User`s Manual
Contents
1. CELL TC cu 23 24 25 26 27 29 30 31 32 DO 1 DO 1 DO 2 DO 2 DO 3 DO 3 DO 4 DO 4 r zg oo l Bo do cbe e Cho cb d 100 240V CONTACT CONTACT CONTACT CONTACT SEE O Esa OUTPUT1 OUTPUT2 OUTPUT3 OUTPUTA MODEL AUTOCALIBRATION UNIT AC1 D 36 N L 20 18 19 CERTIFIED DRAWING 1 THE PROTECTIVE GROUNDING FOR THE CONVERTER SHALL BE CONNECTED EITHER THE PROTECTIVE GROUND TERMINAL IN THE EQUIPMENT OR THE GROUND TERMINAL ON THE CASE STANDARD REGARDING GROUNDING JIS D TYPE CLASS 3 GROUNDING GROUND RESISTANCE 100 OHMS OR LESS 2 ONLY WHEN THE VOLTAGE ON THE ZR402G IS 120V AC 60Hz CAN THE AC1 D BE CONNECTED TO THIS SOURCE OTHERWISE A SEPARATE SOURCE OF 120V AC 60Hz MUST BE SUPPLIED TO THE AC1 D SIGNAL CABLE 16 AWG MIN HEATER CABLE 14 AWG MIN P O NUMBER TAG s ZR22S 02 PROBE MTT30CH WIRING SCHEMATIC FOR ZR4026 28220 or 29228 amp AC1 D OXYGEN SYSTEM ZR402G ZR22G 28225 AC1 D IM 11M06D03 01E A 32 TOP AND SIDE VIEW OF RELAY IM 11M062. Figure 6 1 IM 11M06D03 01E A 15 Vil SETUP PROCEDURES AC1 Locate the reference air flow meters and adjust the flow adjustment knobs as outlined below Reference Air 0 8 LPM Calibration Gas 0 6 LPM AN CAUTION The maximum working pressure of the MC1 and AC1 unit is 35 psi Excessive pressure can damage the Zirconia cell of the ZR22G Oxygen Probe 7 1 INITIAL FLOW RATE SETUP Ensure that the calibration gas and reference air lines are properly plumbed to the left side of the AC1 Auto Cal Unit The zero gas and instrument air should be set at approximately 20 psi 2 psi Power is not required to set the flow rates 7 1 2 SETTING THE REFERENCE AIR FLOW RATES Locate the reference flow meters Adjust the flow adjustment knob on the REFERNCE AIR FLOW METER to 0 8 LPM or 800ml min 7 1 3 BALANCING PRESSURE DROPS IN THE CALIBRATION LINES For accurate calibrations the auto cal system must provide a fixed flow of Zero gas and Span gas To balance the pressure drops perform the following steps Locate the BLOCK and SPAN GAS SOLENOID Using a screwdriver turn the override screw to the manual position See Figure 5 2 Use the flow regulator knob on the CAL GAS FLOW METER to adjust the flow to 1 0 LPM Switch the override screw of the SPAN GAS solenoid to AUTO Turn the override screw for the ZERO GAS solenoid to MANUAL Adjust the pressure regulator on the zero gas cylinder for a flow of 1 0 LPM on the Calibration
3. FO 10E EPS Figure 8 4 FOQEEPS IM 11M06D03 01E A 20 To start calibration using an input contact follow these steps 1 Make sure that Calibration start has been selected in the Input contacts display 2 Apply an input contact to start calibration To stop calibration midway follow these steps 1 Press the Return key If this key is pressed midway during calibration the calibration will stop and the output stabilization time will be set up 2 Press the Return key once again to return to the basic panel display and the analyzer will be in normal measurement 8 5 AUTOMATIC CALIBRATION No execution operations are required for automatic calibration Automatic calibration starts in accordance with a preset start day and time Calibration is then executed at preset intervals A CAUTION Before conducting a semi automatic or automatic calibration run the automatic calibration unit beforehand to obtain a calibration flow of 600 60 ml min IM 11M06D03 01E A APPENDIX A SPARE PART IM 11M06D03 01E A 22 M1123CC FLOW METER BRASS 11322 FLOW METER STAINLESS M1123YL 3 WAY BALL VALVE ZERO GAS 1 M1132CC M1132ZC 2 M1132YL 3 M1132GC M1132RS SPAN GAS ON YOKOGAWA lt gt Flow meter Brass 2 Flow Meter SS 2 3 Way Ball Valve 1 BRASS 1 4 FNPT CONNECTION 4 SS 1 4 FNPT CONNECTION 4 IM 11M06D03 01E A M1132GC BRASS FNPT CONNECTION M1132RS
4. Flow Rate Setup cere idunt e 12 5 3 eae suele di cae s 12 VI Installation Automatic Calibration 1 13 6 1 Pogali ris E 13 6 2 Mounting the AGT C 13 6 3 ere s E 13 6 3 1 Piping to the ZR22G Oxygen 13 6 3 2 Connection to the Calibration Gas 13 6 3 3 Connection to the Reference Gas 13 6 4 Wiring to the AC1 Automatic Calibration 13 6 4 1 Wiring the AGT to the ZR22G 18 VII Setup Procedures ee een 15 Initial Flow Bate Setup iter nn 15 2 Setting the Reference Air Flow 15 7 1 3 Balancing Pressure Drops the Calibration 15 7 2 Standard Operation acide ein 15 7 3 Checking for 16 VIII Setup 8 Operation ZR402G 17 ZR402G Touch Panel Switch Operations 17 GANA OM apnea ee ct een greed 18 8 2 1 Mode Sets rate e eat ar rai 18 8 2 2 Zero gas Goncentrati n rr e 18 8 2 3 Span gas Con
5. INTERNAL 2 PL AC1 5 NEMA 4X 29 1 4 NPT INTERNAL 2 PL E 98 0 80 31 MOUNTING HOLES 4 00 101 6 NOTE 1 FRONT VIEW SHOWS ENCLOSURE DOOR CUT AWAY TO ALLOW VIEWING OF INSIDE 2 DOOR HINGED ON LEFT SIDE O CALIBRATION SYSTEM 14 57 870 0 YOKOGAWA 5 WARNING CALIBRATION GAS OUTLET REFERENCE ET 6 97 177 0 9 84 250 0 Lm 2 62 2 62 82 5 AC1 5 with NEMA 4X Enclosure LI 1 18 L 130 IM 11M06D03 01E A APPENDIX C WIRING DIAGRAM IM 11M06D03 01E A 31 MODEL ZR402G SEPARATE TYPE ZIRCONIA OXYGEN ANALYZER CONVERTER MODEL ZR22G ZR22S SEPARATE TYPE ZIRCONIA OXYGEN ANALYZER DETECTOR ANALOG OUTPUT 1 ANALOG 4 20 mA DC OUTPUT 2 DIGITAL OUTPUT 4 20 mA p lt 1 2 3 4 5 6 7 8 9 10 11 FG 1 AO1 AO2 CJ CJ TC TC CELL CELL H O 0 xjgoicioioeig 12 13 14 15 16 FG Di 2 D C Al FG Fi i zeRo seAN com 9 FG to o4 CONTACT INPUT 2 CONTACT INPUT 1
6. IM 11M06D03 01E A With this analyzer the sensor Zirconia element is heated up to 750 so Equation 2 is valid At that point the relationship as in Figure 2 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 1 LI 120 p F gt 1S7SpP1PpAS 992 p p P 771 Waki sasi sshusa Wa gh babi pasa s A A AA GEL E tit A A It Lo sd ia 11 100 4 4 po 43 11 0534010 bt asas Ot 1r 80 Be Adea aaa a IN m 1 1 1 1 72777777 ARS dp PET EM 11 1 Li 60 2 gt gt 1 na 11 Cell voltage Te DIES a 1 1 mV pete ll 1 3 CO 11 AME 4 4 1 344 1 ta 1 11 10431 1 11 r tt 20 A ass 1 4 0 LI 1 1 4 4 1 4 LI 1 1 20 i m 1 1 Dessen pou L 1 1 1 404 M 1 0 1 0 5 1 5 10 21 0 50 100 Oxygen concentration vol FREEFS Figure 2 1 2 2 CALIBRATION GASES 2 2 1 CALIBRATION ZERO GAS The calibration gas typically used is 1
7. dew point temperature of no higher than 208 If the dew point temperature is higher than 208 use a hand held oxygen analyzer to measure the actual oxygen concentration CAUTION 1 When instrument air is used for the span calibration remove the moisture from the instrument air at a dew point temperature of 208C and also remove any oily mist and dust from that air 2 If dehumidifying is not enough or if foul air is used the measurement accuracy will be adversely affected 8 3 MANUAL CALIBRATION For manual calibration consult Section 7 12 Calibration In the ZR22G ZR402G Instruction Manual IM 11M12A01 02E 8 4 SEMI AUTOMATIC CALIBRATION To start calibration follow these steps 1 Press the Setup key in the basic panel display to display the Execution Setup display 2 Then select Calibration from the Execution Setup display The Calibration display shown in Figure 8 4 appears 3 2 Select Semi auto calibration to display the Semi automatic calibration display shown in Figure 8 4 4 3 Select Start calibration The display shown in Figure 8 4 appears and then start calibration Calibration Manual calibration Semi auto calibration Semi auto calibration Check settings Zero gas conc 1 00 Span gas conc 21 00 Cal time 10min00s Go to setup to change value CP Start calibration Cancel calibration Semi auto calibration 0 5min div 21 0 O2
8. Channel Regulator Automatic Calibration Unit Regulator and M1132ME Gauge Available through Yokogawa Zero Gas Pressure Recommended by Yokogawa M1133AR Switch Available through Yokogawa inlet connection parts Figure 4 1 IM 11M06D03 01E A 12 V SETUP PROCEDURES MC1 5 1 INITIAL FLOW RATE SETUP Locate the reference air flow meters and adjust the flow adjustment knobs as outlined below Reference Air 0 8 LPM Calibration Gas 0 6 LPM A CAUTION The maximum working pressure of the MC1 and AC1 unit is 35 psi Excessive pressure can damage the Zirconia cell of the ZR22G Oxygen Probe 5 2 MC1 FLOW RATE SETUP Performing a calibration For accurate calibrations the manual calibration system must provide a fixed flow of zero and span gas during calibration There are two flow meters and one hand valve for the MC1 The hand valve is used only during calibration to flow either span gas or zero gas to the probe using the CAL GAS flow meter to indicate the flow rate The REF AIR flow meter is used to flow the reference air for the ZR22 probe and remains flowing at all times with a flow rate of 0 8 LPM The ZR402 display will prompt the user to perform the following steps when programmed for One Touch TCH calibration 1 Position the valve knob to SPAN GAS ON This will start the flow of Span Gas to the probe Adjust the CAL GAS flow meter to show 0 6 LPM as the flow rate If necessary adjust the reference flow met
9. SS Y FNPT CONNECTION M1132PB 3 WAY BLOCK MANIFOLD amp SOLENOIDS M1132YX NEMA 4 STEEL ENCLOSURE M1132PF NEMA 4X FIBERGLASS ENCLOSURE gt Bom ge M1132YX M1132PF M1132PB M1132CC M1132ZC M1132GC M1132RS 23 MODEL AC1 M1132CC FLOW METER BRASS CONNECTIONS M1132ZC FLOW METER STAINLESS STEEL CONNECTIONS YOKOGAWA lt gt NEMA 4 STEEL ENCLOSURE 1 NEMA 4X FIBERGLASS ENCLOSURE 1 3 WAY BLOCK MANIFOLD amp SOLENOIDS 1 FLOW METER BRASS CONNECTIONS 2 FLOW METER SS CONNECTIONS 2 BRASS 1 4 FNPT CONNECTION 4 SS 1 4 FNPT CONNECTION 4 IM 11M06D03 01E A 24 Zero Gas Regulator M1132ZX This regulator controls the gas pressure of the zero gas cylinders before it reaches the calibration unit The dual stage regulator is highly recommended for services which require a near constant delivery pressure as the calibration source decays See M1133AR Air diffusion and absorption desorption and off gassing are minimized because of its stainless steel construction NOTE This regulator is used on a zero gas cylinder with a CGA 580 connection The Cylinder connection must be CGA580 used for 596 oxygen balanced in nitrogen FRONT ISOMETRIC Zero Gas Regulator M1132ZX Maximum Inlet Pressure 3 000 psig Operating Temperature Range 40 F to 200 F Bonnet Vents 1 8 NPTF Inlet Outlet Connection CGA 580 with NPTM Purge Ports Y
10. oxygen balanced in nitrogen however an oxygen mixture between 0 4 and 8 is acceptable A compressed gas cylinder is containing certified gas mixtures fitted with a dual stage regulator should be used The maximum working pressure of the calibration systems MC1 amp AC1 is 35 psig The reference gas should be clean dry instrument air 2 2 2 REFERENCE SPAN GAS Reference air is from the same source as the span gas The reference air flows to the backside of the of the Zirconia cell and is used at all times The calibration units are plumbed to provide a continuous flow rate of the reference as well as calibration gas flow during calibration A clean dry air source is recommended such as instrument air Install an inline filter before the calibration unit to remove any moisture or dirt A regulator must be attached to the instrument air source to provide the appropriate working pressure for the calibration unit The maximum pressure is 35 psig NOTE Never use pure nitrogen for calibration NOTE Compressed gas cylinders must have the same CGA connection as the dual stage regulator Refer to the Appendix A Spare Parts section of this manual for the Dual Stage Regulator M1132ZX and the Zero Pressure Switch M1133AR IM 11M06D03 01E A SPECIFICATIONS 1 3 1 MODEL MC1 MANUAL CALIBRATION PANEL The MC1 is the manual calibration unit for a single oxygen probe It provides regulation of the reference air and cal
11. the affected areas Upon completion of repairing the leaks return all solenoids to the AUTO position DARAN IM 11M06D03 01E A 17 CALIBRATION SETUP amp OPERATION ZR402G 8 1 ZR402G TOUCH PANEL SWITCH OPERATIONS The converter uses a touch panel switch which can be operated by just touching the panel display Figure 8 1 shows the basic panel display The switches that appear in the switch display area vary depending on the panel display allowing all switch operations Figure 8 2 shows the switch functions Tag name display area 21 0 0 O2 Alarm and error 17 43mA Output spy ae 17 43mA Output2 Switch display area F7 3E EPS FIGURE 8 1 Tag name display area Displays the set tag name Refer to Section 10 1 4 Entering Tag Name Primary to tertiary display items Displays the selected item Refer to Section 7 9 Setting Display Item Switch display area Displays switches and functions selected according to the panel display Alarm and error display area Displays an error if an alarm or error occurs If you touch this area the details of the error or alarm are then displayed Enter key Home key 4 Enters the input value and sets up the Returns to the Execution Setup display Enter selected item Reject key Moves back to the previous display Setup key Used to enter the Execution Setup display Cursor key D
12. 08 listed E42272 CSA C22 2 No 14 1987 LR 9690 IM 11M06D03 01E A APPENDIX B DIMINSIONAL DRAWINGS IM 11M06D03 01E A 27 9 00 228 61 11 82 MC1 300 2 ZERO GAS ON SPAN GAS ON oz REF AIR ADJUSTO8LPM CAL GAS ADJUSTOSLPM YOKOGAWA lt gt 4 09 103 9 ell 10 82 __ 163 41 3 274 81 419 106 4 VIEW 1 4 FNPT 4 00 25 06 4 MC1 e REF AIR OUT TO PROBES 3 00 76 21 4 00 101 6 163 41 31 IM 11M06D03 01E A AC1 4 NEMA 4 1 4 NPT 2 PLACES 08 0 20 31 MOUNTING HOLES 1 4 NPT 6 10 y 154 9 p 3 00 ES NN 76 2 Bea REFERENCE AIR OUTLET 14 57 370 0 9 25 235 YOKOGAWA lt gt Zu x E F 1 50 1 31 10 24 88 1 83 3 260 0 0 32 E 11 81 8 0 300 0 2 62 66 5 E EY 2X 022 2 20 875 THRU 3 25 NOTE 82 5 1 FRONT VIEW SHOWS ENCLOSURE DOOR CUT AWAY AC1 4 with NEMA 4 Enclosure IM 11M06D03 01E A 1 4
13. 2 probe Clean dry instrument air is recommended as a reference span gas however ambient air may be used as a substitute 6 4 WIRING TO THE AC1 AUTOMATIC CALIBRATION UNIT 6 4 1 WIRING THE AC1 TO THE ZR22G The solenoids of the AC1 are powered by 24VDC from the ZR402G Oxygen Converter The AC1 itself can be powered by the ZR402G if the ZR402G is using 120VAC 60Hz Supply voltage for the AC1 can be obtained from terminals L N amp G on the ZR402G Please refer to the wiring diagram located in Appendix C IM 11M06D03 01E A 14 AN WARNING When wiring electrical components verify that electrical current and all applicable circuit breakers are de energized prior to wiring the AC1 and ZR402G Ensure that all applicable Lock Out and Tagging procedures have been adhered to Verify the integrity of ALL electrical connections and terminations prior to energizing the system A 16 4 conductor cable is recommended for use between the ZR402G and the AC1 Unit The cable should be run in a separate conduit from the detector cables If a conduit is not used the wiring should have a suitable jacket to meet environmental and regulatory codes NOTE To prevent noise from interfering with surrounding electrical lines we recommend the use of shielded cable ground at the ZR402G 2 3 4 7 8 9 10 11 AO1 AO1 AO2 CJ TC TC CELL CELL a a 16 17 18 Al Al 2
14. ALLATION MANUAL CALIBRATION MC1 4 1 LOCATION The following guidelines should be used when selecting a location for the calibration unit 1 Easily accessible for maintenance and inspections 2 Locating the MC1 close to the ZR22 probe minimizes the amount of tubing required for plumbing Conversely mounting the MC1 close to the ZR402G eliminates the need for two technicians to accomplish the calibration Ambient temperature should not exceed 55 131 Humidity is moderate and no corrosive gases are present Minimal vibration Clean dry instrument air is available S SD 4 2 MOUNTING THE MC1 The MC1 unit is designed for wall mounting and can be secured using four 4 standoff and four bolts Sufficient room should be made available for connecting the calibration and reference gas tubing NOTE The unit must be mounted as level as possible to ensure the accuracy of the flow rates 4 3 PIPING Plumbing is required from the instrument air line and zero gas cylinders to the calibration unit Standard 1 4 Stainless Steel tubing is recommended Separate tubing for the instrument air and zero gas are connected to the 1 4 FNPT fittings on the LEFT side of the calibration unit The input output fittings are all 1 4 FNPT fittings and are available in brass or stainless steel The probe connections calibration and reference are located on the RIGHT See figure 4 1 NOTE Never use pure nitrogen for calibration N
15. D03 01E A
16. Gas flow meter A CAUTION DO NOT USE the flow regulator knob of the flow meter to achieve this flow level Sr Os 6 Adjust the flow regulator knob on the Calibration Gas flow meter until the flow meter reads 0 6 LPM 7 Verify that all the manual overrides are set back to AUTO 7 2 STANDARD OPERATION e The Reference Air Flow meter indicates 0 8 LPM during normal operation and calibration e All manual overrides are set to the AUTO position e The Calibration Gas flow meter will show a flow of 0 6 LPM during Calibration only Before considering your calibration unit automated it is good practice to check for leaks along the full distance of the calibration line tubing in addition to performing a CAL CHECK to confirm that the gases are plumbed correctly to each probe IM 11M06D03 01E A 16 7 3 CHECKING FOR LEAKS NOTE To prevent leakage all threaded connections should have Teflon tape or suitable alternative and all compression fittings should be installed per manufacturer s recommendations 1 Locate the BLOCK SOLENOID Turn the override screw on the BLOCK SOLENOID and SPAN SOLENOID to the manual position Use leak detection spray on all compression fittings and bends of the cal and reference line tubing Inspect the full length of the tubing to determine if there is a leak Repair leaks as necessary and within applicable guidelines After repairing the leaking areas repeat the inspection instructions above for
17. OTE Compressed gas cylinders must have the same CGA connection as the dual stage regulator Refer to the Appendix A Spare Parts section of this manual for the Dual Stage Regulator M1132ZX and the Zero Pressure Switch M1133AR 4 3 1 PIPING TO THE ZR22G OXYGEN PROBE 4 3 2 Connection to the Calibration Gas Inlet Connect the tubing from the Zero cal gas output shown in Figure 3 1 to the CAL IN side of the ZR22 probe If the process is a positive pressure application ensure that a check valve Yokogawa Part Number M1234VV A is installed between the CAL IN port and the 1 4 tubing The check valve may already be installed on the detector prior to shipping IM 11M06D03 01E A 11 4 3 3 CONNECTION TO THE REFERENCE GAS INLET Connect the tubing from the Reference gas output shown in Figure 4 3 to the REF IN side of the ZR22 probe Clean dry instrument air is recommended as a reference span gas however ambient air may be used as a substitute ZERO CAL GAS INPUT INSTRUMENT AIR INPUT REFERENCE AIR OUTPUT CALIBRATION GAS OUTPUT Figure 4 1 A list of recommended part for piping to the MC1 or units is listed below in Table 3 1 Calibration Unit Piping Parts Notes Location Recommended by Yokogawa for positive Check valve pressure applications M1234VV A Available through Yokogawa Nipple Re 1 4 or 1 4 inch MNPT parts ni Inlet Recommended by Yokogawa M1132KD Gas Pressure ACI Single
18. a NPT Female Weight 4 7 lbs 1 75 kg Material of Construction Body 316L Stainless Steel Diaphragm 316L Stainless Steel Seat Seal Tetzel Teflon Kel F Gauges 316L Stainless Steel Bonnet brass nickel plated Delivery pressure Range 2 to 75 psig Flow Capacity Air 300 scfh Gauges Delivery O to 100 psig Oylinder pressure O to 3 000 psig 2 diameter IM 11M06D03 01E A Zero Pressure Switch M1133AR 25 The pressure switch is used to alert the Operator via a contact input that the zero gas cylinder needs to be re placed before the cylinder is empty The recommended connection is to the high pressure side of the zero gas regulator Refer to Figure 4 1 Zero Pressure Switch M1133AR Adjustable Set Point Ranges Dead Band Over Range Proof Pressure Storage Temperature Ambient Temperature Set Point Repeatability Switch Output Electrical Rating Enclosure Electrical Connection Pressure Connection Mounting Weight Approvals 30 to 575 psi on fall 50 to 600 psi on rise 8 to 60 psi 2 500 psi 3 000 psi 40 F to 180 F 40 C to 82 C 0 F to 160 F 18 to 71 1 of span One SPDT either NC or NO Rated to 5 amps resistive and 15 amps inductive 75 PF at 125 and 120 VAC 1 4 HP Aluminum with irradiate finish rated for 100 hours of salt spray One SPDT output 1 2 NPTF 5ft cable 1 8 NPTM NPTM pressure connection 120z 340g UL 5
19. ation times Ambient temperature should not exceed 55 131 3 Humidity is moderate and no corrosive gases are present NOTE Use an air purge for the AC1 enclosure if the corrosive gases or high dust content is present 4 Minimal vibration 5 Clean dry instrument air is available 6 2 MOUNTING THE AC1 The AC1 is available in a NEMA NEMA 4X lockable enclosure and the unit is designed for wall mounting It can be secured using four 4 standoffs and four 4 bolts Mount the AC1 unit so that the terminal strip is easily visible for wiring purposes Sufficient room should be made available for connecting the calibration and reference gas tubing NOTE The unit must be mounted as level as possible to ensure the accuracy of the flow rates 6 3 PIPING A list of recommended part for piping to the MC1 and AC1 units is listed previously in Table 4 1 6 3 1 PIPING TO THE ZR22G OXYGEN PROBE 6 3 2 CONNECTION TO THE CALIBRATION GAS INLET Connect the tubing from the Zero cal gas output shown in Figure 5 1 to the CAL IN side of the ZR22 probe If the process is a positive pressure application ensure that a check valve Yokogawa Part Number M1234VV A is installed between the CAL IN port and the 1 4 tubing The check valve may already be installed on the detector prior to shipping 6 3 3 CONNECTION TO THE REFERENCE GAS INLET Connect the tubing from the Reference gas output shown in Figure 5 1 to the REF IN side of the ZR2
20. centration laa a REESE nee RRA 19 8 3 Manual Calibracion GET 19 8 4 Semi automatic GCalibrati On 24 a erlernen 19 8 5 20 Appendix A Spare Par uc 21 Appendix B Dimensional 5 1 24 Appendix C Wiring 28 YOKOGAWA 4 IM 11M06D03 01E A 4th Edition IM 11M06D03 01E A INTRODUCTION There are two types of single channel calibration units offered by Yokogawa These calibration units are used with the ZR402G Single Channel Oxygen Analyzer to perform calibration of either ZR22G or ZO21D obsolete Oxygen Probes The AC1 Automatic Calibration Unit utilizes electrical solenoids that are wired to and actuated by the ZR402G Once activated by the ZR402G the calibration gases flow to the ZR22 without the user opening valves or adjusting flow rates The MC1 Manual Calibration Unit is not electronically controlled by the ZR402G During calibration mode the user must open valves and adjust the flow rates of the calibration gases Both the MC1 and the AC1 provide a single point of control for the calibration system Il OVERVIEW 2 1 CALIBRATION PRINCIPLES This section sets forth the principles of measurement with a Zirconia oxygen analyzer before detailing calibration A solid electrolyte such as Zirco
21. e E User s Manual 1 1 Single Channel Calibration Unit For use with ZR402G IM 11M06D03 01E A EEUU YOKOGAWA gt Yokogawa Corporation of America 4th Edition Feb 2013 e BEES uub REN User s Manual MC1 AC1 Single Channel Calibration Unit For use with ZR402G INTO UCI 4 Il A A 4 2 1 Principles of bec kenne 2 2 GASES teases EHE 5 2 2 1 Span Referernce GS ones Ener nenn sawaka 5 2 2 2 Calibration Gas Zero Gas ioci en ordine ea SPS CIC AU ONS T TN 6 3 1 Model 1 Manual Calibration Panel ninia naci nnd 3 1 2 Ordering Specifications n us nee aura e aao a eh rer 7 3 2 Specifications ACT nina ee elek 8 3 2 1 Model AC1 Single Point Automatic Calibration Unit EE 3 2 2 AC1 Ordering Specifications TE ANE IV Installation Manual Calibration MC1 10 4 1 LOCATION cea 10 4 2 Mounting 16 MO let c 10 4 3 Te 10 4 3 1 Piping to the ZR22G Oxygen iiania 10 4 3 2 Connection to the Calibration Gas Inlet pp 10 4 3 3 Connection to the Reference Gas 4 esses 1 1 V Setup Procedures MC1 12 5 1 Initial Flow Rate 4 2 12 5 2
22. er to show 0 8 LPM To stop the flow of Span gas position the valve knob to the OFF position To start the flow of Zero gas to the probe position the valve knob to ZERO GAS ON 5 Adjust the CAL GAS flow meter to show 0 6 LPM as a flow rate If necessary adjust the reference flow meter to show 0 8 LPM 6 To stop the flow of Zero gas position the valve to the OFF position AN WARNING If reference air is used during calibration the reference air must be left ON after calibration Bo 5 3 CHECKING FOR LEAKS 1 Position the valve to SPAN Apply a leak detection spray on all compression fittings and bends of the cal line tubing for the probe the MC1 gas inlets outlets and the probe inlets for CAL and REF gas Inspect the full length of the CAL and REF lines for leaks Repair leaks as necessary and within applicable guidelines After repairing the leaking areas repeat the inspection instructions above for the affected areas Upon completion return the valve to the OFF position and set the Reference and Cal gas flow rates to 0 8 LPM and 0 6 LPM respectively po IM 11M06D03 01E A 13 VI INSTALLATION AUTOMATIC CALIBRATION AC1 6 1 LOCATION The following guidelines should be used when selecting a location for the calibration unit 1 Easily accessible for maintenance and inspections 2 As close to the ZR22 probe as practical This will minimize the amount of tubing required for plumbing and decrease calibr
23. ero and block solenoids with manual overrides for easy setup of flow rates The user has a choice of copper or stainless steel tubing in addition to NEMA 4 or NEMA 4X enclosures It also contains a 1 amp fuse with an LED indicator to indicate a power surge OY por nn C lt gt O CALIBRATION SYSTEM 3 2 NOTE Cutaway shows internal flow meters solenoids Operating Pressure 20 psig Maximum Pressure 35 psig Flow meter Range 0 15 to 1 0 LPM separate flow meter for cal gas and reference air Tubing 1 4 Copper standard 1 4 Stainless Steel optional Gas Connections 1 4 FNPT Voltage 110 VAC 50 60 Hz standard Flow rates Calibration gas 0 6 LPM Reference Air 0 8 LPM NOTE Exceeding the recommended flow rates will damage the detector cell IM 11MO6D03 01E A 3 2 2 AC1 ORDERING SPECIFICATIONS MODEL NUMBER NN I OMM TUBINGS FITTINGS 1 4 copper Tubing and Brass Fittings 1 4 Stainless Steel Tubing and Fittings CODEC POWER SUPPLY For use with ZA8C For use with ZR402G requires 110 VAC REFERENCE AIR CONNECTION Reference Air Connection Table 3 2 IM 11M06D03 01E A 10 IV INST
24. etailed data key Moves the cursor down Displays the analog input value Cursor Points the cursor at the currently selected item Graph display key Displays a trend graph Alarm Displayed if an alarm arises Error Displayed if an error occurs gt T7 1E EPS FIGURE 8 2 IM 11M06D03 01E A 18 8 2 CALIBRATION The converter is calibrated in such a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases There are three types of calibration procedures available Manual calibration conducting zero and span calibrations or either of these calibrations in turn Manual calibration needs the MC1 Manual Calibration Unit to allow manual supply of the calibration gases Semi automatic calibration which uses the touch panel or a contact input signal and conducts calibration operations based on a preset calibration time and stable time Automatic calibration conducted at preset intervals Semi automatic and automatic calibration needs the AC1 Automatic Calibration Unit to allow automatic supply of the calibration gases The following sections set forth the manual calibration procedures For details on semi automatic and automatic calibrations consult Chapter 9 Calibration in the ZR22G ZR402G Instruction Manual 8 2 1 MODE SETTING For the mode setting do the following 1 Press the Setup key in the basic panel dis
25. ibrations gas while allowing the operator to select zero or span gas for calibration Separate flow meters are used to set cal gas flow rates and reference air 11 82 4 09 300 2 103 9 9 00 228 61 ON x OFF SPAN GAS ON CAL GAS ADJUST O 6LPM REF AIR ADJUST 0 8LPM BE REF AIR OUTTOPROBES 3 00 76 2 7 00 177 81 4 00 101 6 YOKOGAWA lt gt A 10 82 274 8 1 4 FNPT 163 41 3 4 00 25 06 4 Figure 3 1 Maximum pressure 35 psig Calibration Plate Stainless Steel Connections Ya FNPT Calibration Tubing Ya Copper standard Stainless Steel optional Weight Approximately 4 4 Ibs 2 kg Flow rates Calibration gas 0 6 LPM Reference Air 0 8 LPM AN NOTE Exceeding the recommended flow rates will damage the detector cell IM 11M06D03 01E A 3 1 2 ORDERING SPECIFICATIONS SINGLE CHANNEL O2 MANUAL CALIBRATION TUBING FITTINGS 1 4 Copper Tubing and Brass Fittings 1 4 Stainless Steel Tubing and Fittings CODE B REFERENCE AIR FLOW METER Reference Air Flow meter Table 3 1 IM 11M06D03 01E A 3 2 SPECIFICATIONS AC1 3 2 1 MODEL AC1 SINGLE POINT AUTOMATIC CALIBRATION UNIT The AC1 provides control of reference air and cal gas flow rates while maintaining a constant regulation of gases The AC1 includes individual span z
26. nia 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 O2 4e 2 O 2 Positive electrode 2 O 2 02 4 The electromotive force E mV between the two electrodes generated by the reaction is governed by Nernst s equa tion as follows E In PX PA Equation 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 96 Pa Oxygen concentration in a gas in contact with the negative Zirconia electrode 96 Assuming the Zirconia element is heated up to 750 then we obtain equation 1 above 50 74 log Px Pa Equation 2
27. play to display the Execution Setup display 2 Select Maintenance in the Execution Setup display to display the Maintenance panel display 3 Then select Calibration setup to display the Calibration setup display as Figure 8 3 shows 4 Select Mode in this panel and then select Manual Semi Auto or Auto Calibration setup Al Calibration setup Mode Cp Mode Manual Points Semi_Auto Points Auto Zero gas conc Spangasconc 21 00 Timing Timing Figure 8 3 8 2 2 ZERO GAS CONCENTRATION Set the oxygen concentration for zero point calibration Enter the oxygen concentration for the zero gas in the cylinder used in the following procedures 1 Select Zero gas conc from the Calibration setup display The numeric data entry display then appears 2 Enter the desired oxygen concentration for the zero point calibration The zero gas set ranges from 0 3 to 100 02 3 Enter 00098 for an oxygen concentration of 0 98 vol 96 O2 IM 11M06D03 01E A 8 2 3 SPAN GAS CONCENTRATION 19 Set the oxygen concentration for span calibration If instrument air is used as the span gas enter 21 02 1 Select Span gas conc from the Calibration setup display 2 Enter the desired span gas oxygen concentration from the numeric data entry display The span gas set ranges from 4 5 to 100 02 3 Enter 02100 for an oxygen concentration of 21 vol 02 Instrument air is here defined as dry air with a
Download Pdf Manuals
Related Search