7A3 01E lt 9 Inspection and Maintenance gt 9 7 9 2 9 2 1 Inspection and Maintenance of the Converter You need not inspect or perform maintenance work on the converter daily or periodically If the converter fails to work properly it might come from power failure or other causes in most cases However burned out fuses or ambiguous readouts on the message display after long time use are sometimes caused by deterioration of the related parts Replacing Fuses The converter incorporates a total of 6 fuses 2 for the detector heater and 2 for the electric circuit in the converter except 2 main fuses for whole protection If any fuse burns out replace it in the following manner However it is recommended that the fuses for the detector heater F1 F2 be replaced every 2 years even if they are not burned out Note If a replaced fuse blows out immediately a problem may exist in the circuit Completely go over the circuit to find out why the fuse blew Main fuses two A1607EF 3A for steam heater S9503VK 12A for detector heater 0 5A amplifier fuses F3 and F4 F1 F2 3 15A fuse F1 and F2 for detector heater Part no L9021EF Part no A1113EF provided on the back of the cover dte Figure 9 3 Locations of Fuses for
211. w m n l 0o om r c 41100 ro moj j2 0O m o 09 Oo OO op I Igs Ir ur I ozllo Z Z OG Ul m AI On 4H O o zo O U gt E Ze Dl Do lsc zz 0 XI Ao Q gt Zz ol z gt 1 1 om Z c O w c gt z z gt r I A Ir I r e Error Code E 4 Display when an error occurs Example 4 O0O gt gt OC UZ zo gt daj or OO lt Z7 Z0 AU QD O A 4 oz TU mn OO o mo 05 r U E mu pu Ur m am lt U m ES m lt m I IM 11M7A3 01E lt 7 Operating Keys and Display of Converter gt 7 9 e Error Code E 5 Display when an error occurs Example 5 UOIlIoo O gt gt gt Or EF TQI INDI N lt im S rm r m gt OU A mz r llrnr r UO Z UI l MT U 4 U I I oz A mz OoOoj mo o moijizolimr QO I go O Oz izzcriim Oo imzi A AaaJAj izolinx m z l Io Z lt lt o O gt gt T e Error Code E 6 Display when an error occurs Example 6 VAITIAA U O gt gt gt 4r cr IO o lt O gt m gt CA vnr UJ m r r O gt r m UJ 05 ralirz I rr U o z u EE zi iilo UO Oz a z U U c 4 gt I I m m molioo ar IO O Z lt lt o o gt gt gt r U AX nzilor gmiloolj oo r gt 0O gt moul lz l mmn O I RO Oz zEriima4A o l mz gt 44 TITO AXA r o D gt IZ CN wn T e Error Code E 7 o 4
212. with the see USER S GUIDELINES for Electrical Installation for Explosive Gas Atmospheres in General Industry issued by the Research Institute of Industrial Safety of the Ministry of Labor in Japan 1994 This chapter describes procedures for installation of the major units composing the ZS8 flameproof zirconia oxygen analyzer including those in optional use as shown below Section 2 1 Flameproof general purpose detector Section 2 2 Flameproof high temperature detector including high temperature probe adaptor Section 2 3 Flameproof converter Section 2 4 Flow setting unit Section 2 5 Calibration gas unit case Installation of Flameproof General purpose Detector Installation Site The following criteria should be taken into consideration when selecting the location for installing the detector 1 The explosion protection standards are satisfied 2 There should be easy access to the detector to ensure safe work in checking and maintenance 3 The ambient temperature should not be too high below 60 C and the terminal box should not be subject to strong radiant heat 4 There should be no vibration Probe Insertion Hole When constructing the probe insertion hole take the following into consideration 1 Do not point the detector probe tip upward Note This should be observed so that the sensor cell in the probe tip is not affected by droplets which may cause problems such as condensation 2 Mountthe detector pro
213. ygen concentration Doesthe calibration gas tubing have measures to no zero gas leakage 2 Ifthe error does not occur in re calibration it is considered as the cause of the error in the first calibration that the calibrating conditions were not proper In this case no particular restoration is necessary Restart the steady state operation If the error also occur in re calibration it is considered as the cause of error occurrence that the sensor deteriorates or is damaged Confirm that the error corresponds to one or more of the following phenomena and replace it with a new sensor see 10 1 4 When zero gas is passed the sensor cell emf indicated with function No A 3 greatly differs from the theoretical value in that oxygen concentration When three kinds of gas zero gas span gas and the gas having approximately middle oxygen concentration between the above two are measured correlation cannot be found in these measured data for oxygen concentration In addition check the sensor deterioration or damage which caused the error occurrence whether or not it abruptly occurs by the following phenomena If abrupt occurrence may be suspected check the check valve located at the inlet of detector calibration gases whether or not the valve has failed Check valve failure causes condensed water in the calibration gas tubing which is the cause of sensor breakage Examine historical data of the zero point correction factor displayed wit
214. yle amp Format renewed Revised and Corected all over After Sales Warranty added etc 4th Jul 2011 Revised of wiring for explosionproof and parts IM 11M7A3 01E User s Model ZS8 Manual Flameproof Zirconia Oxygen Analyzer Supplement Thank you for selecting our Model Z58 Flameproof Zirconia Oxygen Analyzer User s Manual IM 11M7A3 01E 4th Edition supplied with the product some revisions additions have been made Please replace the corresponding pages in your copy with the attached revised pages Revisions Page 3 4 Section 3 6 Purge Gas Piping Deleted the description partly Page 4 11 Section 4 5 2 Ground Wiring Changed of the Figure 4 11 Wiring Diagram Page 9 7 Section 9 2 1 Replacing Fuses Figure9 3 Changed the part number of fuse Main fuse 3 Changed of the description YOKOGAWA lt gt All Rights Reserved Copyright 2000 3rd Edition Sep 2014 YK IM 1 1 M7A3 01 E Subject to change without notice 4th Edition Yokogawa Electric Corporation 3 4 lt 3 Piping gt 3 6 Purge Gas Piping If there are corrosive gases in the atmosphere or if the ambient temperature at the converter installed location is high purge the inside of the converter with air Connect a copper or stainless steel pipe to the purge air inlet Set the supply air to about 50 kPa Unit mm 28 5 28 5 28 528 5 28 5 28 5 gt lt gt lt gt lt gt lt

Model ZS8 Flameproof Zirconia Oxygen Analyzer

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