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1. Parts No Item or MS code Qty Description 1 AV55CM 00 0 1 Channel Card Refer to MS code 2 A1112EF Max 16 Fuse 3 K9475YA 4 Knob Bolt 4 Y9410ZU 1 Lock Screw 5 L9801BF 1 Washer 6 K9471UF Cable Gland LT G7276YE Grommet 8 L9827AS 1 Allen Wrench for Lock Screw YOKOGAWA All Rights Reserved Copyright 2004 Yokogawa Electric Corporation COMPL 11M12D01 01E n 1st Edition July 2004 YK Yokogawa Electric Corporation Customer Model ZR22G Maintenance Zirconia Oxygen Analyzer Detector Parts List Separate type FO2E EPS Parts No Item MS code Qty Description 1 K9471UA 1 Dust Filter Option 2 essees 1 Detector Assembly 3 E7042BR 1 Plate 4 K9470BM 1 Pipe K9473AN 1 Pipe for Option code C 5 E7042DW 4 Washer SUS316 stainless steel 6 G7109YC 4 Bolt M5x12 SUS316 stainless steel K9470BK 4 Bolt M5x12 inconel for Option code C Fi 1 Cell Assembly ZRO1A01 01 1 piece ZRO1A01 02 2 pieces ZRO1A01 05 5 pi
2. Description in this manual Model Product Name Specification Installation Operation Maintenance CMPL ZR22G General use detector O O O O O ZR22G High temperature detector 0 15m O O O O AV550G Averaging Converter O O O O O ZO21R L Probe protector O O ZO21P H High temperature probe adapter O O O ZA8F Flow setting unit for manual calibration use O O Auxiliary ejector for high temperature use Part No E7046EC EN O O O Calibration gas unit case Part No E7044KF O Oo Check valve Part No K9292DN K9292DS O O Dust filter for the detector Part No K9471UA O O Dust guard protector Part No K9471UC O O CMPL Customer Maintenance Parts List minte IM 11M12D01 01E User s manuals of instruments related to the AV550G Averaging Converter are as follows Model Title Manual No ZR22G Separate Type Zirconia Oxygen Analyzer IM 11M12A01 02E ZO21DW In Site Type Zirconia Oxygen Analyzer IM 11M03A02 E 3rd Edition Sep 2005 YK All Rights Reserved Copyright 2004 Yokogawa Electric Corporation IM 11M12D01 01E Tbl 01 eps This manual consists of twelve chapters Please refer to the reference chapters for installation operation and maintenance Table of Contents Relates to Chapter Outline Installation Operation Maintenance 1 Overview Equipment models and system configuration examples A
3. T10 3E X Cannot perform indication check a Wait Wait until other command finishes before starting indication check A CAUTION When setting observe the following cautions Observe the following cautions when setting the indication check timing 1 You can select Indication check timing and set values but these will be reflected in the Calibration timing settings 2 When indication check is to be started by a contact input signal you need to set the relevant contact input to Indication check start on the Input Contacts display 3 Indication check may be delayed or canceled by status of the channel to be checked or by the status of other channels as explained by Table 10 3 4 If the indication check calibration interval setting is shorter than the sum of indica tion check times plus hold times for all channels then the system will be in indica tion check status when the second indication check cycle attempts to start In this case the second indication check will be cancelled For a 3 point check with zero check span check and third gas check the time required for all three checks is going to be three times as long as for a single check 5 If interval is set to 000 day 00 hour then auto indication check is not performed 6 If you set start date before the current date then auto indication check will not start IM 11M12D01 01E 10 13 Indication chk start in Ch1 Span check gt che
4. Ground External ground prea G terminal and terminal are connected by jumper plate Power supply and Ground terminals are M4 screw 1 Averged analog output with digital communication HART when suffix code E HART communication is selected 2 Used exclusively for communication when suffix code F FOUNDATION Individual Error Contact Output a CH2 PS 5 5 Leo Ly CH3 Solenoid Valve Contact Output individual Error Contact Output Solenoid Valve Contact Output sos soso or e N I 1 1 I I 1 1 I I I I I CH6 CH7 CH4 iii ci i z 1 ee el i e Ip l I CELL I li l Detector CELE Detector CELL Detector CELT Detector l Output ah Output e 1 Output a 1 Output TC i signals TC sionals TC Ha TC l signals E I apd 7 Do a Ii E Ma screws Vy Cu l 1 G io e i la Vy i I 11 E 3 1 1 individual I Individual l Individual Individual p l Analog AO I Analog I Analog Analog AO I output output I as l l I Basic Power Supply Functional Contact Output Common Error output Solenoid Valve output l Individual Error Contact Output Solenoid Valve Contact Output f pot DO2 DO3 Do4 pos Isvcu1 svcualy po cHs DO CH6 SV CH5 Sv CHe i 1 1 1 oT 1 I 1 1o ji C NC NO C NC NO C NCNO C NCNO C NC NO l l C NC NO C NC NO 11 12 13 14 15 16 17 18 19
5. Gre g E Q S lt a amp iij Fig11 8 lt How to replace the fuse gt Fuse Holder Fuse Holder f i Fit Seas 8 holders in basic power supply unit 8 holders in expansion power supply unit 1 Before replacement turn off the power to the averaging converter at the external breaker 2 Remove the front cover and position the power switch to O OFF 3 Remove the fuse from its holder Using an appropriate size flat blade screwdriver turn the fuse holder cap counterclockwise until it stops Pull out the cap The fuse will come out together with the cap 4 Use a recommended fuse shown below or equivalent for replacement Attach a new fuse to the cap place in the fuse holder and push and turn the cap clockwise until it stops with the flat blade screwdriver Fuses used in the averaging converter are as follows Maximum rated voltage 250 V Maximum rated current 2 5 A Type Time lag fuse Compliance UL CSA VDE
6. Item Amount of water vapor in exhaust gas Theoretical amount of air 0 00 m3 kg m3 1 00 m3 kg m3 Absolute humidity of the atmosphere 0 0 kg kg T8 9E ESP 8 23 8 5 4 Setting Password Unauthorized access to lower level menu displays from the Execution Setup display can be protected by passwords You can set separate passwords for Calibration Indication Check Blowback and Maintenance and for Commissioning lt Setting Procedure gt 1 From the basic panel display touch the Setup key and the Execution Setup display appears 2 Select Commissioning and the Commissioning display appears 3 Select Others then Passwords The display shown in Fig 8 23 appears First set the password for Calibration Indication Check Blowback and Mainte nance 4 Select Calibration Indication Check Blowback and Maintenance 5 A text entry display appears Enter password as up to 8 alphanumeric characters You can enter a password for Commissioning by the same procedure 6 Record the passwords and look after them carefully Passwords CF Calibration Blow back and Maintenance Commissioning F51E EPS Fig 8 23 Password Setting lt Default setting gt The passwords are not set as shipped from factory If you reset initialize the parameters and password settings are deleted A CAUTION 1 If you forget the password from the Execution Setup display select Commission ing and ente
7. Contact input Calibration contact outputs Reference gas line IM 11M12D01 01E Power supply Calibration gas line Needle valve lt q Span gas cylinder Solenoid valve Instrument air Flowmeter k J Fl ti E ji g pk X Instrument air Stop valve set Needle valve Zero gas cylinder Figure 4 10 Typical Piping for a System to perform Automatic Calibration The following outlines some points to note regarding the piping for this system e Install a solenoid valve through a nipple on the calibration gas inlet of the detector Note The solenoid valve should be connected directly to the detector If any piping is present between the detector and the solenoid valve condensation may develop in the pipe causing damage to the detector by rapid cooling when the calibration gas is introduced e When a high temperature detector is used and the pressure of a sample gas is negative connect an auxiliary ejector on the sample gas outlet of the high temperature probe adapter See Figure 4 3 in Subsection 4 1 4 e When a high temperature detector is used and the pressure of a sample gas is 0 49 Pa or higher it is recommended that a throttle e g needle valve be installed on the sample gas outlet of the high temperature probe adapter See Figure 4 4 in Subsection 4 1 4 Note This is to lower the temperature of a sample gas below 700 C When both th
8. 5 2 2 Preparation for Wiring to Detectors Follow the instructions below when connecting cables to detectors 1 Install a conduit or cable gland appropriate to the specified screw size to the cable inlet of a detector Allow for the sufficient length of a cable in case that the detector needs to be removed for maintenance 2 If the ambient temperature around the wiring lines exceeds 80 C a flexible metal conduit tube must be used If an unshielded 600 V silicon rubber insulated glass fiber braided wire route the wiring so that the wire cannot pick up external noise 3 Figure 5 4 shows the layout of the detector terminals TC with Si TUBE CELL CELL TC TC CJ Cy 6 To Converter 7 To Converter or To Ground or Terminal Box Terninal Box Figure 5 4 Detector Terminals 5 6 IM 11M12D01 01E 5 Wiring The sizes of the terminal screws are M3 5 Each wire should be terminated with a crimp terminal appropriate to the screw A WARNING e If the ambient temperature at the detector installation site exceeds 60 C use bare crimp terminals e Before opening the detector cover loosen the lock screw If the screw is not loosened first the screw will damage the cover and the terminal box will require replacement When opening and closing the cover remove any sand particles or dust to avoid gouging the thread e Notice when cl
9. 513 C 513 C Ch4 Ch8 514 C 519 C m L F7 4E EPS Fig 7 4 Display during warmup AN Note Depending on furnace conditions the cell temperature may overshoot the target by 10 15 C during the warmup phase This is not an abnormality IM 11M12D01 01E 7 5 7 6 Selection of Gas to be Measured 7 6 Exhaust gas includes steam resulting from combustion of hydrogen and oxygen You may choose whether to display the oxygen concentration including the oxygen contained in the steam or display the computed dry oxygen concentration a value compensated for the oxygen in steam which results in a higher concentration value For details refer to Fuel Settup in Sec 8 5 3 1 Touch the Setup key to switch to the Execution Setup display 2 Select Commissioning gt Basic Setup gt Select Measurement gas and the Measurement gas display appears 3 Touch the Enter key and the Measurement gas selection window opens for you to select the measurement gas The Measurement gas selection applies to all channels you cannot specify it on a channel by channel basis Measurement gas See Manual for details m Cy Select measurement gas Dry Fig 7 5 Measurement gas selection IM 11M12D01 01E 7 Startup 7 7 Current Output Range Setting IM 11M12D01 01E mA output range Al d chn gt Range1 CP max 25 02 min 0 02 Da Range2 The output ranges two ranges of each
10. F8 21E eps 8 20 IM 11M12D01 01E 8 Detailed Data Setting Wet bulb 29 temperature C 0 026 Absolute humidity kg kg 0 024 0 022 0 020 0 018 LININ KERR susie 2S ORES ESSE ac INNEN Ne RERESIK TSN RNR END 0 2 4 6 8 2 14 16 18 20 22 24 26 28 30 32 34 36 38 40 Dry bulb temperature C Ae 0 000 Fig 8 20 Absolute Humidity of Air IM 11M12D01 01E 8 21 Table 8 7 Fuel Data For liquid fuel Fuel P Chemical component Calorific power Theoretical Amount of combustion gas properties weight percentage kJ kg amount of Nm3 kg combustion Higher Lower S g order order Nm kg CO H O SO Total Kerosene Light oil Heavy oil class 1 Heavy oil class 2 No 1 Gas fuel Theoretical amount of air J Fuel properties Chemical component Calorific power Theoretical Combustion product weight percentage kJ Nm3 amont of Nm3 m3 Higher Lower combustion CO CH CmHn O order order Nm3 m gt CO HO Coke oven Sa 0 50 5 2 6 25 9 3 9 0 1 8 18209 Blast furnace s 3349 gas Natural gas i i k 34074 Propane CH 90 C4H o 10 102055 93976 Butane C H 10 C H 90 125496 115868 Gases Molecular Formula Oxygen Nitrogen Hydrogen Carbon monoxide Carbon dioxide Methane 39750
11. Process gas temperature 0 to 700 C Process gas temperature 0 to 1400 C Mounting orci General use Probe Application High temperature detector Application Detector i 7 H l i Boiler H Sr oni ae ZR22G Heatin Sample e eating g outlet T furnace vertical 2m Detector turmace structure Probe protector High Vertical 25m r DW L for high temperature or more ee use detector G t Probe Protector Sample inlet Z021 R Detector For pulverized Temperature Horizontal 3 m Gas Flow ZR22G coal boiler Probe material SUS310S 800 C i or less with gas flow Probe material SiC 1400 C venice velocity Mounting Vertical downwards Sample inlet 10 m s or more Insertion length 1 0m 1 5m When duct pressure is atmospheric ele Black liquid Or neoa e emperane auxiliary Horizontal 0 4 K9471UA Detector recovery boiler ejector E7046EC E7046EN to to or c vertical 2m DustGuard 4R22G i Pressure gauge Protector a ai ii ee K9471UC s Elenor Inlet 2 5m oY fey J ke Vertical or more 4A Blow F1 4E EPS 1 4 IM 11M12D01 01E 2 Specifications 2 Specifications This chapter describes the specifications for the following ZR22G General use separate type detector See Section 2 2 1 ZO21R L Probe protector See Section 2 2 2 ZR22G 0 15 m High temperature separate type detector See Section 2 3 1 ZO21P H Adapter for High temperature probe See Section 2 3 2 AV550G Averaging converter See Section 2 4 ZA8F
12. time an error icon takes precedence Table12 2 Alarm Types and Occurrence Cancellation Conditions Alarm Type Occurrence Cancellation Conditions Unit to be detected Alarm 1 Oxygen concentration alarm Measured oxygen concentration value exceeds or falls below the preset alarm limits For details see sec 8 2 Setting Oxygen Concentration Alarms Each channel Alarm 2 Zero point calibration coefficient alarm In auto or semi auto calibration zero correction factor is outside the range of 100 30 See sec 9 1 3 Compensation To stop alarm Recalibrate stops if the factor falls within the range Each channel Alarm 3 Span point calibration coefficient alarm Span correction factor is outside the range of 0 18 See sec 9 1 3 Compensation To stop alarm Recalibrate stops if the factor falls within the range Each channel Alarm 4 EMF stabilization time up alarm In auto or semi auto calibration cell voltage does not stabilize for 1 minute even after calibration time is up Stabilization means that margin of cell voltage fluctuation is within 0 1 mV and the state continues for about 1 second To stop alarm Recalibrate Stops if the stabilization time falls within the normal range Each channel Alarm 5 Cold junction temperature alarm Temperature of the cold junction placed in the detector terminal box falls below 25 C or exceeds 155 C To stop alarm The cold jun
13. 15 When the graph trace stabilizes touch the Enter key The display changes to like Fig 7 16 The measured value is adjusted to read the same as the zero gas concentra tion set value and a check mark appears in the check box beside Zero calibration Close the zero gas flow setting valve and tighten the lock nut used to prevent it from loosening during measurement Chi Manual cal Span calibration f Zero calibration f Close the zero gas valve F Span calibration End K it Enter F26E EPS Fig 7 16 Calibration complete 16 Select End and touch the Enter key The oxygen concentration graph is displayed and the HOLD TIME status mark appears The graph trace changes gradually from zero gas concentration to measured gas concentration During this Output settling time if Output hold is set then the analog output is held at the corresponding preset value For details of Output hold refer to Sec 8 1 2 Output hold setting Shipping time default setting is for settling time to be set to 3 minutes After the settling time has elapsed then the display reverts to channel select Fig 7 10 so that you can select another channel for calibration If you touch the enter key during settling time then settling time is skipped and you are returned to the channel select display IM 11M12D01 01E 7 Startup 7 10 Analog Output Current Loop Check IM 11M12D01 01E After wiring the cables you can
14. 21 O Table 10 1 shows oxygen concentration versus cell voltage Table 10 1 Oxygen Concentration Vs Cell Voltage cell temperature 750 C O2 mv 117 83 102 56 93 62 87 28 82 36 78 35 74 95 72 01 69 41 02 1 2 3 4 5 6 7 8 9 mv 67 09 51 82 42 88 36 54 31 62 27 61 24 21 21 27 18 67 02 10 21 0 30 40 50 60 70 80 90 mv 16 35 0 7 86 14 2 19 2 23 1 26 5 29 5 32 1 100 T10 1E EPS O2 mv 34 4 10 1 10 1 2 Thermocouple Voltage The cell temperature is measured with a Type K chromel alumel thermocouple The thermocouple cold junction is located in the detector terminal box The cell temperature and the thermocouple voltage including the voltage corresponding to the cold junction temperature are displayed 10 1 3 Cold Junction Resistance C J Voltage The ZR22 Detector measures the cold junction temperature using an RTD Pt 1000 The earlier model of Z021D uses transistors to measure the cold junction temperature If Detector is ZR22 is selected in the Basic setup display the RTD resistance values will be displayed If Z021D is selected the transistor voltage will be displayed 10 1 4 Cell temperature This displays the cell sensor temperature which is determined from the thermocouple emf and cold junction temperature Normally it is 750 C 10 1 5 C J Temperature This indicates the detector terminal box temperature which compen
15. 35820 Ethane 69638 63744 Ethylene 4 62991 59060 Propane 99070 91255 Butane 128452118623 a T8 8E EPS 8 22 IM 11M12D01 01E IM 11M12D01 01E lt Setting Procedure gt 8 Detailed Data Setting 1 Touch the Setup key on the basic panel display and the Execution Setup display appears 2 Select Commissioning and the Commissioning display appears 3 Select Others then Fuel Setup and the display of Fig 8 21 appears 4 Select Content of moisture in exhaust gas and Theoretical air quantity in turn and enter numeric data 5 Select more and touch Enter key and a display like Fig 8 22 is displayed Here enter Value of the X coefficient and Absolute humidity of the atmosphere then select finished to revert to the display of Fig 8 21 Fuel setup See Manual for details cy Cp Contents of moisture in exhaust gas 0 0 0 m3 kg Theoretical air quantity 1 00 m3 kg required Ld Fig 8 21 Fuel Setup display 1 lt Default setting gt CP Value of the X coefficient Fuel setup 1 00 Absolute humidity of the atmosphere 0 0000 kg kg finished cle t a iS in in 5 a Fig 8 22 Fuel Setup display 2 Fuel parameters are set to defaults in Table 8 8 prior factory shipment or after data initialization Table 8 8 Default values of Fuel settings Default setting
16. Commissioning 4 Enter FO6E EPS Figure 6 10 Execution Setup Display 5 Calibration display From the menu on the Execution Setup display select Calibration The Calibration display will appear Calibration can be performed from the menu on this display Calibration CP Manual calibration Semi auto calibration le t m g Figure 6 11 Calibration Display 6 Indication check display From the menu on the Execution Setup display select Indication Check The Indication Check display will appear Indication check can be performed from the menu on this display 7 Blow back display From the menu on the Execution Setup display select Blow back The Blow back display will appear Blow back can be performed from the menu on this display Indication check A Blow back ty CP Manual ind check CP Start blow back Semi auto ind check Eil Cancel blow back K es t m 2 T S F09E EPS Figure 6 12 Indication Check Display Figure 6 13 Blow Back Display O 1 IM 11M12D01 01E 9 8 Maintenance display From the menu on the Execution Setup display select Maintenance The Maintenance display will appear The following can be performed from the menu on this display Display setup Calibration indication check and blowback setups mA output loop and contact checks Channel card power BR WN eS 9 Commissioning
17. JIS 5K 32 FF Gasket Thickness 3 52 over 6124 Detector ZR22G by customer High temperature 2 Reference air inlet lt 2 gt fy Pipe hole 2 G1 2 2 1 2NPT etc Calibration gas inlet lt 3 gt Note 1 1 1000 or 1500 mm Note 2 Sample gas outlet if the sample gas pressure is negative connect the auxiliary ejector lt 1 gt Flange lt 2 gt lt 3 gt joint JIS 5K 50 FF SUS304 Re 1 4 A B Cc 130 105 4 015 ANSI Class 150 4 RF SUS304 1 4 FNPT 228 6 190 5 8 19 F2 4E EPS 2 4 AV550G Averaging Converter 2 4 1 Standard Specification Compatibility of Detectors ZR22G ZO21D ZO21DW Number of Detectors 1 to 8 Expandable up to 8 Bases these for 4CH and 8CH are available Averaging interval 0 2 seconds Display 5 7 inches color LCD display of size 320 by 240 dot with touch screen Output Signal 4 to 20 mA DC maximum load resistance 5500 Average value Output 3 points Independent Output Output to each channel Common isolation Individual isolation selectable Note Number of averaging output is 2 when suffix code F FOUNDATION Fieldbus communication is selected Independent Output Output to each channel Common isolation Individual isolation selectable Used exclusively for communication when suffix code F FOUNDATION Fieldbus communication is selected Contact Output C
18. User s EKA Manual Model AV550G Zirconia Oxygen Analyzer Averaging Converter IM 11M12D01 01E vigilant YOKOGAWA IM 11M12D01 01E 3rd Edition Yokogawa Electric Corporation Introduction The EXAxt Series AV550G Zirconia Oxygen Analyzer Averaging Converter is designed for oxygen measurement at multiple points in flue ducts of industrial furnaces and can be used to optimize the combustion process For the AV550G system various types of EXAxt ZR Series detectors as well as optional accessories are available The best measurement can be achieved by selecting instruments appropriate to your application This manual provides information such as installation operation inspection and maintenance procedures about the instruments used in the AV550G averaging converter measurement system Any sections concerning instruments not included in your system may be skipped Before using the instruments read any descriptions related to your instruments and system to ensure the best performance Regarding the HART communication refer to IM 11M12D01 51E IM 11M12D01 51E has been published as Model EXAxt AV550G HART protocol Regarding the FOUNDATION Fieldbus communication refer to IM 11M12D01 61E IM 11M12D01 61E has been published as Model EXAxt AV550G Fieldbus communication The models and description items in this manual are as follows Models and descriptions in this manual
19. 10 o Detector signal CELL TC CJ Conductor two way resistance 10 o Shielded Individual analog AO Shielded 550 o including load resistance output Averaging analog Ave a Ave b output Av3 c Solenoid output SV COM SV CH1 to SV CH8 Individual error DO CH1 to contact output DO CH8 Common contact DOI to DO4 output Shielded Shielded Unshielded Unshielded Common error DOS5 Unshielded contact output Contact input DI1 DI2 DI COM Loop resistance when contact is closed 200 o Unshielded Note The number of cores is determined by number of contacts to be used IM 11M12D01 01E 5 5 5 2 Wiring for the Averaging Converter and Peripheral Devices 5 2 1 Preparation for Wiring to the Averaging Converter Follow the instructions below when connecting cables to the averaging converter 1 The terminal screws on the control and channel cards are M3 5 and all the other terminal screws are M4 Each wire should be terminated with a crimp terminal appropriate to the screw 2 If a silicone rubber insulated glass fiber braided wire is used for wiring to the detector run the wiring through a terminal box It is recommended that a cable such as a PVC insulated PVC sheathed control cable be used between the terminal box and the averaging converter This is to prevent moisture or corrosive gases from entering into the averaging converter and to ensure the grounding of the detector
20. Construction Dust proof and rainproof construction Case Material SPCC Cold rolled steel sheet Painting Baked epoxy resin Dark green Munsell 2 0 GY 3 1 0 5 or equivalent Pipe Connections Rc1 4 or 1 4FNPT Reference Air pressure Clean air supply of measured gas pressure approx 50 kPa G or measured gas pressure plus approx 150 kPa G when a check valve is used pressure at inlet of the auto calibration unit Maximum 300 kPaG Air Consumption Approx 1 5 l min Weight Approx 2 3kg Calibration gas zero gas span gas flow 0 7 l m at calibration time only A Note Use instrument air for span calibration gas if no instrument air is available contact YOKOGAWA Suffix code Option code Description i ae ie acca Flow setting unit Joint Se le Spee yo Re ua prees EME SUESC Tat With 1 4 NPT adapter Stylecode B_ f Style B T2 5E EPS IM 11M12D01 01E 2 19 e External Dimensions Unit mm REFERENCE CHECK 1 REFERENCE SRAN Reference air outlet Zero gas outlet Span gas inlet Zero gas inlet 4 Re1 4 Piping connection port A A CHECK REF OUT OUT S Flow Flow meter meter A K A ZERO SPAN A GAS IN GAS INi__ N Instrument air ap Approx 1 5 l min Airset Air pressure without check valve measured gas pressure approx 50 kPaG with check valve measured gas pressure approx 150
21. Enable Ch8 Enable Figure 11 3 Channel Card Power Hot Swap Display A DANGER Before the inspection or maintenance of a detector make sure that the power has been turned off by measuring the voltage of the heater terminal in the terminal box of the detector for more than two seconds with a voltmeter A CAUTION The state Enable Disable of the hot swap function is stored even after the power switch of the averaging converter is turned off When the power switch of the averaging converter is turned on power is not supplied to the disabled channel s 11 3 11 3 Inspection and Maintenance of the Detector 11 3 1 Cleaning the Filter in Sensor Assembly If the filter in the tip of the sensor assembly gets blocked by dirt or the like this will affect measurement accuracy If it cannot be cleaned satisfactorily by blowing com pressed air through it use a brush to clean it 11 3 2 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
22. cell internal resistance Q next calibration estimate year month day heater on time rate time year month day hour minute software revision maximum minimum average oxygen concentration vol O2z calibration record ten times internal temperature rise alarm record Calibration Setting Items Span gas concentration vol O2z zero gas concentration vol Oz calibration mode auto semi auto manual calibration type and method zero span calibra tion zero calibration only span calibration only stabilization time minute second calibration time minute second calibration period day hour starting time year month day hour minute Equipment Related Items Measuring gas selection wet dry Detector selection ZR22 Z021 Output Related Items Analog output output mode selection output conditions when warming up maintenance calibrating during blowback abnormal 4 mA 20 mA point oxygen concentration vol Oz time constant preset values when warming up maintenance calibrating during blowback abnormal output preset values on abnormal Alarm Related Items Oxygen concentration high alarm high high alarm limit values vol O2 oxygen concentration low alarm low low alarm limit values vol O2 oxygen concentration alarm hysteresis vol Oz oxygen concentration alarm detection alarm delay seconds Converter Output mA analog output 4 to 20mA DC maximum load resistance of 550Q Average value output 3 points av
23. formed sequentially and manually In Semi auto mode an indication check can be started by key operation on the display or by a contact input signal and then sequen tially performed at a preset check time and hold time In Auto mode indication checks are automatically performed at preset intervals The following restrictions apply When Manual is selected In this mode only Manual Indication Check can be performed Contact input used to start Semi Auto Indication Check has no effect Auto Indication Check does not start at Auto Indication Check start time When Semi Auto is selected In this mode Manual Indication Check or Semi Auto Indication Check can be per formed Auto Indication Check does not start at Auto Indication Check When Auto is selected Indication Check can be performed in any of the three modes A CAUTION When Auto Calibration mode is selected you cannot also select Auto Indication Check mode The reverse also applies if you select Auto Indication Check mode then Auto Calibration mode cannot be selected lt Setting Procedure gt 1 On the basic panel display touch the Setup key to display the Execution Setup display then select Maintenance 2 From the Maintenance display select Indication check setup then Mode A dropdown menu opens allowing you to select between Manual Semi auto or Auto modes see Figure 10 9 Indication check setup ramelan a Fay ints Semi
24. i S _ Range al Liefie lal CP max 25 02 i i Range2 I ea max 25 02 rf IF min 0 02 o 3 lt F8 1E EPS F17E EPS Fig 8 1 Current output range Fig 8 2 Numerical entry IM 11M12D01 01E 8 1 Maximum oxgen concentration 02 for a maximum current of 20mA lt Permissible Setting Range gt The range low and high values are restricted as follows The range min O2 concentration value corresponding to 4 mA output can be set to either 0 Oz or in the range 6 to 76 O2 The range max O2 concentration value corresponding to 20 mA output can be set to any value in the range 5 to 100 Oz however the range max setting must be at least 1 3 times the range min setting If you do not observe this restriction the measurement will be invalid and any previous valid value will be used The gray area in figure represents the valid setting range Setting example 1 If the range minimum corresponding to 4 mA output is set to 10 Oz then range maximum corresponding to 20 mA output must be at least 13 O2 Setting example 2 If the range minimum corresponding to 4 mA output is set to 75 O2 then range maximum corresponding to 20 mA output must be at least 75x1 3 98 O2 rounding decimal part up Ranges over which oxygen concentrations can be set Outside ranges 15 25 35 45 55 65 75 Minimum oxgen concentration 02 for a minimum current of 4mA F8 3 EPS Fig 8 3 Min
25. process side flange Description Probe Protector 0 to 700 C Insertion 100 1 05 m 3 5 ft length 150 1 55 m 5 1 ft 2 05 m 6 8 ft Flange 1 JIS 5K 65 FF SUS304 A 4 ANSI Class 150 4 FF SUS304 Style B Style code T2 2E EPS 1 Thickness of flange depends on dimensions of flange Unit mm Flange lt 1 gt with bolts nuts gasket and washer Washer 12 gasket t1 5 Gas flow Mounting nut wr Insertion length 1 1050 1550 2050 Dimensions of i holes on opposing surface Flange lt 1 gt A B C t D JIS 5K 65 FF SUS304 155 130 4 15 5 40 ANSI Class 150 4 FF SUS304 228 6 190 5 8 19 12 50 F2 3E EPS 2 8 IM 11M12D01 01E 2 Specifications 2 3 High Temperature Separate type Detector and Related Equipment 2 3 1 ZR22G 0 15m High Temperature Separate type Detector IM 11M12D01 01E Standard Specifications Construction Water resistant non explosionproof Probe length 0 15 m Terminal box Aluminium alloy Probe material Probe material in contact with gas SUS 316 JIS Probe SUS 304 JIS Flange Zirconia Sensor Hastelloy B Inconel 600 601 Weight Approx 3 kg Installation Flange mounting The use of high temperature detector probe adapter ZO21P H is necessary Flange standard JIS 5 K 32 FF equivalent thickness varies Mounting angle Any
26. 1 21 0 02 MeL L F7 13E EPS Setting value of A span gas concentration Setting value of zero gas concentration Actual measurement value Fig 7 13 Display during calibration 10 When the graph trace stabilizes touch the Enter key The display changes to like Fig 7 14 The measured value is adjusted to read the same as the span gas concentra tion set value and a check mark appears in the check box beside Span calibration Close the span gas flow setting valve and tighten the lock nut used to prevent it from loosening during measurement 11 Next perform zero calibration Select Zero calibration and touch the Enter key 12 Select Next and touch the Enter key Chi Manual cal Span calibration f Zero calibration Close the span gas valve gt F Zero calibration End ft F7 14E EPS Fig 7 14 Zero calibration start display 13 Open the zero gas flow setting valve and adjust flow to 600 60 ml min 14 Select Valve opened Start Calibration and touch the Enter key An oxygen concentration graph like Fig 7 15 is displayed and CAL TIME status mark flashes Wait for the graph measured value trace to stabilize Calibration has not yet been performed so it is not a problem if the displayed value is different from the correct value of zero gas concentration Chi Manual cal 1min div 21 00 0 98 02 a Fig 7 15 Display during calibration
27. 150 2 A failure of the cold junction temperature sensor located at the detector terminal block occurred 3 A failure of the electrical circuits inside the converter occurred lt Locating cause of failure and countermeasures gt Before proceeding to the following troubleshooting procedure examine whether or not the temperature of the detector terminal block is out of the operating temperature range The operating temperature range varies with the type of detector If the detector terminal block is out of its operating temperature range take the measure to lower the temperature such as situating it so that it is not subjected to radiant heat The case where the Model ZR22 Detector is used 1 Stop the power to the converter 2 Remove the wiring from terminals 5 and 6 of the detector and measure the resistance between these terminals If the resistance value is out of the range of 1 to 1 6 KQO the cold junction temperature sensor is considered to be faulty Replace that tem perature sensor with a new one 3 If the resistance value is within the above range the cold junction temperature sensor seems to be normal Check whether or not the cable is broken or shorted out and whether the cable is securely connected to the terminals Also check that the resistance of the wiring between the converter and detector is 10Q or less 4 If there is no failure in the wiring the electrical circuits inside the converter may possibly f
28. Calibration Start chi Semi autocal p 1min div 21 00 0 98 21 0 02 RZ Baas F9 10E EPS Fig 9 10 Semi Auto Calibration Trend Graph 9 11 Starting Semi Auto Calibration by a Contact input 1 Confirm that on the Input contacts display Calibration Start is selected 2 In Measurement mode with the Basic display displayed when the contact input is detected then Calibration starts 3 To abort calibration touch the reject key door with arrow icon If you abort Span or Zero calibration then calibration time is skipped and stabilization settling time starts After that touch the reject key door with arrow icon again stabilization settling time is skipped and abort calibration completely If you touch the enter key during stabilization settling time abort calibration of corresponding channel and next channel calibration will be started 9 3 3 Starting AutoCalibration 9 12 No user action is required to start autocalibration Autocalibration starts at the preset time and is repeated at the preset interval AN Note Before starting Semi Auto calibration or AutoCalibration operate the calibration gas solenoid valves and adjust calibration gas flow to 600 60ml min for each sensor If you skip Hold time the output hold for output stabilization is released immedi ately after Calibration time ends However in this case if output hold under maintenance status is set to enable the output value is
29. General Solenoid valve 3 way valve for zero span gas switching General Stop valve General Zero gas cylinder Yokogawa recommended G7001ZC Pressure reducing valve Yokogawa recommended G7013XF or G7014XF Connection fitting Flowmeter R1 4 or 1 4NPT M 0 to 1 L min General General Needle valve For flow control Unnecessary if supplied with flowmeter General Air set Yokogawa recommended G7011XF E7040EL or G7004XF K9473XG Connection fitting Auxiliary ejector Equal tee connection fitting R1 4 or 1 4NPT M Yokogawa recommended E7046EC or E7046EN General R1 4 or 1 4NPT male General Needle valve Reducing nipple Note Parts marked with an asterisk are used when requored General parts are commercially available 4 10 Rc1 4 or 1 4NPT General R1 2 R1 4 or R1 2 1 4NPT General T4 2E eps IM 11M12D01 01E 4 Piping 4 2 2 Piping for the Calibration Gases The piping for the calibration gases should be installed between the calibration gas cylinders or instrument air source and the detectors with a flowmeter solenoid valves needle valves and stop valves for performing automatic calibration e Place the calibration gas cylinders in a place not exposed to direct sunlight as much as possible e g house in a gas unit case The cylinder should be equipped with a pressure reducing valve
30. I i i I i E ta 1 I i 7 I i toy ta td 4 4 Bee rRe e a r 4 p4 r I 1 1 1 i E E E pd I I 1 i I i Kop ea iI r r rtr d4 nO poe a 7q t ra rr tt I I I I 1 i k o CA td 1 I I 1 1 1 Moy ord i r li 4 41 i t l Tit S49 S45 PaaS Presa sae 1 i I i I i Ie iy ea Teil 1 i 1 I 1 i E a Tall roc cc Bee pip ee eos Be SS 7 S93 FS Pores ss 1 1 1 1 1 1 1 I 3 ee I 1 1 I 1 I I 1 f I 21 0 O2 OmV a Ton F x i ee p Span origin of calibration I I I i Se SS See ee aS 1 It 1 I EEEE OENE EE ee TE SEAE ee E O r b i 1 I I rill SS oo rtr t4 1 I eli 1 i pi pens oi Sena eee ae eles 4 nei een Sane Se ee ae Dress 1 yl 1 I T e a E E 1 I ryt 1 I E E ES E r i r H 4 r ra ra rrr 4 1 74 pa r 1 1 rat 1 1 Poros y 1 1 0 5 1 5 10 21 0 50 100 Oxygen concentration vol F9 1E EPS Figure 9 1 Oxygen concentration in a Measurement Gas vs Cell Voltage 21 O Equivalent The 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 theoretical Usually in practice a sensor shows a slight deviation from the theoretical value This is the reason why calibration is necessary To meet this require ment an analyzer calibration is conducted so that a calibration curve is obtained which corrects the deviation from the theoretical cell elect
31. Japan s Electrical Appliance and Material Safety Law Part number A1112EF 5 It is recommended that the fuse be replaced every two years even if it has not blown 6 Position the power switch to I ON and attach the front cover IM 11M12D01 01E 11 Inspection and Maintenance Cap Flat blade screwdriver FO Socket Fuse F11 6E EPS Fig 11 9 A WARNING If a replaced fuse blows out immediately there may be a problem in the internal circuit of the averaging converter the detector or the wiring between the averaging converter and the detector Carefully investigate the cause of fuse failure If the cause is unknown contact our service office A DANGER To work safely turn off the power to the averaging converter at the external breaker and position the power switch to O OFF before replacement After replacement position the power switch to I ON attach the front cover and then apply the power to the averaging converter 11 4 2 Cleaning Use a dry soft clean cloth for cleaning during inspection or maintenance IM 11M12D01 01E 11 13 11 5 Adding Channel Cards 11 14 Detectors can be additionally connected to the averaging converter by installing more channel cards Follow the procedure below to add a channel card lt Procedure gt 1 Before the procedure turn off the power to the averaging converter at the external breaker 2 Remove the front cover and position the power switch to
32. Manual Calibration Calibration with opening closing the valve of calibration gas in operation interactively with an LCD touch screen Validation Function Permits control room activation of zero span or midpoint gas concentrations without running an actual calibration Blowback Function Output through the contact in the set period and time Auto semi auto selectable IM 11M12D01 01E 2 13 Maintenance Functions Can operate updated data settings in daily operation and checking Display data settings calibration data settings blowback data settings current output loop check input output contact check Setup Functions Initial settings suit for the plant conditions when installing the converter Equipment settings current output data settings alarm data settings contact data settings other settings Self diagnosis This function diagnoses conditions of the converter or the probe and indicates when any abnormal condition occurs Password Functions Enter your password to operate the analyzer excepting data display Individual passwords can be set for maintenance and setup Display and Setting Content 2 14 Measuring Related Items Oxygen concentration vol O2 Display Items Cell e m f mV thermocouple e m f mV cold junction resistance Q cell temperature C cold junction temperature C span correction factor zero correction factor cell response time second cell condition in four grades
33. Moss green Munsell 2 5Y8 4 1 2 Finish Polyurethane corrosion resistant coating Gas Connection Rc1 4 or 1 4FNPT Wiring Connection G1 2 Pg13 5 M20 by 1 5 mm 1 2 NPT Installation Flange mounting Probe Mounting Angle Horizontal to vertically downward When the probe insertion length is 2 m or less can install at angles from horizontal to vertically downward When the probe insertion length is 2 5 or more mount vertically downward within 5 and if using a probe protector install at angles between horizontal and vertically downward within 5 Weight eee length of 0 4m approx 6 kg JIS 5K 65 approx 11 kg ANSI 150 4 Insertion length of 1 0m approx 8 kg JIS 5K 65 approx 13 kg ANSI 150 4 Insertion length of 1 5m approx 10 kg JIS 5K 65 approx 15 kg ANSI 150 4 Insertion length of 2 0m approx 12 kg JIS 5K 65 approx 17 kg ANSI 150 4 Insertion length of 3 0m approx 15 kg JIS 5K 65 approx 20 kg ANSI 150 4 Insertion length of 3 6 m approx 17 kg JIS 5K 65 approx 22 kg ANSI 150 4 Insertion length of 4 2 m approx 19 kg JIS 5K 65 approx 24 kg ANSI 150 4 Insertion length of 4 8 m approx 21 kg JIS 5K 65 approx 26 kg ANSI 150 4 Insertion length of 5 4m approx 23 kg JIS 5K 65 approx 28 kg ANSI 150 4 IM 11M12D01 01E Model and Codes Suffix code 2 Specifications Style S2 Description Separate type Zirconia Oxygen High Temperature Humidi
34. Purging requires the same piping and wiring as calibration and indication check 10 25 lt Setting procedure gt 1 From the basic panel display touch the Setup key to display the Execution Setup display 2 Select Commissioning and the Commissioning display appears 3 Select Others then Purging and a display such as Fig 10 30 is appears 4 Touch the Enter key and a numerical entry display appears Enter the desired purging time between 0 and 60 minutes If you enter 0 then purging is disabled Purging __ Cr Purging time 0 min Fig 10 30 Purging Time Setting Fig 10 31 Display During Purging lt Shipping time defaults gt At shipping time or after resetting parameters purging time is reset to 0 10 26 IM 11M12D01 01E 10 Other Functions 10 7 Parameter Initialization Parameter settings can be initialized to the factory default settings Initialization can be done for all parameters or for individual parameters The parameters that can be initial ized and their defaults are listed in Table 10 7 lt Initialization procedure gt 1 On the basic panel display touch the Setup key to display the Execution Setup display 2 Select Commissioning next Others then Defaults A display like Figure 10 32 1 appears 3 Select the desired item to be initialized then a display like Figure 10 32 3 appears Select Defaults start then initialization starts 4 When initialization completes then yo
35. This is to lower the temperature of a sample gas below 700 C When both the temperature and the pressure of a sample gas are high the temperature of the sample gas may not fall below 700 C before the gas reaches the detector On the other hand the temperature of a sample gas may drop too much and thus condensation develops in the high temperature probe ejector During wintertime it is recommended that the probe adapter be protected with an insulating material to prevent condensation e When a high temperature detector is used and blowback is required to eliminate dust accumulating in the probe of the high temperature probe adapter air supply piping for purging should be installed Note If a sample gas contains much dust e g in recovery boilers or cement kilns the probe is more likely to become clogged To eliminate this dust accumulation using air pressure piping is generally installed from an air source only when cleaning is performed Some cases however may need a permanent installation of the blowback piping See Subsection 4 1 5 for the installation of blowback piping IM 11M12D01 01E 4 1 1 4 Piping Parts Required for Piping in a System Using Flow Setting Units for Manual Calibration Detector Referring to Table 4 1 check that the parts required for your system are ready Table 4 1 Piping Location Part Description General purpose detector Calibration gas inlet Stop valve Yokogawa recommended L9852C
36. a basic panel display The cascade function may be used to view each trend line of channels clearly in the trend graph display The function offsets the axes so that trend lines do not overlap The following describes graph setup 10 2 1 Trend Graph Screen Figure 10 5 shows how the Trend Graph is displayed Basic panel display Trend graph Cascade display 1 2 3 4 c 8lalblc 25 0 02 30min div 30min div 02 Touch Touch anywhere a anywhere in graph l in graph Graph channel select Crch1 Ch5 Avea Graph channel select El Ch2 Ch6 Ave b Ch3 Ch7 Ave c Ch4 Ch8 F10 5E eps Figure 10 5 Displaying Trend Graph Display IM 11M12D01 01E 10 Other Functions 10 2 2 Time Axis of Trend Graph IM 11M12D01 01E The time axis of the trend graph is determined by the sampling interval For each channel and for each division on the time axis 60 data items can be plotted If data is sampled at 10 second intervals then each division represents 60 x 10 600 seconds or 10 minutes see Figure 10 6 The sampling interval can be set in the range 1 to 30 seconds If it is set to 1 second then trend graph time span is 60 x 1 x 5 300 seconds 5 minutes and if set to 30 seconds then trend graph time span is 60 x 30 x 5 9000 seconds 50 minutes Correspondence Channel no to color 1 2 3 4 5 6 7 8 a b
37. aetna eee esa ene eee aa e 3 15 Bde MOUSE G ep tosses tre EE ccs sods EEE E E EEEE 3 15 ise 4 1 Piping for a System Using Flow Setting Units for Manual Calibration 4 1 4 1 1 Parts Required for Piping in a System Using Flow Setting Units for Manual Calibration sisscsoisersessionser iresi iie isas 4 3 4 1 2 Piping for the Calibration Gases essesessseeeesseesseeesrereseerssreresreerereeeeees 4 3 4 1 3 Piping for the Reference Gas eseseeesseessseeeesresrrrrerrerssrereseeresreseereereees 4 4 4 1 4 Piping to the High Temperature Probe Adapter sesssessesssessesseseseseeee 4 4 4 1 35 Pipine for BlOWDaCK eire 5 c45 cesses sends ve kes t oieee eer EEE Eee Peno eSEE NEn ed 4 6 4 1 6 Piping for Indication Check oo eee cee eeeceeeeeeeeseeesecaeecaecseeaeesaeenees 4 7 4 1 7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs 4 8 4 2 Piping for a System to Perform Automatic Calibration 0 eee 4 9 4 2 1 Parts Required for Piping in a System to Perform Automatic Cala ration a pistes cases rn E aE s E E EE EE EE E AE E causes 4 10 4 2 2 Piping for the Calibration Gases eee cee cee ceseeeeeeseeeeceseeeeeeneeees 4 11 4 2 3 Piping for the Reference Gas oo eee ceeceseeeeceseeeeceeeeeeseaeeeeseneeees 4 12 4 2 4 Piping to the High Temperature Probe Adapter cceeeeeeeeeseeeenees 4 12 4 2 5 Piping for Blowback s sisien sensein 4 12 4 2 6 Piping for Indication Check 00 eee eee ceseeeeceeceee
38. alphabetic character entry panel display first appears If you press any numeral key 0 to 9 the current display then changes to the numeric value entry panel display enabling you to enter numeric values If you press the other key the current display then changes to the code entry display enabling you to enter codes These displays alternate between the three Figure 6 17 shows the relationship between these three displays Three alphabetic characters and three codes are assigned for each individual switch If the alphabetic character key is pressed and held three characters appear in turn Move the cursor to the desired character and release the key to enter it If an incorrect charac ter is entered move the cursor to re enter the characters The following shows an example of entering abc 123 Operation Display Press the ABC key once Press and hold the ABC key AA A B C Release the ABC key when the character B AB appears in the cursor position Enter the character C in the same manner ABC as above Press the other key Press and hold the amp key and enter ABC Then press the 0 9 key Enter the numeric characters 1 2 and 3 in turn ABC 123 Press the Enter key to complete the entry are Enter your password FA your password Entef your password T Cie Ie Figure 6 17 Text Entry Display F7 5E EPS 6 11 6 3 ZA8F Flow Setting Unit Reference gas flow set
39. averaging converter is heavy 100 115 VAC version approx 13 kg 230 VAC version approx 25 kg so needs to be installed on a wall or construction strong enough to support Installation in an Instrument Panel When installing the averaging converter in an instrument panel operability maintainability and environmental resistance should be considered 1 Installation Space and Relationship to Peripheral Devices Follow the instructions below to determine the positions of the averaging converter and peripheral devices Do not place heat generating devices in close proximity of the averaging converter specially avoid a place under the averaging converter Do not place power related devices such as transformers or electromagnetic switches in close proximity of the averaging converter Segregate wiring ducts for signal lines and those for power lines and do not place in close proximity Figure 3 8 shows the requirements for the mounting holes for the averaging converter See Section 2 4 for the dimensions of the averaging converter and maintenance clearance IM 11M12D01 01E 3 Installation Unit mm 6 M5 screws Uy 300 267 Note Dimensions in inches are given in parentheses F3302 EPS Figure 3 8 Mounting holes 2 Preventing Excessive Temperature Rise in an Instrument Panel Use a cooling method such as one of those shown in Figure 3 9 if there is a danger of the temperature inside an instrument panel exc
40. back start and touch the Enter key Blowback is performed starting from Channel 1 2 If a display like Figure 10 27 appears then mode is set to No function Refer to Section 10 5 1 Mode and change the mode appropriately 3 During blowback a display like Figure 10 28 is displayed with the affected channel number blinking 4 To abort blowback you can touch the Reject key to skip the blowback time and enter the hold time If you touch the Enter key here then blowback for the next channel starts if you touch the Reject key then hold time is skipped and you revert to measurement mode Blow back Blow back Blow back mode is Chi Ch5 No function 9 19 02 21 1 02 or Not set contact Ch2 Ch 2 1 9 02 2 0 7 02 Ch3 Ch7 2 0 3 02 2 0 3 02 Ch4 Ch8 2 1 7 02 1 9 6 02 BLOW TIME Fig 10 27 No Function Disabled Fig 10 28 Performing blowback Starting Blowback by a Contact input 1 Confirm that on the Input contacts display Blow back start is selected for the contact to be used to start blowback 2 In measurement mode with the basic panel display displayed when the contact input is detected then blowback starts 3 To abort blowback touch the Reject key Touch the Reject key to skip the blowback time and enter the hold time If you touch the Reject key again during hold time then hold time is skipped and you revert to the basic panel display if instead you touch the Enter key then blowback for the next c
41. be added in the 230 VAC version Cable for Expansion Power Supply F11 11E eps Fig 11 11 11 15 11 7 Replacing Limited Life Components The following components have limited life time It is recommended that these compo nents be replaced at an approximate interval of 5 years 1 LCD panel 2 Switching power supply 2 types located on the left side of the frame not visible from outside For replacement of these components contact our service office When the control card or basic power supply unit breaks down also contact our service office for repair 11 16 IM 11M12D01 01E 12 Troubleshooting 12 Troubleshooting This chapter describes errors and alarms detected by the self diagnostics function of the averaging converter It also explains inspections and remedies when other problems occur 12 1 Displays and Remedies When Errors Occur 12 1 1 Error Types Error Code An error occurs when an abnormality is detected in the detector or averaging converter e g in the cell sensor detector heater or internal circuits of the averaging converter An error message and error contact will not be canceled even after the cause of the error has been removed Follow the procedure below to cancel an error An individual channel error can be canceled by using the hot swap function i e by turning off on the power to the channel where the error is occurring An system e
42. been cleaned away or the cell replaced Alarm status and previous data are cleared b If you clear the calibration history then alarm status and past calibration data is also cleared c If you disable alarm functions then alarm status is cleared but calibration history is not cleared 4 What to do when an alarm occurs It is possible that the detector tip filter is clogged Refer to Sec 11 Inspection and Maintenance on Maintenance for cleaning procedure IM 11M12D01 01E 12 Troubleshooting 5 Alarm setting a From the basic screen touch the setup key to display the Execution Setup screen b Select Setup to display the Setup screen c Select Other the Asymmetry alarm The screen below is displayed d From the Enable Disable window select Enable and touch Enter Asymmetry alarm See Manual for details l F Asymmetry al kd Enable v F12 13E EPS Enter Fig 12 13 Asymmetry alarm screen Ay CAUTION For these alarm functions to be effective first enable them then calibrate three times at intervals of at least 5 days After that the function will be effective 9 Alarm 9 Inside temperature alarm IM 11M12D01 01E Using the averaging converter in the ambient temperature of more than 50 C may cause a failure in internal electronic circuit An IC temperature sensor is installed inside the control card of the averaging converter and monitors the internal temperatu
43. blowback time and hold time on a channel its indi vidual analog output remains held at a value preset in the Output Hold Setup and 10 Other Functions excluded from averaging group calculations After the hold time has elapsed blowback is started on the next channel Blowback start in Ch1 blowback time Ch2 blowback time Ch1 output hold Ch2 output hold Average outpu SV Ch1 contact SV Ch2 contact Solenoid valve switching IM 11M12D01 01E Ch1 output hold Blowback start On Blowback time i Hold time 1 removed from Average Fig 10 26 Blowback Timing lt Default setting gt Blowback time Ch2 output hold Off F10 26E eps I Hold time I j I Blowback parameters are set as shown in Table 10 6 prior factory shipment or after data initializ ation Table 10 6 Blowback Default Setting Item Init Setting Mode No function disabled Hold time 3 minutes 00 second Blowback time 3 minutes 00 second Interv al Start date 30 day 00 hour 01 01 01 Start time 00 00 T10 6E eps 10 23 10 5 5 Performing Blowback 10 5 5 1 Semi Auto Blowback Semi auto blowback can be started from the display or by an external contact input lt Procedure gt Starting blowback from the display 1 On the basic panel display touch the Setup key to display the Execution Setup display Select Blowback Next select Blow
44. cf Supply Unit PS cee SE ASE See Se Ss Carries heater terminals Ab Hh oP I er MP AS sAr ste i ofe fe a ja e l ja po and contact terminals for co l a l s E a E e E n E fey CH5 to CH8 N E amp FA an 12 S ae LI r test 11 ri aA 000000000000000 L 1 O00000000000000 pgagagag gagag 299900999990999 cogggg gael O00000000000000 B O00000000000000 2 iw QO0000000000000 O00000000000000 Al O00000000000000 oO00000000000000 Al 000000000000000 OD O00000000000000 f O00000000000000 La h Ga i oe Ground Terminal Power Switch Cable Shield Ground Terminals Main Power Supply External Protective oh N G connected to internal protective ground terminal by jumper plate Internal protective ground terminal Figure 6 3 Components and Function of AV550G Touchpanel Switch Operations 6 2 2 1 Panels and Switches IM 11M12D01 01E Protection Covers for Heater Terminals The averaging converter uses touchpanel switches which can be operated by just touching the panel display The display viewed upon power up or during oxygen concentration measurement varies depending on the number of channel cards installed in an averaging converter Data of 4 channels will be displayed if 1 to 4 channel cards are installed If more than 4 channel cards are installed data of 8 channels will be displayed Even if the number of channel cards is
45. channel are independently settable Ranges are switched by contact input Contact OFF results in Range 1 and contact ON results in range 2 For details refer to Sec 8 5 Setting Contact Inputs Shipping time default is for each range to be set to 0 to 25 Oz The ratio of the maximum range setting to the minimun is restricted as described in Sec 8 1 Setting Analog Outputs 1 Touch the Setup key to switch to the Execution Setup display 2 From the Commissioning display select mA output setup then Set Range See Fig 7 6 3 Use lt 4 and P keys to select the channel 4 Set Min O2 concentration corresponding to 4 mA output then set Max O2 concentration corresponding to 20 mA output select then touch Enter key 5 The numeric data entry display shown in Fig 7 7 appears enter the desired oxygen concentration setting To set 10 Oz input 010 and touch Enter 6 As necessary repeat for each averaging output a b and c of other channels New value 025 02 LLE moon max 25 02 e oaa E CLIE Fig 7 6 Current output range Fig 7 7 Numerical entry 7 7 7 8 Averaging Group Setting This instrument can determine oxygen concentration average for three averaging groups a b and c a and b can each be arbitrary channel groupings and the corresponding averages are output c output is a b 2 Select the groupings for a and b as per the procedure below 1 Touch the Se
46. channel cards is installed Send output signals for calculations autocalibration Displays data and allows Orange flashing Calibration in progress individual oxygen concentrations and display functions interactive touch screen Red continuous Error condition operation Channel Slot Covers Frame Covers unused channel slots OAR f Basic Power Supply Unit Carries heater terminals ep is 1 and contact terminals for e j CH1 to CH4 on he Ui JE l 1 i l Expansion Power IEE To 4 TO OTF A ei 4 iF 4 OTF Nie ee Calg Chee ea
47. constant after Calibration time ends If stabilization time is skipped and if calibration gas still remains in the sensor the gas affect the accuracy of the output IM 11M12D01 01E 10 Other Functions 10 Other Functions 10 1 Display 10 1 1 Cell Voltage IM 11M12D01 01E On the basic panel display touch the Detailed Data key to view detailed operational data see Figure 10 1 On the detailed data display you can scroll up down a page with the V and A keys and you can switch to another channel with the lt or key A detailed data display has 12 pages screens per channel The following describes each data item q chi gt Cell voltage 0 9mV Thermo voltage 29 4mV C J resistance 1170 20 Cell temperature 750 C C J temperature 43 C Pa wW i Figure 10 1 Detailed Data Display F03 cE EPS The cell sensor voltage will be an index to determine the amount of degradation of the sensor The cell voltage corresponds to the oxygen concentration currently being measured If the indicated voltage approximates the ideal value corresponding to the measured oxygen concentration the sensor will be assumed to be normal The ideal value of the cell voltage E when the oxygen concentration measurement temperature is controlled at 750 C may be expressed mathematically by E 50 74 log Px Pa mV where Px Oxygen concentration in the measured gas Pa Oxygen concentration in the reference gas
48. displayed at the bottom of the display against the certified concentration of zero gas to check for any discrepancy or error Ch2 Manual ind check 1min div al Fig 10 17 Zero Indication Check 13 If you touch the Enter key then zero gas check ends and you are returned to the Check gas selection display Close the zero gas flow control valve and tighten the lock nut used to prevent it from loosening during measurement 14 Select Third gas ind check and touch the Enter key 15 Open the third gas flow control valve and adjust flow rate to 600 60 ml min 16 Select Start ind check and touch the Enter key An oxygen concentration graph like Figure 10 18 is displayed and CHK TIME status mark flashes Wait for the graph measured value trace to stabilize Compare the measured third gas concentra tion displayed at the lower left of the display against the certified concentration of third gas to check for any discrepancy or error 17 If you touch the Enter key then third gas check ends and you are returned to the Check gas selection display Close the third gas flow control valve and tighten the lock nut used to prevent it from loosening during measurement 18 Select End An oxygen concentration graph Figure 10 19 is displayed and hold time begins After the preset time has elapsed then the display reverts to channel select If you touch the Enter key during hold time then hold time is skipped IM
49. does not agree with the value of the zero gas concentration set in Calibration Setup Otherwise the span gas is used as the zero gas 2 The flow rate of the zero gas is out of the specified range 600 ml min 60 ml min 3 The sensor assembly is damaged and so cell voltage is not normal lt Locating cause of failure and countermeasures gt 1 Check that the following have been set up correctly If not correct them Then recalibrate the channel Check the preset zero gas concentration on the Calibration Setup display The dis played concentration value has agreed with the concentration of the zero gas actually used The piping for calibration gases has been constructed so that the zero gas does not leak 2 If the alarm is not generated during the recalibration improper calibration conditions are considered as the cause of the alarm generated in the previous calibration In this case no particular restoration is necessary 3 If the alarm is generated again during the recalibration deterioration of or damage to the sensor assembly is considered as the cause of the alarm It is necessary to replace the cell with a new one Before replacement carry out the following Check the cell voltages when the zero gas and span gas are introduced When the system is configured for automatic calibration let the calibration gas flow from the Indication Check display and measure the voltage between terminals CELL and CELL on the channel
50. for span gas is 21 0 O2 1 Touch the Setup key to switch to the Execution Setup display 2 Select Maintenance to display the Maintenance display 3 From the Maintenance display select Calibration Settings 4 Select Zero Gas Concentration and touch Enter key to display the numerical entry display Enter the oxygen concentration of the zero gas you plan to use To enter a concentration of 0 98 O2 enter 00098 5 Select and set the Span Gas in the same manner Calibration setup CpMode Auto Points Span Zero Zero gas conc 0 98 Span gas conc 21 00 Timing Cal history initialize F7 9E EPS Fig 7 9 Calibration Setting A Note If instrument air is used for the span gas dehumidify the air by cooling to the dew point of 20 C and remove any oil mist or dust 7 9 7 9 2 Performing Manual Calibration 1 Confirm that the zero gas flow setting valve is fully closed then adjust supply gas pressure to measurement gas pressure 50kPa but a maximum of 300 kPa using the valve on the gas cylinder 2 Touch Setup on the touchdisplay to switch to the Execution Setup display 3 Touch Calibration and the Calibration display appears 4 Touch Manual calibration then the Enter key The Channel Select display shown in Fig 7 10 appears Manual cal Select calibration channel e CP Chi Ch5 Ch2 Ch 6 Ch3 Ch7 cCh4 Ch8 m 3
51. force mV Previous zero gas data Corrected calibration curve theoretical calibration curve Span origin 21 0 pl 0 51 Span gas concentration Oxygen concentration percent oxygen by volume Zero point correction factor B A x 100 percent Correctable range 100 30 percent Span correction factor C A x 100 percent Correctable range 0 18 percent F9 3E EPS Figure 9 3 Calculation of a One point Calibration Curve and Correction Factors using a Span Gas IM 11M12D01 01E 9 3 9 1 4 Characteristic Data from a Sensor Measured During Calibration During calibration calibration data and sensor status data listed below are acquired However if the calibration is not properly conducted an error occurs in automatic or semi automatic calibration these data are not collected in the current calibration These data can be observed by selecting the detailed data display key from the basic panel display For an explanation and the operating procedures of individual data consult Section 10 1 1 Detailed Display 1 Record of span correction factor Recorded the past ten span correction factors 2 Record of zero correction factors Recorded the past ten zero correction factors 3 Response time You can monitor the response time provided that a two point calibration has been done in semi automatic or automatic calibration 4 Cell s internal resistance The cell s internal resistance gradually increase
52. from 0 to 5 vol O to 0 to 25 vol O range Sample gas pressure within 4 9 kPa 3 Maximum value of range setting from 0 to 25 vol O to 0 to 50 vol O range Sample gas pressure within 0 49 kPa 5 Maximum value of range setting from 0 to 50 vol O to 0 to 100 vol O range Sample gas pressure within 0 49 kPa Excluding the first two weeks in use Excluding the case where the reference air flow is natural convection Both zero and span 2 Maximum value of range setting month Response Time Response of 90 within 5 seconds Measured from when gas is introduced from calibration gas inlet and analog output start changing IM 11M12D01 01E 2 Specifications 2 2 General use Separate type Detector and Related Equipment General use separate type detector ZR22G can be used in combination with the probe protector ZO21R L see Section 2 2 2 2 2 1 ZR22G General use Separate type Detector Sample Gas Temperature 0 to 700 C Probe only It is necessary to mount the cell using Inconel cell bolts when the temperature is 600 C or greater 700 to 1400 C with High Temperature Probe Adapter For high temperature sample gas apply 0 15 m length probe and High tempera ture Probe Adapter ZO21P H Sample Gas Pressure 5 to 250 kPa When the pressure in the furnace exceeds 3 kPa it is recommended that you compensate for this pressure When the pressure in the furnace exceeds 5 kPa you must perform pressure c
53. is displayed and a CHK TIME status mark blinks Watch the trend graph and confirm that the measured value stabilizes Compare the measure span gas concentration displayed at the bottom of the display against the certified concentration of span gas to check for any discrepancy or error ch2 Manual ind check Open span gas valve Set flow span gas to 600ml min a CP Start ind check Cancel ind check d at 3 g F10 15E EPS Fig 10 15 Manual Indication Check Start IM 11M12D01 01E 10 15 10 16 Channel No under calibration Ch2 Manual ind check 1min div Setting value of i span gas concentration Setting value of zero gas concentration 0 98 20 9 02 Hein Gaal L Actual measurement value F10 16E EPS Fig 10 16 Span Indication Check 9 If you touch the Enter key then span gas check ends and you are returned to the Check gas selection display Close the span gas flow control valve and tighten the lock nut used to prevent it from loosening during measurement 10 Select Zero gas ind check and touch the Enter key 11 Open the zero gas flow control valve and adjust flow rate to 600 60 ml min 12 Select Start ind check and touch the Enter key An oxygen concentration graph like Figure 10 17 is displayed and CHK TIME status mark flashes Wait for the graph measured value trace to stabilize Compare the measured zero gas concentra tion
54. perform a loopback check to check if you can output a specified current from the analog output terminals 1 Touch Setup on the touchdisplay to switch to the Execution Setup display 2 Select Maintenance and touch the Enter key 3 From the Maintenance display select mA output loop check and touch the Enter key 4 The mA output loop check channel select display appears Fig 7 17 CPCh1 Ave a L Ch2 Ave b Ch3 Ave c Fig 7 17 Analog output select 5 Select the Analog output to perform Loop check on and touch the Enter key 6 The numerical entry display appears Set output current somewhere in the range 4 to 20 mA Touching the Entry key outputs this current value 7 Touching the Escape key door with arrow from the numerical entry display returns you to the mA output loop check channel select display 8 You can then perform a loop check on other analog outputs in the same manner 7 13 7 11 Checking Operation of Contact Input Contact Output After wiring the cables you can perform a contact I O check to display the status of contact inputs and to check the operation of contact outputs including contact outputs to operate solenoid valves during autocalibration 7 11 1 Contact Output Operation Check 1 Touch Setup on the touchdisplay to switch to the Execution Setup display 2 Select Maintenance and touch the Enter key 3 From the Maintenance display select Contact check an
55. rir estes iets tht E E EE E thi E E E 10 1 TOW DEE EA TAAI Ki se E AAEE EAEE E EEEE EEE EENE 10 1 10 1 2 Thermocouple Voltage eee ceceeceeceeeeeeeeeeecaeeseecseesaecaecaecneenaes 10 2 10 1 3 Cold Junction Resistance C J Voltage eeeceeeeesseeeneeceeeecneeeeeeeeee 10 2 10 1 4 Cell temperature sissien spss s aaa E aaa ai aE 10 2 10 1 5 C J Temperature n ee tiie E A E A ES 10 2 10 1 6 Span gas and Zero gas Correction Ratios essseeeesseereeeereesereerrsreseees 10 2 10 1 7 Cell Response TIME essssccsscessctsesssssasessscssceapssisessnonessstachestossessasssetsesvses 10 3 10 1 8 Robustness of a Cell 0 cee ceceseeeeceseeeeeeseeeeeeseeesecaeeeaecsaesaeenaes 10 3 10 1 9 Cell s Internal Resistance n eriseeria 10 3 10 1 10 Recommended Next Calibration Date 0 ee ceeeeecseetsecneenseenees 10 4 10 1 11 Heater On Time Ratio cece ee renke o Enae OE E E 10 4 IKOG 2 VAS oe E EA OE E E EE EEEE EEEE 10 4 10 1 13 Ch card Rev Ctrl card Rev cccccccccsscccccecsessceceeceessseceeeeesenseeeeeeees 10 5 10 1 14 Maximum Oxygen Concentration ssseseeesseeesseesrssestreseerrsreerereereses 10 5 10 1 15 Minimum Oxygen Concentration sessseeeesseresesresrsresrrresrrerssrerrsreresre 10 5 10 1 16 Average Oxygen Concentration cece ee eeeeceseeeeceseeeeeceecaecnseeaeenaes 10 5 10 1 17 History of Calibration Time 00 eee ee ceeeeeeeceeeeecseeaeceesaeeneenaes 10 5 10 1 18 Internal Temperature Alarm Logging cece eee eeees
56. sensor can be broken and never re useful To prevent the above nonconformity take the following action when stopping operation 1 If possible keep on supplying the power to converter and flowing reference air to the sensor If impossible to do the above remove the detector 2 If impossible to supply the power or remove the detector at least keep on flowing air at 600m1 min into the calibration gas pipe lt Restarting Operation gt When restarting operation be sure to flow air for 5 10 minutes at 600ml min into the calibration gas pipe before supplying the power to converter This is not necessary if the purging is specified and the detector is configured so that the calibration gas is introduced before warm up 11 11 11 4 Inspection and Maintenance of the Averaging Con The averaging converter does not require routine inspection and maintenance This section describes inspections performed at the time of periodic maintenance service part replacement and addition of channel cards 11 4 1 Fuse Replacement 11 12 The averaging converter has fuses for detector heaters of channels CH1 to CH4 in the basic power supply unit and fuses for detector heaters of channels CH5 to CH8 in the expansion power supply unit Fuses are inserted in both poles of the heater of each channel When the fuse blows out follow the procedure below to replace it
57. the detector is made of ceramic zirconia Do not drop the detector as impact will damage it e A gasket should be used between the flanges to prevent gas leakage The gasket material should be heatproof and corrosion proof suited to the characteristics of the measured gas The following should be taken into consideration when mounting the general use detector lt General use detector gt 1 Make sure that the cell mounting screws four at the probe tip are not loose If a dust filter see Section 2 6 1 is used make sure it is properly attached to the detector Refer to Section 3 1 4 for installation of the dust filter 2 Where the detector is mounted horizontally the calibration gas inlet and the refer ence gas inlet should face downward IM 11M12D01 01E 3 Installation 3 1 4 Installation of the Dust Filter Part No K9471UA etc Ay CAUTION e The dust filter is used to protect the Zirconia sensor from corrosive dust or a high concentration of dust such as in utility boilers and concrete kilns If a filter is used in combustion systems other than these it may have adverse effects such as response delay These combustion conditions should be examined carefully before using a filter e The dust filter requires gas flow of 1 m sec or faster at the front surface of the filter K9471UA When you specify option code F1 the detector is shipped with the dust filter mounted Follow this procedure replace
58. the power to the detector heater is turned off for safety during continuous input of the contact signal The power to the heater will be turned on again after the contact input is removed and then warm up will start After the warm up the averaging converter will go in measurement mode automati cally 7 Alarm 7 Calibration gas pressure low alarm When calibration gas pressure low is assigned to a contact input calibration and indication check are not performed during the input of the contact signal If the averag ing converter receives this contact input during the calibration or indication check process it will abort the ongoing calibration or indication check After the contact input is removed subsequent calibrations and indication checks will be enabled 8 Alarm 8 Asymmetry alarm A CAUTION This function alone is not sufficient to ensure the accuracy and reliability of this instrument Read the following thoroughly and use it as just one of several trouble shooting tools Note that shipping time default is for this function to be disabled 1 Cause In general sensor aging causes a change in the slope of the compensation line If the detector tip is clogged however this can cause a shift in both zero and span calibration results Such an offset can be compensated for by zero shift alone This alarm occurs if when the last two calibration results are compared the shift indicates such a tip clogging pressure related ef
59. the rear for power wiring e g power cables detector heater wires and wiring for solenoid valve contacts and other contact outputs For signal wiring e g detector signal lines and analog output signal lines use holes near the front If more than 30 cables are used and thus more than one cable has to be passed through one wiring hole do not allow signal lines and power lines to pass the same hole Also in the averaging converter the signal lines and power lines should be routed so they can avoid contact and interference A grommet is attached as standard to the wiring hole of the averaging converter An optional cable gland is available When a cable gland is not used make a cable hole in a grommet Wiring Connections Applicable Cable Hole 30 holes 17 mm maximum for grommet 6 to 12 mm for cable gland optional External Wiring Connection Terminals of the Averaging Converter Control Card Averaged analog outputs 2 I Ave c Contact input Power L The connection diagram of the averaging converter is shown in Figure 5 3 The terminal numbers are indicated on the converter Care should be taken to make the wiring connections correctly Channel Card CH1 If 230 V AC is selected channel cards are expandable up to 4 supply
60. time To set an auto return time of one hour enter 060 3 If you set 0 then the auto return function does not operate lt Default setting gt The Auto return time is set to 0 prior factory shipment or after data initialization 10 3 2 Selecting Language You can select a display language from among English Japanese German and French The display language is set to the one specified in the purchase order when the analyzer is shipped from the factory lt Setting procedure gt 1 On the basic panel display touch the Setup key to display the Execution Setup display 2 Select Maintenance then Display setup 3 Select Language and the dropdown selection Figure 10 7 allows you to select the desired language Display setup Trend graph Auto return time 0 min Cp Languag aire i Lcd auto Japanese 0 min p Display c Deutsch Tag name Tran galk F60E EPS Figure 10 7 Selecting the Display Language IM 11M12D01 01E 10 9 10 3 3 LCD Auto Off If no keys are touched during a preset time interval then the display and backlight turn off They are turned back on 1 If you touch the screen 2 If an error or alarm occurs lt Setting procedure gt 1 From Display setup select Lcd auto off time 2 Touch the Enter key and the numerical entry display appears To set an Led auto off time of one hour enter 060 3 You can enter a value in the range 0 to 255 minutes If you set 0 t
61. to contact output You can allocate multiple conditions to a contact output then if any of the conditions is true there will be contact output Contacti Alarms Cp Low Low alarm ON Low alarm 2 g High alarm OFF High High alarm OFF Cal alarm OFF Cal gas low OFF Proc gas alarm OFF gt Error OFF 4 Internal temp OFF ae z g M m 5 a Fig 8 14 Alarm Function Allocation lt Default setting gt Contact output setting are set to defaults in Table 8 5 prior factory shipment or after data initialization Table 8 5 Contact function initial defaults Contact Contact Contact Contact tem output 1 output 2 output 3 output 4 High High Alarm High Alarm ON Low Alarm ON Low Low Alarm CAL coeff Alarm CAL gas pressure low Process gas alarm Temperature alarm Error Under warmup Output range switch Under calibration Under indication check Under maintenance Blowback 3rd check gas Normally Closed Open Other status T8 5E eps IM 11M12D01 01E 8 Detailed Data Setting 8 4 Assigning Contact Inputs IM 11M12D01 01E External contact inputs allow remote operation of the following functions shown in Table 8 6 Table 8 6 Contact Input Functions Item Function Output Range Switching While contact signal is applied output range 2 is selected and Range is dis
62. valves during autocalibration 1 From the Contact check display of Fig 7 18 select Solenoid valve contacts From the corresponding Solenoid valve contact select display of Fig 7 20 select the solenoid to check To check the Autocalibration gas switching valve select Com Touching the Enter key opens the Span Span valve open Zero Zero valve open selection window Selecting an output and touching Enter allows you to test Open Close the corresponding solenoid valve 2 To check a channel switching valve select its channel Ch1 through Ch8 and touch Enter to open the OFF valve closed ON valve open selection window Selecting an output and touching Enter allows you to test Open Close the corre sponding solenoid valve A Note You cannot check a Channel Select valve if the corresponding Channel unit is not installed Solenoid valve contacts Fer Chi Fan gt Ch2 OFF al Ch3 OFF Ls Ch4 OFF Ch5 OFF Ch6 OFF Ch7 OFF Ch8 OFF F30E EPS Fig 7 20 Solenoid valve contact select 7 11 3 Checking Contact Inputs 1 From the Contact check display of Fig 7 18 select Input contacts then touch the Enter key The display of Fig 7 21 appears 2 The input contact status Open or Closed is displayed in real time Input contacts Input contact 1 Open Input contact 2 Open F31E EPS Fig 7 21 Contact input check IM 11M1
63. 0 1 5 2 0 2 5 or 3 0 Dust fi 3 6 4 2 4 8 or 5 4 m ust filter mounting screw Calibration gas pipe opening Contact Metal O ring Pipe support U shaped pipe Bolt F0601e eps Washer or plain washer Figure 6 1 General use Detector standard type IM 11M12D01 01E 6 1 6 1 2 High Temperature Detector Model ZR22G 015 Sample gas outlet When a negative measurement gas pressure is used connect the auxiliary ejector assembly When the measurement gas is high temperature and high pressure and does not fall below 700 C connect a pressure control valve e g a needle valve Refer to Section 3 2 2 Separate type High temperature Detector ZR22G 015 When the temperature of the measurement gas is between 700 and 1400 C mount this detector Flange with a ZO21P H probe adapter Selectable from JIS standards a oe High temperature Probe Adapter ZO21P H The probe is made of either SUS 310S or silicon carbide SiC Its length is either 1 0 m or 1 5 m When using an SiC probe mount it vertically downward or ANSI standards F0602e eps Figure 6 2 High temperature Detector IM 11M12D01 01E 6 2 AV550G Averaging Converter 6 2 1 6 2 2 Components and Function Control Card Controls averaging Touch Screen Display Status Display Lamps Green continuous Channel card is active Orange continuous Alarm condition 6 Components Channel Cards Specified number of
64. 02 01E Subject to change without notice 3rd Edition Sep 2005 YK Needle Valve Yokogawa Electric Corporation Customer Model ZO21P H Maintenance Zirconia Oxygen Analyzer Parts List High Temperature Probe Adaptor 4 5 6 ZR22G Item Parts No Qty Description 1 E7046AL 1 Probe SiC L 1 0m E7046BB 1 Probe SiC L 1 5m E7046AP 1 Probe SUS L 1 0m E7046AQ 1 Probe SUS L 1 5m 2 E7046AD 1 Probe Adaptor for JIS 5K 50 FF E7046CB 1 Probe Adaptor for ANSI CLASS150 4 RF 1 Probe Adaptor for DIN PN10 DN50 A 1 Probe Adaptor for JIS 10K 100 FF 1 Probe Adaptor for JIS 10K 80 FF 1 Probe Adaptor for JIS 10K 65 FF 1 Probe Adaptor for ANSI CLASS150 3 RF 1 Probe Adaptor for ANSI CLASS150 2 1 2 RF 1 Probe Adaptor for JPI CLASS150 4 RF 1 Probe Adaptor for JPI CLASS150 3 RF 3 E7046AC 1 Gasket 4 E7046AB 1 Plate 5 G7030YC 4 Bolt 6 Y9800WU 8 Washer 7 G7073XL 1 Gasket 8 Y9630RU 4 Bolt 9 Y9121BU 4 Nut 10 Y9120WU 4 Washer YOKOG AWA e All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMIPL 11M03B01 10E 1st Edition Dec 2000 YK Yokogawa Electric Corporation 5th Edition Sept 2001 YK Customer E7046EC E7046EN Maintenance Zirconia Oxygen Analyzer Parts List Auxiliary Ejector for Model ZO21P H 1 2 4 5 6 T Item Parts No Qty Description 1 E7046EC 1 Auxiliary Ejector Connection Rce1 4 E7046EN 1 Auxiliary Eject
65. 1 2001 CSA C22 2 No 1010 1 certified UL 61010B 1 certified EMC Conforms to EN 61326 2002 AS NZS CISPR II Maximum Distance between Probe and Converter Conductor two way resistance must be 100 or less when a 1 25mm cable or equivalent is used 300 m or less Construction Indoor installation Wiring Connection Number of wire holes 30 pieces Wire hole size 17 mm for grommet 6 to 12 mm for cable gland option Installation Wall mounting Case Aluminum alloy 100 V type Paint Color Silver Gray Munsell 3 2PB7 4 1 2 Finish Polyurethane corrosion resistance coating Weight Approx 13kg 100 V type 2 4 2 Functions Display Functions Value Display Displays values of the measured oxygen concentration etc Graph Display Displays trends of measured oxygen concentration Data Display Displays various useful data for maintenance such as cell temperature reference junction temperature maximum minimum oxygen concentration or the like Status Message Indicates an alarm or error occurrence with flashing of the corresponding icon Indicates status such as warming up calibrating or the like by icon Alarm Error Display Displays alarms such as Abnormal cell e m f when any such status occurs Calibration functions Auto Calibration It calibrates automatically at specified intervals Semi auto Calibration Input calibration direction on the touch screen or contact then it calibrates automatically afterwards
66. 11 3 2 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 Use a rod 2 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 shaped pipe The pipe can be rinsed with water However it should be dried out thoroughly before reassembly 5 Restore all components you removed for cleaning Follow Section 11 3 2 to restore all components in their original positions Be sure to replace the O ring s with new ones Exploded view of components Calibration gas tube Rod with outside diameter of 2 to 2 5 mm F11 A1E EPS Figure 11 4 Cleaning the Calibration Gas Tube 11 4 IM 11M12D01 01E 11 Inspection and Maintenance 11 3 3 Replacing the Sensor Assembly IM 11M12D01 01E A CAUTION When replacing the sensor assembly allow ample time for the sensor to cool it operates at very high temperature 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 sati
67. 11M12D01 01E 10 Other Functions Ch2 Manual ind check Ch2 Manual ind check 1min div 1min div al 0 98 9 05 02 KaLe L Fig 10 18 Third Gas Indication Check Fig 10 19 Hold Time 0 98 20 4 02 Eoma Ee F10 18E EPS F10 19E EPS 10 4 5 2 Executing Semi Auto Indication Check Semi automatic indication check is started either from the display or by external contacts When started from the display only the channel selected on the display is checked When started by an external contact all working channels can be checked one channel after another Assuming that Span Zero Third is set to points on the Indication check setup display the procedure is described below lt Procedure gt When started from the display 1 From the basic panel display touch the Setup key to display the Execution Setup Select Indication check 2 Select Semi auto ind check The channel select display of Fig 10 20 is displayed 3 Select the channel to perform indication check The screen of Fig 10 21 is displayed 4 When you select Start ind check the Semi auto ind chk trend graph of Fig 10 22 is displayed and Span indication check begins 5 When the preset check time same as calibration time has elapsed Span indication check ends and Zero indication check begins Likewise when the preset check time has elapsed Zero indication check ends and third gas check begins 6 After check time calibration time ends st
68. 2 Specifications Standard specification model code or part number dimension drawing for each equipment 2 2 9 3 Installation Installation method for each equipment A 4 Piping Examples of piping in three standard system A configurations 5 Wiring Wiring procedures such as Power supply wiring output x signal wiring or others 6 Components Major parts and function are described in this manual O O 7 Startup Basic procedure to start operation of AV550G Chapter 7 enables you to operate the equipment immediately a E 8 Detailed Data Setting Details of key operations and displays O A 9 Calibration Describes the calibration procedure required in the course o A of operation 10 Other Functions Other functions described O A 11 Inspection and How to conduct maintenance of AV550G and procedures Maintenance for replacement of deteriorated parts 12 Troubleshooting This chapter describes measures to be taken when an A abnormal condition occurs CMPL parts list User replaceable parts list O Read and completely understand before operating the equipment O Read before operating the equipment and refer to it whenever necessary A Recommended to read it at least once T Int 2E IM 11M12D01 01E For the safe use of this equipment IM 11M12D01 01E A CAUTION The cell sensor at the tip of the detector is made of ceramic zirconia element Do not drop the detector or subject it to pressure
69. 20 21 22 23 24 25 26 27 28 29 I 61 62 63 64 65 66 67 68 69 70 71 72 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 1 81 82 83 84 85 86 87 88 89 90 91 92 NG NO C NC NO C NCNO C NG NO 4 i i C NC NO C NC NO M4 screws L L J i J L J l DO CH1 DO CH2 DO CH3 DO CH4 SV COM SV CH3 SV CH4 I DO CH7 DO CH8 I I L I I I I Grounding plate Fieldbus communication is selected 5 4 Cell Heater I I I I I I I LSVCH7 SVCH8 1 I I I I I I I Cell Heater Detector CH1 Detector CH5 Figure 5 3 External Wiring Connection Terminals of the Averaging Converter IM 11M12D01 01E 5 Wiring 5 1 4 Types of Wiring and Cables Types of wiring and cables to be used are listed in Table 5 1 The purpose of a shield is not only to prevent the effect from noise disturbance but also to restrict the noise emitted from the converter Specified cables must be used Table 5 1 Types of Wiring and Cables Shield Number of Requirement Cores Terminal Indication Requirements Power L N Size 2 mm 14 AWG or larger per core Unshielded 2 or 3 internal grounding External grounding Unshielded Either internal grounding or external Dui grounding will do Detector heater HTR1 to HTR8 Size 1 25 mm 16 AWG or larger Shielded Conductor two way resistance
70. 2D01 01E 7 15 7 16 IM 11M12D01 01E 8 Detailed Data Setting 8 Setting Operating Parameters Detail and Examples 8 1 Setting Analog Outputs 8 1 1 Analog Output Range Per Channel The analog output range is defined by setting the oxygen concentration value corre sponding to the range minimum oxygen concentration corresponding to 4 mA output and the oxygen concentration value corresponding to the range maximum oxygen concentration corresponding to 20 mA output For each channel the range settings can be set independently You can have two ranges for each output switched by contact input Contact OFF results in Range 1 and contact ON results in range 2 For details refer to Sec 8 5 Setting Contact Inputs Factory default setting is 0 to 25 O2 for all ranges lt Setting Procedure gt 1 Touch the Setup key and the Execution Setup display appears 2 From the Commissioning display select mA output setup then Set Range See Fig 8 1 3 Use lt 4 and P keys to select the channel 4 Set Min O2 concentration corresponding to 4 mA output then set Max O2 concentration corresponding to 20 mA output select then touch Enter key 5 The numeric data entry display shown in Fig 8 2 appears enter the desired oxygen concentration setting To set 10 O2 input 010 and touch Enter 6 As necessary repeat for averaging output a b and c and other channels mA output range New value 025 02 d cnt gt
71. 3 RF SUS304 190 5 152 4 4 19 24 B DA ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 B DIN PN10 DN50 A SUS304 165 125 4 18 18 A DIN PN10 DN80 A SUS304 200 160 8 18 20 B DIN PN10 DN100 A SUS304 220 180 8 18 20 B g JIS 5K 65 FF SUS304 155 130 4 15 14 A JIS 10K 65 FF SUS304 175 140 4 19 18 A Flange JIS 10K 80 FF SUS304 185 150 8 519 18 B JIS 10K 100 FF SUS304 210 175 8 19 18 B JPI Class 150 4 RF SUS304 229 190 5 8 19 24 B JPI Class 150 3 RF SUS304 190 152 4 4 19 24 B Westinghouse 155 127 4 11 5 14 A F2 2E EPS IM 11M12D01 01E 2 7 2 2 2 ZO21R L Probe Protector This probe protector is required for the general use detector when it is used for oxygen concentration measurements in powdered coal boilers or in fluidized furnaces to prevent abrasion due to dust particles when gas flow exceeds 10 m s When using a ZR22G general use separate type detector in the horizontal position be sure to select a probe protector ZO21R L L B to support the probe Insertion Length 1 05 m 1 55 m 2 05 m Flange JIS 5K 65A FF SUS304 ANSI Class 150 4 FF without serration However flange thickness is different Material SUS316 JIS SUS304 JIS Flange Weight 1 05 m Approx 6 10 kg JIS ANSD 1 55 m Approx 9 13 kg JJIS ANSD 2 05 m Approx 12 16 kg JIS ANSI Installation Bolts nuts and washers are provided for detector probe adapter and
72. 4 or less data of 8 channels will be displayed if an expansion power supply unit is mounted and a card is installed on any of channels CH5 to CH8 The display means a channel no card is installed in the channel As shown in upper left and right displays in Figure 6 4 data of multiple channels can be viewed in a single screen which is called a multi channel display 6 3 6 4 On this display touch the indication area enclosed by dotted line of the desired channel A display shown in bottom in Figure 6 4 will appear This display will show the oxygen concentration or cell temperature during warm up and average concentra tion data groups a b and c show if all channels are in warm up period of the selected channel which is called a single channel display To return to the previous multi channel display touch the area enclosed by dotted line The operation status of the averaging converter is indicated by yellow marking at the bottom of the display Table 6 1 shows the types and conditions of the markings Switch Indication Area Average Oxygen Concentrations Status Indication Markings Single channel Display Figure 6 4 Multi channel Display and Single channel Display IM 11M12D01 01E Table 6 1 Types of Status Indication Markings Marking Condition 6 Components Displayed if any of the calibration gas channels is being purged Displayed if any channel is in warmup status If any othe
73. 6 Zero point Calibration Complete in Manual Calibration 10 8 4 Operation After Calibration No special operation of the instrument is needed after calibration However it is recommended that the pressure regulator for the zero gas cylinders be closed because calibration is not required so often 10 32 IM 11M12D01 01E 11 Inspection and Maintenance 11 Inspection and Maintenance This chapter describes the inspection and maintenance procedures that are performed to maintain reliable performance of the AV550G Averaging Converter and to keep it in good operating condition The procedure for adding channel cards is also explained in this chapter A DANGER Do NOT touch the probe if it has been in operation immediately just before being checked The sensor at the tip of the probe heats up to 750 C during operation If you touch it you will get burned A WARNING IM 11M12D01 01E When checking the detector carefully observe the following 1 Do not subject the probe to shock or cool it rapidly The sensor is made of ceramic zirconia If the detector is dropped or bumped into something the sensor may be damaged and no longer work 2 Do not reuse a metal O ring to seal the cell assembly If you replace the cell or remove it from the probe for checking be sure to replace the metal O ring Other wise the furnace gas may leak and then the leaking corrosive gas will cause the built in heater or thermocouple to go o
74. 7 Indication check OFF ly Blow back OFF CF Third gas ON Enter F10 11E EPS Figure 10 11 Allocating Third Check Gas Contact IM 11M12D01 01E 10 Other Functions 10 4 4 Setting Indication Check Timing All timing parameters set in the Calibration Setup display applies to indication check timing The timing can also be set from the Indication Check Setup display Note however that the timing parameters set in the Indication Check Setup display are reflected in the timing setting for calibration Once the indication check starts on a channel its individual analog output is held at a value preset in the Output Hold Setup and excluded from averaging group calculations until the output hold time has elapsed After the hold time has elapsed the indication check of the next channel is started A timing chart showing indication check time hold time analog output status check gas switching solenoid contact action is provided in Figure 10 12 For details on solenoid valve piping and wiring refer to Subsection 4 2 6 Piping for Indication Check and Section 5 3 Wiring and Piping Examples Table 10 3 When Auto Indication Check conflicts with Other Processing Purging Indication Blowback in Maintenance CAL chan CAL chan CAL chan the Check in other in warmup in ERR now channel other channel channel status status disabled Man Indication Check SemiAuto Indication Check Auto Indication Check
75. 8 Oxygen Channel Cards Common Isolation 1 Oxygen Channel Card Individual Isolation 2 Oxygen Channel Cards Individual Isolation 3 Oxygen Channel Cards Individual Isolation 4 Oxygen Channel Cards Individual Isolation 5 Oxygen Channel Cards Individual Isolation 6 Oxygen Channel Cards Individual Isolation 7 Oxygen Channel Cards Individual Isolation 8 Oxygen Channel Cards Individual Isolation Japanese English French German Power supply 100 115 V AC 230 VAC 3 Communication HART communication FOUNDATION Fieldbus communication 4 Options Stainless steel tag plate 24 Voltage output for Solenoid valve Cable gland Numbers in OO 5 T02 EPS 1 Select code B 8 Channel Base when future expansion exceeding 4 channels is expected By so doing the expansion can be made economically 2 Common isolation is recommended when the same instrument receives the analog outputs from each channel card Individual isolation is recommended to prevent the trouble by mutual interference when different instrument receives the analog outputs from each channel card 3 When suffix code 2 230 V AC is selected select code A 4 Channel Base 4 When suffix code F FOUNDATION Fieldbus communication is selected used exclusively for communication 5 Input 01 to 30 in 3 Channel Code Model Suffix Code Option Code Specific
76. Auxiliary ejector for high temperature mounting place use Needle valve Pressure gauge Ejector Air source Po kPa Qa l min 200 40 P 0 5 100 30 N EN a Ss 0 5 10 15 040 60 80 L m P kPa Pressure setting characteristics Air consumption characteristics t Gas Pg kPa 3 Qg l min 4 Po kPa Pressure setting 1 0 8 Gas Pressure P kPa Drive pressure at the ejector entrance Pg kPa Suction pressure 0 kPa am Qa l min Air consumption WE alo Qg Vimin Suction flow m Distance between the ejector and the pressure E Gas pressure 15 Pa gauge k_m a A 0 40 60 80 0 40 60 80 P kPa P kPa Suction pressure characteristics Suction flow characteristics F2 9E EPS Note Pipes and connectors are not provided IM 11M12D01 01E 2 23 lt Pressure setting for the auxiliary ejector for high temperature use gt Pressure supply for the auxiliary ejector should be set so that the suction flow of the measured gas becomes approximately 5 l min To set this proceed as follows 1 In Graph 4 draw a horizontal line from the 5 l min point on the vertical axis Suction flow Qg toward the gas pressure line to be used to find the point of intersection Draw a line vertically down from the point of intersection to the axis to find the drive pressure P at the ejector entrance 2 In Graph 1 determine Po pressure setting from L the distance between the ejector and the pr
77. B or G7016XH Rc1 4 or 1 4 NPT Rc1 4 1 4NPT for a b6 Xb4mm soft tube Nipple General Tube fitting General Reference gas inlet sealed up when piping is required refer to 4 1 3 High temperature detector Note Calibration gas inlet Stop valve Yokogawa recommended L9852CB or G7016XH Rc1 4 or 1 4 NPT Rc1 4 1 4 NPT for a 66 Xh4mm soft tube General Nipple Tube fitting Reference gas inlet sealed up when piping is required refer to 4 1 3 Parts marked with an asterisk are used when required Sample gas outlet Auxiliary ejector Yokogawa recommended E7046EC or E7046EN R1 4 or 1 4 NPT Equal tee connection General fitting Needle valve Rc1 4 or 1 4 NPT General R1 2 to R1 4 or R1 2 to 1 4 NPT Reducing nipple General T4 1E EPS General parts are commercially available 4 1 2 IM 11M12D01 01E Piping for the Calibration Gases This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit and between the ZA8F flow setting unit and the ZR22G detector The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 40 C Mount a regulator valve specified by YOKOGAWA on the cylinder Mount a check valve or stop valve specified by YOKOGAWA on the nipple found on the open
78. F7 10E EPS Fig 7 10 Channel Select for Manual Calibration 5 Select the channels to be calibrated channels in warmup or error status can t be selected Here we describe the situation for Channel 1 6 Select Span calibration and touch the Enter key A display like Fig 7 11 appears Ch1 Manual cal Check the span gas concentration value CPNext Cancel calibration Change value 21 00 ale Fig 7 11 Span Calibration setup 7 Touch Next and touch the Enter key The display in Fig 7 12 appears If wiring and piping for autocalibration has been done span gas will start flowing at this point Chi Manual cal Open span gas valve Set flow span gas to 600ml min a F Valve opened Cancel calibration Ld _ a ay 3 sii E aly S m 5 Ole Fig 7 12 Span Calibration start 7 10 IM 11M12D01 01E IM 11M12D01 01E 7 Startup 8 Open the span gas flow setting valve and adjust flow to 600 60 ml min 9 Select Valve opened Start Calibration and touch the Enter key An oxygen concentration graph like Fig 7 13 is displayed and CAL TIME status mark flashes Wait for the graph measured value trace to stabilize Calibration has not yet been performed so it is not a problem if the displayed value is different from the correct value of span gas concentration Channel No under calibration Ch1 Manual cal 1min div 21 00 a 0 98
79. Flow Setting Unit cee orrn ni ea e era ean TEE RERS 6 12 Te UAT UD i cassiivssssvancesninseanesieasnnsGeiacees suivessicnoenslencsoo vase i an EL TA Startup procedure nini a diese ea een uve ni eaten 7 1 7 2 Check Piping and Wiring eee ceseeeeceseeeeceeeeeeceseeeeecseeeeecaeesaecseeaeenees 7 2 TIn Set NAIVE LY Eene seven cdeck sdees dees succes O OE OE seseder Mock teat cd ab E REE EE EEE 7 2 7 4 Setting Detector model oo eee cete cee ceseeeeceseeeeeeseseaeeseeeaecaaeeaecsaesaeenaes 7 3 7 5 Supply Power to Averaging Converter ccc eeeeceesseeeceseeeeeceeeseceeeneenaes 7 5 7 6 Selection of Gas to be Measured 00 00 eee eeeeceeceeeceeeeeeesseeeeecaeesaeseeeaeenaes 7 6 7 17 Current Output Range Setting eee cee eeceeeeeeeeeeeeeecaeeseecseesaecsecsaeenees 7 7 7 8 Averaging Group Setting oe eee eee ceseeeeceeeeseeeseeeeesseeeeecaeesaeseesaeenaes 7 8 T 9 Calibration 83 ssessse5ssesesosscestonsseidestscducec aces ses isdsvasdkeaveavbesyoesdisessysciocsass EESTIT 7 9 7 9 1 Setting Calibration Gas Concentration cece cee ceeceseeeeeeseeeeeeeeees 7 9 7 9 2 Performing Manual Calibration eee eeeeeseeeeceeeeeeceeenecneeeaeenaes 7 10 7 10 Analog Output Current Loop Check 00 ee eeeeceseeeeceeeeeeeeeeeeeeeneeeeeens 7 13 7 11 Checking Operation of Contact Input Contact Output ee 7 14 7 11 1 Contact Output Operation Check eee eeeecceseeeeeeseeesecneeesecneeeaeenaes 7 14 7 11 2 Checking contacts used to operate solenoid valves
80. Flow setting unit See Section 2 5 1 Other equipment See Section 2 6 2 1 General Specifications 2 1 1 Standard Specifications Measured Object Oxygen concentration in combustion exhaust gas and mixed gas excluding inflammable gases To check if sampled gases containing a corrosive gas such as ammonia or chlorine may be applicable to our oxygen gas analyzer contact with YOKOGAWA or its agent Measurement System Zirconia system Oxygen concentration 0 01 to 100 vol O Output Signal 4 to 20 mA DC maximum load resistance 5500 Measurement Range Any setting in the range of 0 to 5 through 0 to 100 vol O in 1 vol O or partial range Digital Communication HART 250 to 5500 depending on number of field devices connected to the loop multi drop mode Note HART is a registered trademark of the HART Communication Foundation Display Range 0 to 100 vol O Warm up Time Approx 20 min Repeatability Excluding the case where the reference air is by natural convection 0 5 Maximum value of range setting range up to 0 to 25 vol O 1 Maximum value of range setting range from 0 to 25 vol O up to 0 to 100 vol O Linearity Excluding standard gas tolerance IM 11M12D01 01E 2 1 2 2 Drift Excluding the case where the reference air flow is natural convection Use oxygen of known concentration in the measuring range as the zero and span calibration gas 1 Maximum value of range setting
81. Function wo eee csesecsecsseceeceseeseceseeseceeeseeeeeeseseeeeeeseneeags 11 2 11 3 Inspection and Maintenance of the Detector eee eeeeeeeeeeeeeeees 11 4 11 3 1 Cleaning the Filter in Sensor Assembly 00 eee eee cseeesecseeeeenees 11 4 11 3 2 Cleaning the Calibration Gas Tube 00 eee eee eeeseeeeecneeeeecneeeneenaes 11 4 11 3 3 Replacing the Sensor Assembly 0 0 0 0 eee cee eceseeeseeeeeeecseecnecnseeaeenaes 11 5 11 3 4 Replacement of the Heater Unit 0 ee ceeeecseeneecneetseceenaes 11 7 11 3 5 Replacement of filter assembly 0 ee eee eee cseceee ce cneeeeeeeeerens 11 10 11 3 6 Replacement of O ring oo oseng ees opos ssessp eis repens eS 11 10 11 3 7 Cleaning the High temperature Probe Adapter eee eeeeeeee 11 10 11 3 8 Stopping and Re starting Operation 0 0 ceeceseceeeeeeeeeees 11 11 11 4 Inspection and Maintenance of the Averaging Converter ee 11 12 11 4 1 Fuse Replacement nunica a a a 11 12 114 2 Cleaning asse siacscesesaistbes sesaesuicediacitel EEEE EEKE EREE EE EESE 11 13 11 5 eAdding Channel CardSrerrneriese enpre esocs se Sos e peo opere iei OTE eres cosstsursh sepsnevtes 11 14 11 6 Adding the Expansion Power Supply Unit eee eee cseeeecneeeeee 11 15 11 7 Replacing Limited Life Component 00 0000 ee eee eceeeeeseseeeseceeeeeeaeeaee 11 16 12 Troubleshooting sesssecesocesooccssecssecesocesoossoosesocessecesocssoossoosssocsssocesocesoosssosssssesssesssso 12 1 12 1 Displays and Remedi
82. Functions 1 Basic panel display Displays measured oxygen concentrations and cell temperatures during warm up period The basic panel display consists of a multi channel display and a single channel display The multi channel display screen shows cell temperatures during warm up period and oxygen concentrations afterward The single channel display screen shows the data of the selected channel the cell temperature or oxygen concentration and average concentrations of each group If an error or alarm occurs a relevant icon will be flashing in its display area If an error and an alarm occurs at the same time the error icon display takes precedence For details on errors and alarms refer to Chapter 12 Trouble shooting OF 02 21 0 02 21 0 02 21 0 02 PJ Multi channel display Showing Single channel Display Showing Oxygen Concentration Oxygen Concentration Red error code is indicated on a relevant channel Ave a 0 96 02 Ave b 0 95 02 Ave c 0 96 02 Multi channel display When Error Occurs Single channel Display When Error Occurs Figure 6 6 Basic Panel Displays IM 11M12D01 01E 6 7 2 Detailed data display 3 Trend graph display To move to the detailed data display touch the Detailed Data key and then touch the indication area of the desired channel in the multi channel display or simply touch the Detailed Data key in the single channel display The detailed data display shows maintenance data such as c
83. IM 11M12D01 01E IM 11M12D01 01E 8 Detailed Data Setting 4 Under Indication Check For Manual Indication Check Under indication check is the time that starts when you move to the Manual ind check display Figure 8 6 from the Indication check display lasts you operating keys for performing indication check manually and ends when a preset hold time has elapsed Chi Manual ind check Open span gas valve Set flow span gas to 600ml min CP Start ind check Cancel ind check F36E EPS Fig 8 6 Manual Indication Check For Semi Automatic Indication Check When indication check is started from the Indication check display under indication check is the time that starts when you touch the Enter key on the Semi auto ind chk display with Start ind check selected Figure 8 6 lasts while indication check is being performed and ends after a preset hold time has elapsed When indication check is started by a contact input indication check is performed for all installed channels Under indication check is the time that starts when indication check is started by the contact input lasts while indication check is being performed sequen tially and ends after preset hold time for the last checked channel has elapsed Ch1 Semi auto ind chk Check settings Span gas conc 21 00 Zero gas conc 0 98 Check time 2 min 0 0 s Points Span Zero Third Go to setup to change value CP Start calibration Cancel calib
84. NDATION Fieldbus H1 communication speed 31 25 kb s Physical layer type 113 standard power signaling bus powered non LS Communication line condition power supply 9 to 32 VDC current supply 15 mA Max Signal insulation communication terminal to grand terminal dielectric strength 500 Vrms 50 60 Hz 1 min Device Link master Function block AI block 3 blocks 1 block for each channels Transfer the data of averaging oxygen concentration to other instruments DI block 2 blocks Transfer the status of error and alarm to other instruments MAT block 1 block 8 channels Transfer the data of oxygen concentration to other instruments MAO block 1 block 8 channels Import the data of other instruments 2 16 IM 11M12D01 01E Model and Suffix Code IM 11M12D01 01E 1 Detector 2 Specifications Refer to GS 11M12A01 01E for a detailed explanation of the detector specifications and available accessories 2 Averaging Converter AV550G Suffix Code Option Code Specification Averaging Converter Base 1 4 Channel Base 8 Channel Base Number of Channel Card 2 Display 1 Oxygen Channel Card Common Isolation 2 Oxygen Channel Cards Common Isolation 3 Oxygen Channel Cards Common Isolation 4 Oxygen Channel Cards Common Isolation 5 Oxygen Channel Cards Common Isolation 6 Oxygen Channel Cards Common Isolation 7 Oxygen Channel Cards Common Isolation
85. O OFF 3 Remove the channel slot cover from the desired channel by removing the screws holding the cover to the slot 4 Slowly insert a channel card into the slot sliding along the guide rail in the slot Make sure that the connector on the back of the channel card is seated properly and firmly in the slot 5 Securely tighten the screws on the channel card 6 Connect the wiring from an additional detector to the terminals on the added channel card and to the corresponding heater terminals Now the additional detector is connected to the averaging converter 7 Turn on the power to the averaging converter Check to ensure that on the display the added channel becomes active and the temperature of the channel is rising Ad DANGER To work safely turn off the power to the averaging converter at the external breaker and position the power switch to O OFF before the work After the work position the power switch to I ON attach the front cover and then turn on the power to the averaging converter at the external breaker A CAUTION e Up to 4 channel cards can be added in the 230 VAC version 88880 RRRA RRN ANNAA SS F11 10 eps Fig 11 10 IM 11M12D01 01E 11 Inspection and Maintenance 11 6 Adding the Expansion Power Supply Unit IM 11M12D01 01E To connect more than 4 detectors to a 4 channel base averaging converter AV550G A the expansion power supply unit is requ
86. T Px E Ee In qpa Seer 1 where R Gas constant T Absolute temperature n 4 F Faraday s constant Px Oxygen concentration in a gas in contact with the positive zirconia electrode Pa Oxygen concentration in a gas in contact with the negative zirconia electrode Assuming the zirconia element is heated up to 750 C then we obtain equation 1 above E 50 74 log RETETE ERA 2 With this analyzer the sensor zirconia element is heated up to 750 C so Equation 2 is valid At that point the relationship as in Figure 9 1 is effected between the oxygen concentration of the measurement gas in contact with the positive electrode and the electromotive force of the sensor cell where a comparison gas of air is used on the negative electrode side 9 1 120 b222sce 100 Gass BO ae see 1 a ania Cell voltage eye mV 40 appr se 20 777555 I tor oe ee ae a ees ee ee ee ee ae ee ee ae cg ee eee fee eh apes ie als 1 1 iy i a ta Ceow ot ei cee ce bed Sie ere es 1 1 Ty td TT 1 i E E fei SEOTI be pepo pee ee ee he ee pe ee pe Pe ppp SS Se ef Se a r t p4 r t 1 1 I Poy ord tl o j ia ine 0 51 02 81 92mV Zero origi pee Ree Soa 1 l I l I l ae l I boyd I 1 l I l I i tot 1 I i p E E r Ns ea qeope ee a a ss I i I I 1 i I ay E ta Loll NS ee eee eee Liou O ee ee I 1 T i 1 1 Dor td TT I I I 1 1 i r at 1 I I I 1 i lop roa pmi r E o O O Sepa ape poss I
87. The following should be taken into consideration when installing the detector 1 Easy and safe access to the detector for checking and maintenance work 2 Ambient temperature of not more than 150 C and the terminal box should not affected by radiant heat 3 A clean environment without any corrosive gases A CAUTION e A natural convection type detector model ZR22G O L L C which uses ambient air as reference gas requires that the ambient oxygen concentration be constant 4 No vibration 5 The measurement gas satisfies the specifications described in Chapter 2 6 No measured gas pressure fluctuations 3 1 2 Probe Insertion Hole Includes those analyzers equipped with a probe supporter and probe protector When preparing the probe insertion hole the following should be taken into consider ation A CAUTION e The outside dimension of detector may vary depending on its options Use a pipe that is large enough for the detector Refer to Figure 3 1 for the dimensions e If the detector is mounted horizontally the calibration gas inlet and reference gas inlet should face downwards e When using the detector with pressure compensation ensure that the flange gasket does not block the reference air outlet on the detector flange If the flange gasket blocks the outlet the detector cannot conduct pressure compensation Where neces sary make a notch in the flange gasket Confirm the outside dimen
88. UG eet LZ mX A0 XI ipsa utsbasteaddecuteress Geass E Equation 2 X Ao xm where Ao Theoretical amount of air per unit quantity of fuel m3 kg or m3 2 in Table 8 7 G Actual amount of exhaust gas including water vapor per unit quantity of fuel ms kg or m3 Gw Water vapor contained in exhaust gas per unit quantity of fuel by hydrogen and moisture content in fuel m3 kg or m3 uann 1 in Table 8 7 Gw1 Water vapor contained in exhaust gas per unit quantity of fuel moisture content in air m3 kg or m3 Go Theoretical amount of dry exhaust gas per unit quantity of fuel m3 kg or m3 m Air ratio X Constant determined depending on low calorific power of fuel 3 in Table 8 7 iz Absolute humidity of the atmosphere Figure 8 20 F8 20E eps Fill in the boxes with fuel parameters in Equation 2 above to calculate the moisture content Use Ao Gw and X shown in Table 8 7 If there are no appropriate fuel data in Table 8 7 use the following equations for calculation Find the value of Z in Equa tions and 2 using Japanese Standard JIS B 8222 etc If a precise measurement is not required obtain the value of Z using a graph for the absolute humidity indicated by a wet and dry bulb hygrometer Figure 8 20 IM 11M12D01 01E 8 19 e For liquid fuel Amount of water vapor in exhaust gas Gw 1 100 1 24 9h w m3 kg Theoretical am
89. Yokogawa recommended part and where necessary a stop valve e Install a normally closed solenoid valve Yokogawa recommended part through a nipple commercially available on the calibration gas inlet of the detector as shown in Figure 4 11 This solenoid valve is activated by a contact signal from the averaging converter Power wiring is separately required Note If the solenoid valve cannot be connected directly to the calibration gas inlet of the detector install a dedicated check valve K9292DN or K9292DS on the inlet and then route the piping to the solenoid valve e After installing the solenoid valve on the calibration gas inlet of the detector route the piping through a flowmeter a needle valve a solenoid valve for switching zero and span gases a stop valve and a pressure reducing valve for the cylinder in this order to the cylinder e Install the piping for the solenoid valve for switching zero and span gases so that the zero gas is introduced to the detector when powered This solenoid valve is activated by a contact signal from the averaging converter Power wiring is separately required e Install the needle valve and flowmeter in close proximity as much as possible e Use stainless steel pipes with 6 OD x 4 ID mm or nominal 1 4 inch or larger inside diameter for the piping for the calibration gases Solenoid valve nomal close Connect directly to piping inlet Calibration gas piping Reference gas pipin
90. a low temperature location such as in the open air cover the probe adapter including the ejector with a heat insulator e g ceramic wool to keep it warm and to prevent condensation of drain on the ejector Wiring connection Mount the probe so that the probe tip is not higher than the probe base il When using an SiC probe mount the probe vertically with an allowable tilt of 5 F3 6E EPS Figure 3 6 Mounting of the High temperature Detector IM 11M12D01 01E 3 Installation 3 3 Installation of the Averaging Converter The averaging converter is designed for indoor installation and should be installed in the instrument panel in a control room For outdoor installation the averaging converter should be installed in an outdoor instrument panel protected from direct sunlight and the weather Ay DANGER High voltages are present inside the averaging converter To prevent unintentional opening of the front cover it is securely attached by a lock screw on the right side of the case Loosen the lock screw to remove the front cover and securely tighten the lock screw after the front cover has been attached How to remove the front cover e Loosen the 4 knob bolts by hand and then loosen the lock screw with the Allen wrench supplied e Remove the front cover by lifting up slightly then pulling away from the case How to attach the front cover e Attach the front cover aligning the slots on t
91. a preset hold time has elapsed Ch1 Manual cal Open span gas valve Set flow span gas to 600ml min es F Valve opened Cancel calibration g t m 3 e g ny N M im D a Fig 8 4 Manual Calibration display For Semi Automatic Calibration When calibration is started from the Calibration display under calibration is the time that starts when you touch the Enter key on the Semi auto cal display with Start calibration selected Figure 8 5 lasts while calibration is being performed and ends after a preset hold time has elapsed When calibration is started by a contact input calibration is performed for all installed channels Under calibration is the time that starts when calibration is started by the contact input lasts while calibration is being performed sequentially and ends after a preset hold time for the last calibrated channel has elapsed chi Semi auto cal Check settings Span gas conc 21 00 Zero gas conc 0 98 Cal time 2min00s Points Span Zero Go to setup to change value CP Start calibration Cancel calibration jes t Enter Fig 8 5 Semi Automatic Calibration display For Automatic Calibration Under calibration is the time that starts when calibration is started at a preset timing lasts while calibration is being performed sequentially and ends after a preset hold time for the last calibrated channel has elapsed
92. abilization time begins After the preset stabilization time the instrument reverts to measurement mode 7 Touch the Reject key to abort indication check If you abort Span or Zero or third gas indication check then check time is skipped and stabilization time starts If you touch the Reject key again then stabilization time is also skipped Semi auto ind check Select ind check channel Al chi Semi auto ind chk Check settings D al Span gas conc 21 00 r e Zero gas conc 0 98 amp Chi ch5 J E Check time 2 min 0 0 s J Ch2 Ch 6 Points Span Zero Third Ch3 Ch7 Ly Go to setup to change value gt Ch4 ch Start calibration 4 Cancel calibration yan Enter Enter Fig 10 20 Channel Select Display Fig 10 21 Indication Check Start IM 11M12D01 01E 10 17 Ch2 Semi auto ind chk 1min div F10 22E EPS Fig 10 22 Indication Check Graph Starting Semi auto Indication Check by a contact input 1 Confirm that on the Input contacts display Ind check start is selected for the contact to be used to start indication check 2 When the contact input is detected then Indication check starts 3 To abort Indication check touch the Reject key If you abort Span Zero or third gas Indication check then Indication check time is skipped and stabilization time starts If you touch the Reject key during stabilization time then stabilization time
93. aeenaes 5 15 Wiring and Piping Examples ec eeeceseeecseecsecneeeaecsseesecesceecnsenseeeees 5 16 5 3 1 Wiring and Piping for Automatic Calibration 2 0 0 0 cece ereeees 5 16 5 3 2 Wiring and Piping for Automatic Calibration and 3rd Gas Indication Checks susecai eet tines aria EE EEE E KEE EEE E EE EE 5 16 5 3 3 Wiring and Piping for Blowback ssssesesseseeesesiesesreerrersrrreerseseresessee 5 17 5 3 4 Wiring and Piping for Automatic Calibration and Blowback 5 17 6 COMPOMEtS visiciacessniecvevsseasssasstaenessuuesscavsassn caps vaessesenssves a a a ana coveuseesoasivess OF L 6 1 6 2 6 3 ZR22G Detector asides ae els ale aaa 6 1 6 1 1 General purpose Detector except for Model ZR22G 015 oe 6 1 6 1 2 High Temperature Detector Model ZR22G 015 oo eee eee eee 6 2 AV550G Averaging Converter ceececeeseeesceseeeeceseeeeeeseeeaecaeeeseceeaeenaes 6 3 6 2 1 Components and Functi N s neeesser ire R 6 3 6 2 2 Touchpanel Switch Operations e seseeeessereseseessseeersresrerrssrerssreresreersresene 6 3 6 2 2 1 Panels and Switches meceni rene eae ee e ENR 6 3 6 2 2 2 Switches and Their Functions s sesseseeesseeeseseesrseesrsressrrreseersserrrsreresreeree 6 5 6 2 2 3 Display Configuration 00 0 ssiri rereeoiri tssir ae sste restai isens as rei 6 6 6 2 24 Display Functions asirasi entse aeiieoo siitoin EE SE 6 7 6 2 2 5 Entering Numeric and Text Data 00 eee ceeeeeseeseeceessecnecnaeeneenaes 6 10 ZA8F
94. ail Contact the service personnel at Yokogawa Electric Corporation The case where the Model ZO21D Detector is used 1 Without stopping the power to the converter remove the wiring from terminals 5 and 6 of the detector and measure the voltage between these terminals If the voltage between the terminals is out of the range of 0 4 to 0 7 V the cold junction tempera ture sensor seems to be faulty Replace the cold junction temperature sensor 2 If the voltage between the terminals is within the above range the cold junction temperature sensor seems to be normal Check whether or not the cable is broken or shorted out and whether the cable is securely connected to the terminals Also check that the resistance of the wiring between the converter and detector is 10Q or less IM 11M12D01 01E 12 Troubleshooting 3 If there is no failure in the wiring the electrical circuits inside the converter may possibly fail Contact the service personnel at Yokogawa Electric Corporation A CAUTION The operating temperature range of the Model ZO21D Detector is 10 C to 80 C except for the high temperature detector ZO21D H Since a cold junction tempera ture alarm for this analyzer is not generated until the temperature exceeds 155 C if the Model ZO21D Detector is used be careful in controlling the ambient temperature of the terminal block 6 Alarm 6 Process gas alarm When process gas alarm is assigned to a contact input
95. ailure between the sensor assembly electrode and the contact 5 Wiring failure inside the detector 6 Abnormality in electrical circuits in the converter lt Locating the failure and countermeasures gt Turn off power to the channel with error by hot swap function or to the averaging converter CRSSES SS Sat erete eres sstosssrcssrsesesass5 Examine the wiring connection to 7 converter terminals CELL and CELL Also check the wiring connection in the repeater terminal box if it is used Is there any breakage or poor contact in the wiring to the converter terminals Replace the damaged portions can a a a a Examine the wiring connection status to detector terminals 1 and 2 Also check that terminals and cable conductors are not corroded Replace the damaged portions A ea ee ee Remove the sensor assembly from the detector and check for the presence of corrosion that may cause a poor contact between the electrode and the contact also check for dirt A sensor assembly in which no abnormality is found may be used again However be sure to use a new metal O ring and contact even in such a case Replace the sensor assembly Is the sensor extremely dirty corroded or broken See Section 10 1 3 for the replacement procedure a aime aleaiiaiaadaamiaiaiad aimdadaiad Remove the wiring conductors from detector g terminals 1 and 2 and short out the removed conduct
96. amp of the corresponding channel turns off 6 Repeat the above procedure for each channel connected to a ZO21D and disable power 7 Touch the Home key to return to the Run Set Data display 8 Select Commissioning gt Basic setup gt Detector then the Detector Selection display appears 9 Select each channel to be connected to a ZO21D and change the ZR22G default to ZO21D 10 After changing the settings for all channels to be connected to ZO21D detectors turn off converter power Detector id Channel card power chi A LH amp Chi Emm Ch2 Ch2 Enable mal Ch3 ZR22G Ch3 Enable Ch4 ZO21D a Ch4 Enable al Ch5 ZR22G Ch5 Enable Ch6 Z021D Ch6 Enable Ch7 ZR22G Ch7 Enable Ch8 Z021D Ch8 Enable i 4 Enter Fig 7 2 Detector Selection Fig 7 3 Channel Card Power Setting IM 11M12D01 01E 7 3 7 4 Disconnect power to the heater this will generate an error If you disconnect the signal wiring from the detector then this will generate an error but this allows you to change the detector model settings without detector warm up 1 Remove all thermocouple TC signal wiring from channel cards which connect to ZO21D detectors 2 Apply power to the averaging converter 3 Error messages are displayed for these channels but you can set their parameters 4 Touch the Setup key and the Execution Setup display appears 5 Select Commi
97. an calibration can be performed manually from the touch display or can be performed semi automatically using contact signal inputs to start calibration allowing preset calibration and stabilization times or it can be performed automatically at preset intervals Here we explain manual calibration 7 9 1 Setting Calibration Gas Concentration IM 11M12D01 01E Before calibrating you need to set the oxygen concentration of the gas you will use for calibration Here we explain how to do this Note that calibration related settings apply to all channels you can t set different values for individual channels A gas with a known oxygen concentration is used for calibration Normal calibration is performed using two different gases a zero gas of low oxygen concentration and a span gas of high oxygen concentration In some cases only one of the gases needs to 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 percent oxygen by volume with a balance of nitrogen gas N The span gas widely used is clean air at a dew point temperature below 20 C and free of oily mist or dust as in instrument air For best accuracy as the span gas use oxygen whose concentration is near the top of the measurement range in a nitrogen mixture Shipping time default setting for zero gas is 1 0 Oz and
98. and the heater of the corresponding channel are mechanically cut off from the other circuits maintenance and inspection work can be done safely Figure 11 2 When the cannel is restored by the hot swap function after inspection or maintenance the cannel card will be included in the original averaging groups after warm up period The individual analog output is held at a value preset in the mA output Setup during warm up period 11 2 IM 11M12D01 01E IM 11M12D01 01E 11 Inspection and Maintenance Averaging Converter Detector CELL TC CJ pieg jeuueup Power supply wire for Heater ywnouig Ajddns samog F11 2E eps Hot Swap Switch Mechanical Relays Fig 11 2 lt Procedure gt 1 On the basic panel display touch the Setup key The Execution Setup display will appear 2 Use the Cursor key to move the cursor to Maintenance Touch the Enter key 3 On the Maintenance display select Channel Card Power Touch the Enter key A display shown in Figure 11 3 will appear 4 On the Channel Card Power display select the channel of a detector to be discon nected for inspection or maintenance Touch the Enter key 5 A dropdown menu Disable Enable will appear Select Disable and touch the Enter key Make sure that all status lamp s of disabled channel s have turned off Channel card power Al a Ch3 Enable Ch4 Enable Ch5 Enable Ch6 Enable lv Ch7
99. angle between horizontal and vertical high temperature probe is fitted with an adapter Reference gas and calibration gas piping connection Rc 1 4 or 1 4 NPT female Cable inlet G 1 2 Pg 13 5 M20 X 15 1 2 NPT Ambient temperature 20 to 150 C Sample gas temperature 0 to 700 C temperature at the measuring point of the sam pling gas 0 to 750 C or 0 to 1400 C when the probe adapter for high temperature is used Temperature of the probe adapter shall not exceed 300 C to protect the gasket and avoid the bolts seizing together Sample gas pressure 0 5 to 5 kPa when used at the range of more than 0 to 25 vol O2 0 5 to 0 5 kPa An auxiliary ejector is required for negative pressure application Model and Code Refer to Model and Code in page 2 5 External Dimensions Refer to the Figure in page 2 6 2 9 2 3 2 2 10 ZO21P H Adapter for High Temperature Probe The probe adapter is used to lower the sample gas to a temperature below 700 C below 300 C at probe adapter surface before it is fed to the detector Insertion length 1 m 1 5 m Material in Contact with Gas SUS 316 JIS Zirconia SiC or SUS 310S SUS 304 JIS flange Probe Material SiC SUS 310S JIS Installation Flange mounting FF type or RF type Probe Mounting Angle Vertically downward within 5 Where the probe material is SUS 310S horizontal mounting is available Construction Non explosion proof Rainproof construction We
100. ard may be swapped Refer to Sec 11 2 Hot Swap Functions Table 8 1 alid output hold values 4mA 20mA Don t Hold last Preset value Status hold value 2 4mA 21 6mA Warmup Purging O IO O Under Maintenance O O O Under Calibration Indication Check O O O Blowback Process Gas Alarm O O Error O O O ane ee T8 1E eps lt Definition of Statuses gt 1 Warmup period Warmup period lasts from power on until cell temperature stabilizes at 750 C and the instrument switches to measurement mode The basic panel display shows cell tempera ture during warmup period Purging is the passing of calibration gas through the calibration gas piping before warmup to remove any condensate in the piping Refer to Sec 10 6 Purging Warmup does not start until after purging ends 8 3 8 4 2 Under Maintenance Under maintenance is the time that starts when you move to the Execution Setup display by touching the Setup key on the basic panel display and ends when you return to the basic panel display It includes when you operates keys on lower level menu displays of the Execution Setup display 3 Under Calibration For Manual Calibration Under calibration is the time that starts when you move to the Manual cal display Figure 8 4 from the Calibration display lasts while you are operating keys for perform ing calibration manually and ends when you press the End key and after
101. armup E o During output range switching OFF a During maintenance o g During calibration E a During indication check During blowback OFF 9 3rd check gas OFF z Relay state when powered Energized z High High Alarm OFF High Alarm ON gt Low Alarm ON 9 3 Low Low Alarm OFF z Calibration coefficient alarm OFF a Calibration gas pressure low OFF Error OFF F Instrument internal temperature alarm OFF Other settings All OFF Relay state when powered Energized Alarms High High Alarm OFF o High Alarm OFF S LowAlarm OFF b 3 Low Low Alarm OFF 5 Calibration coefficient alarm OFF R Calibration gas pressure low OFF Error OFF Instrument internal temperature alarm OFF Other settings All OFF Relay state when powered Energized Contact input 1 Function No function disabled Contact input2 Action Normally closed T10 8E eps 10 29 Table 10 9 Initialization Parameters and Defaults part 3 Initialization Parameter Default Averaging interval 1 hour Max amp Min Average monitoring Interval 24 hours Averaging Moisture content in exhaust gas 0 00 m3 kg m Theoretical air volume 1 00 m kg m3 X value 1 00 Absolute humidity of outside atmosphere 0 0000 kg kg Fuel Setup Detector type ZR22G Sample gas selection Wet Units C Asymmetry alarm disable Averaging group setting All ON Purging time 0 min disabled Clock Not affected Channel card power A
102. arting time hhoOOmm00 T9 2E eps T9 1E eps 9 9 9 3 Performing Calibration A Note 1 Perform calibration under normal working conditions e g continuous operation with sensor mounted on furnace 2 Perform both Span and Zero calibration for best resultant accuracy 3 When instrument air is used for the span calibration remove the moisture from the instrument air at a dew point temperature of 20 C and also remove any oily mist and dust from that air 4 If dehumidifying is not enough or if foul air is used the measurement accuracy will be adversely affected 9 3 1 Performing Manual Calibration To perform manual calibration you open or shut calibration gas valves following messages on the display Solenoid valves can be opened and closed automatically at the same time the messages are displayed on the display For details see Sec 7 9 2 9 3 2 Semi Automatic Calibration Semi automatic calibration is started either from the display or by external contacts When started from the display only the channel selected on the display is calibrated When started by an external contact all working channels can be calibrated one channel after another Here we give an example of the procedure for both of these cases with both Span and Zero calibration selected 9 10 IM 11M12D01 01E 9 Calibration lt Calibration Procedure gt Starting Semi Auto Calibration from the Display 1 From the basic displa
103. atic Calibration Interval can be set in the range 00 days 00 hrs to 255 days 23 hrs Once Auto Calibration starts It is performed for all installed channels so the interval needs to be larger than the sum of span and zero calibration times plus settling times for all channels The Start date and Start time are for the first calibration in the Auto Calibration cycle repeated at the calibration Interval To set 2004 June 21 at 1 30 pm set Start date to YY 04 MM 06 DD 21 and Start time to HH 13 MM 30 lt Setting procedure gt 1 From the Calibration Setup display select Timing and the display shown in Fig 9 7 appears In this example Mode is set to Auto 2 Select items and enter numerical values as required Calibration timing Al Cr Hold time 2 min 00s Cal time 2 min00s al Interval 1d 00h Li Startdate 22 06 04 Starttime 11 00 Fig 9 7 Calibration time setting A Note When setting bear the following points in mind 1 When calibration is to be started by a contact input signal you need to define and enable the contact input signal on the Input Contacts display 2 The starting of Auto Calibration may be delayed by status of the channel to be calibrated or by the status of other channels as explained by Table 9 1 below 3 If the calibration interval is shorter than the sum of stabilization time plus calibration time the second calibration start time will conf
104. ation AV55CM Channel Card Number of Channels 1 1 Oxygen Channel Card Common Isolation 2 Oxygen Channel Cards Common Isolation 3 Oxygen Channel Cards Common Isolation 4 Oxygen Channel Cards Common Isolation 5 Oxygen Channel Cards Common Isolation 6 Oxygen Channel Cards Common Isolation 7 Oxygen Channel Cards Common Isolation 8 Oxygen Channel Cards Common Isolation 1 Oxygen Channel Card Individual Isolation 2 Oxygen Channel Cards Individual Isolation 3 Oxygen Channel Cards Individual Isolation 4 Oxygen Channel Cards Individual Isolation 5 Oxygen Channel Cards Individual Isolation 6 Oxygen Channel Cards Individual Isolation 7 Oxygen Channel Cards Individual Isolation 8 Oxygen Channel Cards Individual Isolation Option 1 A O are common Isolation types Always A Expansion power supply unit for dry contact output of solenoid valve output 2 Expansion power supply unit for 24 volt output of solenoid valve output 3 T03 EPS B O are Individual Isolation types Up to 4 channel cards can be added in the 230 VAC version 2 Expansion power supply unit is required when using the 4 channel base and extending the number of channel cards to five or more The expansion power supply unit cannot be added in the 230 VAC version 3 Expansion power supply unit is required when using the 4 channel base and exte
105. auto h Points Auto ird al Timing Ea Enter F62E EPS Fig 10 9 Indication Check Mode Selection IM 11M12D01 01E 10 11 10 4 2 Procedure for Performing an Indication Check You can perform two point Span and Zero Gas Indication Checks you can include a third gas and perform a three point indication check or you can check just one of the three points lt Setting Procedure gt Select Points on the Indication check setup display A dropdown menu opens allowing you to select the desired indication check point s from Span Zero Span Zero Span Zero Third or Third Figure 10 10 Indication check setup Al Cy Mode Semi auto E Points RA El Timing Span __ Zero Span Zero Third Third d F63E EPS Figure 10 10 Indication Check Point Selection 10 4 3 Setting Contacts for Operating Third Check Gas Solenoid Valve 10 12 When performing a three point Semi Auto or Auto Indication Check you need to allocate a contact to operate the third check gas solenoid valve lt Setting Procedure gt 1 On the basic panel display if you touch the Setup key the Execution Setup display appears Select Commissioning then Contact Setup 2 Select a contact that is not yet allocated to other functions and select Others 3 Select Third gas and turn it ON Contact3 Others Warm up OFF Range change OFF Maintenance OFF Calibration OFF
106. ay 2 Blowback may be delayed or cancelled by status of the affected channel of by the status of other channels as explained by Table 10 5 3 If the Blowback Interval setting is shorter than the sum of blowback times plus hold times for all channels then the system will be in blowback status when the second auto blowback cycle attempts to start In this case the second auto blowback will be cancelled 4 If the blowback interval is set to 000 day 00 hour then auto blowback will not be performed 5 If you set the start date before the current date then auto blowback will not start 10 21 10 22 Purging the channel Table 10 5 When Auto Blowback conflicts with Other Processing Other channel CAL Indication Check in other channel Blowback in other channel Maintenance Chan is in warmup status Chan is in ERR status Chan now disabled SemiAuto Blowback X X X X O Auto Blowback O Perform blowback X Can t perform blowback O T10 5E eps Wait Wait until other ongoing command completion and is executed IM 11M12D01 01E 10 5 4 Operation of Blowback Figure 10 26 shows blowback timing To execute blowback by a contact input use it with an on time period of 1 to 11 seconds Once blowback starts the SV CH contact output repeatedly opens and closes at an interval of approximately 10 seconds during the preset blowback time During the
107. cal entry display appears To enter June 21 2004 enter 210604 Touch the Enter key and you revert to the display of Fig 8 17 6 Select Set time Enter the time in 24 hour format To set 2 30 pm enter 1430 on the numerical display and touch enter Touch the Enter key The clock starts from 00 seconds Others F Clock Averaging Fuel setup Purging Unit setup a Asymmetry alarm Passwords Defaults Fig 8 17 Others setting display Clock CrSetdate 21 06 04 Settime 16 44 21Jun 2004 16 44 45 Fig 8 18 Day and Time setting IM 11M12D01 01E 8 17 8 5 2 Average Value Max and Min Monitoring Time 8 18 This instrument can compute and display Average Max and Min Oxygen concentra tions in a specified time interval The Average Max and Min can apply to each channel and to averaging outputs a b and c Here we explain how to set the time interval for averaging and for monitoring for Max Min lt Setting Procedure gt 1 From the panel basic display touch Setup key and the Execution Setup display appears 2 Select Commissioning and the Commissioning display appears 3 Select Others then Averaging The display of Fig 8 19 appears 4 Select Set period over which average is calculated and numerical entry display appears To set 3 hours enter 003 Entry range is 1 to 255 hours 5 Select Set period over which maximum and minimum is stored an
108. card using a tester or relevant equipment The measured voltage is the cell voltage How to perform the indication check refer to Section 10 4 Indication Check When the valves for the calibration gas can be manually operated the cell voltage can be checked on the display of the averaging converter The procedure is as follows a From the basic panel display move to the Detailed Data display of the channel where the alarm is being generated b The cell voltage should be indicated on the top line Figure 12 8 c Check whether or not the displayed cell voltage is very different from the theoretical value at the oxygen concentration of the relevant gas See Table 12 3 for the theoreti cal cell voltages Although the tolerance to the theoretical value cannot be generally specified a reasonable one may be approximately 10 mV Table 12 3 Oxygen Concentration and Cell Voltage Oxygen Conc 02 Cell Voltage mV 1 67 1 21 0 T12 3E eps 12 9 4 Check whether the deterioration of or damage to the sensor assembly that caused the alarm has occurred suddenly during the current calibration by following the proce dure below a Call up the Detailed Data display b Use the Page Scroll key to check Calibration Data Figure 12 9 The span and zero correction factors of the last ten calibration can be checked here By checking these data whether the sensor deterioration has occurred suddenly or gradually can be determ
109. cation check To perform an indication check using the third check gas the piping to allow the third gas to flow into the calibration gas line is required for the ZA8F Flow Setting Unit in addition to the system configuration shown in Figure 4 1 Connect the piping from the third check gas cylinder through a pressure reducing valve and a stop valve along with the span gas line to the zero gas inlet of the ZA8F Flow Setting Unit To perform an indication check open the stop valve on the line from the third gas cylinder while open the stop valve on the span gas line to perform span point calibration Flowmeter Reference gas line Needle valve O ok Calibration gas line ZA8F flow setting unit Flowmeter Reference gas line Instrument air Needle valve Pressure regulator Calibration gas line Span gas cylinder Instrument air ZAS8F flow setting unit Zero gas cylinder Stop valve Third check gas cylinder F3 eps Figure 4 8 Piping to ZA8F Flow Setting Unit for Indication Check Using 3rd Check Gas IM 11M12D01 01E 4 7 4 1 7 4 8 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs When a process gas alarm an input contact signal of unburnt gas detection occurs the averaging converter will cut off the power supply to the heater of the detector and at the same time it will send a contact output to activate a solenoid valve for introducing a purg
110. ceeeeeeseeeeseseaeeneeeas 4 12 4 2 7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs 4 13 5 Wiri 5 1 IM 11M12D01 01E S E E TE eT EAE ESEE E E EE E E SE ENE 5 1 SLIL Wiring Precautions s sseeisissisinssoort iriserai snoeit Esraa sssr aaora raoi 5 2 D2 Wiring Holes 325 aie astantahsaitehtren ede ik anna ERS 5 4 5 1 3 External Wiring Connection Terminals of the Averaging Converter 5 4 5 1 4 Types of Wiring and Cables 0 cee cece cseeceeceeeesecnseeaeceeeneenseneeees 5 5 5 2 Wiring for the Averaging Converter and Peripheral Devices 5 6 5 2 1 Preparation for Wiring to the Averaging Converter eee eee 5 6 5 2 2 Preparation for Wiring to Detectors eee ceeeseceeeeceeceseeeseeeeees 5 6 5 2 3 Power and Ground Wiring 00 eee ee eeeseseeeeeeecseceeecaecnaeaeceseeeeeeeeeeees 5 8 5 2 4 Power Wiring to Detector Heaters oe eee cee ceeeseceseeseceeenteeeeeeeees 5 8 5 2 5 Signal Wiring to Detectors 0 cece eeeeceeeeeeceseeeeecaeeesecaeeaecaeeaeenees 5 10 5 2 6 Ground Wiring of Detectors eee cee eeeeeeeeeteeeeseeeseeseecaeceeeaeenaes 5 11 5 2 7 Wiring for Individual and Average Concentration Analog Outputs 5 12 5 3 5 2 8 Wiring for Solenoid Valve for Automatic Calibration 0 5 12 5 2 9 Wiring for Individual Common Error Contact Outputs and Common Contact Outputs ee eee cseeceecseeeseceeeeseceseneeeeeeeeees 5 13 5 2 10 Wiring for Contact Inputs 0 eee ceceeeeeeeeeeseeeeseeeseeseeeaecaee
111. ch as turning off the heater power are not carried out The alarm is canceled when the cause of the alarm is removed Alarm 5 cold junction temperature alarm may be generated concurrently with Error 2 heater temperature error In this case the operation when the error occurs has priority If the power to the averaging converter is turned off after an alarm is generated and the averaging converter is restarted before the cause of the alarm has been removed the alarm will be generated again Alarms 2 3 and 4 related to calibration are not gener ated unless calibration is executed An alarm will be automatically canceled after the cause of the alarm is removed Channels Where Alarms Occur displayed in red Alarm Icon Fig12 6E EPS Figure 12 6 Alarm Displays on Multi channel Display Tag Alm6 Process gas 4 Alm7 Cal gas press low Ch1 Alm1 Oxygen Ch2 Alm2 Zero conc ratio Ch3 Alm3 Span conc ratio Ch4 Alm5 C J temp Ch5 Alm4 Cal time over Fm 11E EPS Figure 12 7 Alarm Descriptions IM 11M12D01 01E 12 7 12 2 2 Alarm Displays By touching the alarm icon when an alarm is generated detailed alarm descriptions can be displayed Use the Next key to move to the next page if the alarm descriptions are displayed in multiple pages On the detailed alarm description display touch the Update key to update the alarm occurrence condition When an error and an alarm occur at a 12 8 Alarm Code
112. ck time Ch1 Zero check i Check time Ch 2 Output Hol Ch1 3rd gas check lt Check time Ch1 output hold Ch 1 Output Hold 1 lt gt Hold time Ch2 Span check i f heck time Ch2 Zero check ks i i Check time Ch2 3rd gas check f i Check time Ch2 output hold lt gt Hold time Average output Ch1 removed from average Chi removed from averagd 3 SV Cht contact O On 7 7 SV Ch2 contact Laoi SV Com contact Span gas ON Zero gas oF Span gas ON Zero gas ON Off On Off On 3rd gas contact F10 12E eps Ind check start Fig 10 12 Indication Check timing lt Shipping time defaults gt Indication check parameters are set as shown in Table 10 4 prior factory shipment or after data initialization Table 10 4 Indication Check Default Setting Item Default Mode Manual Points Span Zero T10 4E eps 10 14 IM 11M12D01 01E 10 Other Functions 10 4 5 Running an Indication Check 10 4 5 1 Manual Indication Check A manual indication check is performed by following prompts on the screen and manually opening or closing valves of calibration gas or third check gas When solenoid valves are used valves are opened and closed automatically at the same time that messages appear on the screen The procedure for indication check is virtually the same as for calibration Taking a 3 point indication check using zero span and th
113. con flashes in the switch indication area Figure 12 1 3 On the single channel display a large error code is indicated in the oxygen concentra tion data area and an error icon flashes in the switch indication area if the display shows the relevant channel Figure 12 2 If not only a flashing error icon is indi cated 4 The relevant channel is dropped out of the averaging group The averaging outputs continue with exception of the channel 5 The corresponding individual analog output is put into the status specified in the Output Hold Setup display No other individual analog outputs are affected 6 The red lamp turns on in the status display lamp on the relevant channel 7 The individual error contact and common error contact are activated When a system error occurs 1 The power to the heaters of all detectors is removed 2 The averaging outputs and all individual outputs are put into the status specified in the Output Hold Setup display 3 An error icon flashes in the switch indication area 4 The red lamps turn on in the status display lamps on all channels 5 The individual error contacts for all channels and common error contact are activated IM 11M12D01 01E 12 1 3 Error Displays 12 Troubleshooting By touching the error icon when an error occurs detailed error descriptions can be displayed Use the Next key to move to the next page if the error descriptions are displayed in multiple pages On the detailed er
114. connection IN Primary side OUT Secondary side Rc1 4 K9473XJ Piping connection IN Primary side OUT Secondary side 1 4NPT F 2 26 IM 11M12D01 01E 2 Specifications e Part No G7004XF or K9473XG Standard Specifications Primary Pressure Max 1 MPa G Secondary Pressure 20 to 500 kPa G Connection Rc1 4 or 1 4 FNPT with joint adapter Part No Description G7004XF Joint Re 1 4 Material Zinc Alloy K9473XG Joint 1 4 FNPT Material Zinc Alloy with adapter T2 13E EPS External Dimensions Unit mm Panel cut dimensions View A Horizontal Vertical mounting mounting 92 15 0 5 2 2 2 0 Panel Horizontal r mounting Secondary pressure pes Panel Vertical ea mounting lt A G7004XF Rc 1 4 K9473XG 1 4NPT connector Approx 122 IM 11M12D01 01E 2 27 2 6 7 2 6 8 Zero Gas Cylinder Part No G7001ZC The gas from this cylinder is used as the calibration zero gas and detector purge gas Standard Specifications Capacity 3 4 1 Filled pressure 9 8 to 12 MPa G Composition 0 95 to 1 0 vol O in N Note Export of such high pressure filled gas cylinder to most countries is prohibited or restricted T Unit mm 485 325 140 Weight Approx 6 kg F213E EPS Cylinder Regulator Valve Part No G7013XF or G7014XF Approx 112 This regulator valve is used with the zero gas cyli
115. contact input 1 Opens Start Semi Auto Calibration 1 From the panel basic display touch Setup key and the Execution Setup display appears 2 Select Commissioning and the Commissioning display appears 3 Select Contact Setup then Input Contacts 4 Select Input 1 Function Selection window Fig 8 16 appears 5 Select Calibration Start 6 For Input contact 1 select operate if Closed You can select Open or Closed 7 Change Closed to Open lt Default setting gt All contact inputs are set to No function disabled prior factory shipment or after data initialization Input contacts CF Input 1 Input 1 Range change Calibration start Ind check start Input 2 Blow back start Cal gas press low Input 2 Process gas alarm Close IE F8 16E EPS Fig 8 16 Contact Input Setting display IM 11M12D01 01E 8 Detailed Data Setting 8 5 Other Settings 8 5 1 Date and Time Here we explain how to set date and time Date and time setting are used for Auto Calibration and Auto Indication Check also Auto Blowback Start time lt Setting Procedure gt 1 From the basic panel display if you touch the Setup key the Execution Setup display appears 2 Select Commissioning and the Commissioning display appears 3 Select Others and the display of Fig 8 17 appears 4 Select Clock and the display of Fig 8 18 appears 5 Select Set date and the numeri
116. contacts mechanical relay contact outputs The contact rating is 250 VAC 3A or 30 VDC 3A The individual and common error contacts are set to normally energized and cannot be changed The NC and NO indications on the terminal show energized states States of common contacts to 4 are user selectable normally energized or normally deenergized The NC and NO indications on the terminal show deenergized states 5 13 5 14 Use PVC insulated PVC sheathed control cables for the wiring for these outputs There is no need to use shielded cables If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm Averaging Converter Basic Power Supply Expansion Power Unit gagging reefa leel 25 Annunciator etc Figure 5 13 Wiring for Individual Common Error Contact Outputs and Common Contact Outputs IM 11M12D01 01E 5 Wiring 5 2 10 Wiring for Contact Inputs The averaging converter receives contact inputs to perform the specified functions Follow the instructions below to run the wiring for contact inputs Use 2 core or 3 core PVC insulated PVC sheathed control cable for this wiring The number of cores is determined by the number of contacts to be used There is no need to use shielded cables If a cable gland is not installed on the wiring hole of the averaging con
117. ction temperature becomes a normal value Each channel Alarm 6 Process gas alarm Averaging converter receives a signal of process gas alarm at contact input To stop alarm Contact input signal of process gas alarm is removed System Alarm 7 Calibration gas pressure low alarm Averaging converter receives a signal of calibration gas pressure low alarm at contact input To stop alarm Contact input signal of calibration gas pressure low alarm is removed System Alarm 8 Asymmetry alarm Calibration coefficient unstable Alarm output if alarm enabled and conditions in Sec 12 2 3 7 are satisfied Each channel Inside temperature alarm Internal temperature of the case exceeds limit The limit is about 50 C in terms of case ambient temperature Occurrence cancellation time is recorded System Alarm stops if The internal temperature falls below the limit 712 2E eps IM 11M12D01 01E 12 Troubleshooting 12 2 3 Remedies when Alarms are Generated 1 Alarm 1 Oxygen concentration alarm See Subsection 8 2 Setting Oxygen Concentration Alarms 2 Alarm 2 Zero point calibration coefficient alarm IM 11M12D01 01E In automatic or semi automatic calibration Alarm 2 is generated when the zero correc tion factor is out of the range of 100 30 refer to Subsection 9 1 3 Compensation The following are possible causes of this alarm 1 The zero gas oxygen concentration
118. d numerical entry display appears To set 48 hours enter 048 Entry range is 1 to 255 hours lt Default setting gt Period over which average is calculated is set to 1hr and Period over which maxi mum and minimum is stored is set to 24 hrs prior factory shipment or after data initialization Averaging CF Set period over which L 1 average is calculated Set period over which 7 maximum and minimum is v stored 24h Fig 8 19 Average Max Min Setup IM 11M12D01 01E 8 Detailed Data Setting 8 5 3 Fuel Setup Humid Exhaust Gas or Dry Equivalent Oxygen Content This instrument can convert between humid gas measurements and dry equivalents C o 100 H gas H gas Water content of measured gas H20 Y ary Dry oxygen equivalent 02 Y Oxygen concentration in moist gas 02 Fuelequ eps Vin X 100 To convert between humid and dry gas measurements the water content H gas is computed To compute the water content four parameters Ao Gw X and Z are required and the following expression is used valet vapor caused by combustion and water vapor contained in the exhaust gas Y water vapor contained in air for combustion Moisture quantity x 100 actual exhaust gas including water vapor per fuel Gw Gw1 G x 100 Gw 1 61 x Z x m x Ao x 100 Go Gw m 1 Ao 1 61xZxmxAo P a Equation 1 S
119. d touch the Enter key 4 The Contact check display shown in Fig 7 18 allows you to select contacts to check To check the individual error contacts for channels 1 to 8 select Output contact ch Channel contact output or to select Function contacts contacts 1 to 5 select Output contact ctrl Common contact outputs 5 Next the Contact no select display is displayed Select the contact you want to check then touch the Enter key and the OFF On selection window opens Select then touch the Enter key to open or close the corresponding contact output Output contactch CPch1 Rean Ch2 Ch3 OFF Ch4 OFF Contact check gt Output contact ch Output contact ctrl Solenoid valve contacts gt kA a OOOO a O gt a Input contacts OFF Ch6 OFF lv Ch7 OFF Ch8 OFF 4 Enter l Fig 7 18 Contact check Fig 7 19 Contact select A Note 1 Individual error contacts do not operate if corresponding channel is not installed 2 If you perform a Channel Contact Output Open Close check then Error2 is gener ated The reason is that Channel Contact Output is used as Sensor heater power safety switch and this turns off power to the heater If this error occurs to reset it remove the channel card then reinsert it hot swap functions or turn power OFF then back ON 7 14 IM 11M12D01 01E 7 Startup 7 11 2 Checking contacts used to operate solenoid
120. d valve to switch zero and span calibration gases during calibration in the automatic calibration system and for operating the solenoid valve installed on the calibration gas line to the detector of each channel The contact output for solenoid valve is also used for operating the solenoid valve on the blowback piping For the wiring and piping of the system refer to Section 5 3 Wiring and Piping Examples Use shielded PVC insulated PVC sheathed control cables for the wiring for solenoid valves The shields should be connected to cable shield ground terminals on the case of the averaging converter If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm Like the signal wiring to detectors the shields should be connected to cable shield ground terminals on the case of the averaging converter All contact outputs for solenoid valves are voltage free dry contacts mechanical relay contact outputs The contacts are open under normal conditions when deenergized The contact rating is 250 VAC 1A or 30 VDC 1A If optional 24 V outputs are specified for solenoid valves Option Code 24 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550G Averaging Converter The maximum current that can be supplied to the solenoid valve is 50 mA Use solenoid val
121. display 6 If you select Preset Value and touch the Enter key then the display shown in Fig 8 10 appears 7 Selecting a preset setting and touching the Enter key displays the numeric entry display allowing you to enter a preset current in the range 2 4 mA to 21 6 mA mA outputs hold A Preset vaiue Al CF Warm up 4mA CPWarm up 4 0mA J Maintenance Non Hold Maintenance 4 0 mA J Cal Blow Ind Hold Cal Blow Ind 4 0 mA I Proc gas alm Hold Proc gas alm 4 0 mA 7 Error Hold gt Error 4 0 mA v Ave group invalid n Ave group invalid 4mA l 4 0mA el Enter Enter Fig 8 9 Current output hold Fig 8 10 Preset value setting lt Default setting gt Output hold settings are set to defaults in Table 8 2 prior factory shipment or after data initialization Tbale 8 2 Defaults for output hold and preset values Status Output hold value Preset value Warmup Purging 4mA 4mA Under Maintenance Hold last value 4mA Under Calibration Indication Check Hold last value 4mA Blowback Process Gas Alarm Hold last value 4mA Error Hold last value 4mA IM 11M12D01 01E No Valid Channels in Averaging Group 4mA 4mA T8 2Eeps 8 7 8 1 3 Setting Output Smoothing Coefficient Applies to All Analog Outputs When the oxygen concentration in the measured gas fluctuates rapidly if the measured value is used for control thi
122. display From the menu on the Execution Setup display select Commissioning The Commis sioning display where parameter setups can be selected will appear The following can be selected from the menu on this display 1 Selection of detectors and sample gases 2 Analog output setup 3 Alarm setup 4 Contact input output setup 5 Average group setup 6 Others clock setup password setup etc Maintenance Al Commissioning Al C Display setup L C Basic setup d Calibration setup mA output setup r Indication check setup Alarm set arm setup Blow back setup Contact setup mA output loop check gt Average group setup gt Contact check Channel card power qe 2 Others 4 Enter Figure 6 14 Maintenance Display Figure 6 15 Commissioning Display 6 2 2 5 Entering Numeric and Text Data 6 10 This section sets out how to enter numeric and text data If only numeric values are entered a numeric data entry display as in Figure 6 16 then appears Press the numeral keys to enter numeric values If those values include a decimal point as in Figure 6 16 the decimal point need not be entered because the decimal point position is already fixed so just enter 00098 New value 000 98 O2 F7 4E EPS Figure 6 16 Numeric data Entry Display IM 11M12D01 01E IM 11M12D01 01E 6 Components To enter a password in combination with text data numeric values and codes the
123. during autocalibration7 15 7 11 3 Checking Contact Inputs 00 eececeeeeeeeeeeeeeeeseeeseeseecaecsaeeaeenaes 7 15 8 Setting Operating 8 1 8 2 Parameters Detail and Examples ccssccssssscssssccssssccsssees S L Setting Analog Output oo eee aotre ie aes dte rss Eos EE SEEKERS e 8 1 8 1 1 Analog Output Range Per Channel 000 00 eee eee ceeeeeceeeeeeeeeeeeeeeneeaes 8 1 8 1 2 Output Hold Setting Applies to All Outputs oe eeeeeeeeee 8 3 8 1 3 Setting Output Smoothing Coefficient Applies to All Analog Outputs 0 eee ee ceceseeeeceeeeeesesereeeeaeeeneenee 8 8 8 1 4 Setting Output Mode Applies to All Analog Outputs 8 8 Oxygen Concentration Alarm Setting ccc ccc cseceescsecssessesecesesesesseseeeees 8 9 8 2 1 Setting the Alarm Values Individual Settings eee eeeeeeeeee 8 9 IM 11M12D01 01E 8 2 2 Alarm Delay Time and Hysteresis Applies to All Alarm Settings 8 9 8 3 Assigning Contact Outputs oo eee cee ceecseceseeseceseeseceeeeseceseeeeseeeeeeseneeage 8 13 8 4 Assigning Contact Inputs oo era eiee ae EE S NEEESE N EREE 8 15 8 5 Other SettiNg Sisseneri enen E EEEE EEEE r EEES 8 17 85 10 Date cand Time re EEE e SEEE REEE E Eo EE thas E 8 17 8 5 2 Average Value Max and Min Monitoring Time ee 8 18 8 5 3 Fuel Setup Humid Exhaust Gas or Dry Equivalent Oxygen COMED ics a sess Eei u E E eE Ba havens Ase tees Ae ene Sees 8 19 834 Settings PassWord reene a E athe cel ectedit
124. e Dust Filter Part No K9471UA etc 0 eee 3 3 3 1 5 Procedures for installing the dust guard protector K9471UC 3 4 3 1 6 Detector with a probe protector Model ZO21R L L1 B for enhance forth 0 0 0 eeeeeseeeee 3 4 viii IM 11M12D01 01E 3 1 7 Detector with a probe protector Model ZO21R L 1 B for dust wear protect eee 3 5 3 2 Installation of the Detector Model ZR22G 015 ee ce eeeecceesseeeeeteceesteeesenees 3 6 SQA Installation Location msiseme neee aE e S S 3 6 3 2 2 Usage of the High temperature Probe Adapter Model ZO21P H 3 6 3 223 Probe Insertion Hole ics serar a evans o e E Nee 3 7 3 2 4 Mounting of the High Temperature Detector esessesseeeeeeesrseresrereseesee 3 8 3 3 Installation of the Averaging Converter eesesesseseseeseeesssserersreerrreerreresesresene 3 9 33 1 Anstallation Location esenee a e e ARRE 3 10 3 3 2 Installation in an Instrument Panel 00 eee eeeeeseeeeeeeeceeeeceeeeneecenes 3 10 3 3 3 Outdoor Installation erinan EEE EEEE E E a a 3 12 3 4 Installation of ZA8F Flow Setting Unit sseeesssesseseeeeseeresssreresreererrererreresrsse 3 13 ZAL Location nai i E Bs E RERE his hoe EE ERER 3 13 3 4 2 Mounting of ZA8F Flow Setting Unit esseeeesseresesesesseserersreeresrnreses 3 13 3 5 Installation of the Calibration Gas Unit Case oo eee ceceesceeeneceeeeceteeeneeeees 3 15 3 5 1 Location zema eee
125. e and flowmeter Reference To reference gas flow setting flowmeter and needle valve gas line O Flowmeter Stop valve g k Solenoid valve J Needle valve Pressure regulator Purge gas cylinder If optional 24 V outputs are specified for solenoid valve MS Code 24 no external power supply for solenoid valves is required The solenpid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valvas Figure 4 13 Typical Piping for Purging IM 11M12D01 01E 4 13 4 14 IM 11M12D01 01E 5 Wiring 5 Wiring This chapter describes the wiring connections to the EXAxt AV550G Averaging Converter 5 1 General A DANGER Never apply power to the averaging converter and other instruments connected to the averaging converter until all wiring is completed A WARNING e This product complies with the CE marking Where compliance with the CE marking is necessary the following wiring is required 1 Install an external switch or circuit breaker to the power supply of the averaging converter 2 Use an external switch or circuit breaker rated 20A and conforming to IEC 947 1 or TEC 947 3 3 It is recommended that the external switch or circuit breaker be installed in the same room as the averaging converter 4 The external switch or circuit breaker should be installed within reach of the operator and identified with mar
126. e cell is degrading The updated values obtained during the calibration are displayed 10 3 10 1 10 Recommended Next Calibration Date Recording the cell emf at calibration time and monitoring the drift in cell emf with time gives an idea of how long it will take for measurement error to reach tolerance and thus recalibration can be scheduled before that date The tolerance is a maximum of 0 5 of range so if range is 0 25 Oz then tolerance is 25 O2 0 5 0 125 O2 The instrument extrapolates a line through the most recent three cell emf readings see Fig 10 4 uses this to determine how long it will take for measurement error to exceed tolerance and recommends that a recalibration date Predicts by extrapolating line through CAL 2xago Prev value 2x ago Previous and This present otra Ideal next CAL jwa 89 F10 4E eps Fig 10 4 Predicting Next Recalibration Date After the first three calibrations which however must be separated by at least five days or the data is ignored by the autopredictor the autopredictor starts operating A CAUTION 1 This function does not guarantee accuracy it s just a guide 2 The recommended date for the next calibration with be within the range of between 5 and 90 days 3 If the predictor finds that the slope of the line becomes positive the line slants upward to the right then it may recommend a next calibration date in five days time 4 After the predictor has
127. e flow setting unit 4 The temperature of the case should not exceed 40 C due to rays of the sun or radiated heat 5 No vibration 3 5 2 Mounting Mount the calibration gas unit case on a pipe nominal JIS 50A as follows 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The sum of the calibration gas unit case and the calibration gas cylinder weighs approximately 4 2 kg 2 Mount the unit case on the pipe by tightening the nuts with the U bolt so that the metal fitting is firmly attached to the pipe A pipe to be mounted i nominal JIS 50A O D 60 5 mm F3 16E EPS Figure 3 13 Pipe Mounting IM 11M12D01 01E 3 15 3 16 IM 11M12D01 01E 4 Piping 4 Piping This chapter describes piping procedures for the AV550G Zirconia Oxygen Analyzer Averaging Converter system based on two typical system configurations 4 1 Piping for a System Using Flow Setting Units for Manual Calibration IM 11M12D01 01E The piping for a system using flow setting units for manual calibration is shown in Figure 4 1 ZR22G Detector max 8 detectors Cell output thermocouple output cold contact compensation 0 75mm2 6 core Model AV550G Averaging Converter Analog outputs Averaged and individual outputs 4 to 20 mA DC Contact
128. e gas to the detector In addition to the system configuration shown in Figure 4 1 a purge gas cylinder and a pressure reducing valve and where necessary a stop valve a flowmeter and a needle valve are required Also a check valve should be installed on the calibration gas inlet of the detector A typical piping diagram for purging is shown in Figure 4 9 It is recommended that each instrument be installed to allow for minimum piping between the ZA8F Flow Setting Unit and the detector and between the solenoid valve for introducing the purge gas and the detector Detector Averaging Converter AV550G Bae yea ee TE A ___ Analog outputs te 3 Heater Z7 Averaged and individual outputs Check valve Contact output Calibration gas line To ZA8F Reference gas line Contact output gt Contact input Power supply Check valve Calibration gas line To ZA8F Reference gas line Flowmeter Stop valve g sa Solenoid valve ae ge Needlu valve Pressure regulator purging gas cylinder Figure 4 9 Typical Piping for Purging IM 11M12D01 01E 4 Piping 4 2 Piping for a System to Perform Automatic Calibration Detector The piping for a system to perform automatic calibration is shown in Figure 4 10 Averaging Converter AV550G _ Analog outputs Se S Heater 7 TTT Averaged and individual outputs enoid valve Contact output es M
129. e ground terminal screw is M4 1 The ground resistance should be 100 Q or less equivalent to Class D grounding 2 If the ambient temperature of the wiring installation exceeds 80 C use appropriate heat resistant wires A WARNING The flange bolts alone do not provide durable grounding of the detector Be sure to grounded the ground terminal IM 11M12D01 01E 5 11 5 2 7 Wiring for Individual and Average Concentration Analog Outputs For the signal wiring to analog outputs use shielded PVC insulated PVC sheathed control cables The number of cores is determined by the number of outputs If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm Like the signal wiring to detectors the shields should be connected to cable shield ground terminals on the case of the averaging converter The load resistance from the averaging converter including the wiring resistance should be 550 Q or less Averaging Converter Control Card Channel Card A Averaged Analog Output CH3 Receiver CH1 CH2 Individual Analog output Shield Figure 5 11 Wiring for Individual and Average Concentration Analog Outputs 5 2 8 Wiring for Solenoid Valve for Automatic Calibration This wiring is for operating the solenoi
130. e 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 2 Removal procedures 1 Remove the four bolts and associated washers from the tip of the detector probe 2 Remove the U shaped pipe support together with the U shaped pipe Remove filter also 3 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 sensor flange also comes in contact Otherwise the measurement gas will not be sealed 4 Use tweezers to pull the contact out of the groove in the tip of the probe 5 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 11 5 3 Part assembly procedure 1 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 Gr
131. e single core shielded wire is the cell signal terminal for the two core shielded cable the semi translucent rubber sheathed wire is the thermocouple terminal and the other wire is the terminal If the wires are marked match the markings with those on the terminal board When installing the cell assembly 6 replace the metal O ring 7 with a new one 11 3 5 Replacement of filter assembly Set the filter assembly 1 in place using a special pin spanner with a pin 4 5 mm in diameter part no K9471UX or equivalent If a filter assembly that has already been replaced once is used again apply grease NEVER SEEZ G7067ZA to the threads of the filter assembly 11 3 6 Replacement of O ring The detector uses three different types of O rings 14 21 and 22 One O ring alone 14 or two O rings 21 and 22 are used For a pressure compensating model two O rings are used for individual uses Two O rings 21 and 22 are used for reference gas sealing and require periodic replacement cs me K9470BJ Metal ring 14 K9470ZS Metal ring with grease Two pairs of O rings 22 with grease CD ko470zP T11 1E ESP 11 3 7 Cleaning the High temperature Probe Adapter 11 10 A CAUTION e Do NOT subject the probe of the High temperature Probe Adapter ZO21P H A 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 temp
132. e switching If ON then while contact input range switching signal is detected then there is contact output This is a range switching input answerback signal Corresponding contact input must be allocated to measurement range switching Maintenance If ON then while under maintenance there is contact output For definition of under maintenance see Sec 8 1 2 Setting Output Hold Calibration If ON then while under calibration there is contact output For definition of under calibration see Sec 8 1 2 Setting Output Hold Indication check If ON then during indication check there is contact output For definition of indication check see Sec 10 4 Indication Check Blowback If ON then there is Blowback switch contact output For definition of blowback see Sec 10 5 Blowback 3rd Check Gas If ON then during indication check there is contact output to operate 3rd Check Gas solenoid valve For definition of indication check see Sec 10 4 Indication Check T8 4E eps 8 13 lt Setting Procedure gt 1 Touch the Setup key and the Execution Setup display appears 2 From Commissioning select Contact setup and touch the Enter key 3 Select contact no to set up and touch the Enter key 4 Select Alarms or Others and touch Enter key You can set the condition s allocated to contact output Fig 8 14 5 Select ON OFF pulldown to set items ON and allocate the corresponding condition
133. e temperature and the pressure of a sample gas are high the temperature of the sample gas may not fall below 700 C before the gas reaches the detector On the other hand the temperature of a sample gas may drop too much and thus condensation develops in the high temperature probe ejector During wintertime it is recommended that the probe adapter be protected with an insulating material to prevent condensation Note If optional 24 V outputs are specified for solenoid valves Option Code 24 no external power supply for solenoid valve is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves e When a high temperature detector is used and blowback is required to eliminate dust accumulating in the probe of the high temperature probe adapter air supply piping for purging should be installed Note If a sample gas contains much dust e g in recovery boilers or cement kilns the probe is more likely to become clogged To eliminate this dust accumulation using air pressure piping is generally installed from an air source only when cleaning is performed Some cases however may need a permanent installation of the blowback piping See Subsection 4 1 5 for the installation of blowback piping 4 9 4 2 1 Parts Required for Piping in a System to Perform Automatic Calibration Referring to Table 4 2 check that the parts required for your syste
134. eces ZRO01A01 10 10 pieces 8 E7042BS 1 Contact 9 K9470BJ 1 Metal O ring 10 E7042AY 1 Filter Assembly 11 Bolts and Washeres K9470ZF 1 G7109YC x4 E7042DW x4 K9470ZG 1 K9470BK x4 E7042DW x4 for Option code C 12 Calibration Tube Assembly K9470ZK 1 Cal Gas Tube Assembly K9470ZL i Cal Gas Tube Assembly for Option code C 13 ZR22A DA 1 Heater Assembly YOKOGAWA All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M12A01 02E Subject to change without notice 1 st Edition Aug 2000 YK Yokogawa Electric Corporation 6 th Edition Jul 2005 YK Customer Model ZO21DW L EXA oxy Maintenance Zirconia Oxygen Analyzer Detector Parts List Pressure balance type Item Part No Qty Description 1 E7097BN 1 Cold Junction Assembly 2 G7109YC 4 Bolt M5x12 SUS304 Stainless steel 3 E7042DW 4 Washer 4 E7042BR 1 Plate 5 E7042UD 1 Cell Assembly 6 E7042AY 1 Filter 7 G7048XL 1 Metal O Ring 8 E7042BS 1 Contact 9 1 Cell Assembly 10 K9470BM 1 Pipe K9473AN 1 Pipe for option code C 11 G7011XH Needle Valve for ZO21DW L J E SV G7013XH 1 Needle Valve for ZO21DW L A SV E7042VR 1 Check Valve for ZO21DW L J E CV E7042VV 1 Check Valve for ZO21DW L A CV 12 1 Nipple for ZO21DW L J E SV G7248XA 1 Nipple for ZO21DW L A SV 1 13 G7007XH YOKOGAWA All Rights Reserved Copyright 1992 Yokogawa Electric Corporation CMPL 11M06B
135. eeding the temperature range limits NIC a AV550G AV550G wail Nase Air Filter Natural air cooling Forced air ventilation Forced air circulation Figure 3 9 Preventing Excessive Temperature Rise in Panel A CAUTION If an internal temperature rise alarm occurs use a more effective method to cool the inside of an instrument panel down to within the converter operating temperature range IM 11M12D01 01E 3 11 3 3 3 Outdoor Installation The averaging converter is designed for indoor installation For outdoor installation the averaging converter should be housed in an outdoor case protected from direct sunlight and the weather The outdoor case should be equipped with a cooling system for controlling the internal temperature if necessary Also the outdoor case should be installed in a location that keeps the case free from corrosive gases or dust A CAUTION If an internal temperature rise alarm occurs use a more effective method to cool the inside of an outdoor case down to within the converter operating temperature range 3 12 IM 11M12D01 01E 3 Installation 3 4 Installation of ZA8F Flow Setting Unit 3 4 1 Location The following should be taken into consideration 1 Easy access to the unit for checking and maintenance work 2 Near to the detector and the converter 3 No corrosive gas 4 An ambient temperature of not more than 55 C a
136. eeeeeeecseeeeecaeesaeceesaeeneenaes 2 19 2 6 Other Equipment ia esnean E S a ea a oueetind een 2 21 2 6 1 Dust Filter for the Detector Part No K9471UA eee ceccceeereeeeee 2 21 2 6 2 Dust Guard Protector Part No K9471UC s sseesseesesssseseeseseeessesesssee 2 21 2 6 3 Auxiliary Ejector for High Temperature Part No E7046EC or E7046EN sssesseesssesesssrsresreresreerssreresensesreee 2 22 2 6 4 Stop Valve Part No L9852CB or G7016XH oo eee cte eters 2 24 2 6 5 Check Valve Part No K9292DN or K9292DS sesser 2 25 2 0 0 cAI Setien erasa EE sass sessa sus EEE e EE hate aan aaah S 2 26 2 6 7 Zero Gas Cylinder Part No G7001Z0C seeseesessesssersesressresreseresrereses 2 28 2 6 8 Cylinder Regulator Valve Part No G7013XF or G7014XP 0 00 0 2 28 2 6 9 Calibration Gas Unit Case Part No E7044KF eeesesssssssseessseessesesseeee 2 29 2 6 10 Model ZR22A Heater Assembly seseseeeesseeesssessesreserseseeerssreresrssesreee 2 30 De Installati h coccesesssesdecskectesedeec adel sscasadecssdecsdeceaviseseacadedeueaside cd cdectdeceavsdessccadscsvesssdessocbcdsess L 3 1 Installation of the Detector 20 0 0 ce cccecescecessececeeeceseececesaecesesaeceseseeeesseeenenaes 3 1 SiVsk LOCatOnisintssees hives eases E E E Recieset aay 3 1 3 1 2 Probe Insertion Hole iorsin rei a iee iei 3 1 3 1 3 Installation of the Detector sonneeeenseseesseeeseeeereesereesrreesseeseressereesssessree 3 2 3 1 4 Installation of th
137. eeesecneeeneenaes 10 5 10 2 Trend Graphs sce cot lsh eRe aie Naps asta eee Hehe 10 6 10 2 1 Trend Graph Sereen gt ne ieies iire ee si dt ana iene 10 6 10 2 2 Time Axis of Trend Graph issons nree i kens 10 7 10 2 3 Trend Graph Display Settings 200 eee eeeeeeceeeeseeseecnecneeeneenaes 10 8 10 3 Other Display related Functions 000 0 eee cece ceeceseceeeeseeeeeeeeeeeeeeeeeeeseeees 10 9 10 3 1 Auto return Time i sssccssesssessetsesesesssaed testessttsthssbantoasesshpstossisbeassesvessscs 10 9 IM 11M12D01 01E xi 10 3 2 Selecting Language iv ssccccsscissesesduashsaessenscsspesspesscansendoabapsesssnssnassenseseseed 10 9 103 3 CCD Auto Off tees ais arerioei Een eet EENE alo as EEEE ENES 10 10 10 3 4 Display Contrast Adjustment ssesesseeeseeseeesseesesreresreserreserreseeereseeees 10 10 10 3 5 Tag Name Entry serina E E 10 10 10 4 Indication Check re e re ches ses back S EE E AE EE EEEE EEEE 10 11 TROJS a E KoLa I Ee AEE OA EE EE EEEE E EEEE 10 11 10 4 2 Procedure for Performing an Indication Check o oo 10 12 10 4 3 Setting Contacts for Operating Third Check Gas Solenoid Valve 10 12 10 4 4 Setting Indication Check Timing eeseseeeesseeeseeresssresesreserreserereereees 10 13 10 4 5 Running an Indication Check sseeseseeeessseeeeseeersreereerssrerrserrrsreeerreeese 10 15 10 4 6 Starting Auto Indication Check sssesseseeeeseeeeeresesrssesrrserresreereresees 10 18 10 5 Bl wback i 3 seis cess ces oit
138. efer to chapters 7 to 10 When user changes the operation parameter it is recommended to note down the changed setting data After Sales Warranty vi Do not modify the product 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 If we replace the product with a new one we won t provide you with a repair report 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 mainte nance engineer will be charged to the customer In the following cases customer will be charged repair fee regardless of warranty period e Failure of components which are out of scope of warranty stated in instruction manual e Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Electric did not supply e Failure due to improper or insufficient maintenance by user e Failure due to modification misuse or outside of specifications operation which Yokogawa does
139. ell electromotive force cell temperature and calibration history per channel 02 21 0 02 21 0 21 0 02 21 0 02 gl A Cell voltage Thermo voltage 29 4mV C J resistance 1170 20 Cell temperature 750 C C J temperature 43 C VT momo Figure 6 7 Detailed Data Display Up to 11 user selected data from among the individual outputs from each channel and average concentration outputs groups a b and c can be viewed in graphical format at a time in a single screen To move to the trend graph display touch the graph display key on a basic panel display The cascade function may be used to view each trend line of channels clearly in the trend graph display The function offsets the axes so that trend lines do not overlap 7 2 3 4 5 6 7 8 a b c 1 2 3 4 5 6 7 8 a b c 25 0 0 0 02 30min div 30min div 02 6 8 F0608 eps F0609 eps Figure 6 8 Trend Graph Display Figure 6 9 Cascade Display IM 11M12D01 01E 6 Components 4 Execution Setup display Touch the Setup key on the basic panel display The Execution Setup display will appear From the menu items calibration indication check blow back maintenance or commissioning select the desired item to perform Execution Setup ra Execution l F Calibration Eil Indication check Blow back Setup x Maintenance
140. er Than True Value 12 16 lt Causes and Countermeasures gt 1 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 Dp kPa X Y 1 Ap 101 30 where Y Measured oxygen concentration value at the same pressure as in calibra tion 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 Is performing calibration available under the average measuring gas pressure internal pressure of a furnace 2 Moisture content in a reference gas changes increases 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 O 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 3 Calibration gas span gas is mixing into the detector due to leakage If the span gas is mixing into the detector due to leakage as a result o
141. er power cords 2 The converter may be affected by noise from the power supply Check whether or not the converter power is supplied from the same outlet switch or breaker as other power machines and equipment 3 Poor wiring contact If there is poor contact in the wiring the sensor voltage or thermocouple emf voltage may vary due to vibration or other factors Check whether or not there are loose points in the wiring connections or loose crimping caulking at the crimp on terminal lugs 4 Combustible components in the measured gas may be getting into the sensor If the combustible components show signs of dust the abnormality may be im proved by mounting a dust removing filter K9471UA 5 There may be a crack in the sensor or leakage at the sensor mounting portion If the indication of concentration varies in synchronization with the pressure change in the furnace check whether or not there is a crack in the sensor or whether the sensor flange is sticking tightly to the probe attaching face with the metal O ring squeezed 6 There may be leakage in the calibration gas tubing In the case of a negative furnace inner pressure if the indication of concentration varies with the pressure change in the furnace check whether or not there is leakage in the calibration gas tubing IM 11M12D01 01E 12 17 42 18 IM 11M12D01 01E SSS Customer Maintenance Parts List Model AV550G Averaging Converter
142. erage value a average value b average b 08g IM 11M12D01 01E 2 Specifications Independent Output Output to each channel Range any setting between 0 to 5 through 0 to 100 vol O2 in 1 vol O2 or partial range is available Maximum range value minimum range value 1 3 or more For the log output the minimum range value is fixed at 0 1 vol Oz 4 to 20 mA DC linear or log can be selected Input output isolation Output damping 0 to 255 seconds Hold non hold selection preset value setting possible with hold Contact Output Five points contact capacity 30 V DC 3 A 250 V AC 3 A resistive load Four of the output points can be selected to either normally energized or normally deenergized status Delayed functions 0 to 255 seconds and hysteresis function 0 to 9 9 vol O2 can be added to high low alarms The following functions are programmable for contact outputs 1 Abnormal 2 High high alarm 3 High alarm 4 Low low alarm 5 Low alarm 6 Maintenance 7 Calibration 8 Range switching answer back 9 Warm up 10 Calibration gas pressure decrease answerback of contact input 11 Blowback start 12 Process alarm answerback of contact input 13 Calibration coefficient alarm 14 Internal temperature rise alarm Contact output 5 is set to normally operated fixed error status Contact Output for Individual Channel Fail Output to each channel Normally energized Each channel cards provide
143. erature Probe Adapter 3 When the probe adapter is surrounded by a heat insulator remove the heat insulator Ensure that the temperature of the probe adapter does not fall below the dew point of the gas in winter 4 To prevent temperature rises due to radiant heat insert heat insulator between the wall of the furnace and the probe adapter 5 To prevent temperature rises from thermal conduction place the mounting flange as far from the wall of the furnace as possible 3 6 IM 11M12D01 01E 3 Installation lt When the surface temperature is less than 200 C or the dew point of the measure ment gas gt 1 When the furnace pressure is negative raise the analyzer pressure to increase induction flow of the measurement gas Refer to Section 2 6 3 Auxiliary Ejector for High temperature Use for the setting of induction flow If there is much dust in the gas the ejector may become clogg is induction flow increases 2 When the furnace pressure is positive open the needle valve for the sample gas outlet to increase the gas flow Refer to Section 4 1 4 Piping to the High temperature Probe Adapter 3 Warm the probe adapter Refer to Section 4 2 4 Piping to the High temperature Probe Adapter Ensure that its temperature does not drop below freezing point in winter 4 When the surface temperature is still less than 200 C or the dew point of the mea surement gas even if the above measures have been taken warm the probe adapte
144. erature detector is structured so that the gas to be measured is directed toward the detector with the high temperature probe adapter Therefore if the probe 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 11M12D01 01E 11 Inspection and Maintenance 11 3 8 Stopping and Re starting Operation IM 11M12D01 01E lt Stopping Operation gt When operation is stopped take care of the following so that the sensor of the detector cannot become unused A CAUTION When operating an instrument such as boiler or industrial furnace is stopped with the zirconia oxygen analyzer operation moisture can condensate on the sensor portion and dusts may stick to it If operation is restarted in this condition the sensor which is heated up to 750 C may become permanently contaminated The dust can greatly degrade sensor performance If a large amount of water is condensed the
145. es When Errors Occur ssseseesseessereseeresrsersrrrrsrrerseeee 12 1 12 11 Error Types poire eae E E E EEE TEE EE EAE A 12 1 12 1 2 Operations When an Error Occurs ssesseseeeesseeesssresesrsserreseerrereeresreresre 12 2 121 3 Error Displays ape eare aree E o ne pS 12 3 12 1 4 Remedies When an Error Occurs essssesseseeeessseesesresrsrssrrresrerrsreeresesreses 12 4 IM 11M12D01 01E 12 2 Displays and Remedies When Alarms are Generated 1 0 0 0 teers 12 7 1221 Alir Ty pO socecscsceicbisds sac bencs fos cies vest a co een evilestetes Wasi E estes cadbaceteceuts 12 7 12 2 2 Alarm DISplay S n a A E a E EE EO EE 12 8 12 2 3 Remedies when Alarms are Generated 0 ccccccccccessecccecesenseeeeeeees 12 9 12 3 Countermeasures When Measured Value Shows Error cccccceeeeeee 12 16 12 3 1 Measured Value Higher Than True Value eee eeeeeeeeee 12 16 12 3 2 Measured Value Lower Than True Value ccccccsscceceessseceeees 12 17 12 3 3 Measurements Sometimes Show Abnormal Values 066 12 17 Customer Maintenance Parts List ssccscssssssssssssssssssssssseees CMPL 11M12D01 01E Customer Maintenance Parts List ssccccssssssssssssssssssssssssees C MPL 11M12A01 02E Customer Maintenance Parts List sscscccssssssssssssssssssssesesess Customer Maintenance Parts List sscccssssssssssssssssssessseesess Customer Maintenance Parts List
146. es should be connected to the high temperature probe adapter For the use of the probe adapter when the high temperature detector is used refer to Subsection 3 2 2 e If the pressure of a sample gas is negative connect an auxiliary ejector E7046EC E7046EN as shown in Figure 4 3 Mount the pressure gauge as close as possible to the auxiliary ejector However if the ambient temperature is too high mount the gauge in a location with a temperature below 40 C Detector Auxiliary ejector for high temperature use Adapter for high temperature probe F4 3E EPS Figure 4 3 Mounting the auxiliary ejector e If the temperature of a sample gas is high and its pressure exceeds 0 49 Pa the temperature of the sample gas at the detector may not be below 700 C In this case connect a needle valve commercially available through a nipple commercially available to the sample gas outlet Rc1 2 of the probe adapter so that the sample gas exhaust volume can be restricted In cases where condensation is likely to occur in the probe adapter when the sample gas is cooled protect the probe adapter with an insulating material as shown in Figure 4 5 IM 11M12D01 01E IM 11M12D01 01E 4 Piping Reducing nipple R1 2 R1 4 or R1 2 1 4NTP Needle valve F4 4E EPS Figure 4 4 Mounting the needle valve for restricting exhaust flow of the sample gas Cover flange Sample gas outlet Adapter for high temperature probe Detector Insu
147. ess life gt 1 year Cell resistance 110 Next caldate 0000 2000 WwW Fm 6E EPS Figure 12 10 Detailed Data Display Cell Robustness 12 10 IM 11M12D01 01E 12 Troubleshooting 3 Alarm 3 Span point calibration coefficient alarm In automatic or semiautomatic calibration this alarm is generated when the span correction factor is out of the range of 0 18 refer to Section 9 1 3 Compensa tion The following are suspected as the cause 1 The oxygen concentration of the span gas does not agree with the value of the span gas set Calibration setup 2 The flow of the span gas is out of the specified flow value 600 mL min 60 mL min 3 The sensor assembly is damaged and the cell voltage is abnormal lt Locating cause of failure and countermeasures gt 1 Confirm the following and carry out calibration again If the items are not within their proper states correct them a If the display Span gas conc is selected in Calibration setup the set point should agree with the concentration of span gas actually used b The calibration gas tubing should be constructed so that the span gas does not leak 2 If no alarm is generated as a result of carrying out re calibration it is suspected that improper calibration conditions were the cause of the alarm in the preceding calibra tion In this case no specific restoration is necessary 3 If an alarm is generated again as a result of carrying o
148. essure gauge 3 Open the needle valve to supply air for the ejector to the pressure gauge until it indicates the pressure setting Po AN Note Qg the suction flow may require change according to the conditions of use Refer to Section 3 2 2 and Section 4 1 4 for details Graph explanation 1 Graph 1 is to compensate for pressure loss in piping between the ejector and the pressure gauge and find Po pressure setting 2 Graph 2 shows correlation between P drive pressure and Qa air consumption 3 Graph 3 shows correlation between P drive pressure and Pg suction pressure when the measured gas inlet of the ejector is closed 4 Graph 4 shows correlation between P drive pressure and Qg suction flow for each gas pressure 2 6 4 Stop Valve Part No L9852CB or G7016XH This valve is mounted on the calibration gas line in the system using flow setting unit for manual calibration Standard Specifications Connection Rc 1 4 or 1 4 FNPT Material SUS 316 JIS Weight Approx 80 g Part No Description L9852CB Joint RC 1 4 Material SUS 316 JIS G7016XH Joint 1 4 NPT Material SUS316 JIS T2 9E EPS 943 T D E 2 wo amp 2 g 5 L Rc1 4 or 1 4NPT x F15 EPS 2 24 IM 11M12D01 01E 2 Specifications 2 6 5 Check Valve Part No K9292DN or K9292DS IM 11M12D01 01E This valve is mounted on the calibration gas line in the system such as the one using flow se
149. etal O ring Sensor U shaped pipe i Dust filter v Wo optional Bolts N Probe L gD Yg oN 8 a Filter N shaped pipe iS four 1 8 turn tighten bolts 1 8 turn F11 6E EPS approximately 45 each Figure 11 6 Exploded View of Sensor Assembly 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 IM 11M12D01 01E 11 Inspection and Maintenance 11 3 4 Replacement of the Heater Unit IM 11M12D01 01E This section describes the replacement procedure for the heater unit The sensor or ceramic heater furnace core internal structure is subject to fracturing so do NOT subject it to strong vibrations or shock Additionally the heater unit reaches high temperatures and is subjected to high voltages So maintenance services should be performed after the power is off and the heater unit temperature has returned to normal room temperature For details refer to IM11M12A01 21E Heater Assembly AN Note If the heater strut assembly can not be removed because a screw has fused to its thread one of our service representatives can fix it 11 8 Figure 11 7 Exploded View of Detector When pressure compensation specified Note The parts marked by is not equipped with the types except t
150. f failure of the valve provided in the calibration gas tubing system the measured value shows a value a little higher than normal Check valves needle valves check valves solenoid valves for automatic calibra tion etc in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed states In addition check the tubing joints for leakage 4 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 1 may occur in the sensor Measured gas and or the reference gas may be leaking Visually inspect the sensor If any crack is found replace the sensor assembly with a new one AN Note Data such as cell robustness displayed in the detailed data display should also be used for deciding sensor quality as references IM 11M12D01 01E 12 Troubleshooting 12 3 2 Measured Value Lower Than True Value lt Causes and Countermeasures gt 1 The measuring gas pressure becomes lower Where an increment of the measured value due to pressure change cannot be neglected take measures referring to subsection 12 3 1 1 2 Moisture content in a reference gas changes decreases greatly If air at the detector installation site is used for the reference gas large change of moistu
151. fect IM 11M12D01 01E 12 13 12 14 1st calibration Example When the second calibration result is compared with the first the change in slope indicates sensor degradation 2nd calibration cell emf However when the third calibration result is compared with the second the slope has not changed only the zero offset suggesting clogging and pressure effects 21 F12 11E eps Fig 12 11 Cause of alarm 2 Conditions for generating an alarm When the current result and the twoprevious results for the oxygen concentration resulting in a given cell emf are compared if both of the following conditions are satisfied then an alarm is issued librati cell emf mV Current calibration Previous calibration A B 0 125 O2 B C 0 125 O2 Calibration before previous one O2 value Fig 12 12 Conditions for alarm A repeatability of 0 125 O2 on the 0 to 25 range is determined from the specified precision 25 O2 x 0 5 0 125 Oz However the following restrictions apply a When either span or zero calibration is performed not both the results are ignored in applying the above criteria b If calibrations are separated by an interval of less than 5 days then the results are ignored in applying the above criteria 3 Conditions for releasing alarm status a If calibration results show improvement compared with previous results e g higher cell emf then it is assumed that clogging has
152. flowmeter Detector Averaging Converter AV550G pe E O __ _ Analog outputs Averaged and individual outputs Heater Solenoid valve Contact output M Contact input Calibration contact outputs Power supply Calibration gas line PD aii valve Span gas cylinder Instrument air Reference gas line Flowmeter Flowmeter Instrument air Air set Needle valve Zero gas cylinder Figure 1 2 Typical System Configuration to Perform Automatic Calibration 1 2 IM 11M12D01 01E 1 2 System Components 1 2 1 1 2 2 IM 11M12D01 0 System Components and Their Applicability Item Model Part Number Specifications 1 Overview System 1 System 2 Manual Calibration Automatic Calibration Averaging Converter AV550G A or B Detector See 1 2 2 O Flow setting unit ZA8F O Needle valve For flow control Flowmeter 0 to 1 L min Solenoid valve G7000XP E7057G Solenoid valve for zero span switching Solenoid valve for switching two streams Stop valve L9852CB G7016XH Air set K9473XH K9473XJ G7004XF K9473XG Pressure regulator for zero gas cylinder G7013XF G7014XF Zero gas cylinder G7001ZC Detectors and Accessories Thl 1 2 eps E
153. g 6 X O4mm F4202 EPS or nominal 1 4 inch stainless steel pipe Figure 4 11 Piping for the Calibration Gas Inlet IM 11M12D01 01E 4 11 4 2 3 4 2 4 4 2 5 4 2 6 Piping for the Reference Gas The piping for the reference gas should be installed between the air source instrument air and the detector through flowmeters and needle valves for flow control of the reference air and an air set e Install the piping from the reference gas inlet of the detector to the air source with a flow meter a needle valve where necessary and an air set in this order e Install the flowmeter needle valve and air set in close proximity e Use stainless steel pipes with 6 OD x 4 ID mm or nominal 1 4 inch or larger inside diameter for the piping for the reference gas Piping to the High Temperature Probe Adapter The piping to the high temperature probe adapter is required when a high temperature detector is used This piping is the same as the one in the system using flow setting units for manual calibration See Subsection 4 1 4 Piping for Blowback The piping for blowback is required only when the blowback is conducted in a system using a high temperature detector This piping is the same as the one in the system using flow setting units for manual calibration See Subsection 4 1 5 Piping for Indication Check To perform an indication check using the third check gas the piping to allow the third gas to flow into the calibration ga
154. g interval in the range 1 to 30 seconds Setting trend graph vertical scale 8 From the Trend Graph display select Upper Limit and touch the Enter key The numerical entry display appears and you can enter the upper limit value The lower limit value can be entered in a similar manner Both upper and lower limit values can be entered in the range 0 to 100 O2 however the upper limit value must be set higher than the lower limit value by at least 1 Ox lt Default setting gt The graph parameters are set to the following default prior factory shipment or after data initialization Table 10 2 Item Initial value Displayed channels All channels Sampling interval 30 seconds Upper limit 25 O2 Lower limit T10 2E eps IM 11M12D01 01E 10 Other Functions 10 3 Other Display related Functions 10 3 1 Auto return Time On the Execution Setup display or lower level menu displays if no keys are touched for a preset time the auto return time then the display will automatically revert to the basic panel display The auto return time can be set in the range 0 to 255 minutes If it is set to 0 then the display does not automatically revert lt Setting procedure gt 1 On the basic panel display touch the Setup key to display the Execution Setup display then select Maintenance Select Display setup then Auto return time 2 The numerical entry display appears for you to enter the desired auto return
155. hannel starts 10 5 5 2 Auto Blowback No user action is required to start blowback at the preset time and repeat it at the preset interval 10 24 IM 11M12D01 01E 10 6 Purging 10 Other Functions At the beginning of calibration condensation that has developed in the calibration gas piping may be blown onto the sensor causing sudden cooling and damage to the sensor Purging involves passing span calibration gas through the piping for a preset time before warmup in order to remove any such condensation If the cell temperature is 100 C or greater then purging cannot be performed While purging is being performed a Purge status mark is displayed on the basic panel display as shown in Fig 10 31 Purging is performed in sequence starting with the smallest channel number The timing of purging is shown in Fig 10 29 Chr detector Measurement mode Ch4 detector hogs oe F10 29E eps Power ON IM 11M12D01 01E Fig 10 29 Purging Timing A CAUTION 1 When using hot swap functions to start a single specific channel purging for that channel alone is performed there is no effect on other channels 2 While any such specific individual channel is being purged then manual or semi auto calibration or indication check cannot be started for any channel 3 While any such specific individual channel is being purged then auto calibration auto indication check or auto blowback for any channel will wait until it ends 4
156. he pressure compen sation type IM 11M12D01 01E 11 Inspection and Maintenance Replacement of heater strut assembly ZR22G Style S2 and after IM 11M12D01 01E Refer to Figure 11 7 as an aid in the following discussion Remove the cell assembly 6 following Section 11 3 2 earlier in this manual Open the terminal box 16 and remove the three terminal connections CELL TC and TC Before disconnect the HTR terminals remove the terminal block screw 28 Keeping the other terminal remaining to be connected Disconnect the two HTR connections These terminals have no polarity Remove the two screws 15 that fasten the cover 12 and slide it to the flange side Remove the four bolts 10 and terminal box 16 with care so that the already discon nected wire will not get caught in the terminal box In case of the pressure compensation type detector remove the screw 35 and the plate 37 on the adapter 35 Remove the adapter 35 drawing out the wires of the heater strut assy 23 from it Loosen Screw 19 until Heater Strut Assembly 23 plate can be removed There s no need to remove O ring 18 which prevents Screw 19 from coming out Pull out connector 13 Loosen and remove the screw 8 with a special wrench part no K9470BX or equiva lent and then remove the heater strut assembly 23 from the detector 24 To reassemble the heater strut assembly reverse the above procedure Insert the heate
157. he sides of the cover with the knob bolts on the case and then pull the cover down until it is seated firmly e Hand tighten the knob bolts and then securely tighten the lock screw with the Allen wrench supplied Knob Bolt g Lock Screw St Figure 3 7 How to Remove Attach the front Cover IM 11M12D01 01E 3 9 3 3 1 Installation Location Follow the guidelines below when selecting a location for the averaging converter 1 The touch screen display should be clearly visible and easily accessible for key operation the display at eye level is recommended 2 A wall or construction should be strong enough to support the weight of the converter 3 The converter should be easily accessible for inspections and maintenance 4 The ambient temperature should be in the range of 5 to 50 C and the temperature variation should be small the daily temperature range within 15 C is recommended 5 The humidity should be in the range of 10 to 85 RH and no condensation may occur 6 No corrosive gases are present 7 No dust exists 8 There is minimal vibration 9 The converter should be near the detectors the two way resistance between detector and converter should not exceed 10 Ay DANGER e The averaging converter is heavy Take extra care not to accidentally drop it Installation work should be done by an adequate number of people 3 3 2 A CAUTION The
158. he value is higher than 5 Q it may indicate that the thermo couple wire has broken or is about to break In this case replace the heater unit refer to Subsection 11 2 3 Replacement of the Heater Unit Also check that the wiring resistance between the converter and the detector is 100 or less A CAUTION Measure the thermocouple resistance value after the temperature difference between the detector tip and the ambient atmosphere has decreased to 50 C or less If the thermo couple voltage is large accurate measurement cannot be achieved IM 11M12D01 01E 12 5 3 Error 3 Cannel card failure This indicates that the channel card with an error has failed to operate properly Replace the channel card Before replacing the channel card be sure to turn off power to the channel card to be replaced by hot swap function 4 Error 4 Control card failure This indicates that the control card has failed to operate properly Contact our service office 5 Error 5 Inter card communication failure If Error 5 occurs only on a certain channel the channel card fails to operate properly Replace the channel card If Error 5 occurs on all channels the control card malfunc tions Contact our service office 12 6 IM 11M12D01 01E 12 Troubleshooting 12 2 Displays and Remedies When Alarms are Generated 12 2 1 Alarm Types The following types of alarms may be generated by the averaging converter If an alarm is generated actions su
159. hen the Lcd auto off function does not operate lt Default setting gt The Lcd auto off time is set to 0 prior factory shipment or after data initialization 10 3 4 Display Contrast Adjustment Display contrast can be adjusted by the following procedure lt Setting Procedure gt 1 From Display setup select Display contrast 2 If you press the Enter key then the contrast adjustment display of Fig 10 8 appears 3 Use the lt and gt keys to adjust for best contrast then touch the Enter key 4 If you touch the Reject key then no changes are made ie Enter Low q gt High F10 8E EPS Fig 10 8 Contrast Adjustment Display 10 3 5 Tag Name Entry 10 10 You can enter an arbitrary Tag Name for this instrument lt Setting Procedure gt 1 From Display setup select Tag name 2 A text entry display appears for you to enter an arbitrary tag name You can use alphanumerics and symbols up to 12 characters IM 11M12D01 01E 10 Other Functions 10 4 Indication Check In addition to zero and span calibration gases you can select a third check gas for a 3 point check This is another check to determine if there is any discrepancy between the measured value and the certified concentration of the gas 10 4 1 Mode There are three modes of indication check operation manual semi automatic and automatic In Manual mode zero span and third gas indication checks can be per
160. hould be 1 25 mm2 16 AWG or larger and the conductor two way resistance should be 10 Q or less If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm The shields should be connected to cable shield ground terminals on the case of the averaging converter 5 8 IM 11M12D01 01E IM 11M12D01 01E 5 Wiring Detector 1 Averaging Converter Basic Power Unit CH1 CH2 CH3 CH4 er 2 e so 9 ZR22G ZO021D Shield Detector 2 Detector 3 Detector 4 Figure 5 7 Power Wiring to Detector Heaters If the ambient temperature at the detector installation site exceeds 80 C install a terminal box and connect to the detector using 600 V silicon rubber insulated glass braided wires The distance between the detector and the terminal box should be minimized Detector 1 Averaging Converter Basic Power Unit CH2 CH3 CH4 CH1 selee eE HE Terminal Box Shield Silicon Rubber Insulated Glass Braided Wire To Detector 2 To Detector 3 To Detector 4 Figure 5 8 Power Wiring to Detector Heaters Using Terminal Box 5 9 5 2 5 5 10 Signal Wiring to Detectors This wiring is for transmitting signals of cell electromotive force thermocouple output and cold junction compensation from a detecto
161. ic 25 0 O2 10min div oN Time per division calculated from sampling interval Preset upper limit Preset lower limit 0 0 O2 60 data otny eneen taspats Pod F10 6E eps Sampling interval Fig 10 6 A CAUTION If a rapid change in the measured value occurs during sampling no sampled data are plotted on the graph Use the graph indication tentatively Check the output current for accurate data 10 7 10 2 3 Trend Graph Display Settings lt Setting procedure gt Selecting channels to be displayed 1 On the basic panel display touch the Graph Display key to display the Trend Graph display 2 If you touch anywhere in the Graph display area the Graph Channel Select display will appear The colors of the channel numbers correspond to the colors of the trend graphs Grayed out channels are not selected for display 3 To suppress display of the Ave a graph move the pointer to Ave a and touch the Enter key The color of Ave a turns gray and its trend graph is no longer dis played Entering the sampling interval 4 On the basic panel display touch the Setup key to display the Execution Setup display 5 Select Maintenance then Display Setup and touch the Enter key 6 Select Trend Graph and tough the Enter key 7 Select Sample Interval and touch the Enter key and the numerical entry display appears You can enter a value for the samplin
162. ich sistas Aas atte sartana neroa ea ta Eies EE EEEE EE 10 19 105 1 M dems irena a Sette a Ge ae E ene eae 10 19 10 5 2 Setting Contacts for Operating Solenoid Valves essseeeeeseeeeseee 10 20 10 5 3 Setting Blowback Start Time ssessssesseeseeesseeeresrsresrssesresrrrrsreereseeses 10 21 10 5 4 Operation of Blowback sesessseesesseeeseesreerssrerssrsesreresreserrrnererenesess 10 23 10 5 5 Performing Blowback rnio oaeen een etereoa a enaa eeso e s ireo enei 10 24 10 6 PUrgiNg a eean aier eeren eiro r seas arao RARER AE woos easnsssssscisasbescpeateseescasaeesees 10 25 10 7 Parameter Initialization esseseseeseeeseseeeesseeesereessresresreesrsserresrenrsreereseneses 10 27 10 8 Methods of Operating Valves in the ZA8F Flow Setting Unit 10 31 10 8 1 Preparation Before Calibration eee esecseesecseeseeeeeeseeneees 10 31 10 8 2 Operating the Span Gas Flow Setting Valve n 10 31 10 8 3 Operating the Zero Gas Flow Setting Valve eee eeseeeeeeees 10 32 10 8 4 Operation After Calibration 0 e eeececseececsseesecnseeeeeseeseeneees 10 32 11 Inspection and Maintenance sccssccssssscssssccssssccsssscssssscssseccssssscssssccssssccsssece L1 1 11 1 Removing and Attaching the Front Cover eeesceeeeeeeeeeeeeeeeeene 11 2 11 1 1 Removing the Front Cover oc eeececeeeeeeeeeeeeeceseeeeeeseecnecaeeneenaes 11 2 11 1 2 Attaching the Front Cover oo eee eceeeeeeeeeeecseeseecneesaecsecsaeeneenaes 11 2 11 2 Hot Swap
163. ield The in situ probe is mounted on the duct wall and directly measures the oxygen concentration of a sample gas at a temperature of up to 700 C For higher temperature applications up to 1400 C the ZO21P H High Temperature Probe Protector is available for use in conjunction with a 0 15 m ZR22G general purpose detector The averaging converter system is ideal for combustion control in large utility boilers or various industrial furnaces This chapter explains system configurations with some typical examples Configuration The AV550G Zirconia Oxygen Analyzer Averaging Converter system can be configured by selecting detectors and an averaging converter that meet the individual requirements and flow setting units for calibration Subsection 1 1 1 presents a typical system configuration using flow setting units for manual calibration A typical system configuration to perform automatic calibration is provided in Subsection 1 1 2 1 1 1 System Configuration Using Flow Setting Units for Manual Calibration IM 11M12D01 01E This system consists of detectors an averaging converter and flow setting units Model ZA8F as shown in Figure 1 1 Note that the ZA8F Flow Setting Units are required as many as the detectors connected to the averaging converter A reference gas needs to be supplied at a constant flow rate to the detectors This reference gas must be clean dry air having a constant percentage of oxygen Typically instrument air tha
164. if there is a check valve then adjust it to approximately 150 kPa above that of the measured gas but pressure should be no greater than 300 kPa Adjust reference gas flow so that it is in the range 800 1000 ml min 7 2 IM 11M12D01 01E 7 Startup 7 4 Setting Detector model The default detector model set before shipment from the factory is ZR22G If you plan to use the ZO21D then before starting warmup you need to change the default setting If you do not change the setting before starting warmup then detector tempera ture control will not work properly and serious damage to the detector may result There are two ways of changing this setting before warmup as follows How to use Channel card Hot Swap feature This converter allows you to toggle the power supply of individual channel cards OFF ON while power to the converter is applied This method also allows you change the detector model settings without detector warm up 1 Touch the Setup key and the Execution Setup display appears 2 Move the arrow pointer key to Maintenance and touch the Enter key 3 On the Maintenance display select Channel card power and touch the Enter key A display like that shown in Fig 7 3 appears 4 On the Channel Card Power display select the channel no of a channel connected to a ZO21D then touch the Enter key 5 A Disable Enable selection window is displayed Select Disable and touch Enter Confirm that the status display l
165. ight Insertion length of 1 0m approx 6 5 kg JIS approx 8 5 kg ANSI Insertion length of 1 5 m approx 7 5 kg JIS approx 9 5 kg ANSI Sample gas temperature 0 to 1400 C when using SiC probe 0 to 800 C when using SUS 310S probe adapter Sample gas pressure 0 5 to 5 kPa When using in the range of 0 to 25 vol O or more the sample gas pressure should be in the range of 0 5 to 0 5 kPa Where the sample gas pressure for the high temperature probe is negative an auxiliary ejector is necessary Model and Codes Option code Description High Temperature Probe Adapter A e wl SIC Material po pees SUS 310S Insertion 100 berets 1 0m length SUB EET EEEE 1 5m Flange NE T A E JIS 5K 50 FF SUS304 ssis JIS LOK 65 FF SUS304 ere JIS LOK 80 FF SUS304 Sass JIS LOK 100 FF SUS304 wees ANSI Class 150 4 RF SUS304 re ANSI Class 150 2 1 2 RF SUS304 ssis ANSI Class 150 3 RF SUS304 sin JPI Class 150 3 RF SUS304 4 JPI Class 150 4 RF SUS304 sson DIN PN10 DN50 A SUS304 Style code eperecesene Style A T2 3E EPS IM 11M12D01 01E IM 11M12D01 01E External Dimensions Measured gas outlet Approx 351 2 Specifications Unit mm R1 2 Note2 Insertion length Note1 wo 2 N lt 2 o Qo N lt yy A 4 4 oO oO x lt O 9 T lt 180 7 Flange Thickness
166. imum Maximum setting range of oxygen concentration lt Default setting gt Both range 1 and the second range range 2 are set to 0 to 25 O2 prior factory shipment IM 11M12D01 01E 8 Detailed Data Setting 8 1 2 Output Hold Setting Applies to All Outputs IM 11M12D01 01E During warmup during calibration and when an error occurs output hold status applies the analog output is held at a preset value In this instrument the permissible hold values which may be set are shown in Table 8 1 The hold setting applies to the outputs of all channels Warmup Calibration Indication check Blowback or Error statuses may occur independently for each channel only the outputs of any channels in these statuses are in HOLD status However the Error status Control Card Abnormal causes all the individual channel outputs and all the averaging outputs to be in HOLD status Both Under Maintenance and Process Gas Alarm statuses also apply to the whole system and cause all the individual channel outputs and all the averaging outputs to be in HOLD status No Valid Channels in Averaging Group status applies to individual averaging groups it means that either no channels are assigned to an averaging group or that the status of all channels in the averaging group is set to disabled and the output of groups in this status will be in HOLD status A CAUTION Disable means setting channel card power OFF so that c
167. in this product but does not warrant that those will suit the particular purpose of the user e Every effort has been made to ensure accuracy in the preparation of this manual However should any errors or omissions come to the attention of the user please contact the nearest Yokogawa Electric representative or sales office e This manual does not cover the special specifications This manual may not be changed on any change of specification construction and parts when the change does not affect the functions or performance of the product e If the product is used in a manner not specified in this manual the safety of this product may be impaired 2 Safety and Modification Precautions e Follow the safety precautions in this manual when using the product to ensure protec tion and safety of personnel product and system containing the product 3 The following safety symbols are used on the product as well as in this manual A DANGER This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injury electric shock or fatalities The manual describes what special care the operator must exercise to avoid such risks A WARNING This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardware or software from being damaged or a system failure from occurring CAUTION This symbol draws at
168. ined d chi gt aal dch gt Calibration data Cell voltage 0 9 mV 1 24Jun 2004 12 01 Thermo voltage 29 4mV Span gas ratio 0 1 C J resistance 1170 20 Zero gas ratio 101 3 2 0000 2000 00 00 Cell temperature 750 C Span gas ratio 0 0 C J temperature 43 C Zero gas ratio 0 0 v fon Ea F03 cE EPS Fm 5E EPS Figure 12 8 Detailed Data Display Figure 12 9 Calibration History 5 If the sensor assembly has deteriorated suddenly the check valve that prevents moisture in the furnace from entering into the calibration pipes may have malfunc tioned If the furnace gas flows into calibration lines the gas is cooled and thus condensation develops and accumulates in the pipe During calibration the conden sate is carried with the calibration gas and blow onto the sensor assembly whereby the cell is cooled quickly This results in the failed sensor assembly 6 If the sensor assembly has deteriorated gradually check the condition of the sensor assembly following the procedure below a Use the Page Scroll key to check Cell Resistance It should be 2000 or less if the cell sensor is new On the other hand if the cell sensor is approaching the end of its service life it will be 3 to 10 KQ b Use the Page Scroll key to check Cell Robustness It should say Life gt 1 year if the cell sensor is in good condition dch gt E Span gas ratio 0 1 Zero gas ratio 101 3 Response time Os Cell robustn
169. ing valve of the flow setting unit and adjust the flow rate to 600 ml min 60 ml min Turn the valve slowly counterclockwise after loosening the lock nut if the valve has a lock nut To check the flow rate use the calibration flow meter If the measurement gas pressure is extremely high adjust the measurement gas pressure to obtain pressures listed in Table 10 6 10 Table 10 10 Measurement gas pressure kPa 50 100 150 200 250 Flowrate ml min 500 430 380 250 320 T10 10E EPS 2 Adjust the flow rate and select Valve opened from the Manual calibration display Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Figure 10 34 appears Close the span gas flow setting valve to stop the span gas air flow If the valve has a lock nut be sure to tighten the lock nut to prevent any leakage of span gas into the sensor during measurement Ch1 Manual cal Al Open span gas valve Set flow span gas to Chi Manual cal Span calibration Nf Zero calibration 600ml min CP Valve opened Close the span gas valve gt Cancel calibration CP Zero calibration End F22E EPS F24E EPS Fig 10 33 Fig 10 34 IM 11M12D01 01E 10 31 10 8 3 Operating the Zero Gas Flow Setting Valve Operate the zero gas flow setting valve during zero point calibration in the following procedures 1 When the display
170. input representing the process gas alarm occurs until the input turns off 7 Error Error status exists from when the error occurs until it is cleared 8 No valid channels in averaging group When no channels are assigned to an averaging group or when the statuses of allocated channels are Disabled Error Warmup or the like so that no valid channel average value can be calculated lt Output Hold status priority order gt When several different statuses that result in Output Hold occur the following priority applies For individual channels outputs Priority 1 Error status Priority 2 Process Gas Alarm Priority 3 Calibration Indication Check or Blowback Priority 4 Under Maintenance Priority 5 Warmup For averaging outputs Priority 1 Process Gas Alarm Priority 2 Under Maintenance Priority 3 No valid channels in Averaging Group IM 11M12D01 01E 8 Detailed Data Setting lt Parameter Setting Procedure gt 1 From mA output setup on the Commissioning display select mA outputs hold and touch the Enter key A display like Fig 8 9 is displayed 2 Select an item you want to change and touch the Enter key 3 In the selection window that appears select the desired Hold method and touch the Enter key 4 Select other items as desired and set as desired as in the previous step If you select Preset Value then you can set a current output value 5 Touch the Reject key to return to the mA outputs hold
171. iption ZR22A Heater Assembly for ZR22G 0 15m 10 4m 0 7m 1m 1 5m 2m 2 5 m 3m Jig for change with Jig 2 None Reference air 3 Reference air Natural convention External connection Instrument air Pressure compensated for ZR22G S2 Pressure compensated for ZR22G S1 1 Suffix code of length should be selected as same as ZR22G installed 2 Jig part no is K9470BX to order as a parts after purchase 3 Select appropriately among A B C according to the reference air supply method and style Note The heater is made of ceramic do not drop or subject it to pressure stress T23 EPS External Dimensions Jig for change K9470BX 30 Unit mm 21 7 O 45 L 12 L length Model amp Code Weight kg ZR22A 015 Approx 0 5 ZR22A 040 Approx 0 8 ZR22A 070 Approx 1 2 ZR22A 100 Approx 1 6 ZR22A 150 Approx 2 2 ZR22A 200 Approx 2 8 ZR22A 250 Approx 3 4 F2 16E EPS ZR22A 300 Approx 4 0 2 30 IM 11M12D01 01E 2 Specifications IM 11M12D01 01E 2 31 3 Installation 3 Installation This chapter describes installation of the following equipment Section 3 1 Detector except model ZR22G 015 Section 3 2 Detector model ZR22G 015 Section 3 3 Averaging Converter Section 3 4 ZA8F Flow Setting Unit Section 3 5 Calibration Gas Unit Case E7044KF 3 1 Installation of the Detector 3 1 1 Location
172. ird gases for example the procedure is described below lt Procedure gt 1 Confirm that zero span and third gas flow control valves are fully closed then adjust supply gas pressure to a sample gas pressure 50 kPa but a maximum of 300 kPa using regulator valves or air sets on the zero span and third check gas cylinders 2 Touch Setup on the basic panel display to switch to the Execution Setup display 3 Touch Indication check and the Indication Check display appears 4 Touch Manual Ind check then the Enter key The Manual Ind check Channel Select display shown in Figure 10 13 appears Manual ind check Select ind check channel Ch2 Manual ind check F Span gas ind check Zero gas ind check a CP Chi Ch5 Third gas ind check Ch2 Ch6 Ch3 Ch7 Lv Ch4 Ch8 pam Enter f Fig 10 13 Channel select screen Fig 10 14 Manual Span Ind check 5 Select the channels to be checked channels in warm up or error status cannot be selected Here Channel 2 is taken as an example 6 Select Span indication check and touch the Enter key A display like Figure 10 15 appears 7 Open the span gas flow control valve and adjust flow rate to 600 60 ml min If auto indication check piping and wiring are installed then span gas starts to flow automatically 8 Touch Start ind check touch the Enter key Figure 10 15 An oxygen concentration trend graph like Figure 10 16
173. ired to be installed as well as addition of channel card s described in Section 11 5 Adding Channel Cards Follow the proce dure below to add the expansion power supply unit lt Procedure gt 1 Before the procedure turn off the power to the averaging converter at the external breaker 2 Remove the front cover and position the power switch to O OFF 3 The power cable to be connected to the expansion power supply unit is fixed inside the averaging converter with plastic bands See figure below Cut a plastic band nearest to the connector on the end of the power cable with a nipper or relevant tool Take care not to damage the cable sheath 4 Insert the connector of the power cable into the expansion power supply unit Fix the expansion power supply unit to the frame of the averaging converter with the 4 screws supplied Make sure that the connector in the rear of the expansion power supply unit is seated properly and firmly and the screws are securely tightened 5 Connect the heater wiring of the added detector to the corresponding heater terminals and attach the protection cover A DANGER To work safely turn off the power to the averaging converter at the external breaker and position the power switch to O OFF before the work After the work position the power switch to I ON attach the front cover and then apply the power to the averaging converter A CAUTION e The expansion power supply unit cannot
174. is skipped and indication check for the next channel starts 10 4 6 Starting Auto Indication Check 10 18 No user action is required to start auto indication check Auto indication check starts at the preset time and is repeated at the preset interval same as calibration interval A CAUTION Before starting Semi auto indication or Auto indication check operate the calibration gas and 3rd check gas solenoid valves and adjust gas flow to 600 60ml min for each sensor If you skip stabilization time then indication check status also ends and output hold status is released unless under maintenance hold is set in which case this hold applies However while traces of calibration gas remain in the sensor the analog output may not be accurate IM 11M12D01 01E 10 Other Functions 10 5 Blowback 10 5 1 Mode IM 11M12D01 01E This section explains the parameter settings for performing blowback There are three modes of blowback operation no function semi automatic and auto matic Blowback is not performed when the mode is set to No Function In Semi auto mode blowback can be started by key operation on the display or by a contact input signal and then sequentially performed at a preset blowback time and hold time In Auto mode blowback is automatically performed at preset intervals For Semi auto or Auto modes blowback is performed one channel at a time until all channels have been covered The following restrictio
175. ith Auto Calibration mode There fore If the mode of Indication Check is set to Auto you cannot set the mode of Calibration to Auto and vice versa lt Setting Procedure gt 1 From the basic panel display if you touch the Setup key the Execution Setup display appears Select Maintenance 2 From the Maintenance display select Calibration setup then Mode and you can select Manual Semi Auto or Auto in the selection pulldown that appears Fig 9 4 Calibration setup CpMode el Semi Aut emi Auto F pea Auto El Zero gas conc 0 98 lL Span gas conc 21 00 ha Timing l Cal history initialize Fig 9 4 Calibration mode setting IM 11M12D01 01E 9 5 9 2 2 Calibration Setup Procedure You can perform both Span and Zero calibration or either one or the other Normally select both Span Zero lt Setting Procedure gt From Maintenance gt Calibration setup display select Points then a selection window opens and you can select Span Zero Span or Zero Fig 9 5 Calibration setup Mode Auto C gt Points Zero gas ant ero Span gas conc Timing Cal history initialize F9 5E EPS Fig 9 5 Procedure for Setting Calibration Mode 9 2 3 Zero Gas Concentration This sets the oxygen concentration of the zero gas used for calibration Enter the value from the label of the corresponding gas bottle 9 2 4 Span Gas C
176. jector for High Temperature Part No E7046EC or E7046EN This ejector is used where pressure of measured gas for high temperature detector is negative This ejector consists of an ejector assembly a pressure gauge and a needle valve Standard Specifications Ejector Assembly Ejector Inlet Air Pressure 29 to 68 kPa G Air Consumption Approx 30 to 40 l min Suction gas flow rate 3 to 7 I min Connection to high temperature probe adapter R 1 2 Connection Rc1 4 or 1 4 FNPT SUS304 JIS Tube Connection 6 4 mm or 1 4 inch copper tube or stainless tube Pressure Gauge Assembly Type JIS B7505 A1 5U3 8 x75 Material in Contact with Gas SUS316 JIS Case Material Aluminum alloy Paint color black Scale 0 to 100 kPa G Bushing G3 8 x Rc1 4 or 1 4NPT SUS304 JIS Needle Valve Connection Rc1 4 or 1 4FNPT Material SUS316 JIS Part No Description E7046EC RC 1 4 6 4 TUBE joint SUS304 JIS E7046EN 1 4 NPT 1 4 TUBE joint SUS304 JIS T2 8E EPS 2 22 IM 11M12D01 01E 2 Specifications E7046EC Piping connections Rc1 4 part or Re1 4 part E7046EN Piping connections 1 4NPT female part or 1 4NTP male part Pressure gauge 39 6X4 or 1 4 inch conduit stainless Ejector assembly PT 1 2 male Detector fully open Approx 67 3 s Y _40_ Not included in high temperature use auxiliary ejector Instrument air inlet
177. k 5 3 4 Wiring and Piping for Automatic Calibration and Blowback Blowback Solenoid Valve High Temperature Detector Averaging Converter aV550G Golenoid ___ Analog Output Valve Averaged and Individual Output Contact Output Contact Input Power Supply Needle Valve Calibration Gas Line Span Gas Cylinder Instrument Air Reference Gas Line Zero Gas Cylinder Note If optional 24 V outputs are specified for solenoid valves Option Code 0 240 this system cannot be established This is because the contact to activate a solenoid valve is used in common for autocalibration and blowback Figure 5 18 Typical Diagram for Automatic Calibration and Blowback IM 114M12D01 01E 5 17 5 18 IM 11M12D01 01E 6 Components 6 Components In this Chapter the names and functions of components are described for the major equipment of the AV550G Averaging Converter 6 1 ZR22G Detector 6 1 1 General purpose Detector except for Model ZR22G 015 Terminal box Non explosion proof JIS C0920 equivalent to IP44D Equivalent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version Flange used to mount the detector Select from JIS or ANSI standard models A 4 Probe Ss this part is inserted in the furnace Select length from 0 4 0 7 1
178. kPaG F2 6E EPS 2 20 IM 11M12D01 01E 2 Specifications 2 6 Other Equipment 2 6 1 Dust Filter for the Detector Part No K9471UA This filter is used to protect the detector sensor from a corrosive dust component or from a high concentration of dust when the oxygen concentration in utility boilers or concrete kilns are to be measured This filter requires a measurement gas flow of 1m sec or faster for circulation of the gas in the sensing part e Standard specification Applicable detector Standard type detector for general use the measurement gas flow should be approximately perpendicular to the probe Mesh 30 microns Material Sic Filter SUS316 JIS Weight Approx 0 2 kg Part No Description K9471UA Filter K9471UX Tool T2 7E EPS SiC Caborundum filter ee ae 32 Increasing of insertion length F2 8E EPS 2 6 2 Dust Guard Protector Part No K9471UC IM 11M12D01 01E Recommended to be used when sample gas is likely to flow directly into the cell due to its flow direction in the stack or the like flammable dust may go into the cell or water drops are likely to fall and remain in the cell during downtime or the like due to the installation position Material SUS316 Weight Approx 0 3 kg Increasing of insertion length 100 ON qi S E To WA 4 06 ql 122 lt gt F11 1 eps 2 21 2 6 3 Auxiliary E
179. king as a power supply switch to the averaging converter 5 Power lines such as power cables and heater wires should be fixed securely onto a wall or construction using cable racks conduit tubing nylon bands or other appropriate ways Accidental removal from terminals by pulling may result in electric shock L IM 11M12D01 01E 5 1 5 1 1 Wiring Precautions 5 1 1 1 Precautions Concerning the Correspondence Between Detectors and Channel Cards Multiple detectors are connected to the averaging converter Make sure that the wiring is run properly between the detector and its corresponding channel card on the averaging converter Special care should be exercised so that the channel number of the detector signal line from the channel card corresponds the one of the detector heater line from the power supply unit Disagreement may result in malfunction of the detector as well as invalid operation A channel number is indicated in the channel card slot The specified number of channel cards per purchase order is factory installed in channels in order from CH1 The factory installed channels can be changed as desired All the channels are the same Note that in a 4 channel base averaging converter AV550G A channels CH5 to CH8 cannot be used To remove a channel card loosen the 2 screws attached to the top and bottom of the card and then while holding the loosened screws pull straight away from the slot To install a channel card insert the ca
180. l 10 min 00 sec 30 days 00 hours Start date day month year Start time Minimum Maximum 01 01 01 00 00 0 O2 25 O2 Output smoothing time constant ebued jndino Output mode During warmup Preset value Under maintenance 0 sec disabled Linear 4mA 4mA Last measured value Preset value Under calibration Indication check During Blowback Preset value 4mA Last measured value 4mA Error Last measured value Preset value Buiy s pojoy dno Group invalid Preset value 4 mA 4 mA 4mA Process alarm Last measured value Preset value 4mA T10 7E eps IM 11M12D01 01E IM 11M12D01 01E 10 Other Functions Table 10 8 Initialization Parameters and Defaults part 2 Item Initialization Parameter Default Hysteresis 0 1 O2 Alarm contact action delay 3 sec High High Alarm OFF z Alarm setting 100 0 O2 3 High Alarm OFF Alarm setting 100 0 O2 Low Alarm OFF Alarm setting 0 0 O2 Low Low Alarm OFF Alarm setting 0 0 O2 Instrument internal temperature alarm log Deleted Removal of channel in alarm condition NO Alarms All OFF During warmup 9 Q During output range switching z 2 During maintenance 2 During calibration E 8 During indication check During blowback 3rd check gas Relay state when powered Alarms During w
181. l Mins E elon tey 8 24 R 9 Cali DR atiOi ascdiciciseocsvatast siccacstecsiaediceceveccecalasstescsntesecaececscscageets cadasetesesacses casdecscscesecsevsied 9 1 Calibration Briefs setis iniseti ereen raer eaea ara aTa EE E eE ESE 9 1 9 1 1 Principle of Measurement essssesesseeesseeesereeresessesessrerrsreersrenresreresessee 9 1 9 1 2 Calibration Gass si n eoe ESE E EE AEE E les EEE EEE teks 9 2 91 3 Compensati N sissies kirria ose iape e O Enpe EEEE EEEE S aE 9 3 9 1 4 Characteristic Data from a Sensor Measured During Calibration 9 4 92 Calibration Setpro reer n EE E E RE E E R E 9 5 OD Mode nerro ia er aE E E E a aae Ei e 9 5 9 2 2 Calibration Setup Procedure ssseseseeeesseeeseseesrsessrsersrerrsreerssrereseeresrrse 9 6 9 2 3 Zero Gas Conc mtratiON eiseressen enesega p oee geass ESNE EEEE SPREE Se 9 6 9 2 4 Span Gas Concentration 0 eee ee eceeeeeeeseeesecseesseceesaecnecesecneceseeeeeeseees 9 6 9 37 Performing Calibration iss ices cic niassa ierisinde iek svete seeds cescoss 9 10 9 3 1 Performing Manual Calibration 0 eeeeeeeeeseeeeecneeseeceensecnecsaeenees 9 10 9 3 2 Semi Automatic Calibration 0 0 0 cee cece eeeeeeceseeeeecseeesecseesecseeeaeenees 9 10 9 3 3 Starting AutoCalibration 0 eeeeeceeeeeeceseeeeeeseeesecaeecaeseesaeenaes 9 12 10 Other PUM tr Ons ciisaseecccdcs ccdecceses cscs cesses esse te teaseeesisksases asas osae soos se eas assasi LOL 10I Display crine nren
182. l be displayed If the setup period of time is changed the current minimum oxygen concentration will be displayed for more details see Section 8 6 2 earlier in this manual 10 1 16 Average Oxygen Concentration The average oxygen concentration during the periods over which average values are calculated is displayed If the setup period elapses the average oxygen concentration that has been displayed so far will be cleared and a new average oxygen concentration will be displayed If the setup period of time is changed the current average oxygen concentration will be displayed for more details see Section 8 6 2 earlier in this manual 10 1 17 History of Calibration Time The calibration conducted dates and times and span gas and zero gas ratios for the past ten calibrations are stored in memory 10 1 18 Internal Temperature Alarm Logging You can view a history of past instrument internal temperature alarms Refer to Section 12 2 Displays and Remedies When Alarms Are Generated The instrument internal temperature alarms log is deleted if you clear the alarm log storage area Refer to Section 10 7 Operational Data Initialization IM 11M12D01 01E 10 5 10 2 Trend Graphs Up to 11 user selected data from among the individual outputs from each channel and average concentration outputs groups a b and c can be viewed in graphical form at a time in a single screen To move to the trend graph display touch the graph display key on
183. lating material 4 F4 5E EPS Figure 4 5 Preventing to condensation 4 1 5 Pipinf for Blowback This piping is required when the blow back function is carried out The piping described below provides automatic blow back operation when the blow back start command is entered to the converter Blowback air Regulator valve Solenoid valve Y Pipe coupling Note If blowback is done under control of a contact output from the averaging converter a hold is placed on analog output signals from all detector while blowback is in progress See Section 10 5 for details on the blowback function Wiring for solenoid valves is described in Section 5 3 Blow pipe F4302 EPS Figure 4 6 Blowback Piping The following parts are required for blow back piping e Blow pipe to be prepared as illustrated in Figure 4 7 e Two way solenoid valve Open when electric current is on Found on the open market e Air set recommended by YOKOGAWA G7011XF E7040EL or G7004XF K9473XG lt Blow pipe manufacturing gt Manufacture the blow pipe as illustrated in Figure 4 7 and mount it on the high temperature probe adapter Unit mm Blind flange of the adapter for C N high temperature probe AS F n Welded Rc1 4 W W T O D by 6 I D Stainless steel pipe Approximately 200 a F4 11E EPS Figure 4 7 Blow pipe Construction IM 11M12D01 01E 4 Piping 4 1 6 Piping for Indi
184. ld be taken not to drop the detector during installation The same applies to a probe made of silicon carbide SiC A gasket should be used on the flange surface to prevent gas leakage The gasket material should be selected depending on the characteristics of the measurement gas It should be heatproof and corrosion proof The parts which should be supplied by the user are listed in Table 3 2 Table 3 2 Accessories for mounting high temperature probe adapter Mounting flange specification Accessory name Number Note JIS 5K 50 FF equivalent Gasket 1 Heatproof and corrosionproof Bolt M12 by 50 Nut M12 ANSI Class 150 RF equivalent Gasket Bolt M16 by 60 Nut M16 Washer for M16 16 Heatproof and corrosionproof 4 4 Washer for M12 8 1 8 8 T3 2E EPS A high temperature detector should be mounted as follows 1 It is recommended to mount the detector vertically When it is impossible due to the physical arrangements and the detector is mounted horizontally ensure that the probe tip be placed no higher than the probe base 2 When mounting a high temperature probe adapter be sure to insert a gasket between the flanges to prevent gas leakage When the furnace pressure is negative ensure that there is no leakage of air into the furnace 3 When mounting the detector in a position other than vertical the cable inlet should face downward 4 When installing the detector in
185. lenoid contact action timing is provided in Figure 10 26 When mode is set to Auto In addition to the above hold time and blowback time interval start date and start time should be set The interval between blowback cycles can be set in the range 000 day 00 hour to 255 days 24 hours Once blowback is started it is performed for all installed channels Thus blowback interval must be longer than the sum of blowback time and hold time for all channels Start date and start time specify the day and time that auto blowback is first performed To set June 21 2004 at 1 30 pm set Start date to 21 06 04 and Start time to 13 00 lt Setting procedure gt When the blowback mode is set to Semi auto on the Blow Back Setup display Hold time and Blow back time items appear Select Hold time and then touch the Enter key A numerical data entry display will appear Enter the desired value and touch the Enter key In the same manner set the blow back time When the blowback mode is set to Auto on the Blow Back Setup display In addition to Hold time and Blow back time items Interval Start date and Start time items appear Enter the desired values for each item in the same manner as above nin CAUTION Observe the following cautions when setting the blowback timing 1 When blowback is to be started by a contact input signal you need to set the relevant contact input signal to Blow back start on the Input Contacts displ
186. lict with the first calibration In such a case the second calibration will not be conducted When both zero and span calibrations are to be performed the calibration time is double that required for a single zero or span calibration 4 If the Calibration Interval is set to DD 00 HH 00 then Auto Calibration will not be performed 5 If you set the start date before the current date then Auto Calibration will not start 6 Cal time of Calibration timing display will be equalized to Check time of Semi auto ind Chk display IM 11M12D01 01E 9 Calibration Table 9 1 When Auto Calibration conflicts with Other Commands Other commands Purging the channel Indication Check in other channel Blowback in other channel Maintenance CAL chan in warmup status CAL chan in ERR status CAL chan now disabled Man Cal SemiAuto IM 11M12D01 01E AutoCal X Cannot perform calibration Wait Wait until other command finishes before starting calibration lt Shipping time defaults gt At shipping time or after resetting parameters default values are as shown in Table 9 2 below Table 9 2 Item Initial value Mode Manual Points Span Zero Zero gas conc 1 00 Span gas conc 21 00 Hold time 3 min 00 sec Cal time 3 min 00 sec Interval 1 days 00 hrs Starting date yyO1mm01dd01 St
187. ll installed cards are enabled T10 9E eps 10 30 IM 11M12D01 01E 10 Other Functions 10 8 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F Flow Setting Unit is used for manual calibration as described in Section 1 1 1 Calibration in such a system is to be manually operated So you have to operate the valve of the Flow Setting each time calibration is made starting and stopping the calibration gas flow and adjusting the flow rate This applies even if you are using the ZR40H Autocalibration Unit For operation of the converter see Section 7 12 earlier in this manual 10 8 1 Preparation Before 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 equals measured gas pressure approx 50 kPa or measured gas pressure plus approx 150 kPa when a check valve is used maximum pressure rating is 300 kPa 2 Check that the oxygen concentration of the zero gas and span gas instrument air 21 vol O in the cylinder is set in the converter 10 8 2 Operating the Span Gas Flow Setting Valve The following description is given assuming that instrument air the same as the refer ence gas is used as the span gas 1 When the display shown in Figure 10 33 appears during calibration open the span gas flow sett
188. m If ON then Low alarm results in contact output However Low alarm must be ON enabled Refer to Sec 8 2 Oxygen Concentration Alarms Low Low Alarm If ON then Low Low alarm results in contact output However Low Low alarm must be ON enabled Refer to Sec 8 2 Oxygen Concentration Alarms CAL coefficient alarm If ON then calibration time Zero coefficient error Span coefficient error or an electrode potential stability error results in contact output CAL gas pressure lowlf ON then a contact input indicating calibration gas pressure low results in contact output This is a calibration gas pressure low answerback signal Corresponding contact input must be allocated to calibration gas pressure low Process gas alarm If ON then a contact input indicating process gas pressure alarm results in contact output This is a process gas pressure alarm answerback signal Corresponding contact input must be allocated to process gas pressure alarm Temperature alarm If ON then if internal temperature of averaging converter is over limit contact output occurs When the converter is used under severe environmental temperature conditions you can use this contact to switch on a cooler Error Warmup If ON then any type of error causes contact output Acts the same as common error contact If ON then during warmup there is contact output For definition of warmup see Sec 8 1 2 Setting Output Hold Output rang
189. m are ready Table 4 2 Parts Required for Piping in a System to Perform Automatic Calibration Detector Piping Location Part Description General purpose detector High temperature detector Calibration gas inlet Reference gas inlet Calibration gas inlet Reference gas inlet Sample gas outlet Solenoid valve Yokogawa recommended E7057G G700 XP Nipple R1 4 or 1 4NPT M M General Flowmeter 0 to 1 L min General Needle valve For flow control General Tee fitting For branch connection Manifold substitutable General Solenoid valve 3 way valve for zero span gas switching General Stop valve General Zero gas cylinder Yokogawa recommended G7001ZC Pressure reducing valve Yokogawa recommended G7013XF or G7014XF Connection fitting Flowmeter R1 4 or 1 4NPT M 0 to 1 L min General General Needle valve For flow control Unnecessary if supplied with flowmeter General Air set Yokogawa recommended G7011XF E7040EL or G7004XF K9473XG Connection fitting Solenoid valve R1 4 or 1 4NPT M General Yokogawa recommended E7057G G700 XP Nipple R1 4 or 1 4NPT M M General Flowmeter 0 to 1 L min General Needle valve For flow control General Tee fitting For branch connection Manifold substitutable
190. made a calculation changing the current output range does not affect this does not cause a recalculation 10 1 11 Heater On Time Ratio The probe sensor is heated to and maintained at 750 C When the measured gas tem perature is high the amount of heater ON time decreases 10 1 12 Time The current date and time are displayed These are backed up with built in batteries so the clock continues to run even if the power is switched off 10 4 IM 11M12D01 01E 10 Other Functions 10 1 13 Ch card Rev Ctrl card Rev This shows the revision number of the channel card software and Control card software 10 1 14 Maximum Oxygen Concentration The maximum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed After the preset monitoring interval has elapsed the maximum oxygen concentration that has been displayed so far will be cleared and a new maximum oxygen concentration will be displayed If the setup period of time is changed the current maximum oxygen concentration will be displayed for more details see Section 8 6 2 earlier in this manual 10 1 15 Minimum Oxygen Concentration The minimum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed If the setup period elapses the mini mum oxygen concentration that has been displayed so far will be cleared and a new minimum oxygen concentration wil
191. market at the calibration gas inlet of the detector as illustrated in Figure 4 8 The check valve or the stop valve may have been mounted on the detector when shipped Connect the flow setting unit and the detector to a stainless steel pipe 6 mm O D 4 mm or larger I D or nominal size 1 4 inch joint F4 2E EPS Figure 4 2 Connection to the calibration gas inlet 4 3 4 1 3 4 1 4 4 4 Piping for the Reference Gas This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit and between the ZA8F flow setting unit and the ZR22G detector The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 40 C Mount a regulator valve specified by YOKOGAWA on the cylinder Mount a check valve or stop valve specified by YOKOGAWA on the nipple found on the open market at the calibration gas inlet of the detector as illustrated in Figure 4 8 The check valve or the stop valve may have been mounted on the detector when shipped Connect the flow setting unit and the detector to a stainless steel pipe 6 mm O D 4 mm or larger I D or nominal size 1 4 inch Piping to the High Temperature Probe Adapter A sample gas should be at a temperature below 700 C before it reaches the detector Also a sample gas needs to be sucked if its pressure is negative The piping for these purpos
192. may be sticking to the tip of the detector probe If dust is found clean the probe see Section 11 3 1 In addition if an error occurs in calibration even after the sensor assembly is re placed the influence of measured gas flow may be suspected Do not let the mea sured gas flow toward the tip of the detector probe for example by changing the mounting position of the detector IM 11M12D01 01E 12 11 5 Alarm 5 Cold junction temperature alarm 12 12 This alarm is generated when the temperature of the cold junction located at the terminal block of the detector falls below 25 C or exceeds 155 C Check the following Display C J Temperature in the detailed data display If C J Temperature is indi cated as 2008C or 508C the following can be considered 1 Breakage of the cold junction signal wires between the converter and the detector or the cable is not securely connected to the connecting terminals 2 The positive and negative poles of the cold junction signal wiring are shorted out in the wiring extension or at the connection terminals 3 A failure of the cold junction temperature sensor located at the detector terminal block occurred 4 A failure of the electrical circuits inside the converter occurred If C J Temperature exceeds 150 C or falls below 20 C the following can be considered 1 The temperature of the detector terminal block is out of the operating temperature range 20 C to
193. nd little changes of temperature 5 No vibration 6 Little exposure to rays of the sun or rain 3 4 2 Mounting of ZA8F Flow Setting Unit IM 11M12D01 01E The flow setting unit can be mounted either on a pipe nominal JIS 50A or on a wall It should be positioned vertically so that the flowmeter works correctly lt Pipe Mounting gt 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The unit weighs approximately 2 to 3 5 kg 2 Mount the flow setting unit on the pipe by tightening the nuts with the U bolt so that the metal fitting is firmly attached to the pipe F3 12E EPS Figure 3 10 Pipe Mounting 3 13 lt Wall Mounting gt 1 Make a hole in the wall as illustrated in Figure 3 11 Vi 14 Unit mm 4 A 5 hole or M6 screw F3 13E EPS Figure 3 11 Mounting holes 2 Mount the flow setting unit Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit securely on the wall with four screws F3 14E EPS Figure 3 12 Wall mounting 3 14 IM 11M12D01 01E 3 Installation 3 5 Installation of the Calibration Gas Unit Case The calibration gas unit case is used to store the G7001ZC zero gas cylinders 3 5 1 Location The following should be taken into consideration 1 Easy access for cylinder replacement 2 Easy access for checking 3 Near to the detector and converter as well as th
194. nders Standard Specifications Pressure gauge Primary 0 to 25 aa G Secondary 0 to 0 5 MPa G Connection Inlet W22 14 threads right hand screw Outlet Rc1 4 or 1 4NPT F Material Brass body Secondary Primary pressure gauge pressure gauge 0 5 MPaG 25 MPaG Regulator handle W22 Right handed screw Approx 59 Approx 163 i Outlet LoS s Secondary safety valve Primary safety valve Approx 82 Approx 174 2 28 Part No Outlet G7013XF Re1 4 G7014XF 1 4 NPT female screw IM 11M12D01 01E 2 Specifications 2 6 9 Calibration Gas Unit Case Part No E7044KF IM 11M12D01 01E This case is used to store the zero gas cylinders Standard Specifications Case Paint Baked epoxy resin Jade green Munsell 7 5 BG 4 1 5 Installation 2B pipe mounting Material SPCC Cold rolled steel sheet Weight 3 6 kg Approx 10 kg with gas cylinder Note Export of such high pressure filled gas cylinder to most countries prohibited or restricted 324 Pressure regulator G7019 F 180 I G7014XF oi Zero gas cylinder G7001ZC Note E7044KF case assembly has no zero gas cylinder and pressure regulator 2B pipe 60 5 F2 15E EPS 2 29 2 6 10 Model ZR22A Heater Assembly Style S2 Suffix code Option code Descr
195. nding the number of channel cards to five or more Available only in U S 2 17 Unit mm 480 e External Dimensions lo SSeessseeseees ojo seseescassesees LO Z seeseseseeeeses O gosea D 889909999999999 rt H fle gt ra 2 Qawwo pue pueb aqe jnoyyM 08y E 2 4 U D De gt i amp Q E Q F D r 2 S z E a Q G oO z ive N o o o ire a S vt vt o oO Oo i H Q Z a ooz m ne Q D 00 OSI J 2 Q GEE 2 997 FS9L c is lt A amp S a oc _ _____ g 6 TI y Gy k al H 00 J osL J eZh 2992 L SOL GGE Extension view IM 11M12D01 01E T01 EPS 2 5A Remarks For lock screw 2 1 Quantity Part No A1112EF L9827AS Name Fuse Hexagonal Allen Wrench e AV550G Standard Accessories 2 18 2 Specifications 2 5 ZA8F Flow Setting Unit 2 5 1 ZA8F Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration System 1 This unit consists of a flow meter and flow control valves to control the flow of calibra tion gas and reference air Standard Specifications Flowmeter Calibration gas 0 1 to 1 0 l min Reference air 0 1 to 1 0 l min
196. ndividual Output Contact Output 4 SV COM F Contact Input oO Power Supply Span Gas Cylinder Instrument Air Referece Gas Line Solenoid Valve 7 Instrument i Air Set Air SL Zero Gas Cylinder Needle Valve Stop Valve Third Check Gas Cylinder If optional 24 V outputs are specified for solenoid valves Option Code 0 240 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves Figure 5 16 Typical Diagram for Automatic Calibration and 3rd Gas Indication Check IM 11M12D01 01E 5 Wiring 5 3 3 Wiring and Piping for Blowback Averaging Converter AV550G Blowback Solenoid Valve _ Analog Output High Temperature Averaged and Individual Output Detector Contact Output oes l Stop Valve Contact Input Power Supply Calibration Gas Line To ZA8F Flow Setting Unit Reference Gas Line Calibration Gas Line i To ZA8F Flow Setting Unit Reference Gas Line S Z Instrument Air Air Set If optional 24 V outputs are specified for solenoid valves Option Code 0 240 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves Figure 5 17 Typical Diagram for Blowbac
197. nection port a q E X Flange Rc1 4 or 1 4NPT 5 Calibration gas inlet ange Flange A B C t C ANSI Class 150 2 RF SUS304 152 4 120 6 4 19 19 ANSI Class 150 3 RF SUS304 190 5 152 4 4 19 24 ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 DA DIN PN10 DN50 A SUS304 165 125 4 18 18 DIN PN10 DN80 A SUS304 200 160 8 218 20 DIN PN10 DN100 A SUS304 220 180 8 518 20 2 JIS 5K 65 FF SUS304 155 130 4 15 14 O JIS 10K 65 FF SUS304 175 140 4 19 18 JIS 10K 80 FF SUS304 185 150 8 519 18 Flange JIS 10K 100 FF SUS304 210 175 8 219 18 9 JIS 5K 32 FF SUS304 115 90 4 15 5 JPI Class 150 4 RF SUS304 229 190 5 8 19 24 JPI Class 150 3 RF SUS304 190 152 4 4 19 24 F2 1E EPS Westinghouse 155 127 4 11 5 14 2 6 IM 114M12D01 01E 2 Specifications Model ZR22G P with pressure compensation Separate type Zirconia Oxygen Analyzer Detectors L 303 50 8 L 0 4 0 7 1 0 1 5 2 0 2 5 3 0 3 6 4 2 4 8 5 4 m Re1 4 or 1 4NPT Reference air inlet c L fe o B 2 G1 2 2 1 2NPT etc t ag Cable connection port ial Lot 6 i G 3 pai Reference gas outlet K PIPING Flange B Rc1 4 or 1 4NPT Calibration gas inlet Flange Stop Valve PIPING A C Flange A B Cc t_ PIPING ANSI Class 150 2 RF SUS304 152 4 120 6 4 19 19 A ANSI Class 150
198. ng to troubleshooting for Alarm 5 in Subsection 12 2 3 5 The following are possible causes of Error 2 when it occurs independently 1 Fuse for the heater on the power supply unit has brown 2 Failure in wiring between the averaging converter and the detector e g loose connection at terminals wire breakage short circuit 3 Faulty cold junction compensation sensor on the detector terminal block loose connection at terminals 4 Faulty thermocouple in the detector wire breakage short circuit in internal wiring 5 Faulty heater in the detector wire breakage etc 6 Failure in electrical circuits inside the averaging converter lt Locating cause of failure and countermeasures gt 1 Turn off power to the channel with error by how swap function or to the averaging converter 2 Remove the cable from terminals 7 and 8 of the detector and measure the resistance between these terminals The heater unit is normal if the resistance is lower than about 90 If the resistance value is higher failure of the heater unit is suspected In this case replace the heater unit refer to Subsection 11 2 3 Replacement of the Heater Unit In addition check that the two way wiring resistance between the converter and the detector is 100 or less 3 Remove the wiring from terminals 3 and 4 of the detector and measure the resistance between these terminals The thermocouple is considered normal if the resistance value is 5 Q or less If t
199. not authorize e Failure due to power supply voltage frequency being outside specifications or abnormal e Failure caused by any usage out of scope of recommended usage e Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and other natural changes IM 11M12D01 01E IM 11M12D01 01E 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 Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the nearest sales office described in this instruction manual vii viii IM 11M12D01 01E Contents is TCO CUCHION ceslasvesicccsicssecectesiccecacesecactsecsenss d setoceesaccbapsecececvosacdessesbesedoodaccesasbeus de sosssdesaceboscocessell For the safe use of this equipment ccccccccesessessesesseseeeececscesececsecseeseceeeesesseees iii C ASLO H LOI SEN AEE EE E EE Meh tev EEE vi After Sales Warranty opeising i eies rsin S E oin aeee E aN EE vi T OV ORVIOCW sonunsnesununnnuin enun a a a a a a MeL 1 1 System Configuration 0 ce eeeecsessesessecceecssesseeeceecsaeneeseceecneeseeseenesaeeaeeaeens 1 1 1 1 1 System Config
200. ns apply When No function is selected Blowback is not performed When Semi auto is selected Semi auto blowback can be performed Blowback does not start at Auto blowback start time When Auto is selected Blowback can be performed in either Auto or Semi auto mode lt Setting Procedure gt 1 From the basic panel display touch Setup key on the Execution Setup display which appears select Maintenance 2 On the Maintenance display select Blow back setup and the Mode selection pull down allows you to select between No function Semi auto and Auto see Fig 10 23 Blow back setup Blow bd Auto 30min00s F75E EPS Fig 10 23 Mode Selection 10 19 10 5 2 Setting Contacts for Operating Solenoid Valves 10 20 The same contacts used for operating solenoid valves to perform channel switching during Auto calibration SV CH1 to SV CH 8 are also used for starting and stopping blowback gas Therefore when both blowback and Auto Semi auto calibration are used contact outputs used for operating solenoid valves need to be assigned as shown in Fig 10 24 Refer to Fig 10 26 for blowback timing chart For wiring and piping of blowback solenoid valves refer to Subsection 4 1 5 Blowback piping and Section 5 3 Wiring and Piping Examples AV550G CH1 detector Solenoid valve switch F10 24E eps Fig 10 24 lt Setting procedure gt 1 From the basic panel display
201. ompensation For 0 15m probe 0 5 to 5 kPa No pressure fluctuation in the furnace should be allowed Note When the detector is used in conjunction with a check valve and a ZA8F Flow Setting Unit the maximum pressure of sample gas is 150 kPa When with a check valve and a ZR40H Auto Calibration Unit it is 200 kPa If the pressure of your sample gas exceeds these limits consult with Yokogawa Probe Length 0 15 0 4 0 7 1 0 1 5 2 0 2 5 3 0 3 6 4 2 4 8 5 4 m Probe Material SUS 316 JIS Ambient Temperature 20 to 150 C Reference Air System Natural Convection Instrument Air Pressure Compensation other than for probe length 0 15 m Instrument Air System excluding Natural Convection Pressure 200 kPa the pressure inside the furnace It is recommended to use air which has been dehumidified by cooling to dew point 20 C or less and had dust or oil mist removed Consumption Approx 1 Nl min Material in Contact with Gas SUS 316 JIS Zirconia SUS 304 JIS flange Hastelloy B Inconel 600 601 Construction Heater and thermocouple replaceable construction Non explosion proof JIS C0920 equivalent to IP44D Equivalent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version IM 11M12D01 01E 2 3 2 4 Terminal Box Case Material Aluminium alloy Terminal Box Paint Color Case Off white Munsell 0 6GY3 1 2 0 Cover
202. on function Section 2 4 2 Model and Codes Revised Section 2 6 6 Air Set Changed part numbers and drawings Section 2 6 8 Cylinder Regulator Valve Part No G7013XF or G7014XF Changed drawings Section 3 3 1 Installation Location Added in Danger and Caution Section 5 1 3 Figure 5 3 External Wiring Connection Terminals of the Averaging Converter Changed Section 10 3 2 Selecting Language Added display language options German and French Section 11 5 Adding Channel Cards Added Caution Section 11 6 Adding the Expansion Power Supply Unit Added Caution CMPL 11M12A01 02E Upgrade CMPL 11M06B02 01E Upgrade
203. oncentration This sets the oxygen concentration of the span gas used for calibration When the instrument air supply is used as the span gas enter 21 O2 A Note When the instrument air supply is to be used as span gas cool it to 20 C below dew point to remove moisture oil mist and dust from the air If you do not do this to purify the air then the accuracy of the calibration may be affected lt Setting procedure gt 1 From the Calibration setup display select Zero gas conc and the numerical data entry display is displayed Enter the oxygen concentration of the zero gas used for calibration For example enter 0 98 vol O2 as 00098 2 From the Calibration setup display select Span gas conc and the numerical data entry display is displayed Enter the oxygen concentration of the span gas used for calibration For example enter 21 vol O2 as 02100 9 6 IM 11M12D01 01E Cal start in Ch1 Span CAL Ch1 Zero CAL Ch1 output hold Ch2 Span CAL Ch2 Zero CAL Ch2 output hold Average output SV Ch1 contact SV Ch2 contact SV Ch2 contact IM 11M12D01 01E 9 Calibration 3 Calibration time setting If the mode is Man Select Hold time This is the output stabilization settling time required from calibra tion end until measurement mode is reentered During this time the calibration gas is switched to measurement gas and the measurement is allowed time to stabilize Setting range i
204. ontact capacity 30V DC 3A 250V AC 3A resistive load Normally open normally closed selectable Common Contact Output 5 points Four of the output points can be selected to either normally energized or normally deenergized status Contact output 5 is normally energized Contact Output for Individual Channel Fail Output to each channel Normally energized Solenoid Valve Contact Output Contact capacity 30V DC 1A 250V AC IA 24V DC option code 24 maximum output current 50 mA Contact Input 2 points voltage free contacts Ambient Temperature 5 to 50 C Storage Temperature 20 to 70 C Humidity Range 10 to 85 RH non condensing Installation Altitude 2000 m or less Category based on IEC 1010 II Note Pollution degree based on IEC 1010 2 Note Note Installation category called over voltage category specifies impulse withstand voltage Category II is for electrical equipment Pollution degree indicates the degree of existence of solid liquid gas or other inclusions which may reduce dielectric strength Degree 2 is the normal indoor environment Power Supply Voltage Ratings 100 115 V AC 230 V AC Acceptable range 85 to 126 5 V AC 195 5 to 253 V AC Power Supply Frequency Rating 50 60 Hz Acceptable range 50Hz 5 60Hz 5 Power Consumption Max 1 kw for steady operation Max 1 8 kw for warm up 2 12 IM 11M12D01 01E 2 Specifications Safety and EMC conforming standards Safety Conforms to EN 61010
205. oove in which the contact E7042BS is placed F11 2EEPS Figure 11 5 Installing the Contact 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 3 Attach the U shaped pipe to its support with filter then fully insert the U shaped pipe and its support into the probe 4 Coat the threads of the four bolts with antiseize grease and then screw 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 M
206. or Connection 1 4NPT 2 L9852CB 1 Needle Valve Connection Rc1 4 G7016XH 1 Needle Valve Connection 1 4NPT 3 E7046EK 1 Pressure Gauge Connection Rce1 4 E7046EV 1 Pressure Gauge Connection 1 4NPT 4 E7046ED 1 Ejector Assembly Connection Rc1 4 E7046EP 1 Ejector Assembly Connection 1 4NPT 5 E7046EF 1 Connector Connection Re1 4 E7046ER 1 Connector Connection 1 4NPT 6 G7031XA 1 Ejector Connection Re1 4 7 E7046EJ 1 Ejector Connection R1 4 YOKOG AWA All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M03B01 05E 1st Edition Dec 2000 YK Yokogawa Electric Corporation 6th Edition Sept 2001 YK Revision Record Manual Title Model AV550G Zirconia Oxygen Analyzer Averaging Converter Manual Number IM 11M12D01 01E Edition Date Remark s Ist Aug 2004 2nd Oct 2004 3rd Sep 2005 Newly published Asymmetry alarm added Figure 8 17 Table 12 2 and 7 of Sec 12 2 3 changed Revised Section Introduction Added description For the safe use of this equipment Added description in DANGER After Sales Warranty Added description regarding modification Section 1 1 1 Figure 1 1 Typical System Configuration Using Flow Setting Units for manual calibration Added 230 VAC power supply Section 1 2 1 System Components and Their Applicability Change part numbers Section 2 4 1 Standard Specification Added 230 VAC power supply 195 5 to 253 V and FOUNDATION Fieldbus communicati
207. or checking and maintenance work 2 Ambient temperature of not more than 150 C and the terminal box should not be exposed to radiant heat 3 A clean environment without any corrosive gases 4 No vibration 5 The measured gas should satisfy the specifications described in Chapter 2 3 2 2 Usage of the High temperature Probe Adapter Model ZO21P H During analysis the surface temperature of the probe adapter should be within the range from the dew point of the measured gas and 300 C to prevent ejector clogging gasket deterioration or bolt scoring Where the dew point of the measured gas is not known keep within the range 200 C to 300 C The temperature shall be measured at the probe in the probe adapter and the surface of the blind flange at the opposite side When the surface temperature is not within the above range the following measures can be taken to change the temperature lt When the surface temperature exceeds 300 C gt 1 When the furnace pressure is negative lower the pressure setting to reduce induction flow of the measurement gas Refer to Section 2 6 3 Auxiliary Ejector for High Temperature for the setting of induction flow When you reduce induction flow ensure that the ejector inducts air when the furnace pressure fluctuates 2 When the furnace pressure is positive close the needle valve for the sample gas outlet to reduce the exhaust gas flow Refer to Section 4 1 4 Piping to the High temp
208. ors Measure the resistance of these wiring conductors on the converter side The resistance value is normal if it indicates 10 Q or less Is there any disconnection or poor continuity in the wiring between the detector and converter Replace the wiring cable 27 Turn on the power to the converter and temporarily place the analyzer in the operating status Replace the sensor Is an error indicated assembly and temporarily The analyzer operates normally on the display place the analyzer in the operating status No See Section 11 3 2 for the replacement procedure A failure in the detector or the converter is suspected End Carry out calibration Contact Yokogawa Electric Corporation F12 5E EPS Figure 12 5 12 4 IM 11M12D01 01E 12 Troubleshooting 2 Error 2 Heater Temperature Failure Possible causes of heater temperature failure This error occurs if the detector heater temperature does not rise during warm up falls below 730 C after warm up or exceeds 780 C When Error 2 occurs Alarm 5 cold junction temperature alarm may be generated at the same time Be sure to touch the error icon to get the error description and confirm whether or not this alarm is being generated simultaneously If Alarm 5 is generated simultaneously a failure in the cold junction system on the detector terminal block is suspected In this case follow the procedure accordi
209. osing the cover of the detector After screwing the cover in the detector body secure it with the lock screw Detector Cover F5 8E EPS Figure 5 5 IM 11M12D01 01E 5 7 5 2 3 Power and Ground Wiring Connect the power wiring to the L and N terminals in the averaging converter Use wires with a size of 2 mm2 14 AWG or larger If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm A lock washer must be installed Connect the ground wiring to the protective ground terminal in the averaging converter or the external ground terminal on the side of the case Run the ground wiring so the ground resistance is 100 Q or less equivalent to Class D grounding Make sure that the jumper plate is connected between the G terminal and the protective ground terminal Grounding to the ground terminal on the Averaging converter case Converter Case y Crimp Terminal A Lock Wash FG Terminal AEE ES Figure 5 6 Grounding to the Ground Terminal A WARNING Operating the instrument with the jumper plate disconnected may result in poor resistance to noise 5 2 4 Power Wiring to Detector Heaters This wiring provides electric power from the averaging converter to the heater for heating the sensor in a detector Use 2 core shielded PVC insulated PVC sheathed control cables The wire size s
210. ount of air Ao 12 38 10000 x H1 1 36 m kg Low calorific power H1 X value 3 37 10000 x Hx 2 55 m kg where H1 low calorific power of fuel h Hydrogen in fuel weight percentage w Moisture content in fuel weight percentage Hx Same as numeric value of H1 e For gaseous fuel Amount of water vapor in exhaust gas 1 100 h2 1 2 Sy Cy hy w ne In J Theoretical amount of air 11 2 x H1 10000 m m Low calorific power H1 X value 1 05 10000 x Hx m m where H1 low calorific power of fuel h Hydrogen in fuel weight percentage w Moisture content in fuel weight percentage Hx Same as numeric value of H1 e For solid fuel Amount of water vapor in exhaust gas Gw 1 100 1 24 9h w m3 kg Theoretical amount of air 1 01 x H1 1000 0 56 m kg Low calorific power H1 Hh 25 9h w kJ kg X value 1 11 0 106 1000 x Hx m m where w Total moisture content in use weight percentage h Hydrogen content weight percentage The average hydrogen content of coal mined in Japan which is a dry ash free type is 5 7 percent Accordingly h may be expressed mathematically by h 5 7 100 w a 100 x 100 w 100 w1 where a Ash content w1 Moisture content analyzed on a constant humidity basis Hh Higher calorific power of fuel kJ kg H1 Low calorific power of fuel kJ kg Hx Same numeric value of H1
211. output Contact input Power supply 100 115 V AC 50 60 Hz 5 Instrument air Span gas Calibration gas unit same as for zero gas Heater 1 25mm2 2 core Ql 1 lt Check QJ Valve oe DN Flowmeter ave K9292DS Reference gas m ny Airset Calibration gas ry K Calibration gas Model ZA8F flow setting unit pressure regulator Zero gas cylinder Calibration gas unit case F01 EPS Figure 4 1 Typical Piping for System Using Flow Setting Units for Manual Calibration 4 2 The following outlines some points to note regarding the piping for this system e Install a stop valve through a nipple on the calibration gas inlet of the detector Note The stop valve should be connected directly to the detector If any piping is present between the detector and the stop valve condensation may develop in the pipe causing damage to the detector by rapid cooling when the calibration gas is introduced e When a high temperature detector is used and the pressure of a sample gas is negative connect an auxiliary ejector on the sample gas outlet of the high temperature probe adapter See Figure 4 3 in Subsection 4 1 4 e When a high temperature detector is used and the pressure of a sample gas is 0 49 Pa or higher it is recommended that a throttle e g needle valve be installed on the sample gas outlet of the high temperature probe adapter See Figure 4 4 in Subsection 4 1 4 Note
212. pen circuit or the detector may corrode 3 Handle the probe with care so that the dust filter mounted screws on the tip of the probe do not hurt your finger s 4 Before opening or closing the terminal box first remove dust sand or the like from the terminal box cover 11 1 Removing and Attaching the Front Cover 11 1 1 Removing the Front Cover 1 Loosen the 4 knob bolts by hand and then loosen the lock screw with the Allen wrench supplied 2 Remove the front cover by lifting up slightly then pulling away from the case 11 1 2 Attaching the Front Cover 1 Attach the front cover aligning the slots on the sides of the cover with the knob bolts on the case and then pull the cover down until it is seated firmly 2 Hand tighten the knob bolts and then securely tighten the lock screw with the Allen wrench supplied Knob Bolt i r Lock Screw nn F11 1E eps Figure 11 1 How to Remove Attach the Front Cover 11 2 Hot Swap Function The averaging converter features a function that allows a desired detector to be discon nected reconnected for inspection or maintenance just by turning off the power of the relevant channel without system shutdown This function is called hot swap While power to a channel is being removed the channel is automatically eliminated from the averaging groups and does not affect any other channels Since the output circuits for both the channel card
213. played on the display See Fig 8 15 CAL start Contact input starts Semi Automatic Calibration Calibration Mode setting must be Semi Auto or Auto Contact signal must be applied for at least 1 sec Even if input signal continues to be applied calibration is not repeated unless contact input is released then reapplied Indication Check Start Contact input starts Semi Automatic Indication Check Indication Check setting must be Semi Auto or Auto Contact signal must be applied for at least 1 sec Even if input signal continues to be applied Indication Check is not repeated unless contact input is released then reapplied Blowback start Contact input starts Blowback Contact signal must be applied for at least 1 sec Even if input signal continues to be applied Blowback is not repeated unless contact input is released then reapplied CAL gas pressure low Contact input disables Semi Auto or Auto Calibration Process Gas Alarm While contact signal is input for safety reasons heater power is turned off When contact input is released heater power is reapplied and warmup begins When warmup ends then Measuring mode starts T8 6E eps Tag Ch1 21 0 Ch2 21 0 Ch3 21 0 Ch4 21 0 Ch5 Ch6 Ch7 21 0 21 0 21 0 Ch8 20 7 Pa F8 15 EPS Fig 8 15 During Range Switching 8 15 8 16 lt Setting Procedure gt This setting example shows how to set When
214. put span in Time Start calibration The response time is obtained after the corrected calibration curve has been found The response time is calculated as the time interval between the ten percent and 90 percent output points Calibration complete F10 3E EPS Figure 10 3 Typical response time characteristic 10 1 8 Robustness of a Cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed as one of four time periods during which the cell may still be used 1 more than a year 2 more than six months 3 more than three months 4 less than one month The above four time periods are tentative and only used for preventive maintenance not for warranty of the performance This cell s robustness can be found by a total evaluation of data involving the response time the cell s internal resistance and calibration factor However if a zero or span calibration was not made the response time cannot be measured In such a case the response time is not used as a factor in evaluating the cell s robustness 10 1 9 Cell s Internal Resistance IM 11M12D01 01E A new cell sensor has an internal resistance of 200Q maximum As the cell degrades so will the cell s internal resistance increase The degradation of the cell cannot be evaluated just by changes in cell s internal resistance however Those changes in the cell s internal resistance are just a guide to the extent th
215. r Dust Guard Protector 7 Stainless steel tag plate Printed tag plate 8 8 Used with the ZO21P High Temperature Probe Adapter Select flange Q When installing horizontally the probe whose insertion length is 2 5 meters or more use the Probe Protector Be sure to specify Specify the flange suffix code either C or K Not waterproof avoid rain Operating maximum temperature is 80 C Available only in the U S 10 Available only in the U S DERAKANE is a registered trademark of the Dow Chemical Company 11 Recommended if measured gas contains corrosive gas like chlorine 12 Piping for reference air must be installed to supply reference air constantly at a specified flow rate IM 11M12D01 01E Not used in conjunction with P pressure compensation for reference air The flange thickness does not conform to JIS specification Inconel probe bolts and U shape pipe are used Use this option for high temperature use ranging from 600 to 700 C T2 1 EPS 2 5 EXTERNAL DIMENSIONS 1 Model ZR22G Separate type Zirconia Oxygen Analyzer Detectors L ou 283 to 292 7 t e a g ll x amp dll Q i s O U L 0 15 0 4 0 7 1 0 3 6 4 2 4 8 5 4 m Reference air inlet 155 to 163 69 Cc gt 2 G1 2 2 1 2NPT etc Cable con
216. r JAVAJAVA to enter Commissioning Select Password Setting and confirm the password set 2 From the Password setting display you can type spaces over an existing password to erase it 8 24 IM 11M12D01 01E 9 Calibration 9 Calibration 9 1 Calibration Briefs 9 1 1 Principle of Measurement IM 11M12D01 01E This section sets forth the principles of measurement with a zirconia oxygen analyzer before detailing calibration A solid electrolyte such as zirconia allows the conductivity of oxygen ions at high temperatures 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 become 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 the oxygen molecules This reaction is indicated as follows Negative electrode O 4e 2 O gt Positive electrode 20 O 4e The electromotive force E mV between the two electrodes generated by the reaction is governed by Nernst s equation as follows R
217. r using a heat source such as steam 3 2 3 Probe Insertion Hole A high temperature detector consists of a ZR22G 015 Detector and ZO21P High temperature Probe Adapter When forming the probe insertion hole the following should be taken into consideration 1 If the probe is made of silicon carbide SiC the probe hole should be formed so that the probe is mounted vertically no more than a 5 tilt 2 In the case where the probe is made of stainless steel and the probe adapter is to be mounted horizontally the probe hole should be formed so that the probe tip is not higher than the probe base Figure 3 5 illustrates examples of the probe insertion hole JIS 5K 50 FF equivalent or Aspace of 52mmor ANSI Class 150 4 RF more in diameter and equivalent flange long enough the length of the probe 100mm Aspace of 52 mm or more in diameter and long enough for the length of the probe Never mount the probe JIS 5K 50 FF equivalent with its tip higher than or ANSI Class 150 4 RF the base equivalent flange The allowable margin for probe tilt is within 5 An SiC probe shall be mounted vertically Horizontal mounting is used with a SUS probe F3 5E EPS Figure 3 5 Examples of the probe insertion hole IM 11M12D01 01E 3 7 3 2 4 3 8 Mounting of the High Temperature Detector AN Note Ceramic zirconia is used in the sensor cell portion on the detector probe tip Care shou
218. r channel is in Purge status then Purge status display takes preference introduced Channel is in calibration period calibration gases are being Purge gas are being introduced Channel is in check period check gases including 3rd check Blowback is being performed indication check or blowback Channel is in stabilization period after calibration Output is being held as e g a Eq m 6 2 2 2 Switches and Their Functions Range is being switched by contact input Switch icons displayed on the right side of the display vary depending on the panel display allowing all switch operations Table 6 2 shows the functions of the switches Table 6 2 Switches and Their Functions Home key Returns to the Execution Setup display D Reject key Moves back to the previous display Cursor key Moves the cursor downward Graph display Displays a trend graph Alarm Displayed if an alarm arises Page scroll key In detailed data display scrolls up down one page 4 gt OR es Update key In error or alarm display updates the information displayed lt IM 11M12D01 01E Enter key Confirms data entry or selected item Setup key Moves to the Execution Setup display Detailed data key Displays detailed operation data Graph display key Displays a trend graph in cascade pattern Error Displayed if an error occurs Channel sc
219. r strut assembly 23 into the detector 24 while inserting the calibration pipe in the detector 24 into the heater section in the heater strut assembly 23 as well as in the bracket hole Coat the screw 8 with grease NEVER SEEZ G7067ZA and tighten the screw 8 with a special tool part no K9470BX or equivalent with a tightening torque of 12N m 10 percent Next to install the O rings 22 on the calibration gas and reference gas pipes disas semble the connector 13 in the following procedure First remove the screw 25 and then remove the plate 17 and two caps 20 If the O ring 22 remains in the hole pull them out from the back Pass the heater and thermo couple leadwire through the connector 13 Also pass the calibration gas and reference gas pipes through the opening of the connector 13 If the O ring 22 fails replace it with a new one Push the two caps 20 into the associated opening of the connector 13 Insert the plate 17 aligning it with the groove of the cap 20 and tighten it with the screw 25 If you attempt to insert the calibration gas and reference gas pipes into the connector 13 without disassembling the connector 13 the O ring may be damaged Tighten Screw 19 in Heater Strut Assembly 23 until connector 13 can t move Reassemble in reverse order to the above disassembly procedure The two wires with ceramic insulators from the heater strut assembly are heater wires and th
220. r to the averaging converter Use 6 core shielded PVC insulated PVC sheathed control cables The conductor two way resistance should be 10 Q or less Keep the cables away from the power wiring If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm The shields should be connected to cable shield ground terminals on the case of the averaging converter Channel Card Averaging Converter Detector 1 CH1 CH2 CH3 ZR22G ZO21D Shield To Detecter 2 Figure 5 9 Signal Wiring to Detectors IM 11M12D01 01E 5 Wiring If the ambient temperature at the detector installation site exceeds 80 C install a terminal box and connect to the detector using 600 V silicon rubber insulated glass braided wires The distance between the detector and the terminal box should be minimized Channel Card Averaging Converter Detector 1 CH1 CH2 CH3 ZR22G Z021D Shield Silicon Rubber Insulated Glass Braided Wire Terminal Box To Detector 2 Figure 5 10 Signal Wiring to Detectors Using Terminal Box 5 2 6 Ground Wiring of Detectors Connect the ground wiring to the external ground terminal on the detector case or the internal ground terminal Follow the instructions below Th
221. ration ile at oO g F37E EPS Fig 8 7 Semi Auto Indication Check For Automatic Indication Check Under indication check is the time starts when indication check is started at a preset timing lasts while indication check is being performed sequentially and ends after a preset hold time for the last checked channel has elapsed 8 5 8 6 5 During Blowback For Semi Automatic Blowback When blowback is started from the Blowback display during blowback is the time that starts when you touch the Enter key on the Blowback display with Start blow back selected Figure 8 8 lasts while blowback is being performed for all installed channels and ends after a preset hold time has elapsed When blowback is started by a contact input during blowback is the time that starts when blowback is started by the contact input lasts while blowback is being performed sequentially for all installed channels and ends after a preset hold time for the last performed channel has elapsed For Automatic Blowback During blowback is the time that starts when blowback is started at a preset timing lasts while blowback is being performed sequentially and ends after a preset hold time for the last performed channel has elapsed Blow back A CP Start blow back coal Cancel blow back Enter FOSE EPS Fig 8 8 Blow back display 6 Process Gas Alarm Process gas alarm status lasts from when a contact
222. rd by sliding along the guide rail in the slot and then securely tighten the 2 screws A WARNING e Using a channel card installed without 2 screws tightened may result in poor resistance to noise 5 1 1 2 Precautions in Processing Shields When a shielded cable is required for wiring follow the instructions below to process the shield 1 All the shields should be connected on the averaging converter side Connect to the cable shield ground terminals inside the averaging converter 2 The shields should not be connected on the other side of the cable To avoid any possible contact with housings of instruments connected or metal parts conductors of the shields should be processed using insulating tapes or in an appropriate way 3 The shields should be connected to the cable shield ground terminals immediately after the cable is inserted into the averaging converter through the wiring hole Having a long distance between the wiring hole and the cable end where the shield goes out may result in poor resistance to noise 5 2 IM 11M12D01 01E IM 11M12D01 01E 5 Wiring Good Bad i To Terminal Cores To Terminals o Terminals N Shield Cable Shield Ground Long Terminal nT Short Wiring Holes oe Figure 5 1 Shield Processing Figure 5 2 Cable Shield Ground Terminals 5 3 5 1 2 5 1 3 Wiring Holes The averaging converter has 30 wiring holes Use holes near
223. re constantly If the internal temperature exceeds the limit an inside temperature alarm will be generated The limit is approximately 50 C in terms of case ambient temperature The occurrence cancellation time of this alarm is recorded for the last three times The record can be viewed in the Detailed Data display Figure 12 14 For frequent occurrence of this alarm take a measure to lower the ambient temperature By assigning the inside temperature alarm to the contact output a contact may be used as an On Off switch for cooling equipment e g fan q chi gt Inside temp alarm log a ON 24Jun 2004 16 25 OFF 24Jun 2004 16 25 ON 24Jun 2004 16 23 OFF 24 Jun 2004 16 25 ON 24Jun 2004 16 22 OFF 24Jun 2004 16 23 F12 14E EPS Figure 12 14 Inside Temperature Alarm Log 12 15 12 3 Countermeasures When Measured Value Shows 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 measur ing 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 will be described 1 The measured value is higher than the true value 2 The measured value is lower than the true value 3 The measured value sometimes shows abnormal values 12 3 1 Measured Value High
224. re content in the air may cause an error in measured oxygen concentration value vol O 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 3 Calibration gas zero gas is mixed into the detector due to leakage If the zero gas is mixed into the detector due to leakage as a result 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 needle valves check valves solenoid valves for automatic calibra tion etc in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed states 4 Combustible components exist in the measured gas If combustible components exist in the measured gas they burn in the sensor and thus oxygen concentration decreases Check that there are no combustible components 5 Temperature of the detector cell reaches 750 C or more 12 3 3 Measurements Sometimes Show Abnormal Values lt Cause and Countermeasures gt 1 Noise may be mixing in with the converter from the detector output wiring Check whether the converter and detector are securely grounded Check whether or not the signal wiring is laid along oth
225. roll key In detailed data display or data setup display moves to the previous next channel Cursor Points to the currently selected item T0602 EPS 6 5 6 2 2 3 Display Configuration Display configuration is shown below 21 0 02 21 0 02 25 02 Execution Setu d cm gt Execution P Calibration Indication check Cell voltage 0 9mvV Thermo voltage 29 4mV Blow back Setup Maintenance C J resistance 1170 20 Cell temperature 750 C C J temperature 43 C wv Commissioning Warmup Calibration Indication check Blow back Maintenance Commissioning Entry your password Entry your password Password entry display will appear only if the desired operation is protected by password Password protection is factory set to disabled Password Entry for Maintenance Password Entry for Commissioning Calibration Maintenance P Manual calibration i pDisplay setup Semi auto calibration Lal Calibration setup Indication check setup Blow back setup mA output loop check Contact check Commissioning a Channel card power i pBasic setup mA output setup Alarm setup Indication check Blow back P Manual ind check P Start blow back Semi auto ind check Cancel blow back Contact setup a Average group setup Others Figure 6 5 Display Configuration of AV550G 6 6 IM 11M12D01 01E 6 Components 6 2 2 4 Display
226. romotive force 9 1 2 Calibration Gas 9 2 A gas with a known oxygen concentration is used for calibration Normal calibration is performed using two different gases a zero gas of low oxygen concentration and a span gas of high oxygen concentration In some cases only one of the gases needs to 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 percent oxygen by volume with a balance of nitrogen gas N The span gas widely used is clean air at a dew point temperature below 20 C and free of oily mist or dust as in instrument air For best accuracy as the span gas use oxygen whose concentration is near the top of the measurement range in a nitrogen mixture IM 11M12D01 01E 9 Calibration 9 1 3 Compensation The deviation of a measured value from the theoretical cell electromotive force is checked by the method in Figure 9 2 or 9 3 Figure 9 2 shows a two point calibration using two gases zero and span Cell electromo tive forces for a span gas with an oxygen concentration pl and a zero gas with an oxygen concentration p2 are measured while determining the calibration curve passing between these two points The oxygen concentration of the measurement gas is deter mined from this calibration curve In addition the calibration curve corrected by calibration is compared
227. ror description display touch the Update key to update the error occurrence condition When an error and an alarm occur at a time an error icon takes precedence Channels Where Errors Occur displayed in red Tag Ch1 Ch Ch Ch Err2 2 0 96 3 0 96 4 0 96 i Ale Error Icon F02 cE EPS Figure 12 1 Error Displays on Multi channel Display Tag Ch 1 Ave a Ave b Ave c r2 0 96 02 0 95 02 0 96 02 EBER F02 dE EPS Figure 12 2 Error Displays on Single channel Display Tag Err4 Ch1 Err1 Ch2 Err2 Ch3 Err2 Ch4 Err1 Ch5 Err1 Ch6 Err2 Ch7 Err2 Ctrl card Cell voltage Heater temp Heater temp Cell voltage Cell voltage Heater temp Heater temp Next a ag Ch8 Err3 Ch card Previous Fm 8E EPS Figure 12 3 Error Descriptions page 1 IM 11M12D01 01E Fm 9E EPS Figure 12 4 Error Descriptions page 2 12 3 12 1 4 Remedies When an Error Occurs 1 Error 1 Cell Voltage Failure Error 1 occurs when the cell sensor voltage input to the converter falls below 50 mV corresponding to about 200 O2 The following are considered to be the causes for the cell voltage falling below 50 mV 1 Poor contact in terminal connections between the converter and detector 2 Breakage in wiring cable between the converter and the detector 3 Damage or deterioration of the sensor assembly 4 Continuity f
228. rror can be canceled by turning off on the main power There are five types of errors as shown in the table below Table 12 1 Error Types and Occurrence Conditions Error Type Occurrence Conditions Unit to be Detected Error 1 Cell voltage failure Cell sensor voltage signal input to the converter falls each channel below 50 mV for 1 5 seconds or longer continuously Error 2 Heater temperature failure 1 Heater temperature rise during warm up is not more than each channel 5 C per 5 minutes 2 Heater temperature during warm up exceeds 780 C for 1 5 seconds or longer continuously 3 After warm up heater temperature falls below 730 C or exceeds 780 C for 10 seconds or longer continuously Error 3 Channel card failure 1 Failure is detected by memory check each channel 2 Communication failure occurs between card and A D converter Error 4 Control card failure Failure is detected by memory check System Error 5 IM 11M12D01 01E Inter card Communication failure occurs between each channel communication failure control card and each channel T12 1E eps 12 1 12 1 2 Operations When an Error Occurs 12 2 When an error occurs the averaging converter operates as follows When a channel specific error occurs 1 The power to the heater of the corresponding detector is removed 2 On the multi channel display a red error code is indicated under the relevant channel and an error i
229. s a failure contact output 1 Abnormal cell 2 abnormal cell temperature high low 3 abnormal channel card 4 abnormal control card 5 abnormal card commu nication Contact Input Two points contact input The following functions are programmable for contact inputs 1 Calibration gas pressure decrease alarm 2 Range switching 3 External calibration start 4 Process alarm if this signal is received the heater power turns off 5 Validation start 6 Blow back start Self diagnosis Abnormal cell abnormal cell temperature high low abnormal channel card abnormal control card abnormal card communication Calibration Method zero span calibration Calibration mode automatic semi automatic and manual All are operated interactively with an LCD touchscreen Either zero or span can be skipped Zero calibration gas concentration setting range 0 3 to 100 vol O2 0 01 vol Oz2 in smallest units Span calibration gas concentration setting range 4 5 to 100 vol O2 0 01 vol O2 in smallest units Use nitrogen balanced mixed gas containing 0 to 10 scale of oxygen and 80 to 100 scale of oxygen for standard zero gas and standard span gas respectively Calibration period date time setting maximum 255 days 23hours IM 11M12D01 01E 2 15 FOUNDATION Fieldbus communication function The bi directional digital communication as standard for FOUNDATION Fieldbus that is established by Fieldbus foundation Interface FOU
230. s as the cell sensor deteriorates You can monitor the values measured during the latest calibration However these values include the cell s internal resistance and other wiring connection resistance So the cell s degrading cannot be estimated from these values only When only a span calibration has been made these values will not be measured and previously measured values will remain 5 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 four levels 9 4 IM 11M12D01 01E 9 Calibration 9 2 Calibration Setup 9 2 1 Mode There are three calibration modes for zero and span calibration manual mode semi auto mode started from the display or started by contact input using preset calibration time and stabilization settling time and autocalibration at preset intervals Restrictions related to each mode are described here When Manual Mode is selected In this mode only Manual calibration can be performed Contact input used to start semi auto calibration has no effect Autocalibration does not start at autocalibration start time When Semi Auto Mode is selected In this mode manual calibration or semi auto calibration can be performed Autocalibration does not start at autocalibration start time When Auto Mode is selected Any calibration mode is valid A CAUTION Indication Check mode of Auto cannot coexist w
231. s can lead to problems with undesirable frequent ON OFF switching You can set a smoothing time constant of between 0 and 255 seconds to reduce the effect A single time constant setting applies to all analog outputs lt Setting Procedure gt 1 From mA output setup on the Commissioning display select Output damping and touch the Enter key A numerical data entry display is displayed 2 To set 30 sec enter 030 and touch the Enter key lt Default setting gt Factory default setting is 0 sec no smoothing 8 1 4 Setting Output Mode Applies to All Analog Outputs 8 8 You can select whether the relationship between the measured oxygen concentration and the analog output signal be linear or logarithmic The same setting applies to all analog outputs lt Setting Procedure gt 1 From mA output setup on the Commissioning display select Output Mode and touch the Enter key 2 A selection window appears allowing you to select Linear or Log Touch the Enter key to confirm lt Default setting gt Output mode is set to linear prior factory shipment or after data initialization A CAUTION If you select an output mode of logarithmic then regardless of range setting the minimum output value becomes 0 1 O2 fixed IM 11M12D01 01E 8 Detailed Data Setting 8 2 Oxygen Concentration Alarm Setting You can set four oxygen concentration alarm settings High High HH High H Low L and Low Low LL If an alarm occ
232. s from OOmin 00 sec to 60 min 59 sec The analog outputs of individual chan nels which are under calibration remain in Output Hold status from the start of calibra tion until the end of the stabilization settling time and their output is not included in averaging group calculations during this time If the mode is Semi Auto In addition to the above Hold output stabilization settling time there is also a Cal time setting This is the settling time from when calibration gas flow is started until calibration is performed The same time settingis used for both Zero and Span calibra tion Setting range is from 00min 00 sec to 60 min 59 sec Calibration time and stabilization time and analog output status are shown on the calibration timing chart of Fig 9 6 below For Solenoid Valve SV piping and wiring see Sec 4 2 on AutoCalibration 1 b Oka o ko Stabilizn lt 1 CAL time FER EES Ch 1 Qutput hold CAL time 1 lt 4 i 4 i 1 1 1 Ch 2 Output hold Ch1 removed from average Ch2 removed from average 1 4 1 J b 3 Stabilizn ie CO peers en TEN Off On Off a t Span gas on Zero gas ON Span gas ON Zero gas ON F9 6E eps CAL start Fig 9 6 Calibration Timing 9 7 9 8 If the mode is Auto In addition to the above Hold output stabilization settling time and Cal time setting thereAfs also Cal Interval Start date and Start time The Autom
233. s line is required in addition to the system configuration shown in Figure 4 9 Route the piping from the third check gas cylinder through a pressure reducing valve and a stop valve to the solenoid valve for switching the span gas and the third check gas as shown in Figure 4 12 It is recommended that the piping and wiring for the solenoid valve for switching the span gas and the third check gas be installed to allow the third check gas to be introduced when powered This solenoid valve is activated by a contact signal from the averaging converter Power wiring is separately required Detector Averaging converter AV550G Signal ___ Analog outouts Averaged and individual output Heater Contact output Contact output Contact input Calibration contact outputs j Calibration gas line Reference gas line Span gas cylinder Instrument air Flowmeter Instrument air Stop valve Air set Zero gas cylindr N Third check gas cylinder If optional 24 V outputs are specified for solenoid valve MS Code 24 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves Ds Needle valve Figure 4 12 Piping for Automatic Indication Check Using 3rd Check Gas IM 11M12D01 01E 4 Piping 4 2 7 Piping to Introduce P
234. sates for the cold junction temperature for a thermocouple measuring the cell temperature When the ZR22 Detector is used the maximum C J temperature will be 150 C If the terminal box temperature exceeds this take measures to shield the terminal box from heat radiation The maximum C J temperature varies depending on the type of detector 10 1 6 Span gas and Zero gas Correction Ratios These are used to check for degradation of the sensor cell If the correction ratio is beyond the limits as shown in Figure 10 2 the sensor should no longer be used These ratios can be found by calculating the data as shown below 81 92 ez 7 Zero origin Cell Calibration curve zg j before correction TDR Previous orce m zero gas data Ka el oN 7 Corrected calibration curve theoretical calibration curve Span origin Span gas concentration Oxygen concentration vol O2 Zero gas ratio B A x 100 Correctable range 100 30 Span gas ratio C A x 100 Correctable range 0 18 F10 2E EPS Figure 10 2 10 2 IM 11M12D01 01E 10 1 7 10 Other Functions Cell Response Time The cell s response time is obtained in the procedure shown in Figure 10 3 If only either a zero point or span calibration has been carried out the response time will not be measured just as it will not be measured in manual calibration Five minutes maximum Response time mA 10 of analog out
235. se To use the High alarm select H and a window to allow you to select OFF or ON appears Select ON to enable the High alarm setting 8 To set the High Alarm setting value use the pointer key to movethe pointer to the value then touch the Enter key The numeric entry display appears so you can enter a value in units of 0 1 O2 To enter the value 10 Oz enter 0100 You can set other alarms in a similar way Alarm set points A i aia tia d chi gt HH CF OFF 100 0 H OFF 100 0 L OFF 0 0 v LL OFF 0 0 Fig 8 13 Alarm setting To remove channels in alarm status from the associated Averaging Group 9 From the Alarm Setup display select Except alarm ch and touch the Enter key 10 A YES NO selection window appears IM 11M12D01 01E 8 11 8 12 lt Default setting gt Alarm settings are set to defaults in Table 8 3 prior factory shipment or after data initialization Table 8 3 Item Default Hysteresis 0 1 O2 Delay time 3 sec High High HH Alarm OFF HH Alarm Setting 100 O2 High H Alarm High Alarm Setting OFF 100 O2 Low L Alarm OFF Low Alarm Setting 0 O2 Low Low LL Alarm OFF LL Alarm Setting A CAUTION 0 O2 T8 3E eps If an alarm setting is OFF then the alarm is disabled You need to turn alarms ON to enable them IM 11M12D01 01E 8 Detailed Data Setting 8 3 Assigning Contact Ou
236. sfy a zero gas ratio of 100 30 percent or a span gas ratio of 0 18 percent 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 A CAUTION If the 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 replace the contact If there 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 mini mized Use sensor assemblies manufactured in or after Sept 2000 the serial number on the side of the sensor assembly should be 0J000 or later for example OK123 1AA01 etc 1 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 th
237. shown in Figure 10 35 appears during calibration open the zero gas flow setting valve of the flow setting unit and adjust the flowrate to 600 ml min 60 ml min To rotate the valve shaft if the valve has a lock nut loosen the lock nut and slowly turn it counterclockwise To check the flowrate monitor the calibration gas flow meter If the measurement gas pressure is extremely high adjust the measurement gas pressure to obtain pressures listed in Table 10 6 10 Table 10 10 Measurement gas pressure kPa 50 100 150 200 250 Flowrate ml min 500 430 380 250 320 T10 10E EPS Chi Manual cal Open zero gas valve Set flow span gas to 600ml min F Valve opened Cancel calibration F22E EPS Figure 10 35 Manual Calibration Display 2 Adjust the flowrate and select Valve opened from the Manual calibration display Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Figure 10 36 appears Close the zero gas flow setting valve to stop the zero gas flow If the valve has a lock nut 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 Chi Manual cal Span calibration f Zero calibration f Close the zero gas valve C gt Span calibration End K pa Enter F26E EPS Figure 10 3
238. sions of the detector in Chapter 3 8 of IM 11M12A01 02E before installation e The sensor zirconia cell at the probe tip may deteriorate due to thermal shock if water drops are allowed to fall on it as it is always at high temperature IM 11M12D01 01E 3 1 1 Do not mount the probe with the tip higher than the probe base 2 If the probe length is 2 5 meters or more the detector should be mounted vertically no more than a 5 tilt 3 The detector probe should be mounted at right angles to the measurement gas flow or the probe tip should point downstream Figure 3 1 illustrates an example of the probe insertion hole Bounds of the probe vertical insertion hole location Flange matches the detector size Al 100 mm Type Outside diameter of detector Standard 50 8 mm in diameter Note With dust filter 51 mm in diameter Note With probe protector 60 5 mm in diameter Note horizontal 100 mm CH Four hole flange Eight hole flange Note When using the detector with pressure compensation ensure that the flange gasket does not block the reference air outlet on the detector flange If the flange gasket blocks the outlet the detector cannot perform pressure compensation EE Where necessary make a notch in the flange gasket O Figure 3 1 Example of forming probe insertion hole 3 1 3 Installation of the Detector A CAUTION e The cell sensor at the tip of
239. ssioning gt Basic setup gt Detector then the Detector Selection display Fig 12 appears 6 Select channels to be connected to ZO21D and change ZR22G to read ZO21D 7 After changing the channels settings of all channels to be connected to ZO21D detectors turn off converter power 8 Reconnect the removed thermocouple TC signal wiring to the channel cards IM 11M12D01 01E 7 Startup 7 5 Supply Power to Averaging Converter A CAUTION To avoid temperature changes around the sensor it is recommended that rather than turning it on and off power be continuously supplied to the Oxygen Analyzer if it is used in an application where it is used periodically It is also recommended to flow a span gas instrument air beforehand Before connecting power check that power switch is set to O Off After connecting power Turn power switch to I On The startup display is displayed for about 10 seconds then the multi channel cell temperature display shown in Fig 14 appears Confirm that the displayed temperatures of each channel gradually increase After the cell temperatures reach their target setting of 750 C and stabilize the display switches to show oxygen concentration When all the channels have switched to display oxygen concentration the red Warmup and Hold alarm marks at the bottom of the display disappear Tag e cn os 514 C 514 C gt Ch2 Ch6 515 C 514 C al Ch3 Ch7
240. ssscccssssssssssssssssssssessseees MPL 11M06B02 01E C CMPL 11M03B01 10E C MPL 11M03B01 05E REVISION Record waseisicsiscetcscatecsidsencicanlaZecasacdocetacces toroo rossos aseen osooso se aeaoe eeose toesea o M IM 11M12D01 01E xiii 1 Overview 1 Overview 1 1 System Zirconia oxygen analyzers are used in combustion facilities to measure the flue gas oxygen concentration Boiler operators use the oxygen measurement to optimize fuel usage minimize atmospheric emissions and reduce energy consumption A multiple point oxygen measurement system may be required for situations when gas stratification in the flue duct affects combustion control The AV550G Averaging Converter can accept inputs from up to eight zirconia oxygen detectors It sends output signals for the individual as well as averages of multiple oxygen concentrations A robust multipoint converter reduces installation and maintenance costs A large 5 7 inch color LCD display shows various measurement setup calibration and trend screens Its intuitive touch screen is easy to read and makes set up and mainte nance simple Other standard features include new self diagnostics and a hot swap function that allows a desired probe to be disconnected reconnected for inspection or maintenance just by turning off the power of the relevant channel The ZR22G separate type detector uses a highly reliable zirconia sensor and its heater assembly can be replaced in the f
241. stress e Do NOT allow the sensor probe tip to make contact with anything when installing the detector e Avoid any water dropping directly on the probe sensor of the detector when install ing it e Check the calibration gas piping before introducing the calibration gas to ensure that there is no leakage of the gas If there is any leakage of the gas the moisture drawn from the measured gas may damage the sensor e The detector especially at the tip becomes very hot Be sure to handle it with gloves A DANGER AV550G is very heavy Handle it with care Be sure not to accidentally drop it Handle safely to avoid injury Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment In addition confirm that the power is switched off when connecting power supply Some process gas is dangerous to people When removing this equipment from the process line for maintenance or other reasons protect yourself from potential poisoning by using a protective mask or ventilating the area well When carrying the AV550G Averaging Converter mark sure this is done by two or more people 1 About This Manual e This manual should be passed on to the end user e The contents of this manual are subject to change without prior notice e The contents of this manual shall not be reproduced or copied in part or in whole without permission e This manual explains the functions contained
242. surement value goes outside an alarm limit alarm status is entered only if the alarm stays outside the limit for the delay time The delay time also affects release of alarm status The effect of hysteresis is similar delaying alarm action and release except that it is an offset value rather than a time to release an alarm the alarm has to move the hysteresis value inside the alarm setting You can combine delay with hysteresis to both minimize spurious alarms and lengthen brief but valid alarm output 8 9 The action of delay and hysteresis are illustrated in Figure below Alarm delay and hysteresis settings apply to all alarm settings for all channels and all averaging groups Alarm range 7 5 High limit alarm setpoint Hysteresis 2 0 Coy eerie italy ion a a inna Cale mea S gnu Gan n Winters palais ae Oxygen concentration Delay time Delay time Delay time 5 seconds 5 seconds 5 seconds Alarm output ON OFF F8 4E EPS Fig 8 11 Alarm Output Action with Delay and Hysteresis Fig 8 11 shows an example with high alarm setting of 7 5 Oz alarm delay of 5 sec and hysteresis of 2 Oz A Although the measured value exceeds the high alarm setting within the delay time of 5 sec it falls within alarm setting hysteresis so no alarm is output B The measured value stays outside the alarm setting for longer than the delay time so an alarm is output delayed by the delay time C Although the meas
243. t has been dehumidified down to a dew point of approximately 20 C and is free from oil mist or dust is used as the air source This air is also used as a span gas for the detectors during calibration A zero gas for calibration is supplied from a cylinder to the detectors 1 1 ZR22G Detector max 8 detectors Cell output thermocouple output cold contact compensation 0 75mm2 6 core Heater 1 25mm 2 core gt Analog outputs Averaged and individual outputs fe Model AV550G Averaging Converter f 4 to 20 mA DC amm en Contact output Stop Check Qi Contact input Valve Valve Ceres r poo Flowmeter Valve Power supply G7016XH 7 K8282D8 Reterence gas_ fy pk a a 100 118 V AC 230V AC Calibration gas aP Instrument air SUE 60h25 Vi gt q L Span gas Calibration gas unit same as for zero gas gt q H Calibration gas unit case Calibration gas Model ZA8F pressure regulator flow setting unit Zero gas cylinder F01 EPS Figure 1 1 Typical System Configuration Using Flow Setting Units for Manual Calibration 1 1 2 System Configuration to Perform Automatic Calibration A typical system configuration to perform automatic calibration is illustrated in Figure 1 2 The system consists of detectors an averaging converter solenoid valves needle valves for flow control and a float type
244. tention to information essential for understanding the operation and functions A Tip This symbol gives information that complements the present topic CX SEE ALSO This symbol identifies a source to which to refer Protective Conductor Terminal A Function Earth Terminal Do not use this terminal as the protective conductor terminal v Alternating current IM 11M12D01 01E e Special descriptions in this manual This manual indicates operation keys displays and drawings on the product as follows n Displays on the panel Ex message display BASE Ex data display 102 IM 11M12D01 01E V NOTICE e Specification check When the instrument arrives unpack the package with care and check that the instrument has not been damaged during transportation In addition please check that the specification matches the order and required accessories are not missing Specifi cations can be checked by the model codes on the nameplate Refer to Chapter 2 Specifications for the list of model codes e Details on operation parameters When the AV550G Averaging Converter arrives at the user site it will operate based on the operation parameters initial data set before shipping from the factory Ensure that the initial data is suitable for the operation conditions before conducting analysis Where necessary set the instrument parameters for appropriate operation For details of setting data r
245. the filter on the detector It is recommended that you read Chapter 11 prior to filter mounting for it is necessary to be familiar with the detector s construction especially the sensor assembly 1 Mount the dust filter assembly by putting it on the end of the detector and screw the assembly clockwise Put a hook pin wrench K9471UX 52 to 55 in diameter into the hole on the assembly to fasten or remove it Apply a heat resistant coating see Note 1 to the threads on the detector When remounting Filter assembly after having once removed it from the detector reapply the heat resistant coating Note 1 As the detector is heated to 700 C it is recommended to use heat resistant coating on the threads to prevent seizing up Name of the heat resistant coating material NEVER SEIZE NICKEL SPECIAL Unit mm SiC Carborundum filter Detector 51 Attach the filter unit to the tip of the detector by screwing it clockwise MOWAAA SSS Additional length F3 2E EPS Figure 3 2 Installation of the dust filter IM 11M12D01 01E 3 3 3 1 5 Procedures for installing the dust guard protector K9471UC The ZR22G detector is shipped with the dust guard protector when the option code F2 is specified in case of ordering the detector The protector should be used when preventing dusts and water drops from lowering the detector performance is desired Screw the protector on
246. the top of the detector so as to cover the top When attaching or detaching the protector perform by hooking holes of its side with a hook pin wrench for 52 55 hole Pin diameter 4 5 mm P N K9741UX or the like or by pass a screwdriver through the holes When re attaching the protector after detaching it apply the Never Seize Nickel Special to it Increasing of insertion length 100 50 8 L 122 gt F11 1 eps 3 1 6 Detector with a probe protector Model ZO21R L LJULI L B for enhance forth The detector is used with a probe protector to support the probe ZR22G when the probe length is 2 5m or more and it is mounted horizontally 1 Put a gasket provided by the user between the flanges and mount the probe protector in the probe insertion hole 2 Make sure that the cell assembly mounting screws four at the probe tip are not loose 3 Mount the detector so that the reference gas and calibration gas inlet faces down ward Flow direction of the Unit mm measurement gas Gasket t1 5 gy 1050 1550 2050 60 5 Probe top Reference gas inlet Calibration gas inlet F3 3E EPS Figure 3 3 Probe protector supporting the mounting strength 3 4 IM 11M12D01 01E 3 Installation 3 1 7 Detector with a probe protector Model ZO21R L LIUL L B for dust wear protect The detector is used with a probe protector to prevent the sensor from being worn by dust particles when
247. there is a high concentration of dust and gas flow exceeds 10m s fine carbon boiler or fluid bed furnace 1 Put a gasket provided by the user between the flanges and mount the probe protector in the probe insertion hole The probe protector should be installed so that the notch is downstream of the measurement gas flow 2 Make sure that the cell assembly mounting screws four at the probe tip are not loose 3 Where the detector is mounted horizontally the reference gas and calibration gas inlet should face downward Ay CAUTION When the probe protector is used in the Zirconia Oxygen Analyzer version with pressure compensation P instrument air leaking from the probe protector may affect the measured value Gasket t1 5 Unit mm 1050 1550 2050 fo Direction of the measurement gas flow Probe top Mount the protector so that the notch is or the downstream side of the gas flow Reference gas inlet Calibration gas inlet F3 4E EPS Figure 3 4 Mounting of detector with a probe protector IM 11M12D01 01E 3 5 3 2 Installation of the Detector Model ZR22G 015 3 2 1 Installation Location This model detector is used with the High temperature Probe Adapter Model ZO21P H when the temperature of sample gas exceeds 700 C or when it is required due to maintenance spaces The following should be taken into consideration when installing the detector 1 Easy and safe access to the detector f
248. ting valve Span gas flow setting valve l Zero gas flow O setting valve DD D L D d 5 S ke Yo Flow meter for calibration gas lt Feaeers Figure 6 18 ZA8F Flow Setting Unit Flow meter for reference gas 6 12 IM 11M12D01 01E 7 Startup 7 Startup This section explains the startup procedures for the Averaging Converter supplying power setting parameters as required and performing manual calibration 7 1 Startup procedure The startup procedure is as follows A CAUTION If you connect Model ZO21D detectors then you need to change the detector parameters Before connecting power refer to Sect 7 4 Setting Detector Model Check settings Check piping amp wiring Check valve type setting If connecting ZO21D Briefly power on Set detector to ZO21D front panel If all detectors are ZR22G Power OFF Permanent power wiring Start set parameters Warmup then calibrate F7 1E eps IM 11M12D01 01E 7 2 Check Piping and Wiring Check piping and wiring refer to Sec 4 for piping and Sec 5 for wiring 7 3 Set Valve type Set valves which depend on your system configuration as follows 1 If there is a shutoff valve at the calibration gas inlet shut it 2 Assuming that instrumentation air supply is used as the reference gas adjust air set secondary pressure to approximately 50 kPa above that of the measured gas
249. touch Setup key on the Execution Setup display which appears select Commissioning then Contact setup 2 Select a contact that is not already assigned to another function then select Others 3 For this contact turn Blow back to ON Contact3 Others Warm up OFF Range change OFF Maintenance OFF Calibration OFF Indication check OFF F Blow back Third gas rem a Ki zt m 3 F10 25E EPS Fig 10 25 Assigning Solenoid Valve Switching Contact IM 11M12D01 01E 10 Other Functions 10 5 3 Setting Blowback Start Time IM 11M12D01 01E When mode is set to Semi auto Hold time and blowback time should be set Hold time is the time required from the end of blowback to the restart of measurement Set the time so that a sample gas that flows through the sensor after blowback can displace the blowback gas in the sensor and thus the output returns to normal Setting range is from 00 minute 00 second to 60 minutes 59 seconds Once the blowback starts on a channel its individual analog output is held at a value preset in the Output Hold Setup and excluded from averaging group calculations until the preset output hold time has elapsed Blowback time is the time for blowback in one channel Setting range is from 00 minute 00 second to 60 minutes 59 seconds A timing chart showing blowback time hold time analog output status and blowback gas switching so
250. tputs Item The averaging converter provides the following outputs 1 Function contact outputs DO1 DO4 Function can be allocated by user 2 Common representative error contact DOS Represents an error in any channel 3 Individual channel error contacts DO CH1 DO CH8 Individual channel error outputs one per channel For details of errors refer to Sec 12 1 Displays and Remedies When Errors Occur Each contact output is Form C transfer contact with three terminals COM NC NO COM common NC Normally Closed NO Normally Open using a mechanical relay with non wetted contacts Ensure that contact rating is not exceeded The four function specific contact outputs can be programmed to be normally operated NC or NO selectable For safety the error contacts are factory fixed to be normally closed How to assign conditions to function contact outputs is described below Table 8 4 shows the conditions that can be assigned to function specific contacts Table 8 4 Conditions that can be allocated to function specific contacts Condition for contact output IM 11M12D01 01E Other statuses High High Alarm ON then High High alarm results in contact output However High High alarm must be ON enabled Refer to Sec 8 2 Oxygen Concentration Alarms High Alarm If ON then High alarm results in contact output However High alarm must be ON enabled Refer to Sec 8 2 Oxygen Concentration Alarms Low Alar
251. tting units for manual calibration or the one performing when unburnt gas is generated This valve prevents the process gas from entering the calibration gas line Although it functions as a stop valve operation is easier than a stop valve as it does not require opening closing at each calibration Screw a check valve instead of a stop valve into the calibration gas inlet of the detector Standard Specifications Connection Rc1 4 or 1 4FNPT Material SUS304 JIS Pressure 70 kPa G or more and 350 kPa G or less Weight Approx 40 g Part No Description K9292DN Joint RC 1 4 Material SUS304 JIS K9292DS Joint 1 4 NPT Material SUS304 JIS T2 10E EPS K9292DN Rc 1 4 Apart R 1 4 B part Unit mm K9292DS 1 4FNPT A part 1 4NPT Male B part Approx 19 Approx 54 F2 11E EPS 2 25 2 6 6 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases e Part No K9473XH or K9473XJ Standard Specifications Primary Pressure Max 2 MPa G Secondary Pressure 9 8 to 196 kPa G Connection Rc1 4 or 1 4NPT F includes joint adapter Weight Approx kg Part No Description K9473XH Joint Re 1 4 Material Aluminum K9473XJ Joint 1 4 NPT F Material Body Aluminum Adapter SUS316 T2 11E EPS Unit mm Dimensions in parentheses are approximate O54 63 53 5 Bracket Mounting Dimensions K9473XH Piping
252. tup key to switch to the Execution Setup display 2 From the Commissioning display select Average group setup then Average group a Fig 7 8 shows the display 3 Select the group to set a or b then touch Enter Channels that you can select are displayed 4 Channels that are set to ON belong to that group Use the pointer cursor keys to move the pointer to any channel whose status you want to toggle then touch the Enter key The ON OFF selection window opens and you can toggle status 5 Any or all channels may belong to both groups a and b Average group a CPChi ON Ch2 ON Ch3 ON Ch4 ON Ch5 OFF Lle Ch6 OFF Ch7 OFF Ch8 OFF at 3 F7 8E EPS Fig 7 8 Setting Averaging Group lt Shipping time defaults gt At shipping time averaging groups a and b contain all channels all channels ON AN Note If you set all channels in a group to OFF then the averaged output will be held at the current set by Ave group invalid on the mA outputs hold display In this case the status mark at the bottom of the display will be HOLD For details refer to Sec 8 1 2 Output Hold Settings 7 8 IM 11M12D01 01E 7 Startup 7 9 Calibration To calibrate this instrument the procedure is to measure zero gas and span gas and set the instrument to read the known concentrations The procedure for both zero and span calibration or for either zero or sp
253. ty Analyzer Detector aaa 0 15 m for high temperature use 1 Seeete saree 0 4m sengena SoS 0 7m P a 1 0m See Sesiaetees 1 5m 2 0 m 2 5m 2 3 0m 2 Paneer 3 6m 2 eopemet hoes 4 2m 2 ne aS 4 8m 2 Aa 5 4m 2 Si oe SUS316 Stainless steel with Inconel calibration gas tube 11 Flange 3 Westinghouse ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 A SUS304 DIN PN10 DN80 A SUS304 DIN PN10 DN100 A SUS304 JIS 5K 65 FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JIS 5K 32 FF SUS304 for high temperature use 4 JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Reference air Natural convection External connection Instrument air 12 Pressure compensated 12 Gas Thread Re 1 4 1 4 FNPT Connection box thread G1 2 Pg13 5 M20 x1 5 mm 1 2NPT Quick connect C9 Instruction manual Japanese English Options Valves Filter Tag plates 4 2 ZO21R L 200 The thickness of the flange depends on its dimensions 3 4 5 6 7 8 9 Specify either CV or SV option code Not used with the high temperature humidity analyzer Specify either SCT or PT option code Always A DERAKANE coating 10 Inconel bolt Check valve Stop valve Dust Filte
254. u are returned to a display like Figure 10 32 2 Defaults CP Display Calibration Blow back data mA outputs Alarms Contacts data Others All data 2 a LAR A A AE a AE g Fig 10 32 1 Defaults Display Defaults Alldata gt a F Cancel Defaults start d t Enter F10 32 2E EPS Fig 10 32 2 Initialize All Data Start Display A WARNING Do not turn off power during initialization Otherwise initialization will not be per formed properly IM 11M12D01 01E 10 27 10 28 Table 10 7 Initialization Parameter Initialization Parameters and Defaults part1 Default Tag name Deleted Displayed channels All ON Sampling interval 30 sec Graph upper limit 25 0 O2 yde pu iL Graph lower limit 0 0 O2 Auto Return Time Display contrast Display Auto power off Q min disabled Medium 0 min disabled Display language Not affected y9949 uoleolpul WO Mode Points Zero gas concentration Span gas concentration Hold time Manual Span Zero 1 00 O2 21 00 O2 3 min 00 sec Calibration Indication check time 3 min 00 sec Calibration Indication check interval Start date day month year Start time 1 day 00 hrs 01 01 01 00 00 w fe ioe D fa x yndjno yw Mode Hold time No function disabled 3 min 00 sec Blowback time Blowback interva
255. uration Using Flow Setting Units for Manual Calibration1 1 1 1 2 System Configuration to Perform Automatic Calibration 0 1 2 1 2 System Components 0 0 0 eee a e E E A a E O RA 1 3 1 2 1 System Components and Their Applicability eeeseeeeeeseeeersereseereeeree 1 3 1 2 2 Detectors and ACCeSSOTIES 2 0 0 0 iinei serei tessioieis essre Titonas 1 3 Dis 5 KE LECI 1 e EE E E ASE 2 1 General Specifications s2 5 5 62 5 5ccpcsbssessssecdssastieassassch septate cb estscciastusctpsbevesioess 2 1 2 1 1 Standard Specifications 2 eee eee eee eseeeeecseesseceesaececeseceeeeseeeeeeeees 2 1 2 2 General use Separate type Detector and Related Equipment 2 3 2 2 1 ZR22G General use Separate type Detector 0 eeeeteeeeeeeeee 2 3 2 2 2 ZOZIR L Probe Protector sv sccssc iscesscedescneesctscscs ses ce ounce cvnsbovecssuestevsevsensts ove 2 8 2 3 High Temperature Separate type Detector and Related Equipment 2 9 2 3 1 ZR22G 0 15m High Temperature Separate type Detector 00 2 9 2 3 2 ZO21P H Adapter for High Temperature Probe 0 0 0 0 eee eeeeeeee 2 10 2 4 AV550G Averaging Converter eee nea n i a 2 12 2 4 1 Standard Specification 0 eee cee eeeceeceeeceeeeeeecseeesecseesaeceesaeeseenaes 2 12 DAD PUNCtOns eeen e E EE bs A EEEE E TEET 2 13 2 5 ZA8F Flow Setting Unit ccscissciscssceteseisstestusnsseusctssesyassedessssessintesestaenetsenscs 2 19 2 5 1 ZA8F Flow Setting Unit ee ceeeee
256. ured value falls within alarm setting hysteresis it does not stay there for the delay time so the alarm is not released D After the measured value falls within alarm setting hysteresis and stays there for the delay time the alarm is released lt Setting procedure gt 1 From basic panel display touch Setup key and the Execution Setup display appears 2 Select Commissioning gt Alarm setup and the Alarm setup display Fig 8 12 appears Alarm setup CpHysteresis 0 1 02 Contact delay 3s gt A Alarm set points Except alarm ch Yes m t zi oO R F41E EPS Fig 8 12 Alarm setting 8 10 IM 11M12D01 01E 8 Detailed Data Setting Setting Alarm Hysteresis 3 From the Alarm Setup display select Hysteresis A numeric entry display appears for you to enter the hysteresis value The units are 0 1 Oz To enter 2 5 O2 enter 25 You can enter a hysteresis setting in the range 0 to 9 9 O2 Setting Alarm Delay Time 4 From the Alarm Setup display select Contact Delay The numeric entry display is displayed for you to enter Alarm Action Delay time Units are seconds To set 3 sec enter 003 You can set delay time in the range 0 to 255 sec Alarm value setting 5 From the Alarm Setup display select Alarm Set Points and the display shown in Fig 8 13 appears 6 Use the Channel Select arrow keys to select a channel to set 7 Enable any alarms you want to u
257. urge Gas When a Process Gas Alarm Occurs When a process gas alarm an input contact signal of unburnt gas detection occurs the averaging converter will cut off the power supply to the heater of the detector and at the same time it will send a contact output to activate a solenoid valve for introducing a purge gas to the detector The piping for purging in a system to perform automatic calibration is the same as the one in the system using flow setting units for manual calibration As instructed in Subsection 4 1 7 this piping also requires that a check valve be installed on the calibration gas inlet of the detector A typical piping diagram for purging is shown in Figure 4 13 It is recommended that each instrument be installed to allow for minimum piping between the solenoid valve for introducing the calibration gases and the check valve and between the solenoid valve for introducing the purge gas and the check valve Detector Averaging converter AV550G SS ee Se ___ Analog output Averaged and individual outputs Contact output Contact input Calibration contact outputs Contact output Calibration gas line To calibration gas flow setting i i needle valve and flowmeter Reference T0 reference gas flow setting gas line flowmeter and needlre valve A Power supply Check valve Calibration gas line To calibration gas flow setting needle valv
258. urs while the basic panel display is displayed then an alarm mark appears on the display and at the same time the oxygen concentra tion display color of the channel in alarm status turns orange An orange status display lamp also lights at the top of the corresponding channel card If the function contact outputs are allocated to alarms then the corresponding contact output also occurs Here we explain how to set this alarm action 8 2 1 Setting the Alarm Values Individual Settings The alarm values can be set individually for all channels and for all averaging groups 1 High High HH and High H alarms An alarm occurs when the measured value is bigger than the alarm limit The alarm settings can be in the range 0 to 100 O2 However you need to enable each alarm set point HH H by setting it to ON rather than OFF 2 Low L and Low Low LL alarms An alarm occurs when the measured value is smaller than the alarm limit The alarm settings can be in the range 0 to 100 O2 However you need to enable each alarm set point LL L by setting it to ON rather than OFF 8 2 2 Alarm Delay Time and Hysteresis Applies to All Alarm Settings IM 11M12D01 01E If the measured oxygen concentration fluctuates between the normal value and the alarm setting then alarm status will keep turning ON and OFF You can reduce this annoyance by setting alarm action delay and hysteresis Delayed alarm action prevents immediate alarm output after mea
259. ut re calibration deterioration of or damage to the cell sensor is suspected as the cause of the alarm Replace ment of the cell with a new one is necessary However before replacement carry out the procedure described in step 3 and later of lt Search for cause of failure and taking measure gt in Section 12 2 3 2 Alarm 6 Zero point Calibration Coefficient Alarm 4 Alarm 4 EMF stabilization time up alarm This alarm is generated if the sensor cell voltage has not stabilized even after the calibration time is up for the reason that the calibration gas zero gas or span gas has not filled the sensor assembly of the detector lt Cause of alarm gt 1 The flow of the calibration gas is less than normal a specified flow of 600 mL min 60 mL min 2 The length or thickness of the calibration gas tubing has been changed lengthened or thickened 3 The measuring gas flows toward the tip of the probe 4 The sensor cell response has deteriorated lt Locating cause of failure and countermeasures gt 1 Carry out calibration by passing the calibration gas at the specified flow 600 mL min 60 mL min after checking that there is no leakage in the tubing 2 If calibration is carried out normally perform a steady operation without changing the conditions If the error occurs again check whether or not the reason is appli cable to the following and then replace the sensor assembly e A lot of dust and the like
260. verter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm Like the signal wiring to detectors the shields should be connected to cable shield ground terminals on the case of the averaging converter Contact inputs should be voltage free The open closed state of the contact is determined by the resistance from the averaging converter side Note that the resistance should include the wiring resistance Closed contact 200 or less Open contact 100 KQ or more Averaging Converter Control Card Contact Input 1 Figure 5 14 Wiring for Contact Inputs IM 11M12D01 01E 5 15 5 3 5 3 1 5 3 2 5 16 Wiring and Piping Examples Wiring and Piping for Automatic Calibration Detector Averaging Converter AV550G Power Supply Span Gas Cylinder Ai Reference Instrument Air Gas Line K NE Air Set Needle Valve Zero Gas Cylinder If optional 24 V outputs are specified for solenoid valves Option Code 0 240 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves Figure 5 15 Typical Diagram for Automatic Calibration Wiring and Piping for Automatic Calibration and 3rd Gas Indication Check Averaging Converter AV550G Detector __ Analog Output Averaged and I
261. ves that consume not more than 1 2 W to operate 5 12 IM 11M12D01 01E 5 Wiring Averaging Converter Basic Power Unit Expansion Power Unit 26 27 28 29 69 70 71 72 44 45 46 47 4B 49 89 90 91 92 Solenoid Valve for Switching Shield Zero Span Cal Gases x Power Supply to Solenoid Valve A Solenoid Valve for Cal Gas to Detector 1 ok Power Supply to Solenoid Valve A Solenoid Valve for Cal Gas to Detector 2 x Power Supply to Solenoid Valve M If optional 24 V outputs are specified for solenoid valves Option Code 24 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves 5 2 9 Wiring for Individual Common Error Contact Outputs and Common Contact Outputs IM 11M12D01 01E The averaging converter has the following contact outputs 1 Common function specific contact outputs DO1 to DO4 User specified functions can be assigned 2 Common error contact output DOS Activated when any error occurs 3 Individual error contact outputs DO CH1 to DO CH8 Channel specific contacts One output is provided per channel For details on errors refer to Section 12 1 Display and Remedies When Error Occur All contact outputs are Form C transfer contact and consist of 3 terminals of COM NC and NO All contacts are voltage free dry
262. with the theoretical calibration curve for determining the zero point correction ratio represented by B A X 100 percent on the basis of A B and C shown in Figure 9 2 and a span correction ratio of C A X 100 percent If the zero point correction ratio exceeds the range of 100 30 percent or the span correction ratio becomes larger than 0 18 percent calibration of the sensor becomes impossible 81 92 ez e2 zy Zero origin Calibration curve Cell before correction electromotive force mV 7 Corrected calibration curve theoretical calibration curve Span origin 21 0 pi p2 0 51 Span gas concentration Zero gas concentration Oxygen concentration percent oxygen by volume Zero point correction factor B A x 100 percent Correctable range 100 30 percent Span correction factor C A x 100 percent Correctable range 0 18 percent F9 2E EPS Figure 9 2 Calculation of a Two point Calibration Curve and Correction Factors using Zero and Span Gases Figure 9 3 shows a one point calibration using only a span gas In this case only the cell electromotive force for a span gas with 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 principle of calibration using only a span gas also applies to the one point calibration method using a zero gas only 81 92 ez z Zero origin Cell electromotive
263. y display if you touch the Setup key the Execution Setup display appears Select Calibration 2 Next select Semi auto calibration The Semi autocal channel select display Fig 9 8 is displayed 3 Select the channel to be calibrated The Semi auto cal display Fig 9 9 is dis played 4 When you select Start calibration the Semi autocal trend graph of Fig 9 10 is displayed and Span calibration begins 5 When the preset calibration time has elapsed Span calibration ends and Zero calibra tion begins Likewise when the preset calibration time has elapsed Zero calibration ends After a preset stabilization settling time the instrument reverts to measure ment mode 6 Touch the Escape key icon of door with arrow to abort calibration If you abort Span or Zero calibration then calibration time is skipped and stabilization settling time starts If you touch the Escape key again then stabilization settling time is also skipped and you revert to the Basic display IM 11M12D01 01E Semi autocal Al chi Semi auto cal A ee a Select calibration channel A Check settings I Span gas conc 21 00 r Zero gas conc 0 98 Crp ch ch5 Caltime 2minoos Le Ch2 Ch 6 Points Span Zero Ch3 Ch7 Go to setup to change value e Ch4 Ch8 C Start calibration 4 Cancel calibration E Enter Fig 9 8 Channel Select Display Fig 9 9 Semi Auto

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