Home

User`s Manual

1. L 342 4 2 G1 2 2 1 2NPT etc t Cable connection port a c iip SA K y ge Reference gas outlet SANZ Flange T B Il Flange EF TJ __PIPING A J 156 3 Stop Valve 256 4 49 Model Code Weight Specification PIPING kg 3 12 ZR202G 040 ZR202G 300 DIN PN10 DN80 SUS304 Approx 10 F3 22E EPS IM 11M12A01 05E 3 Installation 6 DIN PN10 DN100 ZR202G 0 G P Flange DIN PN10 DN100 SUS304 Rc1 4 or 1 4NPT Reference air inlet L 342 4 2 G1 2 2 1 2NPT etc t Cable connection port 45 ge Reference gas outlet Flange Flange ICE p PIPING A J 156 3 Stop Valve 256 4 49 Weight PIPING kg Model Code Specification ZR202G 040 Approx 11 DIN PN10 DN100 SUS304 ZR202G 300 Approx 21 F3 23E EPS 7 JIS 5K 65 FF ZR202G LJ K P Flange JIS 5K 65 FF SUS304 Rc1 4 or 1 4NPT Reference air inlet L 34244 2 G1 2 2 1 2NPT etc t Cable connection port 33 Reference
2. T10 6B EPS 10 13 10 14 Item Output related Items in Group C Tuning Engineering unit Default setting Analog output Oxygen concentration Humidity Mixed ratio Humidity Output mode Linear Logarithm Linear Output during warm up up Held at 4 mA Held at 20 mA Set value remains held Held at 4 mA Output during maintenance Not held Held output just before oly off sb maintenance service 2 Set value remains held Held output just before maintenance service Output during calibration 0 Not held 1 Held output just before calibration Set value remains held Held output just before calibration Output in abnormal state 0 Not held 1 Held output just before abnormal state occurs 2 Set value remains held Held output at a preset value Min oxygen concentration See Section 8 1 0 O2 Max oxygen concentration See Section 8 1 25 O2 Minimum humidity See Section 8 1 0 H20 Maximum humidity See Section 8 1 25 H20 Minimum mixing ratio See Section 8 1 0 kg kg Maximum mixing ratio Output damping factor See Section 8 1 0 to 255 Seconds 0 2kg kg 0 second Set value during warm up 2 4 to 21 6 mA 4mA Set value during maintenance 2 4 to 21 6 mA 4mA Set value during calibratio
3. Touch the ENT key again to stop the numeric value from flashing V gt m Z j F 01 Touch the ENT key once again and the display will change to the parameter code Basic Touch the gt key together with the ENT key to return to the basic panel display panel This is not required if you proceed to make another setting The displayed numeric display SAV D charactores indicate the measurment gas concentration T7 3E EPS The symbol ae indicates that the corresponding keys are being touched and the light characters indicate flashing 7 10 IM 11M12A01 05E 7 Startup 7 6 Setting Display Item Display items are those items that are displayed on the basic panel display Parameter code A00 or F08 is used to set the display items as shown in the table below If the humidity analyzer HS option was specified at the time of purchase the equipment is a humidity analyzer For other than the above the equipment is set to oxygen concentra tion at the factory before shipment If mix ratio is to be measured change the existing setting as follows Additionally when humidity analyzer is selected in the Detector Type Setting in the previous section the display item will be humidity if data initialization is performed Table 7 4 Display Items Values set with Items displayed on the basic panel display A00 or F08 Indicates the oxygen concentration Indicates the humi
4. Touch the keys and enter the current time in same way as the date has been entered on a 24 hour basis 2 30 p m Displayed on the left means 2 40 p m If you touch the ENT key all the digits flash Touch the ENT key again to set the time If you touch the gt and ENT keys together the parameter code selection display appears T8 14E EPS The symbol SD indicates that the key is being touched Light characters indicate that the digits are flashing 8 18 IM 11M12A01 05E 8 Detailed Data Setting 8 62 Setting Periods over which Maximum and Minimum Values Are Monitored and Average Values are Calculated 8 6 2 1 Procedure 8 6 2 2 Default Value The equipment enables the display of oxygen concentration average values and maxi mum and minimum values under measurement see Section 10 1 later in this manual The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored Use the parameter code table below to set the average maximum and minimum oxygen concentration values Periods over which average is calculated and periods over which maximum and minimum values are monitored can be set ranging from 1 to 255 hours If the set ranges are beyond the limits specified an ERR will be displayed Table 8 14 Parameter Codes for Average Maximum and Minimum Values Set item Parameter cod
5. Zero gas cylinder 6 cylinder E7050BA IM 11M12A01 05E Style A T2 6E EPS Unit mm Flow checker Span gas valve Zero gas valve Gas outlet F2 7E EPS 2 15 2 4 Other Equipment 2 4 1 Stop Valve part number L9852CB or G7016XH This valve is mounted on the calibration gas line in the system to allow for one touch calibration This applies to the system configuration shown for System 1 in section Standard Specifications Connection Re 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 SUS 316 JIS T2 9E EPS Full open length E s Rc1 4 or 1 4NPT F15 EPS 2 4 2 Check Valve part number K9292DN or K9292DS This valve is mounted on the calibration gas line directly connected to the detector This is applied to a system based on the system configuration System 2 and 3 This valve prevents the process gas from entering the calibration gas line Although it functions as the stop valve operation is easier as it does not require opening closing at each calibration Screw the check valve into the calibration gas inlet of the detector instead of the stop valve Standard Specification 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
6. Autocalibration unit Zero gas flowmeter F4 11 1E EPS IM 11M12A01 05E 2 Specifications 2 3 ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system configu ration based on System 1 It is used in combination with the detector only during calibration Standard Specifications Function Portable unit for calibration gas supply consisting of span gas air pump zero gas cylinder with sealed inlet flow rate checker and flow rate needle valve Sealed Zero Gas Cylinders 6 provide E7050BA Capacity 11 Filled pressure Approx 686 kPa G at 35 C Composition 0 95 to 1 0 vol 0 N balance Power Supply 100 110 115 200 220 240 V AC 10 50 60 Hz Power Consumption Max 5 VA Case Material SPCC Cold rolled steel sheet Paint Epoxy resin baked Paint Color Mainframe Munsell 2 0 GY3 1 0 5 equivalent Cover Munsell 2 8 GY6 4 0 9 equivalent Piping 46 lt 4 mm flexible tube connection Span Gas Internal pump drains in air from atmosphere and feeds to detector Weight Approx 3 kg Non CE Mark Model and Codes Suffix code ZO21S Option code Description Standard gas unit PE 200 V AC 50 60 Hz 220 V AC 50 60 Hz Power T E ee 240 V AC 50 60 Hz supply De iens Efans Rusi enans 100 V AC 50 60 Hz 7 ee ane ae 110 V AC 50 60 Hz ee 115 V AC 50 60 Hz ba Ihre Japanese version English version Style code
7. Panel cut dimensions View A Horizontal Vertical mounting mounting 22 15 Unit mm RL Ars lel 40 2 6 screw depth 10 0 5 2 2 2 0 Panel Horizontal 1 mounting Secondary pressure G7004XF Rc 1 4 K9473XG 1 4NPT connector Approx 122 Panel Vertical gauge a mounting lt A IM 11M12A01 05E 2 Specifications 2 44 Zero gas Cylinder part number G7001ZC The gas from this cylinder is used as the calibration zero gas and detector purge gas Standard Specifications Capacity 341 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 cylinders to most countries is prohibited or restricted Unit mm 10 ee re a re 140 Weight Approx 6 kg F2213 EPS 245 Pressure Regulator for Gas Cylinder part number G7013XF or G7014XF This regulator valve is used with the zero gas cylinders Standard Specifications Primary Pressure Max 14 8 MPa G Secondary Pressure 0 to 0 4 MPa G Connection Inlet W22 14 threads right hand screw Outlet Rc1 4 or 1 4FNPT Material Brass body Secondary Primary pressure gauge Pressure gauge Unit mm Approx 112 Regulator handle W22 Right handed Screw _ 2 Outlet Secondar
8. 2 G1 2 2 1 2NPT etc 156 3 Stop Cable connection port 256 4 Valve 49 Rc1 4 or 1 4NPT Calibration gas inlet Model Code PIPING Specification ZR202G 040 JIS 10K 80 FF SUS304 ZR202G 300 F3 26E EPS 3 14 IM 11M12A01 05E 3 Installation 10 JIS 10K 100 FF ZR202G P P Flange JIS 10K 100 FF SUS304 Rc1 4 or 1 4NPT Reference air inlet L 342 4 2 G1 2 2 1 2NPT etc t Cable connection port ns 45 jeg 4 Reference gas outlet Flange Il Flange CT T _PIPING A Fi 156 3 Stop Valve 256 4 49 Model Code L PIPING Specification ZR202G 040 JIS 10K 100 FF SUS304 ZR202G 300 F3 27E EPS 11 JPI Class 150 4 RF ZR202G LI R P Flange JPI Class 150 4 RF SUS304 Rc1 4 or 1 4NPT Reference air inlet 342 4 2 G1 2 2 1 2NPT etc t Cable connection port LA 9 oth 45 Reference gas outlet Flange g L Flange TJ _PIPING A Jf 156 3
9. 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 viii IM 1M12A01 05E Contents Introductio Een nan este sas evesobasdebaceestecaosivastasatvenssancivelusetieconansced r For the safe use of this equipment ccssccsssscssssscssssccssssscssssccssssccsssscsssssscsssscceeee bil r After Sales Warranty sessseessecccoseccoseocsocsocossocccoseccoesoooososoccocecooseosesssoosseocsosecsosesseesoees VIL RON a LA E T E E T LP 1 1 lt EXAxt ZR gt System Configuration 1 2 1 11 System duc iani i A A Gueadeasvess 1 2 LEZA SyS 2 aa E a trie Ne A E A 1 2 151 3 System Soun O A E A A A 1 3 1 2 lt EXAxtZR gt System Components ss 1 4 1 241 System Components ttes nt S Aa iE 1 4 1 2 2 High temperature Humidity Analyzer and Accessories eee 1 4 2e Specifications mn inserer nn hear A 2 1 General Specifications sense 2 1 21 1 Standard Specifications sister 2 1 2 1 2 ZR202G Integrated type Zirconia High temperature Humidity Analy Zer fine rien thine achieved ets 2 2 2 1 3 ZH21B Dust Protector satin nm ttes a 2 10 2 2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit 2 11 221 ZASE Flow Set
10. 0 00 11 11 12 Troubleshooting Re Ra mentee oe 12 1 Displays and Measures to Take When Errors Occur eee eects 12 1 12151 What IS ancBrron sis ita mn A en a we ade eee 12 1 12 1 2 Measures to Take When an Error Occurs 0 ccccecsccceceessseeeceeeseeeeees 12 2 12 2 Displays and Measures to Take When Alarms are Generated 12 4 12 231 What isan Alarmi Shine en rendra drift eita 12 4 12 2 2 Measures Taken When Alarms Occur ss 12 4 12 3 Countermeasures When the Measured Value Shows Error cccceee 12 9 12 3 1 Measured Value Higher Than True Value 12 9 12 3 2 Measured Value Lower Than True Value 12 10 12 3 3 Measurements Sometimes Show Abnormal Values 0s0ssnens0sese0es 12 11 Customer Maintenance Parts List sccccsssssssssssssssssssssssesees CMPL 11M12A01 05E Customer Maintenance Parts List ccccsssssssssssssssssssssesesees CMPL 11M12A01 12E Customer Maintenance Parts List cscccssssssssssssssssssssssssssseseesOMIPL 11M3D1 01E Revision Record sissisicscicccidccisisccscucccicstesesiessvevsidssiersvessvecsi sssessbessdevst ssdersbessvecst vcdesdbesevessd ces IM 11M12A01 05E xiii 1 Overview 1 Overview IM 11M12A01 05E The EXAxt ZR Integrated type Zirconia High temperature Humidity Analyzer integrates the detector and the converter in one unit This analyzer can measure humidity of hot air continuou
11. 5 indicates that the corresponding keys are being touched and the light characters indicate flashing SEES WARNING e If you conduct an open close check for the contact output 2 Error 1 cell voltage failure or Error 2 heater temperature abnormal will occur This is because the built in heater power of the detector which is connected to contact output 2 is turned off during the above check So if the above error occurs reset the equipment or turn the power off and then back on to restart refer to Section 10 4 Reset later in this manual IM 11M12A01 05E 7 17 792 Checking Calibration Contact Output The calibration contacts are used for the solenoid valve drive signals for the Automatic Calibration Unit This output signal enables you to check the equipment operation Check the flowmeter gas flow for that operation Follow the steps in Table 7 10 The table uses an example with a zero gas solenoid valve Table 7 10 Checking Calibration Contact Output Switch operation Display Description gt ENT A01 Display after the password has been entered Touch the A key to switch to Group G Touch the gt key to move the position of the digit that is flashing to the right one digit Touch the A key to enter 1 Touch the gt key to move the position of the digit that is flashing to the right one digit Touch the A key to enter 5 Touch the ENT key to have 0 flash The sol
12. The analyzer provides four alarms high high high low and low low alarms settable with measured values The following sections describe the alarm operations and setting procedures for the oxygen concentration humidity and mixing ratio 8 3 1 Alarm Values 1 High high and high alarm values High high alarms and high alarms are issued when they are set to be detected and if the measured values exceed the preset values 2 Low and low low alarm values Low alarms and low low alarms are issued when they are set to be detected and if the measured values are lower than the preset values 8 3 2 Alarm Output Actions If the measured values of the oxygen concentration fluctuate between normal steady state values and alarm setpoints there may often be a lot of alarm output issuing and canceling To avoid this set the delayed time and allow for hysteresis for alarm cancel ing uneAZ Othe alarm output conditions as Figure 8 2 shows When the delay time is set an alarm will not be issued so quickly even though the measured value differs from the steady state and enters the alarm setpoint range If the measured value remains within the alarm setpoint range for a certain period of time for the preset delay time an alarm will result On the other hand a similar way as in the above will be done each time the measured value returns to the steady state from the alarm setpoint range canceling the alarm status If hysteresis is set alarm
13. Calibration time Zero point calibration zero gas valve open Calibration time I Analog output status Stabilization time i Analog output remains hold when output remains hold F9 4E EPS Figure 94 Calibration and Output stabilization Time Settings When the calibration mode is in automatic In addition to the above output stabilization time and calibration time set the interval start date and start time Interval means the calibration intervals ranging from 000 days 00 hours to 255 days 23 hours Set the first calibration day and the start calibration time to the start date and start time respectively After the first calibration is carried out the next calibration will be ex ecuted according to the preset calibration intervals IM 11M12A01 05E 9 7 9 2 1 6Setting When setting calibration timing requirements bear the following precautions in mind A CAUTION 1 If the calibration interval is shorter than the sum of stabilization time plus calibration time the second calibration start time will conflict 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 2 For the same reason if the calibration start time conflicts with manual calibration or semi automatic calibration the current calibration will not be co
14. K9292DN Joint RC 1 4 Material SUS304 JIS K9292DS Joint 1 4 NPT Material SUS304 JIS T2 10E EPS 2 16 IM 11M12A01 05E 2 Specifications K9292DN Re 1 4 A part R 1 4 B unit mm K9292DS 1 4FNPT A part 1 4NPT Male B part Approx 19 Approx 54 F2 11E EPS 2 4 3 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases Part number K9473XH or K9473XJ Standard Specifications Primary Pressure Max 2 MPa G Secondary Pressure 0 to 0 25 MPa G Connection Rc1 4 or 1 4FNPT included joint adapter Weight Approx l kg Part No Description K9473XH Joint Re 1 4 Material Aluminum K9473XJ Joint 1 4 NPT F Material Body Aluminum Adapter Zinc alloy T2 11E EPS Unit mm Dimensions in parentheses are approximate 53 5 Bracket Mounting Dimensions K9473XH Piping connection IN Primary side OUT Secondary side Rc1 4 K9473X4J Piping connection IN Primary side OUT Secondary side 1 4NPT IM 11M12A01 05E 2 17 e Part no G7004XF or K9473XG Standard Specification Primary Pressure Max 1 MPa G Secondary Pressure 0 02 to 0 5 MPa G Connection Rc1 4 or 1 4 FNPT with joint adapter Weight Approx kg Part No Description G7004XF Joint Re 1 4 Material Zinc Alloy K9473XG Joint 1 4 NPT F Material Body Zinc Alloy Adapter SUS316 T2 13E EPS
15. The displayed numeric characters indicate the measurement gas concentration The symbo Sy indicates that the corresponding keys are being touched and the light characters indicate flashing T7 13E EPS IM 11M12A01 05E 7 21 7 102 Manual Calibration The following describes how to perform a calibration 7 10 2 1 Preliminary Before performing a manual calibration be sure that the ZA8F Flow Setting Unit zero gas flow valve is fully closed Open the zero gas cylinder pressure regulator so that the secondary pressure equals measured gas plus approx 50 kPa or measured gas pressure plus approx 150 kPa when a check valve is used maximum pressure rating is 300 kPa 7 22 IM 11M12A01 05E 7 Startup 7 10 2 2 Performing Calibration This manual assumes that the instrument air is the same as the reference gas used for the span gas Follow the steps below to conduct manual calibration When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a hand held oxygen analyzer to measure the actual oxygen concentration and then enter it Table 7 14 Performing Calibration Switch operation Display Description A ENT A 01 Display after the password has been entered ENT b1 0 Switch the parameter code to BO1 The key operations for this procedure are omitted CA L Touch the ENT key and CAL will be displayed Cancel Touch the gt key and ENT key together to return to the B10 displa
16. and the flow setting unit and between the flow setting unit and the analyzer Insert the air set next to the flow setting unit in the piping between the air source and the flow setting unit Use a 6 mm O D X 4 mm 1 D or nominal size 1 4 inch or larger stainless steel pipe between the flow setting unit and the analyzer IM 11M12A01 05E 4 Piping 43 Piping for System Configuration 3 IM 11M12A01 05E Piping in System 3 is illustrated in Figure 4 9 In System 3 calibration is automated however the piping is basically the same as that of System 2 Refer to Section 4 2 Adjust secondary pressure of both the air set and the zero gas regulator so that these two pressures are approximately the same The flow rate of zero and span gases normally instrument air are set by individual needle valve After installation and wiring check the calibration contact output see Sec 7 9 2 and adjust zero gas regulator and calibra tion gas needle valve so that zero gas flow is within the permitted range Next check span gas calibration contact output and adjust air set so that span gas flow is within the permitted range Model ZR202G Integrated type Zirconia High Temperature Humiddity Analyzer Q 100 to 240 V AC sets Contact input cia cae aaa ang gt Analog output contact output Digital output HART Auto Calibration unit ZR20H T Air Set Reference gas Span gas Calibration gas Calibration gas gt unit case
17. shown in Table 8 16 Table 8 16 Parameter Codes for Exhaust Gas Temperature and Pressure Settings Default setting Exhaust gas temperature 300 C Exhaust gas pressure 101 33 kPa abs T8 6 3 2 1 EPS 8 64 Setting Purging 8 6 4 1 Procedure 8 6 4 2 Default Value 8 20 Purging is to remove condensed water in the calibration gas pipe by supplying a span calibration gas for a given length of time before warm up of the detector This prevents cell breakage during calibration due to condensed water in the pipe Open the solenoid valve for the automatic calibration span gas during purging and after the purge time has elapsed close the valve to start warm up Purging is enabled when the cell temperature is 100 C or below upon power up and the purge time is set in the range of 1 to 60 minutes Displayed alternately Pkire m F8 03 EPS Figure 8 3 Display during Purging Use the parameter code table below to set the purging time The allowable input ranges from 0 to 60 minutes Table 8 17 Parameter Code Set item Parameter code Set range Units Purging time F15 0 to 60 minutes T8 17E EPS When the analyzer is delivered or if data are initialized purging time is set to 0 minutes IM 11M12A01 05E 9 Calibration 9 Calibration The following describes the calibration procedures for the ZR202G Zirconia High temperature Humidity Analyzer integrated model 9 1 Calibration
18. 0 Not detected Detection Not detected Detection Not detected Not detected Oxygen concentration low limit alarm detection Not detected Detection Not detected Oxygen concentration low low alarm detection Not detected Detection Not detected Humidity high high alarm detection No detection Detection No detection Humidity high alarm detection Humidity low alarm detection No detection Detection No detection Detection No detection No detection Humidity low low alarm detection No detection Detection No detection Mix ratio high high alarm No detection Detection No detection Mix ratio high alarm detection No detection Detection No detection IM 11M12A01 05E Mix ratio low alarm Mix ratio low low alarm detection No detection Detection No detection ole ol Oo KE Ole Of of Of si Of of of Detection No detection No detection T10 6D EPS 10 15 10 16 Contact related Items in Group E Item Tuning Engineering unit Default setting Selection of input contact 1 Invalid Calibration gas pressure drop Measurement range change Calibration start Detection of non combusted gas Invalid Selection of input contact 2 Invalid Calibration gas pressure drop Measurement range change Calibration s
19. 16 T8 13E EPS IM 11M12A01 05E 8 Detailed Data Setting 8 5 2 Default Values When the analyzer is delivered or if data are initialized both input setting are invalid and operated when closed IM 11M12A01 05E 8 17 8 6 Input Contact Settings 8 6 1 Setting Input Contact The following describe how to set the date and time Automatic calibration works following this setting Use parameter code F10 to set the date and time Table 8 13 Data and time Settings Switch operations Display Brief description ENT F1 0 Select the parameter code F10 gt A ENT 00 01 01 If you touch the ENT key the current date will be displayed The display gt on the left indicates the date January 1 2000 To set June 21 2000 follow the steps below 00 i 01 01 Touch the gt to move the position of the digit that is flashing to the right gt D 00 06 01 Touch the key to change to 6 00 i 06 i 01 Touch the gt key to move the position of the digit that is flashing to the right one digit 00 06 e 2 1 Touch the to change to 2 00 06 2 1 Touch the gt key to move the position of the digit that is flashing to the soe right one digit 07 1 8 Let the rightmost character flash and touch the gt key to display the time j Continuously touch the gt key then the date and time are alternately displayed Displayed on the left is 7 18 a m Omitted here
20. 4 RF SUS304 229 190 5 8 19 24 JPI Class 150 3 RF SUS304 190 152 4 4 19 24 F11_01 EPS Westinghouse 155 127 4 11 5 14 e Standard Accessories Item Part No Qty Description Fuse A1113EF 1 3 15A Allen wrench L9827AB 1 For lock screw IM 11M12A01 05E T02 01 EPS Model ZR202G P with pressure compensation Integrated type Zirconia High Temperature Humidity Analyzer L 342 4 L 0 4 0 7 Rc1 4 or 1 4NPT 1 0 1 5 2 0 Reference air inlet 2 5 3 0 m i 50 8 25 dint 1 Reference air outlet PIPING A 256 4 Valve 49 T PIPING B IE 4 G1 2 2 1 2NPT etc Cable connection port Re1 4 or 1 4NPT Calibration gas inlet Unit mm O123 Display side iol i A Terminal side 170 C DA ge 122 48 5 Flange C Flange A B C t PIPING ANSI Class 150 2 RF SUS304 152 4 1206 4 19 19 A ANSI Class 150 3 RF SUS304 190 5 152 4 4 19 24 B CA ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 B DIN PN10 DN50 SUS304 165 125 4 18 18 A DIN PN10 DN80 SUS304 200 160 8 18 20 B o DIN PN10 DN100 SUS304 220 180 8 518 20 B O JIS 5K 65 FF SUS304 155 130 4 15 14 A JIS 10K 65 FF SUS304 175 140 4 19 18 A FI JIS 10K 80 FF SUS
21. 7 7 3 Minimum Current 4 mA and Maximum Current 20 mA Settings 7 14 7 8 Checking Current Loop sisi 7 15 T9 Checking Contact VO mirenan iste chs RE ptet fine 7 16 LIA Contact Output Check nn abris runs 7 17 7 9 2 Checking Calibration Contact Output ss 7 18 7 9 3 Checking Input Contacts 7 19 7 10 Calibration Lt int inner tete tri tr entente ere 7 20 7 10 1 Calibration Setup ss 7 20 7402 Manual Cali bration ssac 3ivevestet ite es dus Monnet nie du 7 22 8 Detailed Data Settings D L Sil Current Output Setting srei an na nn nets 8 1 8 1 1 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA 8 2 8 1 2 Entering Output Damping Constants sesessesessesesesersrerrssrsrssrsrrsresesees 8 5 8 1 3 Selection of Output Mode orane e Er E E TE 8 5 8 1 4 Default Values 55e nes A AAA wee tana 8 5 8 2 Output Hold Setting ei a a ele a iA 8 6 8 2 1 Definition of Equipment Status sseessesesssesesseeeesetsrsrrsrerrssesrssrrresressees 8 6 8 2 2 Preference Order of Output Hold Values 0 0 eee eee ereeeeees 8 8 82 3 Output Hold Settin 2 2 cera dei men ent dae 8 8 8 24 Default Values ii secu ieee cies ee ee 8 8 8 3 Alarm Ses cure his aE aa aa EEE 8 9 83 Alarm Values ai a A TE ES SESE 8 9 8 3 2 Alarm Output ACTIONS sise 8 9 8 3 3 Alarm Setting Procedure 8 11 8 34 Default Val eS suce nes da E pe 8 12 84 Output Contact Setup is 8 13 SALT Output Contact none done andere den td nes ds 8
22. IM 11M12A01 05E 7 Startup 7 Startup IM 11M12A01 05E The following describes the minimum operating requirements from supplying power to the converter to analog output confirmation to manual calibration Check current loop Check piping and Wiring connections Set up valves Supply power Check contact action Confirm converter type setting Select gas to be measured HHH Calibrate analyzer Set detailed data Place in normal operation F7 0E EPS Figure 7 1 Startup Procedure System tuning by the HART communicator refer to IM 11M12A01 51E HART Communication Protocol 7 1 Checking Piping and Wiring Connections Refer to Chapters 4 and 5 earlier in this manual for piping and wiring confirmations 7 2 Valve Setup Set up valves and associated components used in the analyzer system as follows proce dures 1 If a stop valve is used in the detector s calibration gas inlet fully close this valve 2 If instrument air is used as the reference gas adjust the air set secondary pressure so that an air pressure of measured gas pressure plus approx 50 kPa or measured gas pressure plus apporox 150 kPa when a check valve is used maximum pressure ration is 300 kPa is obtained Turn the reference gas flow setting valve in the flow setting unit to obtain a flow of 800 to 1000 ml min Turning the valve shaft counter clockwise increases the rate of flow Before turning the valve shaft if the
23. If operation is restarted in this condition the sensor which is heated up to 750 C firmly fix the dusts on itself Consequently the dusts can make the sensor performance very lower If a large amount of water is condensed the 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 unavoidably impossible to supply the power and removing the detector keep on following air at 600ml 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 IM 11M12A01 05E 11 Inspection and Maintenance 11 2 Inspection and Maintenance of the Converter The converter does not require routine inspection and maintenance If the converter does not work properly in most cases it probably comes from problems or other causes 11 2 1 Replacing Fuses IM 11M12A01 05E This equipment incorporates a fuse If the fuse blows out turn off the equipment power and replace it in the following procedure A CAUTION If a replaced fuse blows out immediately there may be a problem in the circuit Check the circuit carefully to find out why the fuse has blown Before removing
24. MM Average humidity H20 Maximum mixing ratio Occurrence of max mixing ratio kg kg YY MM DD HH MM Occurrence of minimum min mixing ratio kg kg Occurrence of min mixing ratio YY MM DD HH MM Average mixing ratio kg kg Notel indicates that both are displayed alternately Note2 Parameter codes with no items in the above table are not used in the humdity analyzer T10 6A EPS IM 11M12A01 05E Calibration related Items in Group B Item Tuning Engineering unit 10 Other Functions Default setting Zero gas concentration 0 3 to 100 O2 1 O2 Span gas concentration 4 5 to 100 O2 21 O2 Calibration mode 0 Manual calibration 1 Semi automatic and manual calibration 2 Automatic semi automatic and manual calibration Manual calibration Output stabilization time 0 minutes 0 seconds to 60 minutes 59 seconds MM SS 10 minutes 0 seconds Calibration time 0 minutes 0 seconds to 60 minutes 59 seconds MM SS 10 minutes 0 seconds Calibration period 0 days 0 hours to 255 days 23 hours DD HH 30 days 0 hours Start time YY MM DD HH MM 00 01 01 00 00 Calibration 0 Zero and span 1 Span only 2 Zero only Zero and span Calibration concentration measurement Display only Manual calibration Semi automatic calibration IM 11M12A01 05E
25. Operating state When no power is applied to this equipment Output contact 1 Open deenergized or closed Open energized selectable Output contact 2 Closed deenergized only Closed T8 9E EPS 8 4 2 Setting Output Contact Set the output contacts following Table 8 9 Table 8 9 Parameter Codes for Output Contact Setting Set item Parameter Set value code Output contact 1 Operation E10 0 Operated in closed status Normally deenergized 1 Operated when open Normally energized Note 1 Error E20 0 Not operated if an error occurs 1 Operated if an error occurs High high limit alarm E21 0 Not operated if a high high limit alarm occurs 1 Operated if a high high limit alarm occurs Note 2 High limit alarm E22 0 Not operated if a high limit alarm occurs 1 Operated if a high limit alarm occurs Note 2 Low limit alarm E23 0 Not operated if a low limit alarm occurs 1 Operated if a low limit alarm occurs Low low limit alarm E24 0 Not operated if a low low limit alarm occurs 1 Operated if a low low limit alarm occurs Note 2 Maintenance E25 0 Not operated during maintenance 1 Operated during maintenance see Section 8 2 1 Calibration E26 0 Not operated during calibration 1 Operated during calibration see Section 8 2 1 Range change E27 0 Not operated when changing ranges 1 Operated when changing ranges Note 3 Warm up E28 0
26. Two points one is fail safe normally open Contact Input Signal Two points Sample Gas Temperature 0 to 700 C It is necessary to mount the cell using Inconel cell bolts when the temperature measures more than 600 C or greater Sample Gas Pressure 5 to 20 kPa When the pressure in the process exceeds 3kPa it is recommended that you compensate the pressure When the pressure in the process exceeds 5kPa you must perform pressure compensation No pressure fluctuation in the process should be allowed Probe Length 0 4 0 7 1 0 1 5 2 0 2 5 3 0m Probe Material SUS 316 JIS Ambient Temperature 20 to 55 C 5 to 70 C on the case surface Storage Temperature 30 to 70 C Humidity Ambient 0 to 95 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 with stand 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 to 240 V AC Acceptable range 85 to 264 V AC Power Supply Frequency Ratings 50 60 Hz Acceptable range 45 to 66 Hz Power Consumption Max 300 W approx 100 W for ordinary use Safety and EMC conforming standards Safety EN61010 1 C
27. an applied one second time interval single output contact signal Even if a continuous contact signal is applied a calibration is not repeated If you want to perform a second calibration turn the contact signal off and then back on Unburnt gas detection A CAUTION If the contact signal is on the heater power will be switched off A one second time interval single output signal is available as a contact signal If this operation starts the sensor temperature decreases and an error occurs To restore it to normal turn the power off and then back on or reset the analyzer T8 5 0 1 EPS To conduct a semi automatic calibration be sure to set Calibration setup mode to Semi Auto or Auto 8 5 1 Setting Input Contact To set the input contacts follow the parameter codes given in Table 8 12 Table 8 12 Parameter Codes for Input Contact Settings Set item Parameter code Set value Input contact 1 function E01 Invalid Calibration gas pressure decrease Measuring range change Calibration Unburnt gas detection S D Input contact 2 function E02 Invalid Calibration gas pressure decrease Measuring range change Calibration Unburnt gas detection S D Of Input contact 1 action E03 Operated when closed Operated when open Input contact 2 action E04 Operated when closed Operated when open Oj oO 8
28. 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 with the theoretical calibration curve for determining the zero point correction ratio represented by B AX100 on the basis of A B and C shown in Figure 9 2 and a span correction ratio of C A X100 If the zero point correction ratio exceeds the range of 100 30 or the span correction ratio becomes larger than 0 18 calibration of the sensor becomes impossible pune 7 Zero origin ez e2 Calibration curve Cell before correction electromotive force mV el 7 Corrected calibration curve theoretical calibration curve Span origin 21 0 p1 p2 0 51 Span gas concentration Zero gas concentration Oxygen concentration vol 02 Zero point correction factor B A x 100 Correctable range 100 30 Span correction factor C A x 100 Correctable range 0 18 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
29. 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 1 About This Manual E This manual should be passed on to the end user M The contents of this manual are subject to change without prior notice M The contents of this manual shall not be reproduced or copied in part or in whole without permission M This manual explains the functions contained in this product but does not warrant that those will suit the particular purpose of the user M 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 M If the product is used in a manner not specified in this manual safety of this product may be affected 2 Safety and Modification Precautions M Follow the safety preca
30. 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 When installing the cell assembly 6 replace the metal O ring 7 with a new one 11 14 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 IM 11M12A01 05E 11 7 11 15 Stopping and Re starting Operation lt Stopping Operation gt When operation is stopped take care of the followings 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
31. 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 EXAxt ZR and procedures o 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 nie O Read before operating the equipment and refer to whenever necessary A Recommended to read at least once IM 1M12A01 05E For the safe use of this equipment A CAUTION DANGER IM 1M12A01 05E The cell sensor at the tip of the probe is made of ceramic zirconia element Do not drop the equipment or subject it to pressure stress e Do NOT allow the sensor probe tip to make contact with anything when installing the analyzer e Avoid any water dropping directly on the probe sensor of the analyzer 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 measuring gas can condense in the calibration gas pipe and damage the sensor e The probe especially the tip becomes very hot Be sure to handle it with gloves EXAxt ZR is very heavy Be sure not to accidentally drop it Handle safely to
32. characters indicate that the digits are flashing WARNING e Do not attempt to turn off the equipment power during initialization while USR GO is flashing IM 11M12A01 05E 10 9 10 4 Reset Resetting enables the equipment to restart If the equipment is reset the power is turned off and then back on In practical use the power remains on and the equipment is restarted under program control Resetting will be possible in the following conditions 1 Error 1 if the cell voltage is defective 2 Error 2 if a temperature alarm occurs 3 Error 3 if the A D converter is defective 4 Error 4 if an EEPROM write error occurs For details on error occurrence consult Chapter 12 Troubleshooting later in this manual If any of the above problems occurs the equipment turns off the power to the detector heater To cancel the error reset the equipment following the steps below or turn the power off and then back on Note Make sure that before resetting or restarting the power that there is no problem with the equipment CAUTION If a problem arises again after the resetting turn the power off and troubleshoot the problem by consulting the Troubleshooting chapter later in this manual When there is no error the Basic panel display will appear 10 10 IM 11M12A01 05E Table 10 6 Resetting 10 Other Functions Switch operation Display Brief description JX ENT If an error occurs the
33. display However the output hold is released at the time of starting the calibration and the output will be again held at 4 mA after completing the calibration and when the output stabilization time elapses 8 2 3 Output Hold Setting Table 8 4 lists parameter codes with set values for individual set items Table 8 4 Parameter Codes for Output Holding Set items Parameter code Set value During warm up C04 4mA 20 mA Holds Set value During maintenance C05 Without hold feature Last measured value Holds set values During calibration C06 Without hold feature Last measured value Holds set values During error occurrence C07 Without hold feature Last measured value D COIN fF Olh fF COIN Holds set values 8 24 Default Values 8 8 T8 5E EPS When the analyzer is delivered or data are initialized the output current settings are by default as shown in Table 8 5 Table 8 5 Output Current Default Values Status Output hold min and max values Preset value During warm up 4 mA 4mA Under maintenance Holds output at value just before maintenance started 4 mA Under calibration or blow back Holds output at value just before starting calibration 4 mA or blow back On Error occurrence Holds output at a preset value 34 mA T8 6E EPS IM 11M12A01 05E 8 Detailed Data Setting 8 3 Alarm Setting
34. during the equipment s warm up time or calibration or if an error arises Table 8 3 shows the analog outputs that can be retained and the individual states Table 8 3 Current Output Parameter Codes Equipment status During warm up Under Under calibration On Error maintenance occurrence Output hold values available 4mA 20 mA Without hold feature O O Retains output from just before OJO occurrence O O O Set value 2 4 to 21 6 mA O O O O O The output hold functions are available FRERES 8 2 1 Definition of Equipment Status 1 Warming up Warming up is the time required after applying power until the sensor temperature stabilizes at 750 C and the equipment is in the measurement mode This status is that the sensor temperature is displayed on the basic panel 2 Under maintenance Under maintenance is the time from when a valid password is entered in the basic panel display to enable the parameter code selection display until the display goes back to the basic panel display 3 Under calibration see Chapter 9 Calibration In the manual calibration proceed with the calibration operation with the parameter code B10 to display the span gas confirmation display for the first span calibration thus starting the calibration time when the ENT key is touched After a series of calibra tions is complete and the preset output stabilization time has elapsed t
35. error number and are displayed alternately as given on the left ee Hold down the ENT key for at least three seconds SD Touch the ENT key again to switch to the password entry display Enter the password 1102 Intermediate switch operations omitted 1102 AO1 G01 Change the parameter code to G30 G01 G30 IM 11M12A01 05E All the digits light up Touch the ENT key to execute resetting T10 5aE EPS The symbol ue indicates that the key are light characters indicate flashing indicate that the characters are displayed alternately 10 11 10 12 A Note e Parameters of blank item are not used for High Temperature Humidity Analyzer Table 10 7 Parameter Codes Display related Items Parameter Item in Group A Engineering unit Engineering unit Selection of display items 0 Oxygen concentration 1 Oxygen analyzer 0 0 2 Oxygen analyzer 0 0 3 Analog output selected Span gas ratio 0 Span gas ratio Span gas ratio 2 Span gas ratio 3 Oxygen concentration Span gas ratio 4 Humidity Span gas ratio 5 Mixing ratio Span gas ratio 6 Relative humidity Span gas ratio 7 Dew point Span gas ratio 8 Span gas ratio 9 Cell temperature Zero gas ratio 0 Cold junction temperature Meas gas temperature C Zero gas ratio Zero gas ra
36. es Pressure compensation 10 Gas Thread R ess Re 1 4 1 4 FNPT Connection box thread P ____ G1 2 Pg13 5 Instruction manual y _ ___ Options M20x1 5 mm 1 2NPT Japanese English Always A DERAKANE coating 9 Inconel bolt 3 Set for Humidity Analyzer 4 Check valve 5 Stop valve 5 Hood 8 Stainless steel tag plate 6 Printed tag 6 8 9 T12 For the horizontal installed probe whose insertion length is 2 5 meters or more use the Probe Protector Be sure to specify ZO21R L Specify the flange suffix code either C or K The thickness of the flange depends on its dimensions EPS Inconel probe bolts and U shape pipe are used Use this option for high temperature use ranging from 600 to 700 C For humidity measurements be sure to specify HS options Specify either CV or SV option code Specify either SCT or PT option code No need to specify the option codes CV and SV since the check valves are provided with the auto calibration unit Auto calibration cannot be used when natural convection is selected as reference air Sun shield hood is still effective even if scratched Hood is necessary for outdoor installation out of sun shield roof Piping for reference air must be installed to supply reference air constantly at a s
37. inlet Specification PIPING PIPING F3 29E EPS ZR202G 040 ZR202G 300 Westinghouse F3 30E EPS IM 11M12A01 05E 4 Piping 4 Piping This chapter describes piping procedures in the three typical system configurations for EXAxt ZR Integrated type Zirconia High Temperature Humidity Analyzer Ensure that each check valve stop valve and joints used for piping are not leaking Especially if there is any leakage of the calibretion gas from piping and joints it may cause clogging of the piping or incorrect calibration e Be sure to conduct leakage test after installing the piping Basically apply instrument air dehumidified by cooling to the dew point 20 C or lower and removing any dust oil mist and the like for the reference gas when piping e When the instrument uses natural convection for reference gas Model ZR202G LI L1 C ambient air near the probe is used for reference gas therefore the accuracy of analysis will be affected by ambient temperature changes or the like If more accurate analysis is necessary use instrument air dehumidified by cooling to the dew point 20 C or lower and removing any dust oil mist and the like for reference gas Stable analyzing can be conducted when using instrument air 4 1 Piping for System Configuration 1 The piping in System 1
38. is an Alarm Table 12 2 Added Alarms 11 and 13 Alarm 6 Changed descriptions Alarm 7 Changed descriptions e p 12 7 and 12 8 Added Sections 12 2 2 6 and 12 2 2 7 e CMPL 11M12A01 05E Changed part numbers of Items 4 and 12 IM 11M12A01 05E
39. is illustrated in Figure 4 1 Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Stop valve 100 to 240 V AC Fesses Contact input bene eee seen ened gt Analog output Contact output Digital output HART Model ZO21S Standard gas unit Calibration gas lt Q 100 110 115 F4 1E EPS A 200 220 240 V AC Figure 4 1 Piping in System 1 Piping in System 1 is as follows e Place a stop valve through the nipple at the calibration gas inlet of the equipment Then mount a joint for a 6 mm O D x 4 mm 1D soft tube at the stop valve connection hole of the inlet side see Section 4 1 2 The tube is to be connected to this joint only during calibration A CAUTION e The stop valve should be connected directly to the equipment If any piping is present between the analyzer and the stop valve water may condense in the pipe which may cause damage to the sensor by rapid cooling when the calibration gas is introduced e The reference gas should have an oxygen concentration identical to that of fresh air 21 IM 11M12A01 05E 4 1 4 1 1 Piping Parts for System Configuration 1 Check that the parts listed in Table 4 1 are provided Table 4 1 Piping Parts Equipment Piping location Parts Description Humidity Analyzer Calibration gas inlet Stop valve L9852CB or G7016XH recommended by YOKOGAWA Nipple Rc1 4 or 1 4 NPT Commercially av
40. is placed F11 2E EPS Figure 11 2 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 filter 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 Nem 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 IM 11M12A01 05E 11 Inspect
41. 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 11 1 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 with filter 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 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 1 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 1E EPS Figure 11 1 Cleaning the Calibration Gas Tube 11 2 IM 11M12A01 05E 11 Inspection and Maintenance 11 12 Replacing the Sensor Assembly IM 11M12A01 05E 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 sat
42. low alarm setpoint 0 H20 Humidity low low alarm setpoint 0 H20 Mixing ratio high high alarm setpoint 1 kg kg Mixing ratio high alarm setpoint 1 kg kg Mixing ratio low alarm setpoint 0 kg kg Mixing ratio low low alarm setpoint 0 kg kg Oxygen concentration hysteresis 0 1 O2 Humidity hysteresis 0 1 H20 Mixing ratio hysteresis 0 001 kg kg Delayed time 3 seconds High high alarm detection Not detected High alarm detection Not detected Low alarm detection Not detected 8 12 Low low alarm detection Not detected T8 3 4 1 EPS IM 11M12A01 05E 8 4 Output Contact Setup 8 4 1 Output Contact IM 11M12A01 05E 8 Detailed Data Setting Mechanical relays provide contact outputs Be sure to observe relay contact ratings For details see Section 2 1 General Specifications The operation modes of each contact output are as follows Output contact 1 enables the selection of an open or closed contact when the contact is operated For output contact 2 contact remains closed The relay for output contact 1 is energized when its contacts are closed and vice versa Accordingly when no power is supplied to the equipment those contacts remain open In addition the relay for output contact 2 is energized when the corresponding contact is open and de energized when that contact is closed Table 8 8 Setting Output Contacts
43. lt i LI vt i GC 8 Reference gas outlet a Flange co Flange N PIPING A J 156 3 Stop Valve 256 4 49 Model Code PIPING Specification ZR202G 040 ANSI Class 150 4 RF SUS304 ZR202G 300 F3 20E EPS IM 11M12A01 05E 3 11 4 DIN PN10 DN50 33 ZR202G E P Flange DIN PN10 DN50 SUS304 342 4 Rc1 4 or 1 4NPT Reference air inlet 2 G1 2 2 1 2NPT etc Cable connection port Fi in dl Reference gas outlet Flange PIPING A 156 3 256 4 E Stop Valve Il 49 Model Code Specification Weight PIPING kg ZR202G 040 ZR202G 300 5 DIN PN10 DN80 42 ZR202G DIN PN10 DN50 SUS304 F P Approx 9 Approx F3 21E EPS Flange DIN PN10 DN80 SUS304 Rc1 4 or 1 4NPT Reference air inlet
44. of the zero gas concentration set refer to Section 9 2 1 Calibration Setup Otherwise the span gas is used as the zero gas 2 The zero gas flow is out of the specified flow 600 60 mL min 3 The sensor assembly is damaged and so cell voltage is not normal 12 4 IM 11M12A01 05E 12 Troubleshooting 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 ranges correct them a If the indication for Zero gas conc is selected in Calibration setup the set value should agree with the concentration of zero gas actually used b The calibration gas tubing should be constructed so that the zero 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 out re calibration deterioration of or damage to the sensor assembly 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 following Check the cell voltages when passing the zero gas and span gas a Display the cell voltage with the parameter code A11 b Check whether or not the value of the displayed cell voltage is very different
45. 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 out re calibration deterioration of or damage to the cell sensor is suspected as the cause of the alarm Replacement 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 2 2 Alarm 6 Zero point Calibration Coefficient Alarm 12 2 2 4 Alarm 8 EMF Stabilization Time Over 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 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 60 mL min after checking that there is no leakage in the tubing 2 If calibration is carried ou
46. s Calibration gas pressure regulator Instrument air Zero gas cylinder F4 9E EPS Figure 4 9 Piping for System 3 4 5 Installation of ZR20H AutoCalibretion Unit Horizontal mounting on the ZR202G A display side ZH terminal box side as 214 L 44 MAX lt Span gas inlet Rc1 4 or 1 4NPT Female 258 244 Zero gas inlet Unit mm Rc1 4 or 1 ANPT Female Vertical mounting on the ZR202G B Span gas inlet Rc1 4 or 1 4NPT Female Reference air inlet Rc1 4 or 1 4NPT Female 166 5 Reference air inlet Rc1 4 or 1 ANPT Female Zero gas inlet 40_ _ 66 5 gt Rc1 4 or 1 4NPT Female 180 44 MAX gt F4 10E EPS IM 11M12A01 05E 4 Piping Piping Diagram of ZR20H ZR202G body Calibration gas Span gas Reference gas solenoid valve Span gas flowmeter Check valve Reference gas flowmeter SPAN IN V Zero gas solenoid valve To Air set V REF IN l To Zero gas cylinder Needle valve ZERO IN Autocalibration unit Span gas flow
47. temperature decreases to 50 C or less If the thermo couple voltage is large accurate measurement cannot be achieved IM 11M12A01 05E 12 7 Thermocouple Multimeter Q F12 3E EPS Figure 12 6 4 If the inspection indicates that the thermocouple is normal the electronics may be defective Consult your local Yokogawa service or sales representative 12 2 2 7 Alarm 13 Battery Low Alarm An internal battery is used as backup for the clock After this alarm occurs removing power from the instrument may cause the clock to stop but should not affect stored parameters The internal clock is used for blowback scheduling if you use this then after a battery alarm occurs until the battery is replaced be sure to check correct the date and time every time you turn on the power lt Corrective action gt When the battery low alarm occurs remember that the battery cannot be replaced by the user Contact your Yokogawa service representative AN Note Battery life varies with environmental conditions If power is applied to the instrument continuously then the battery should not run down and life is typically about ten years However the battery will be used during the time interval between shipment from the factory and installation If power is not applied to the instrument at normal room temperatures of 20 to 25 C then battery life is typically 5 years and outside this range but within the rang
48. the electronics touch the grounded metal part to discharge any static electricity 1 Remove the display cover Figure 11 5 2 Remove the three screws that are located toward you among the four screws shown in Figure 11 6 Loosen the remaining one 3 Move the electronics up to remove it Cover of Display F11 5E EPS F11 6E Figure 11 5 Lock Screw Figure 11 6 Location of Screw 4 Disconnect the three connectors from the printed circuit board as shown in Figure 11 7 by holding the connector housing Do not pull the leadwire out to remove the connectors otherwise disconnection may result 5 Remove the electronics completely to gain access to the fuse on the bottom of the equipment case Figure 11 8 6 Replace the fuse with a new one F11 7E EPS Figure 11 7 Locations of Connectors Figure 11 8 Location of Fuse 7 To restore the electronics reverse the above removal procedures When restoring the electronics do not get leadwire jammed in any part of the unit 8 Place the electronics and the printed circuit board on which the fuse is installed properly these are directly connected with connectors 9 Tighten the four screws in their positions 10 Replace and tighten the display cover properly If the cover is not tightened sufficiently the infrared switches will not operate correctly E Fuse rating Check the rating of the fuse and that it satisfies the following Maximum rated voltage 25
49. the indication of the measured value varies with the pressure change in the furnace check whether or not there is leakage in the calibration gas tubing 12 11 12 12 IM 11M12A01 05E Customer Model ZR202G Maintenance Zirconia High Temperature Humidity Parts List Analyzer Integrated type Oo oa 2 1 1 FO4E EPS Parts No Item MS code Qty Description 2 we teennnennn 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 A 1 Cell Assembly ZRO1A01 01 1 piece ZRO1A01 02 2 pieces ZRO1A01 05 5 pieces ZRO1A01 10 10 pieces 8 E7042BS 1 Contact 9 K9470BJ 1 Metal O ring 10 E7042AY 1 Filter Assembly ee Bolt and Washeres K9470ZF 1 G7109YC 3 4 E7042DW 3 4 K9470ZG 1 K9470BK 3 4 E7042DW 3 4 for Option code C 12 ms Calibration Tube Assembly K9470ZK 1 Calibration Tube Assembly K9470ZL 1 Calibration Tube Assembly for Option code C 13 ZR202A D A 1 Heater Assembly YOKOGAWA All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M12A01 05E Subject to change without notice 1 st Edition Aug 2000 YK Yokogawa Electric Corporation 5t h Edition Jul 2005 YK Hood for ZR202G ZR202G_F eps Item Parts No Qty Descript
50. the power supply system or whether the converter and detector are securely grounded If the error occurs again after restarting a failure in the electronics is suspected Consult the service personnel at Yokogawa Electric Corporation IM 11M12A01 05E 42 3 12 2 Displays and Measures to Take When Alarms are Gen erated 12 2 1 What is an Alarm When an alarm occurs the alarm indication blinks in the display to notify of the alarm Figure 12 4 Pressing the alarm indication displays a description of the alarm Alarms include those shown in Table 12 2 Displayed alternately AL 06 0 0 F12 4E EPS Figure 12 4 Table 12 2 Types of Alarms and Reasons Alarm Type of alarm Reason for occurrence Oxygen concentration alarm Alarm 1 concentration alarm Occurs when a measured value exceed or falls below through 3 humidity and mixing ratio alarms the set alarm value refer to Section 8 3 Alarm Setting Alarm 6 Zero point calibration coefficient alarm Generated when the zero correction factor is out of the range of 100 30 in automatic and semiautomatic calibration refer to Section 9 1 3 Compensation Alarm 7 Span point calibration coefficient alarm Generated when the span correction factor is out of the range of 0 18 in automatic and semiautomatic calibration refer to Section 9 1 3 Compensation Alarm 8 EMF stabilization time up Generated when the cell sensor voltage is not stabilized even afte
51. this system uses ambient air for the reference gas measuring accuracy will be affected by the installation location e A stop valve should be connected to the calibration gas inlet of the equipment The valve should be fully closed unless calibration is being performed Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Stop valve io Ma 100 to 240 V AC raai Contact input gt Analog output Contact output Digital output HART Model ZO21S Standard gas unit Calibration gas 100 110 115 F1 1E EPS lt 200 220 240 V AC Figure 1 1 This system is used where the installation atmosphere is polluted by gases other than air or where accurate monitoring and controlling of the humidity is required Instrument air clean and dry air of oxygen concentration 21 is used as the reference gas and the span gas for calibration Zero calibration gas is supplied from the cylinder The gas flow is controlled by the ZA8F flow setting unit for manual valve operation Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Check valve 100 to 240 V AC CR RIRE Contact input Stop valve gt Analog output Contact output Digital output HART Model ZA8F flow setting unit Needle sen Flowmeter valve Instrument air Span gas Same as Zero gas calibration unit Calibration gas Calibration gas pressure regulator Zero gas C
52. values on abnormal Alarm Related Items Oxygen concentration high alarm high high alarm limit values vol O Oxygen concentration low alarm low low alarm limit values vol O Moisture quantity high alarm high high alarm limit values vol H O moisture quantity low alarm low low alarm limit values vol H O mixture ratio high alarm high high alarm limit values kg kg mixture ratio low alarm low low alarm limit values kg kg oxygen concentration alarm hysteresis vol O moisture quantity alarm hysteresis vol H O mixture ratio alarm hysteresis kg kg oxygen concentration moisture quantity mixture ratio detection alarm delay seconds Contact Related Items Selection of contact input 1 and 2 selection of contact output 1 and 2 abnormal high high alarm high alarm low alarm low low alarm maintenance calibrating range switching warming up calibration gas pressure decrease flameout gas detection Converter Output One mA analog output point 4 to 20 mA DC maximum load resistance of 550 Q with mA digital output point HART minimum load resistance of 250 QO Range any setting between 0 to 25 through 0 to 100 vol H O and partial range is available Maximum range value minimum range value 1 3 or more For the log output the minimum range values are fixed to 0 1 vol O for the oxygen concentration 0 1 vol H O for the moisture quantity and 0 01 kg kg for the mixture ratio 4 to 20 mA DC linear or log can be s
53. valve has a lock nut first loosen the lock nut After completing the valve setup be sure to tighten the lock nut AN Note The calibration gas flow setting is described later Fully close the needle valve in the flow setting unit 7 3 Supplying Power to Converter CAUTION To avoid temperature changes around the sensor it is recommended that rather than turning it on and off the power be continuously supplied to the Humidity 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 Supply power to the converter A display as in Figure 7 1 which indicates the detector s sensor temperature then appears As the heat in the sensor increases the temperature gradually rises to 750 C This takes about 20 minutes after the power is turned on depending somewhat on the ambient temperature and the measured gas temperature After the sensor temperature has stabilized at 750 C the converter is in measurement mode The display panel then displays the oxygen concentration as in Figure 7 2 This is called the basic panel display F7 1E EPS F7 2E EPS Figure 7 1 Display of Sensor Temperature Figure 7 2 Measurement During Warmup Mode Display 7 2 IM 11M12A01 05E 7 Startup 74 Operation of Infrared Switch 7 4 1 Display and Switches This equipment uses an infrared switch that enables operation with the cover closed Figure 7 3
54. zero or span can be skipped Zero calibration gas concentration setting range 0 3 to 100 vol O 0 01 vol in smallest units Span calibration gas concentration setting range 4 5 to 100 vol O 0 01 vol in smallest units Use nitrogen balanced mixed gas containing 10 scale of oxygen for standard zero gas and 80 to 100 scale of oxygen for standard span gas Calibration period date time setting maximum 255 days 2 5 Model and Codes Suffix code Option Description code ZR202G cesses cece rss ss Integrated type Zirconia High Temperature Homidity Analyzer Length 040 2 essre 0 4m SE Pag RSE 0 7m E 1 0m Pre 1 5m s ries sers 2 0m 2 5m 1 Sree eee 3 0m 1 Wetted material S sss SUS316 Moore Stainless steel with Inconel calibration gas tube Flange A ANSI Class150 2 RF SUS304 2 o B l e ANSI Class150 3 RF SUS304 e ANSI Class150 4 RF SUS304 DIN PN10 DN50 SUS304 DIN PN10 DN80 SUS304 DIN PN10 DN100 SUS304 ee a JIS 5K 65 FF SUS30 S JIS 10K 65 FF SUS3 eSa JIS 10K 80 FF SUS3 JIS 10K 100FF SUS304 HSE JPI Class150 4 RF S 4 04 04 US304 JPI Class150 3 RF SUS304 Westinghouse Auto Calibration N No auto calibration unit mounted Horizontal mounting Vertical mounting 7 7 Reference air CC Natural convection con External connection Instrument air 10 Pee gp
55. 0 1 0 1 0 1 0 1 0 1 Reset T10 6G EPS 10 18 IM 11M12A01 05E 10 Other Functions 10 5 Handling of the ZO21S Standard Gas Unit The following describe how to flow zero and span gases using the ZO21S Standard Gas Unit Operate the ZO21S Standard Gas Unit for calibrating a system classified as System 1 according to the procedures that follow 10 51 Standard Gas Unit Component Identification Carrying case Flow checker Checks the zero and span gas flow Span gas valve Controls the span gas air flow Zero gas valve regulator Cover screws six pcs Tube connection Gas cylinder Contains the zero gas A gas of 7 Nl is charged to 700 kPa Pump Supplies span gas air Zero gas valve Attaches to the gas cylinder for use Clamp Clamps the gas cylinder Power cord Applies the power to operate the pump to supply the span gas peers Figure 10 4 Standard Gas Unit Component Identification IM 11M12A01 05E 10 19 10 5 2 Installing Gas Cylinders Each ZO21S Standard Gas Unit comes with six zero gas cylinders including a spare Each gas cylinder contains 7 liters of gas with a 0 95 to 1 0 vol O concentration varies with each cylinder and nitrogen at a pressure of 700 kPaG at 35 C The operating details and handling precautions are also printed on the product Please read them beforehand To install the gas cylinder follow these steps 1 Attach the ze
56. 0 V Maximum rated current 3 15 A Type Time lag fuse Standards UL CSA and VDE approved Part number A1113EF 11 10 IM 11M12A01 05E 11 Inspection and Maintenance 11 3 Replacement of Flowmeter for ZR20H Autocalibration Unit 1 Remove pipe holding piping connection 2 Remove bolts holding flowmeter and replace it white back plate to make the float easy to see is attached The end of the pin holding down the back plate must be on the bracket side 3 Replace piping and fix M6 bolts between brackets 1 1 When disassembling and reassembling mark original positions and tighten an extra 5 10 when reassembling After tightening do a liquid leakage test Vertical mounting Connect piping pairs A A B B C C g Fixing screw pairs A A Horizontal a ree CRIE eY Figure 11 9 Fixing Flowmeter Zr20h_g0 eps IM 11M12A01 05E 11 11 12 Troubleshootin g 12 Troubleshooting This chapter describes errors and alarms detected by the self diagnostic function of the converter This chapter also describes the check and restoration methods to use when problems other than the above occur 12 1 Displays and Measures to Take When Errors Occur 12 11 What is an Error An error is detected if any abnormality is generated in the detector or the converter e g in the cell sensor or heater in the detector or
57. 13 8 4 2 Setting Output Contact sois 8 14 843 Default Valles ist sine ter nt Nr nn ne dpt tn 8 15 85 Input Contact Settings iii nier ap A tirant a ete 8 16 SS Setting Input Contact ccs sannemn nn nes nissan nn 8 16 8 9 2 gt Default Valles aisun nn tes ni Seve a a esdetuereataees 8 17 8 6 Input Contact Seung acne cei ceeded he A MED ata 8 18 8 6 1 Setting Input Contact ss 8 18 8 6 2 Setting Periods over which Maximum and Minimum Values Are Monitored and Average Values are Calculated 0 eee 8 19 8 6 3 Setting Measurement Gas Temperature and Pressure eeeeee 8 19 8 6 4 Settings P ra sin nue monnaie mit GEEET 8 20 IM 11M12A01 05E Xi Ds Calibration sistema art tin re secs diese Dei 9 1 Calibration Briefs 2558 naib Rte iii ia ital s hee nn tte 9 1 9 1 1 Measurement Principle of Zirconia Humidity Analyzer 0 9 1 971 9 Calibration Gas rss fen tre sal 9 3 91 3 Compensation is eesti adi A ete aie eee 9 4 9 1 4 Characteristic Data from a Sensor Measured During Calibration 9 5 92 Calibration Procedures ii si timide aa ARER aA 9 6 9 2 1 Calibration Setting ss 9 6 922 Calibration br aia me A RE adie ae ee 8 9 9 10 Other Functions cccccccccccscssssssccsssssscssscsssccsssssessssssscssssssscssssssssssssssssssscssscscees LO 1 10 1 D ta d Display sistema inner ARLAS 10 1 10 1 1 Oxygen Concentration ss 10 3 1031 2 Humidity 224445 in detente dans 10 3 101 3 M
58. 1M12A01 05E 7 Startup 7 8 Checking Current Loop The set current can be output as an analog output This enables the checking of wiring between the converter and the receiving instrument Current loop checking is performed using parameter code G01 Table 7 7 Checking Current Loop Switch operation Display Description A ENT A01 Display after the password has been entered ENT G 01 Touch the A key to switch to Group G Touch the ENT key The output current remains preset with the output hold feature Section 2 3 Touch the A key to set the numeric value 1 to set a 10 mA output Touch the key to have all the digits flash Touch the ENT key again to stop the flashing A 10 mA output is then issued Touch the ENT key once again to switch to the parameter code selection display At that point the output current returns to the normal value Basic Touch the gt key together with the ENT key panel to return to the basic panel display display T7 7E EPS The symbol ei indicates that the corresponding keys are being touched and the light characters indicate flashing IM 11M12A01 05E 7 15 7 9 Checking Contact I O Conduct a contact input and output check as well as an operation check of the solenoid 7 16 valves for the optional automatic calibration unit Table 7 8 Parameter Codes for Checking Contact I O Check item Parameter code Set value and cont
59. 2 Easy access for checking 3 Near to the detector and converter as well as the flow setting unit 4 The temperature of the case does not exceed 40 C due to rays of the sun or radiated heat 5 No vibration 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 combination 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 7 Pipe Mounting IM 11M12A01 05E 3 Installation 3 5 Insulation Resistance Test Even if the testing voltage is not so great it causes dielectric breakdown testing may cause deterioration in insulation and a possible safety hazard Therefore conduct this test only when it is necessary The applied voltage for this test shall be 500 V DC or less The voltage shall be applied for as short a time as practicable to conform that insulation resistance is 20 MQ or more Remove wiring from the converter and the detector 1 Remove the jumper plate located between terminal G and the protective grounding terminal Connect crossover wiring between L and N Connect an insulation resistance teste
60. 2G Integrated type Zirconia High Temperature Humidity Analyzers e e Model ZH21B Dust Protector OO 0O Model ZO21S Standard Gas Unit J Model ZA8F Flow setting unit for manual calibration e Model ZR20H Automatic Calibration Unit for integrated type Analyzer e L9852CB G7016XH Stop Valve for Calibration gas line K9292DN K9292DS Check Valve for Calibration gas line K9473XH K9473XJ G7004XF K9473XG Air Set G7001ZC Zero gas Cylinder ele G7013XF G7014XF Pressure Regulator for Gas Cylinder E7044KF Case Assembly for Calibration gas Cylinder e o Items required for the above system example Mere O To be selected depending on each application Select either 1 22 High temperature Humidity Analyzer and Accessories General use Analyzer gas temperature 0 to 700 C General use probe Components ZR202G Installation Horizontal to Vertical when insertion length is 0 4 to 2 m Vertical when insertion length is 2 5 to3m Probe with Dust Protector Components ZR202G 040 and ZH21B Installation Horizontal to Vertical when insertion length is 0 4 m F1 2 2 1 EPS IM 11M12A01 05E 2 Specifications 2 Specifications This chapter focuses on the specifications for the High temperature Humidity Analyzer integrated model and associated equipment including ZR202G Integrated type Zirconia High temperature Humidity Analyzer See Section 2 1 2 ZH21B Du
61. 3 4 3 3 Installation of ZR20H Automatic Calibration Unit 3 6 3 31 Locatore ARE Rs nr LAN ned ee le 3 6 3 3 2 Mounting of ZR20H Automatic Calibration Unit 3 6 34 Installation of the Calibration gas Unit Case E7044KF 0 eeeeeeeeeenees 3 8 SAM Locatii residan nee te eens re der se ve 3 8 3 42 Mounting i n ares otis net ARR Se hee ne ne 3 8 3 5 Insulation Resistance Test ss 3 9 3 6 Installation of the High Temperature Humidity Analyzer with pressure COMPENSATION r ne nel nn ren rente net us 3 10 4 1 Piping for System Configuration 1 4 1 4 1 1 Piping Parts for System Configuration 1 eee cereeeeeeteeeeeeees 4 2 4 1 2 Connection to the Calibration Gas Inlet cee eeececseceeeeenteeeneeeeeeeeaees 4 2 4 1 3 Connection to the Reference Gas Inlet cece ceseeeeceneeeeeeees 4 2 42 Piping for System Configuration 2 4 3 42 1 Piping Parts for System Configuration 2 0 0 lees cee ceteeeeceneeeeeeees 4 3 42 2 Piping for the Calibration Gas ss 4 4 42 3 Piping for the Reference Gas 4 4 43 Piping for System Configuration 3 4 5 SA G n ral 225242 nies nan A 5 1 5 1 1 Terminals for the External Wiring eee ese crsececeeeeecneeeeeees 5 2 eb WTB E E d eee eal ete tea a cea oie area E 5 2 5 1 3 Mounting of Cable Gland ss 5 3 5 2 Wiring for Analog Output sise 5 4 5 2 1 Cable Specifications ss 5 4 9 22 Waiting Procedure oie ennemie enter 5 4 5 3 Wiring Power and Ground Terminals cecceee
62. 304 185 150 8 19 18 B ange 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 F11_02 EPS Westinghouse 155 127 4 11 5 14 A e Standard Accessories Item Part No Qty Description Fuse A1113EF 1 3 15A Allen wrench L9827AB 1 For lock screw TO2 01 EPS IM 11M12A01 05E 2 Specifications Hood Option code H i 274 4 Hood Material Aluminum Hood Weight Approx 800g ZR202G F eps IM 11M12A01 05E 2 9 2 13 ZH21B Dust Protector This protector is designed to protect the probe output from dust agitation i e to prevent combustible materials from entering the probe cell where humidity measurements are made in a dusty environment Insertion length 0 428m Flange JIS 5K 80 FF equivalent or ANSI Class 150 4 FF SUS304 However flange thickness is different Material SUS 316 JIS SUS 304 JIS flange Weight Approx 6kg JIS approx 8 5kg ANSD Mounting Mounted on the probe or process flange with bolts and associated nuts and washers Model and Codes Model Suffix code Option code Description Dust protector 0 to 600 C Insertion length 0 428 m Flange JIS 5K 80 FF SUS304 1 ANSI Class 150 4B FF SUS304 2 Style code The flange thickn
63. 3rd 4th Sth Nov 2000 Mar 2001 Sept 2001 July 2003 Apr 2005 Newly published Revised Section 2 1 2 Some parts of MS Code changed Sun shield hood external dimensions added 2 2 ZA8F Flow setting unit style changed adjusting pressure value changed when a check valve is used ZR20H Autocalibration unit added 3 3 Installation of ZR20H added 4 3 Piping procedure for system 3 revised 6 2 Names of ZR20H added 7 2 Pressure value changed when a check valve is used 10 6 1 Pressure value changed when a check valve is used 11 1 Some parts of maintenance procedure changed Sun shield hood added to CMPL 11M12A01 05E ZR20H Autocalibration unit added to CMPL 11M12A01 12E Revised Section 1 2 Model ZR202A Heater Assembly added 2 2 1 ZA8F Flow setting Unit error correction 2 4 7 Model ZR202A Heater Assembly 8 5 Table 8 11 Input Contact Functions changed 11 1 3 Reference document added to Replacement of the Heater Unit Heater Assembly added to CMPL 11M12A01 05E CMPL 11M12A01 12E Model ZR20H changed Notation of flange specification unified G7004XF K9473XG Airset added CMPL 11M12A01 05E Cell assembly parts no changed revised to 4th edition Revised Section Introduction Added description regarding modification 1 2 1 System Components Changed part numbers of air set in table 2 1 2 Changed safety and EMC conforming standards and paint colors 2 2 2 Changed Finish color 2 3 Added discr
64. 8 10 Output Contact Default Settings Item Output contact 1 Output contact 2 High high limit alarm High limit alarm Low limit alarm Low low limit alarm Error Q Warm up O Output range change Calibration Maintenance O High limit temperature alarm Calibration gas pressure drop Unburnt gas detection Operating contact status Open Closed fixed O Present T8 11E EPS AN Note The above blank boxes indicate the items have been set off IM 11M12A01 05E 8 15 8 5 Input Contact Settings The equipment input contacts execute set functions by accepting a remote contact signal Table 8 11 shows the functions executed by a remote contact signal Table 8 11 Input Contact Functions Calibration gas pressure decreased Function While the contact signal is on neither semi automatic nor automatic calibration is possible Measuring range change While contact input is On range of Analog Output is switched as follows When analog output range is set to Humidity then output range is switched to 0 to 100 H20 When analog output range is set to Mixing ratio then output range is switched to 0 to 1 kg kg When analog output range is set to Oxygen then range is switched to 0 to 25 O2 Calibration start If the contact signal is applied semi automatic calibration starts only if the semi automatic or automatic mode has been setup Calibration is started with
65. A 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 33 Pipe Mounting 3 4 IM 11M12A01 05E IM 11M12A01 05E 3 Installation lt Wall Mounting gt 1 Make a hole in the wall as illustrated in Figure 3 4 WE 4 eee hole or M5 screw F3 13E EPS unit mm Figure 3 4 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 5 Wall mounting 3 5 3 3 Installation of ZR20H Automatic Calibration Unit 3 3 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 and little change of temperature 5 No vibration 6 Little exposure to rays of the sun or rain 3 3 2 Mounting of ZR20H Automatic Calibration Unit 3 6 ZR202G LJ O O O A or B is shipped with autocalibration unit attached The autocalibration unit includes flowmeters and solenoid valves so to ensure reliable and accurate operation Flowmeter should be mounted vertic
66. Briefs 9 1 1 Measurement Principle of Zirconia Humidity Analyzer A solid electrolyte such as zirconia allows the conduction 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 oxygen ions flow from a high partial oxygen pressure to a low partial oxygen pressure causing a voltage When a sample gas introduced into the zirconia plated element with the measurement electrode and air 21 0 vol O is flowed through the reference electrode an electromotive force mV is produced between the two elec trodes governed by Nernst s equation as follows E RT nF log e y a cceceeceee scene scesceees Equation 1 where R Gas constant T Absolute temperature n 4 F Faraday s constant y O vol on the zirconia element measurement electrode a O vol to 21 0 vol O on the zirconia element reference electrode The humidity analyzer uses a sample gas composed of water vapor and air A For the vol H O measurement x Assuming that H O vol in a mixed gas is measured y 100 x X 0 21 Equation 2 From the above equations 1 and 2 we obtain E K log y a Klog 100 x X0 21 21 K log 1 0 01 x Equation 3 where K Constant Using the above equation 3 we can calculate the water vapor in vol from the electromotiv
67. ENT key to display the currently set value D 00 1 a 00 Touch the gt key to move the position of the digit that is flashing to 1 000 00 Touch the A key to change to 0 000 00 Touch the gt key to move the position of the digit that is flashing to the right one digit 000 90 Touch the key to change the numeric value to 9 000 90 Touch the gt key to move the position of the digit that o z an is flashing to the right one digit 000 98 Touch the key to change the numeric value to 8 0 0 0 i 98 Touch the key to have all the digits flash 000 98 Touch the key again to stop the flashing b01 Touch the ENT key once again to switch to the parameter code selection display Set the span gas concentration by above procedure set 21 to BO2 A Next set the calibration mode Switch the parameter code to B03 b03 0 Touch the ENT key to display the currently set value If it is 0 you can leave it as is If it is other than 0 change it to 0 zero Touch the ENT key The numeric value will flash Touch the key again to stop the flashing b0 3 Touch the key once again to switch to the parameter code selection display Basic Touch the gt key together with the ENT key to return to the basic panel display panel This is not required if you proceed to make another setting display
68. I z L Il Flange j PIPING A 2 G1 2 2 1 1NPT etc 156 3 Stop Cable connection port 256 4 Valve 49 33 Reference gas outlet a Re 1 40r1 4NPT Calibration gas inlet Model Code PIPING Specification ZR202G 040 L gt ANSI Class 150 2 RF SUS304 Di ZR202G 300 F3 18E EPS 3 10 IM 11M12A01 05E 3 Installation 2 ANSI Class 150 3 RF ZR202G B P Flange Equivalent to ANSI Class 150 3 RF SUS304 Rc1 4 or 1 4NPT Reference air inlet L 34224 2 G1 2 2 1 2NPT etc t Cable connection port c di N 5 dl a Reference gas outlet pine Flange PIPING A 156 3 Stop Valve 256 4 49 Model Code PIPING Specification ZR202G 040 ANSI Class 150 3 RF SUS304 ZR202G 300 Approx F3 19E EPS 3 ANSI Class 150 4 RF ZR202G O C P Flange ANSI Class 150 4 RF SUS304 Rc1 4 or 1 4NPT Reference air inlet L 342 4 2 G1 2 2 1 2NPT etc Cable connection port
69. Item Tuning Engineering unit 10 Other Functions Default setting Equipment setup 0 Oxygen analyzer 1 Humidity analyzer Not initialized Selection of temperature units degree C degree F degree C Selection of pressure units kPa psi kPa Selection of display items Oxygen concentration Humidity Mixed ratio Item selected with analog output on ol or 0 Humidity Date YY MM DD H H MM Period over which average values are calculated 1 to 255 hours Hours One hour Period over which max and min values are monitored 1 to 255 hours Hours 24 hours Process gas temperature 0 to 3000 C 300 C Process gas pressure 0 to 300 101 33 kPa abs Initializing all data Initializing data in group A Initializing data in group B Initializing data in group C Initializing data in group D Initializing data in group E Initializing data in group F IM 11M12A01 05E T10 6F EPS 10 17 Inspection related Items in Group G Code Tuning Engineering Default unit setting mA output loop 4 to 20 Output contact 1 Open Closed Open Closed Off On Off On Open Closed Open Closed Output contact 2 Automatic calibration solenoid valve zero Automatic calibration solenoid valve span Input1 contact Input2 contact 0 1
70. Max and Min Mix Ratio Set Ranges 8 4 IM 11M12A01 05E 8 Detailed Data Setting 8 12 Entering Output Damping Constants If a measured value which is adversely affected by rapid changes in the process is used as the basis for control frequent on off actions of the output may result To avoid this the analyzer allows the setting of output damping constants ranging from 0 to 255 seconds 8 1 3 Selection of Output Mode There are two output modes available linear mode and logarithmic mode Select the either mode for your desired analog output vs measured value characteristics CAUTION e When you select logarithmic mode the minimum output remains constant at 0 1 O and the humidity remains set to 0 1 H O and mixing ratio is set to 0 01 kg kg regardless of the set values Set value of C11 to C16 remains unchanged 8 14 Default Values When the analyzer is delivered or data are initialized the output current settings are by default as shown in Table 8 2 Table 8 2 Output Current Default Values Item Default setting Min oxygen concentration 0 Oo Max oxygen concentration 25 Or Minimum humidity 0 H 0 Maximum humidity 25 H20 Minimum ratio setting 0 kg kg Maximum ratio setting 0 2 kg kg Output damping constant 0 seconds Output mode Linear T8 1 4 1E EPS IM 11M12A01 05E 8 5 8 2 Output Hold Setting The output hold functions hold an analog output signal at a preset value
71. Not operated during warming up 1 Operated during warming up Calibration gas E29 0 Not operated while a calibration gas pressure drop contact is being closed pressure drop 1 Operated while a calibration gas pressure drop contact is being closed Note 4 Unburnt gas E32 0 Not operated while a unburnt gas detection contact is being closed detection 1 Operated while a unburnt gas detection contact is being closed Note 5 T8 10E EPS Note 1 Output contact 2 remains closed Note 2 For the high high alarm the concentration alarm must be preset see Section 8 3 Note 3 Range change answer back signal For this action the range change must be preset during the setting of input contacts Section 8 5 Note 4 Calibration gas pressure decrease answer back signal Calibration gas pressure decrease must be selected beforehand during the setting of input contacts Note 5 Non combusted gas detection answer back signals Non combusted gas detection must be selected during the setting of input contacts A WARNING e Output contact 2 is linked to the detector s heater power safety switch As such if output contact 2 is on the heater power stops and an Error 1 cell voltage abnormal or Error 2 heater temperature abnormal occurs 8 14 IM 11M12A01 05E 8 Detailed Data Setting 8 4 3 Default Values When the analyzer is delivered or if data are initialized output contacts are by default as shown in Table 8 10 Table
72. Oxygen Analyzer O O O Probe protector O O ZA8F Flow setting unit for manual calibration use O O O ZR20H Automatic Calibration unit O O O O Calibration gas unit case Part No E7044KF O O Check valve Part No K9292DN K9292DS O O Dust filter for the detector Part No K9471UA O O Q ZO21S Standard gas unit O O O O T Int 1E CMPL Customer Maintenance Parts List IM 11M12A01 05E 6th Edition Sep 2006 YK All Rights Reserved Copyright 2000 Yokogawa Electric Corporation IM 1M12A01 05E This manual consists of twelve chapters Please refer to the reference chapters for installation operation and maintenance References Chapter Outline Installation Operation Maintenance 1 Overview Equipment models and system configuration examples O A 2 Specifications Standard specification model code or part number dimension drawing for each equipment 9 9 3 Installation Installation method for each equipment A 4 Piping Examples of piping in three standard system configurations 5 Wiring Wiring procedures such as Power supply wiring output signal wiring or others 6 Components These are described in this manual O O 7 Startup Basic procedure to start operation of EXAxt ZR Chapter 7 enables you to operate the equipment immediately A 8 Detailed Data Setting Details of key operations and displays O A 9 Calibration Describes the
73. Piping 4 2 Piping for System Configuration 2 Piping in System 2 is illustrated in Figure 4 7 Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Stop valve or Check valve 100 to 240 VAC sine tes Contact input gt Analog output Contact output Digital output HART Model ZA8F flow setting unit Flowmeter Needle a valve Reference gas Air Set Instrument air Span gas Same as Zero gas Calibration unit Calibration gas Calibration gas pressure regulator Zero gas F4 7E EPS cylinder Calibration gas unit case Figure 4 7 Piping for System 2 System 2 illustrated in Figure 4 7 requires piping as follows e Mount the stop valve or the check valve through a nipple to the reference gas inlet of the equipment 4 2 1 Piping Parts for System Configuration 2 IM 11M12A01 05E Check that the parts listed in Table 4 2 are provided Table 4 2 Piping Parts Equipment Piping location Parts Description General use Calibration gas inlet Stop valve or check valve Stop valve L9852CB or G7016XH Analyzer provided by YOKOGAWA check valve K9292DN or K9292DS recommended by YOKOGAWA Re1 4 or 1 4 NPT User s scope G7013XF or G7014XF recommended by YOKOGAWA Re1 4 or 1 4 NPT Commercially available K9573XH K9473XJ or G7004XF K9473XG recommended by YOKOGAWA Re1 4 or 1 4 NPT Commercially available Nipple Zero gas cylinder Regulator v
74. SA C22 2 No 61010 1 UL61010 1 2 2 IM 11M12A01 05E Functions IM 11M12A01 05E 2 Specifications EMC EN 61326 Class A EN 55011 Class A Group 1 EN 61000 3 2 AS NZS CISPR 11 Reference Air System Natural Convection Instrument Air Instrument Air System excluding Natural Convection Pressure 200 kPa the pressure inside the dryer It is recommended to use air which is dehumidified to dew point 20 C or less and with 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 recircula tion pressure compensated version Gas Connection Rc 1 4 or 1 4 NPT F Wiring Connection G1 2 Pg13 5 M20 by 1 5 mm 1 2 NPT select one type 4 pieces Installation Flange mounting Probe Mounting Angle Horizontal to vertically downward When the probe insertion length is 2 m or less installing at angles from horizontal to vertically downward is possible When the probe insertion length is 2 5 m or more mount vertically downward within 5 or both mount horizontally within 5 and use a probe protector Case Aluminum alloy Paint Color Cover Mint green Munsell 5 6BG3 3 2 9 Case Mint green Muns
75. Stop Valve 256 4 49 Weight PIPING kg Model Code Specification ZR202G 040 Approx JPI Class 150 4 RF SUS304 ZR202G 300 F3 28E EPS IM 11M12A01 05E 3 15 12 JPI Class 150 3 RF ZR202G O S P Flange JPI Class 150 3 RF Rc1 4 or 1 4NPT Reference air inlet 342 4 oth f Reference gas outlet 7 Flange 156 3 Stop ji IL O0 l PIPING A 256 4 Valve 49 Model Code ZR202G 040 ZR202G 300 13 Westinghouse Rc1 4 or 1 4NPT Calibration gas inlet E 2 G1 2 2 1 2NPT etc Cable connection port Specification JPI Class 150 3 RF SUS304 ZR202G O W P Flange Westinghouse 342 4 Rc1 4 or 1 4NPT Reference air inlet m oO oO Reference gas outlet QO T PIPING Flange E B PIPING A j 2 G1 2 2 1 2NPT etc 156 3 Stop Cable connection port 256 4 Valve 49 Model Code Rc1 4 or 1 4NPT Calibration gas
76. T key again the flashing stops and Zero Y appears Close the span gas flow valve Secure the span gas lock nut for leakage If the automatic calibration unit is connected close the span gas solenoid valve If zero gas calibration is omitted touch the gt key to change Y to N Next if you touch the ENT key the display jumps to CALEND Touch the ENT key to display the calibration gas value This value must be the zero gas concentration set in Section 7 10 1 Calibration Setup earlier in this manual To cancel the above touch the gt key and ENT key together Then the display returns to ZERO Y The symbo SI indicates that the corresponding keys are being touched and the light characters indicate flashing 17 14E 1 EPS IM 11M12A01 05E 7 23 Table 7 14 Performing Calibration Continued Switch operation Display Description O P E n If you touch the ENT key OPEN and the currently measured value are displayed alternately Open the Flow Setting Unit zero gas flow valve 0 89 and adjust the zero gas flow to 600 60 ml min To do this a loosen the valve lock nut and gently turn the valve control shaft counterclockwise Check the calibration gas flowmeter for confirmation If the automatic calibration unit is connected open the zero gas solenoid valve and then the measured value changes to the zero gas value When the display becomes stable proceed to the next step To cancel the above tou
77. User s Manual EXA Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer IM 11M12A01 05E vigilant YOKOGAWA IM 11M12A01 05E 6th Edition Yokogawa Electric Corporation Introduction The EXAxt ZR series of Integrated type Zirconia High temperature Humidity Analyzers was developed for humidity control in various industrial processes There are versions for virtually every application Optional accessories are also available to improve measurements and automate calibra tion An optimal control system can be realized by adding appropriate options This instruction manual describes installation operator inspection and maintenance for almost all of the equipment related to the EXAxt ZR You may skip any section s on the equipment which is are not included in your system Regarding the HART communication Protocol refer to IM 11M12A01 51E IM11M12A01 51E is titled Model EXAxt ZR series HART protocol The separate version sensor and converter separated is described in IM 11M12A01 03E lt Before using the equipment please read any related descriptions in this manual for the equipment and the system you have on appropriate use and operation of the EXAxt ZR gt Models and descriptions in this manual are listed below Description in this manual Model Product Name Specification Installation Operation Maintenance CMPL ZR202G Integrated type
78. Z electromotive before correction force mV Previous zero gas data A 7 ei TN 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 Figure 10 2 10 1 22 History of Calibration Time The calibration conducted dates and times for the past ten calibrations are stored in memory 10 1 23 Time The current date and time are displayed These are backed up by built in batteries so no adjustment is required after the power is switched off The following shows an example of displaying June 21 2000 3 06 p m Displayed alternately 00 06 21 7 15 06 F10 3E EPS Figure 10 3 Date and time Display 10 1 24 Software Revision The revision number of the software installed is displayed IM 11M12A01 05E 10 7 10 2 Operational Data Initialization Individual set data initialization enables you to return to the default values set at the time of delivery There are two types of initializations an all set data initialization and a parameter code based initialization Table 10 7 lists the initialization items by a param eter code and default values Table 10 4 Parameter Codes for Initialization Parameter code Data to be initialized F30 All data F31 Data in Group A F32 Data in Group B F33 Dat
79. a in Group C Data in Group D Data in Group E Data in Group F T10 4EPS A CAUTION If the above group F is initialized with parameter code F36 items corresponding to parameter codes F01 F08 and F10 will not be initialized 10 8 IM 11M12A01 05E 10 Other Functions 10 3 Initialization Procedure Follow the table below to initialize parameters The password for initialization is 1255 Table 10 5 Initialization Procedure Switch operation Display Description gt AN ENT F30 Enter the parameter code for the item to be initialized The following show an example of entering F30 Previous needed operations are omitted gt A ENT 0000 Touch the ENT key to switch to the password entry display gt A ENT 1000 Enter the password 1255 for initialization gt A ENT 1000 gt A ENT 1200 gt A ENT 1200 gt A ENT 1250 gt A ENT 1250 gt A ENT 1255 gt AN ENT After you enter the password and then touch the ENT key all the digits flash gt N ENT USr Go Touch the ENT key again to display USR GO j Touch the ENT key once more GO gt A ry gt o All the digits then flash for two to three seconds and data initialization starts The initialization is complete and the parameter code selection display gt A ENT 30 then appears T10 5E EPS The symbol Si indicates that the key is being touched Light
80. 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 7 Zero origin Cell electromotive force mV Previous zero gas data el Corrected calibration curve theoretical calibration curve es cf 0 Span origin 21 0 Span gas concentration Oxygen concentration vol Oz Zero point correction factor B A x 100 Correctable range 100 30 Span correction factor C A x 100 Correctable range 0 18 F9 3E EPS Figure 9 3 Calculation of a One point Calibration Curve and Correction Factors using a Span Gas IM 11M12A01 05E 9 Calibration 9 1 4 Characteristic Data from a Sensor Measured During Calibration IM 11M12A01 05E 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 using parameter codes A20 to A22 and A50 to A79 For an explanation and the operating procedures of individual data consult Section 10 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 monit
81. accordance with a preset start day and time Calibration is then executed at preset intervals CAUTION Before conducting a semi automatic or automatic calibration run the automatic calibra tion unit beforehand to obtain a calibration flow of 600 60 ml min IM 11M12A01 05E 9 9 10 Other Functions 10 Other Functions 10 1 Detailed Display Select the desired parameter code to display the detailed operation data see Table 10 1 Parameter Codes for Detailed Operation Data IM 11M12A01 05E 10 1 10 2 Parameter code Table 10 1 Parameter Codes for Detailed Operation Data Item Engineering unit Engineering unit A00 Selection of display items 0 Oxygen concentration 1 Oxygen analyzer 0 0 2 Oxygen analyzer 0 0 3 Analog output selected Span gas ratio 0 Span gas ratio 1 Span gas ratio 2 Span gas ratio 3 Oxygen concentration Span gas ratio 4 Humidity Span gas ratio 5 Mixing ratio Span gas ratio 6 Relative humidity Span gas ratio 7 Dew point Span gas ratio 8 Span gas ratio 9 Cell temperature Zero gas ratio 0 Cold junction temperature Meas gas temperature Zero gas ratio Zero gas ratio 2 Zero gas ratio 3 Cell voltage Zero gas ratio 4 TC voltage Zero gas ratio 5 Cold junction voltage Output current mA Zero gas ratio 6 Zero gas ratio 7 Cell response time Se
82. act action Contact output 1 G11 0 Open Closed Contact output 2 Open Closed Automatic calibration solenoid valve zero gas Automatic calibration solenoid valve span gas Contact input 1 Closed Contact input 2 Open Closed T7 8E EPS IM 11M12A01 05E 7 Startup 7 9 1 Contact Output Check Follow Table 7 9 to check the contact output The table uses an example with contact output 1 Table 7 9 Checking Contact Output Switch operation Display Description ENT A01 Display after the password has been entered ENT G 01 Touch the A key to switch to Group F G 01 Touch the gt key to move the position of the digit that is flashing to the right one digit G 1 1 Touch the key to enter 1 Touch the ENT key to have 0 flash The contact is then open Touch the A key to set 1 one Touch the key The flashing continues Touch the ENT key again to stop the flashing and the contact will be closed G 1 1 Touch the ENT key once again to switch to the parameter code selection display The contact then returns to the original state Basic Touch the gt key together with the ENT key to return to the basic panel display panel This is not required if you proceed to make another setting display The displayed numeric characters indicate the measurement gas concentration The symbol
83. ailable Joint for tube connection Rc1 4 1 4NPT for a Commercially available 6 x 4mm soft tube Reference gas inlet Sealed up when piping is required refer to Section 4 1 3 Note Parts marked with are used when required TEES 4 1 2 Connection to the Calibration Gas Inlet When carrying out calibration connect the piping 6 0 D X 4 D mm tube from the standard gas unit to the calibration gas inlet of the equipment Mount the stop valve of a quality specified by YOKOGAWA through a nipple found on the open market as illustrated in Figure 4 2 and mount a commercially available joint at the stop valve tip The stop valve may be mounted on the equipment prior to shipping the equipment Note 1 Mount the stop valve in the vicinity of the equipment F4102 EPS Figure 4 2 Connection to the Calibration Gas Inlet 4 1 3 Connection to the Reference Gas Inlet e Normally no piping is required for the reference gas inlet when the equipment uses natural convection for reference gas models ZR202G L1 L1 L1 C Leave the plug as it is If the air around the probe is polluted and the necessary oxygen concentration 21 vol O cannot be obtained make an instrument air piping as in Section 4 2 System 2 e When the equipment uses instrument air for the reference gas piping is required as described in Section 4 2 System 2 models ZR202G LJ LI L E or P 4 2 IM 11M12A01 05E 4
84. alibration gas unit case cylinder F1 2E EPS Figure 1 2 IM 11M12A01 05E 1 13 System 3 IM 11M12A01 05E 1 Overview This system is also used where accurate monitoring and controlling of the humidity is required Instrument air clean and dry air of oxygen concentration 21 is used as the reference gas and span gas for calibration A calibration zero gas is supplied from a cylinder This system uses an automatic calibration unit to control the calibration gas flow automatically 2 Model ZR202G Integrated type Zirconia High Temperature Humdity Analyzer with auto calibration ZR202G 0 0 A 0 0 01 0 A 1 Contact input gt Analog output contact output Digital output HART Auto Calibration unit ZR20H Instrument air Calibration gas unit case Zero gas cylinder Note The installation temperature limits for an integrated unit range from 20 to 55 C F1 3E EPS 1 Shield cable Use shielded signal cables and connect the shields to the FG terminal of the con verter 2 Select the desired probe from the Probe Configuration table on page 1 4 3 100 N gas cannot be used as the zero gas Use approx 1 vol O gas N based Figure 1 3 1 3 1 2 lt EXAxtZR gt System Components 1 2 1 System Components Integrated type System config System Components Ex Ex Model ZR20
85. ally The associated probe is designed for horizontal or vertical mounting If you buy the autocalibration unit afterward and need to install it or replace it contact our service representative IM 11M12A01 05E 3 Installation Basic spec code A Horizontal mounting Display Terminal box LD fan 1 ED 17 M Zero gas inlet 44 MAX Lao 66 5 Re 1 4 or 1 4NPT Female 166 5 unit mm 258 244 Reference gas inlet Span gas inlet Re 1 4 or 1 4NPT Female He UE Or VANE IEgmalg Basic spec code B Vertical mounting 166 5 Span gas inlet Re 1 4 or 1 4NPT Female En 160 x Zero gas inlet Rc 1 4 or 1 4NPT Female Reference gas inlet 180 44 MAX Rc 1 4 or 1 4NPT Female F3 6E EPS Figure 3 6 Automatic Calibration Unit Mounting IM 11M12A01 05E 3 7 3 4 Installation of the Calibration gas Unit Case E7044KF 34 1 Location 3 4 2 Mounting 3 8 The calibration gas unit case is used to store the G7001ZC zero gas cylinders The following should be taken into consideration 1 Easy access for cylinder replacement
86. alve Commercially available Joint for tube connection Air set Reference gas inlet Joint for tube connection Note Parts marked with are used when required T4 2E EPS 4 3 4 2 2 Piping for the Calibration 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 ZR202G analyzer 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 pressure regulator recommended by YOKOGAWA on the cylinder Mount a stop valve or the check valve recommended by YOKOGAWA on the nipple commercially available at the calibration gas inlet of the equipment as illustrated in Figure 4 8 The check valve or the stop valve may have been mounted on the equip ment when shipped Connect the flow setting unit and the analyzer to a 6 mm O D X 4 mm I D or nominal size 1 4 inch or larger stainless steel pipe Piping for the reference gas 6 mm O D by 4 mm I D stainless steel pipe Piping for the calibration gas 6 mm O D by 4 mm I D stainless steel pipe Ly LEK Stop valve or check valve F4 8E EPS Figure 4 8 Piping for the Calibration Gas Inlet 4 2 3 Piping for the Reference Gas 4 4 Reference gas piping is required between the air source instrument air
87. ameter code C14 to set the maximum mixing ratio at 20 mA Refer to Table 7 6 for the parameter codes For more details consult Section 8 1 Cur rent Output Settings later in this manual Table 7 6 Parameter codes for analog output range Parameter code Set value 0 Oxygen concentration 1 Humidity Mix ratio Minimum oxygen concentration at 4 mA Maximum oxygen concentration at 20 mA Minimum humidity at 4 mA Maximum humidity at 20 mA Minimum mix ratio at 4 mA Maximum mix ratio at 20 mA T7 6 EPS 7 73 Minimum Current 4 mA and Maximum Current 20 mA Settings This section describes how to set the humidity readings corresponding to 4 mA and 20 mA to 30 H O and 80 H O respectively Switch operation Display Description A ENT 01 Display after the password has been entered A ENT 01 Set the humidity reading at 4 mA Change the parameter code to C13 Touch the key to switch to Group C ENT C01 Touch the gt key to move the position of the digit that is flashing to the right ENT C11 Touch the key to enter the number 1 ho ENT C1 Touch the gt key to move the position of the digit that is flashing to the right ENT C1 Touch the key to enter the number 3 ac ENT 00 Touch the ENT key to display the current set value The humidity 0 H20 is now being displayed 000 Touch the gt key to move the position of the digit that is flas
88. and C14 for those settings and when the mix ratio setting was selected with parameter code C01 use parameter codes C15 and C16 for those settings Oxygen concentration setting range The minimum concentration of oxygen for the minimum current 4 mA is 0 O or 6 to 76 O The maximum concentration of oxygen for the maximum current 20 mA ranges from 5 to 100 O and must be at least 1 3 times the concentration of oxygen set for the minimum Setting example 1 If the setting for a 4 mA current is 10 O you must set the oxygen concentration for the maximum 20 mA point at more than 13 O Setting example 2 If the setting for a 4 mA current is 75 O you must set the oxygen concentration for the maximum 20 mA point at 98 O or greater 75 X 1 3 O Numbers after the decimal point are rounded up Ranges over which oxygen concentrations can be set Outside ranges 15 25 35 45 55 65 75 Minimum oxygen concentration O2 for a minimum current of 4 mA F8 1 1 1 EPS Figure A Max and Min Oxygen Concentration Set Ranges IM 11M12A01 05E 8 Detailed Data Setting Humidity setting range The minimum humidity is set to 0 H O or ranges from 26 to 100 H O The maxi mum humidity ranges from 25 to 100 H O and must be greater than 0 8 times plus 23 the humidity set for the minimum Setting example 1 If the setting for a 4 mA current is 0 H O you must set the maximum 20 mA point at more than 25 H O Sett
89. anual Calibra tion earlier in this manual 1 When OPEN and the measured oxygen concentration appear alternately during the span calibration open the span gas flow setting valve of the flow setting unit and adjust the flow rate to 600 60 ml min Loosen the lock nut if the valve shaft has a lock nut and turn the valve regulator slowly counterclockwise 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 8 10 Table 10 8 Measurement gas 50 100 150 200 250 pressure kPa Flow rate ml min 500 430 380 350 320 T10 6 2 EPS 2 Adjust the flow rate After the measured oxygen concentration has stabilized touch the ENT key then all the digits will flash Touch the ENT key again to display ZERO Y 10 23 3 Close the span gas flow setting valve to stop the span gas air flow If the valve shaft has a lock nut be sure to tighten the lock nut to prevent any leakage of span gas into the sensor during measurement 10 63 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 OPEN and the measured oxygen concentration appearalternately during calibration open the zero gas flow setting valve of the flow setting unit and adjust the flow rate to 600 60 ml min To r
90. as follows 1 Use a two core or three core shielded cable 2 M4 screws are used for the terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections 5 32 Wiring for Ground Terminals The ground wiring of the analyzer should be connected to either the ground terminal of the equipment case or the terminal inside of the equipment Proceed as follows 1 Keep the ground resistance of 1000 or less JIS Class D grounding 2 When connecting the ground wiring to the ground terminal of the equipment case be sure that the lock washer is in contact with the case surface see Figure 5 5 3 Ensure that the jumper plate is connected between the G terminal and the FG terminal of the equipment 4 The size of external ground screw thread is M4 Each cable should be terminated corresponding crimp on terminals IM 11M12A01 05E 5 5 54 Wiring for Contact Output The equipment can output a maximum of two contact signals These contact outputs can be used for different applications such as a low limit alarm or high limit alarm Do the contact output wiring according to the following requirements Analyzer Terminal box Annunciator or the like O 1 Output Q 2 Output F5 6E EPS Figure 5 6 Contact Output Wiring 54 1 Cable Specifications The number of wires in cable varies depending on the number of contacts used 542 Wiring Procedure 5 6 1 M4 screws are used for the terminals Use cr
91. at is flashing will increase d 01 continuously from D to E to F to G to A Numeric values will change from 0 to to 2 to 3 to 8 to 9 and back to 0 However numbers that are not present in the parameter codes will be skipped Each digit is changed independently Even though a low order digit changes from 9 to 0 a high order digit will not be carried Set Value After you select the desired character touch the ENT key The set data will be displayed 17 4 4EEPS The symbol gt indicates that the key is being touched Light characters indicate that the digits are flashing IM 11M12A01 05E 7 7 745 Changing Set Values 1 Selecting numeric values from among preset values Switch operation Display Description A ENT 0 The set value is displayed after the parameter code selection An example of how to select either 0 1 or 2 as the set value is given below The currently set value is 0 Touch the A key once to change the current value from 0 to 1 Touch the A key again to change to the numeric value 2 If you touch the A key again the numeric value will return to 0 Continuously touch the key and the numeric values will change continuously Display the desired numeric value and touch the ENT key The display will then return to the parameter code selection 17 4 5 1E EPS 2 Entering numeric values for the humidity and factors Switch operation D
92. ate to 600 60 ml min the flow check ball stops floating on the green line when the valve is slowly opened Turn the regulator of the zero gas valve back slowly counterclockwise At that time the flow rate also decreases as the inner pressure of the gas cylinder decreases Monitor the flow check and when the ball s position changes greatly readjust the valve 3 Touch the ENT key after the measured oxygen concentration becomes stable Then all the digits flash Touch the ENT key again so that the CALEND flashes AN Note Be sure not to terminate the calibration in progress because of a shortage of gas in the cylinder Each gas cylinder is operable for nine minutes or more provided the gas is discharged at the specified rate Therefore if your calibration time is estimated at four minutes you can operate the zero point calibration twice 4 Stop the zero gas flow Turn the zero gas valve regulator fully clockwise If this valve regulator is not properly adjusted the needle valve will not close completely and a cylinder gas may leak When the output stabilization time elapses the calibra tion is complete IM 11M12A01 05E 10 21 lt Treatment after completion of calibration gt 1 Fully close the needle valve mounted on the calibration gas inlet of the detector 2 Remove the tube connecting the detector to the standard gas unit WARNING Store the standard gas unit with the gas cylinder mounted where t
93. bly status in the following procedure a Display Cell resistance by specifying the parameter code A21 A new cell will show a cell resistance value of 200 or less On the other hand a cell sensor that is approaching the end of its service life will show a resistance value of 3 to 10 KQ b Display Cell robustness by specifying the parameter code A22 A good cell sensor will show 5 Life gt 1 year refer to Section 10 1 15 IM 11M12A01 05E 12 5 12 2 2 3 Alarm 7 Span Calibration Coefficient Alarm In calibration this alarm is generated when the span gas ratio is out of the range of 0 18 refer to Section 9 1 3 Compensation 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 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 value 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
94. by gray characters Flashing n e Displays on the LCD display panel LCD display EPS IM 1M12A01 05E 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 EXAxt ZR Integrated type High temperature Humidity Analyzer 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 operating conditions before starting analysis Where necessary set the instrument parameters appropriately For details on setting data refer to Chapters 7 to 10 When the user changes the operation parameters it is recommended that original and new setting data be noted down After Sales Warranty 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 d
95. ccesseceeeeesteeeeeeceeeeeaeceeeeeeeeeaee 5 5 5 3 1 Wiring for Power Line 5 5 5 3 2 Wiring for Ground Terminals 00 0 0 ec eeeseeseeseecsecneecneceseeeeneeerenees 5 5 5 4 Wiring for Contact Output ss 5 6 5 4 1 Cable Specifications esse 5 6 947 Witing Procedure 2280 mine nl ni Ba A le eh ee 5 6 5 5 Wiring for Contact Input ss 5 7 5 5 1 Cable Specifications ss 5 7 5 52 Nirimo Procedure seen A a E diner A 5 7 0 COMPONENES ennemies Oil 6 1 ZR202G High temperature Humidity Analyzer oo eee eee ereereeneeeee 6 1 6 1 1 Integrated type High temperature Humidity Analyzer eee 6 1 6 2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit 6 2 EC EL CUD PORTER SERRE eee RER SRE ER RE TR EME ees mk 7 1 Checking Piping and Wiring Connections 000 0 eeeceeceesteceneeceeeeeteeeeneenaeeeens 7 2 V2 Valve S pia itl plied uae nine 7 2 7 3 Supplying Power to Converter 7 2 IM 1M12A01 05E 7 4 Operation of Infrared Switch ss 7 3 TAA Display and Switches ss 7 3 TAZ Display Configuration sise ur den mien As Aus 7 5 74 3 Entering Parameter Code Selection Display 0 0 0 0 cee ceeeeeeeeeeeeeees 7 6 TAA Selecting Parameter Codes ss 7 7 TAS Changing Set Values norrena eran avatens i 7 8 7 5 Confirmation of Equipment Type Setting 0 ee eeeeseeeeetreeeeee 7 10 7 6 Setting Display Item ss 7 11 T73 Current Output S nart die es 7 12 7 71 Analog Output Setting ss 7 12 7 7 2 Output Range Setting see 7 13
96. ch the gt key and ENT key together Then the display returns to ZERO Y If you touch the ENT key all the digits flash At that point no calibration is conducted yet Touch the ENT key again to get the measured value to agree with the zero gas concentration Close the zero gas flow valve Secure the valve lock nut for leakage during measurement If the automatic calibration unit is connected close the span gas solenoid valve CALEND flashes during the output hold time If output hold is specified in the Output Hold setting it remains as an analog output see Section 8 2 When the preset output hold time is up the calibration is complete b1 0 The output hold time is set to 10 minutes at the factory If you touch both the gt key and ENT key at the same time during the preset Output Hold Time the calibration is aborted and the parameter code selection display appears Basic If you touch the gt key and ENT key together panel then the basic panel display appears display The above display is a result of switch operations 17 14E 2 EPS The symbo SY indicates the keys are being touched and the light characters indicate flashing indicates that the characters are displayed alternately Cancel indicates the procedure to stop the key operations 7 24 IM 11M12A01 05E 8 Detailed Data Setting 8 Detailed Data Setting 8 1 Current Output Setting This secti
97. conds Zero gas ratio 8 Cell internal resistance Q Zero gas ratio 9 Cell robustness Calibration history 0 YY MM DD HH MM Heater on time ratio Calibration history 1 YY MM DD HH MM Oxygen concentration with time constant Humidity with time constant H O Calibration history 2 Calibration history 3 YY MM DD HH MM YY MM DD HH MM Mixing ratio with time constant kg kg Calibration history 4 YY MM DD HH MM Max oxygen concentration O2 Calibration history 5 YY MM DD HH MM Occurrence of maximum oxygen concentration YY MM DD HH MM Calibration history 6 YY MM DD HH MM Min oxygen concentration Or Calibration history 7 YY MM DD HH MM Occurrence of minimum oxygen concentration YY MM DD HH MM Calibration history 8 YY MM DD HH MM Average oxygen concentration O2 Calibration history 9 YY MM DD HH MM Maximum humidity Occurrence of maximum humidity Minimum humidity H O H O Time YY MM DD HH M MMDDAHMM A00 onware revision Occurrence of minimum humidity YY MM DD HH MM Average humidity H O Maximum mixing ratio kg kg Occurrence of maximum mixing ratio YY MM DD HH MM Minimum mixing ratio Occurrence of minimum mixing ratio kg kg YY MM DD HH MM Average mixing ratio kg kg Note The blank parameter cod
98. d in the suffix code of the ZR202G Integrated type by selecting either A Horizontal mounting or B Vertical mounting The ZR20H should be arranged when auto calibration is to be required after the ZR202H has been installed Ask Yokogawa service station for its mounting Construction Dust proof and rainproof construction NEMA4X IP67 excluding flow meter Mounting Mounted on ZR202G no vibration Materials Body Aluminum alloy Piping SUS316 JIS SUS304 JIS Flowmeter MA Methacrylate resin Bracket SUS304 JIS Finish Polyurethane corrosion resistance coating Case Mint green Munsell 5 6BG3 3 2 9 Cover Mint green Munsell 5 6BG3 3 2 9 Piping Connection Refer to Model and Suffix Codes Power Supply 24V DC from ZR202G Power consumption Approx 1 3 W Reference Air Pressure Sample gas pressure plus Approx 150 kPa 690 kPa max Pressure at inlet of auto calibration unit Air Consumption Approx 1 5 1 min Weight Approx 2 kg Ambient Temperature 20 to 55 C no condensing or freezing Ambient Humidity 0 to 95 RH Storage Temperature 30 to 65 C e Model and Codes Suffix code Option code Description ZR2OM A toda meninme ss ean ea nt Automatic calibration unit for ZR202G 1 Gison fon LR hee Re 1 4 as piping connection e re He Wecessceveeerneace Instrument air a de Pressure compensated Reference air 2 Mounting OD gee Horizontal mounting s
99. d when the emf voltage of thermocouple falls below 5 mV about 170 C or exceeds 42 1 mV about 1020 C 1 A failure of the thermocouple at the detector occurred 2 A failure of the electrical circuits occurred lt Search for cause of failure and taking measure gt 1 Turn off the power to the analyzer 2 Remove the probe from the analyzer Also remove all the connectors between the converter and probe Measure the resistance of the heater wire yellow wire from the probe as indicated in Figure 12 5 The heater unit is normal if the resistance is lower than about 900 If the resistance is higher than that value the heater unit may be defective In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit Heater wire Multimeter Q F12 2E EPS Figure 12 5 3 Next check the resistance of the thermocouple from the probe Use a multimeter to measure the thermocouple resistance between terminal 3 red cable connected and terminal 4 white cable connected as indicated in Figure 12 6 The thermocouple is normal if the resistance is 5Q or less If the value is higher than 5Q the thermocouple wire may be broken or about to break In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit A CAUTION e Measure the thermocouple resistance value after the difference between the probe tip temperature and the ambient
100. dity Indicates the mix ratio Displays an item for the current output If the output damping has been set for the current output values involving the output damping are displayed T7 4 EPS Table 7 5 Display Item Setting Procedure Display after the password has been entered Touch the gt key to move the position of the digit that is flashing to the right Touch the A key to change the parameter code to 0 The number will change from 1 to 2 to 3 9 and back to 0 Touch the ENT key to display the current set value Set the mix ratio Touch the ENT key to change the number to 2 Touch the ENT key The number 2 will be flashing Touch the ENT key again to stop flashing Touch the ENT key to return to the parameter code selection display Touch the gt and ENT keys simultaneously to return to the basic panel display on which the mix ratio appears The symbol Yy indicates that the corresponding keys are being touched and the light ara gt indica ashing characters indicate flashing 17601 EPS IM 11M12A01 05E 7 11 7 7 Current Output Setting 7 7 1 Analog Output Setting Select any one of the analog output settings oxygen humidity and mixing ratio If the HS option was specified at the time of purchase the equipment is a humidity analyzer For other than this setting the analyzer is an oxygen analyzer If mixed measurement is requi
101. duit from power and heater cables Be sure to ground the metal conduit 4 Install the attached two blind plugs to unused cable connection gland s of the equipment 5 The cables indicated in Table 5 1 are used for wiring 6 After completing the wiring screw the cover in the terminal box body and secure it with a lock screw Table 5 1 Cable Specifications Terminal name of equipment Name Need for shields Cable type Number of wires L N Power supply CVV 2 or 3 AO AO Analog output O CVVS 2 DO 1 DO 2 Contact output CVV 2t0 8 DI 1 DI 2 DI C Contact input CVV 3 R T5 1E EPS Note When the case is used for protective grounding use a 2 wire cable A Note IM 11M12A01 05E e Select an appropriate cable O D to match the cable gland size e Protective grounding should have the grounding resistance of 1000 or less JIS Class 3 ground e Special cable length is required for HART communication For detail of the HART communication refer to IM11M12A01 51E HART Protocol Section 1 1 2 Communi cation line Requirement 5 1 5 1 1 Terminals for the External Wiring Remove the terminal cover on the opposite side of the display to gain access to the external wiring terminals DI 1 2 C DO1 DO2 0000000000 20000000 O Figure 5 1 Terminals for External Wiring 5 1 2 Wiring Make the following wiring for the equipment It requires a maxi
102. e Set range Units Periods over which average F11 1 to 255 Hours values are calculated Periods over which maximum F12 1 to 255 Hours and minimum values are monitored T8 15E EPS When the analyzer is delivered or if data are initialized periods over which average values are calculated are set to one hour and periods over which maximum and mini mum values are monitored are set to 24 hours 8 63 Setting Measurement Gas Temperature and Pressure The analyzer calculates the moisture content contained in exhaust gases and saturated water vapors from the entered gas temperature and pressure to obtain the relative humidity and dew point Enter the exhaust gas temperature and pressure absolute pressure necessary for the calculation see Section 10 1 later in this manual A CAUTION 8 6 3 1 Setting Procedure 8 6 3 2 Default Values IM 11M12A01 05E The critical temperature of the saturated water vapor pressure is 374 C If a gas tempera ture exceeding 370 C is entered no correct calculation will be obtained To set the gas temperature and pressure follow the parameter code table for fuel setting If you set a value exceeding the setting ranges an error ERR will result Table 8 15 Fuel Setting Default Value Exhaust gas temperature 0 to 3000 Exhaust gas pressure 0 to 300 E kPa abs T8 6 3 1 1 EPS When the analyzer is delivered or data are initialized the parameters are by default as
103. e 30 to 70 C then battery life is typically 1 year 12 8 IM 11M12A01 05E 12 Troubleshooting 12 3 Countermeasures When the 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 Higher Than True Value lt Causes and Countermeasures gt 1 The measuring gas pressure becomes higher When the process gas pressure is higher than that in calibration by Ap kPa the measured oxygen concentration value X vol O may be expressed mathematically by X Y 1 Ap 101 30 where Y Measured oxygen concentration value at the same pressure as in calibration vol O If an increment of the measured value by a pressure change cannot be neglected appropriate measures must be taken Observe the following points for possible improve ment in each process e Can the facility s characteristics be improved so that a pressure change does not occur e Can a calibration be conducted
104. e internal electrical circuit in the converter IM 11M12A01 05E T12 1E EPS 12 1 12 12 Measures to Take When an Error Occurs 12 1 2 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 O The following are considered to be the causes for the cell voltage falling below 50 mV 1 Continuity failure between the sensor assembly electrode and the contact 2 Damage or deterioration of the sensor assembly 3 Improper connection between the sensor and the electronics 4 Wiring failure inside the detector 5 Abnormality in the converter electronics lt Locating cause the failure and countermeasures gt 1 Turn off the power to the equipment 2 Remove the sensor assembly from the probe Check for dirty or corroded sensor parts including electrode and contact 3 If the contact part is normal the sensor assembly may be damaged or deteriorated Replace the sensor assembly In this case be sure to replace the metal O ring and contact 4 If Error 1 still occurs check that the sensor and the electronics are properly con nected 5 Remove the probe to gain access to the two connectors four connectors for the optional automatic calibration unit as indicated in Figure 12 2 Check these connectors are properly connected 6 If Error 1 still occurs the electronics may be defective Contact your local Yokogawa service or sale
105. e the timing for flowing span gas air is included in the manual calibration flowchart described in Section 7 102 earlier in this manual For operation of the converter see Section 7 10 2 1 When the OPEN and the measured oxygen concentration are alternately dis played during calibration plug the power cord into the power supply socket to start the pump of the standard gas unit 2 Next adjust the flow rate to 600 60 ml min using the span gas valve AIR the flow check ball stops floating on the green line when the valve is slowly opened To rotate the valve shaft loosen the lock nut and turn it using a flat blade screwdriver Turning the valve shaft counterclockwise increases the flow rate 3 After adjusting the flow rate tighten the valve lock nut 4 After the measured oxygen concentration is stabilized touch the ENT key then all the digits flash Touch the ENT key again to display ZERO Y Disconnect the power cord to stop the pump lt Flow of zero gas gt Touch the ENT key to display a zero gas value set with the parameter code B01 Touch the ENT key again to flash OPEN and the measured oxygen concentration alternately To cause the zero gas flow follow these steps 1 Use the needle of the zero gas valve CHECK GAS to puncture a hole in the gas cylinder installed as described in Section 10 5 2 Fully clockwise turn the valve regulator by hand 2 Next adjust the flow r
106. e been properly made or not Touch the gt key together with the ENT key to return to the basic panel display T7 11E EPS The symbol 1 indicates that the corresponding keys are being touched and the light characters indicate flashing IM 11M12A01 05E 7 19 7 10 Calibration The converter is calibrated in such a way that the actual zero and span gases are mea sured and those measured values are used to agree with the oxygen concentrations in the respective gases There are three types of calibration procedures available 1 Manual calibration conducting zero and span calibrations or either of these calibra tions in turn 2 Semi automatic calibration which uses the infrared switches or a contact input signal and conducts calibration operations based on a preset calibration time and stable time 3 Automatic calibration conducted at preset intervals Manual calibration needs the ZA8F Flow Setting Unit to allow manual supply of the calibration gases Semi automatic and automatic calibrations need the 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 later in this manual 7 10 1 Calibration Setup 7 20 Set the following three items before carrying out a calibration Parameter codes for these set items are li
107. e force IM 11M12A01 05E 9 1 Cell output mV 50 74 log PX 20 6 E Water vapor Air Zirconia element 100 100 ESS SSI I NS NS ST A Com par ison Sample gas pa AE CG water vapor 79 100 concentration indicator A 21 LG Et Sample gas composition ASSIS I LLYN IS S SN A V Electrode F9 1 EPS Figure 9 1 Schematic Diagram of Measurement Principle B For the mixing ratio measurement Assuming that the mixing ratio is r kg kg then r can be calculated from the value of H O vol as follows r 0 622 X x 100 x Equation 4 From the above equations 1 2 and 4 we obtain E K log y a K log 0 622 X 21 0 622 r 21 K log 0 622 0 622 r Equation 5 where K Constant With Equation 5 we can obtain the mixing ratio r kg kg from the electromotive force Oxygen concentration vs cell output 120 r N CIE SE AS EEE SE RE EEE EE EL STE DORE DE DER D EN 100 EE DE D DS D Tunnen PRE ee US EN EE EE KT D DE EN EE om aoe g0 bee Cr T1 EEE RE DE VER D RENE es DES ARE ee ee EE EE ee DE DRE CE RUE GR i DRE HN es PE 60 EE LEE FE 1 1 SET pr SE 4 a ee ed Oo EEK RE VE pS RENE E LEE RE RE DRE ER RE E EN 20 RE ee a ee ns O ee RE ee PRE DRE MN DE D RM UNE FE EE a Lt ET SS ee fo LR PRE LE E See roa ese cd aioe a 0 LL EL E aioe eet ert E 0 1 1 10 100 Oxygen concentration PX 02 FAE EPS IM 11M12A01 05E Humidity
108. e of 5500 or less Analyzer Receiver Shielded cables yor F5 4E EPS Figure 5 4 Wiring for Analog Output 5 2 1 Cable Specifications Use a 2 core shielded cable for wiring 5 22 Wiring Procedure 1 M4 screws are used for the terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections Ensure that the cable shield is connected to the FG terminal of the equipment 2 Be sure to connect and polarities correctly A CAUTION 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 After screwing the cover on the equipment body secure it with the lock screw 5 4 IM 11M12A01 05E 5 Wiring 5 3 Wiring Power and Ground Terminals Wiring for supplying power to the analyzer and grounding the equipment Ground DI 1 2 C DO1 DO2 0000000000 Grounding to the ground terminal on the equipment case Equipment case Crimp contact of the grounding line Jumper plate Lock washer Grounding terminal 100 240 V AC 50 60 Hz F5 5E EPS Figure 5 5 Power and Grounding Wiring 5 3 1 Wiring for Power Line Connect the power wiring to the L and N terminals of the equipment For a three core cable ground one core appropriately Proceed
109. e that the cell mounting screws four at the probe tip are not loose 2 Where the detector is mounted horizontally the calibration gas inlet and the refer ence gas inlet should face downward 3 1 4 Installation of ZH21B Dust Protector 1 Place the gasket between the flanges and mount the dust 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 calibration gas inlet and the reference gas inlet face downward Unit mm FERRER PORK KKK OI LISIS RR SKK KK KRY SSS SIRI A Va Reference gas inlet Calibration gas inlet F3 1 4 1 EPS Figure 3 2 Detector with Dust Protector IM 11M12A01 05E 3 3 3 2 Installation of ZASF Flow Setting Unit 3 2 1 Location The following should be taken into consideration 1 Easy access to the unit for checking and maintenance work 2 Near to the analyzer for operating keys on the panel 3 No corrosive gas 4 An ambient temperature of not more than 55 C and little changes of temperature 5 No vibration 6 Little exposure to rays of the sun or rain 3 2 2 Mounting of ZA8F Flow Setting Unit The flow setting unit can be mounted either on a pipe nominal JIS 50 A or on a wall It should be positioned vertically so that the flow meter works correctly lt Pipe Mounting gt 1 Prepare a vertical pipe of sufficient strength nominal JIS 50
110. eins een ea Vertical mounting set et ester ee eeee Always A 1 Ask Yokogawa service station for additional mounting of ZR20H to the preinstalled ZR202G 2 Select the appropriate reference air of ZR20H according to the one of ZR202G T22E EPS IM 11M12A01 05E 2 13 External Dimensions 1 For Horizontal Mounting A Unit mm 4 WN alt 242 257 a So p 80 odo P K H V H 40 40 66 5 44 MAX 56 166 5 Zero gas inlet Rc1 4 or 1 4NPT Female Span gas inlet et or ANP Tiremele Rei or 1ANPT Female 2 Vertical Mounting B AUTO CAL UNIT T SPANIN REFIN ZEROIN Na 0 z lt 40 66 5 SS 44 wash 180 166 5 Zero gas inlet Rc1 4 or 1 4NPT Female Reference gas inlet Rc1 4 or 1 4NPT Female Span gas inlet Rc1 4 or 1 4NPT Female ZR20H E eps ZR202G body Calibration gas Span gas Reference gas solenoid valve Span gas flowmeter Check valve Reference gas flowmeter a SPAN IN V l Zero gas solenoid valve To Air set REF IN To Zero gas cylinder j Needle valve ZERO IN
111. elected Input output isolation Output damping 0 to 255 seconds Hold non hold selection preset value setting possible with hold Contact Output Two points contact capacity 30V DC 3A 250V AC 3A resistive load Normally energized or normally de energized can be selected Delayed functions 0 to 255 seconds and hysteresis function 0 to 9 9 vol O can be added to high low alarms The following functions are programmable for contact outputs IM 11M12A01 05E IM 11M12A01 05E 2 Specifications 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 Flameout gas detection answerback of contact input Contact Input Two points voltage free contacts The following functions are programmable for contact inputs 1 Calibration gas pressure decrease alarm 2 Range switching switched range is fixed 3 External calibration start 4 Process alarm if this signal is received the heater power turns off Contact capacity Off leakage current 3 mA or less Self diagnosis Abnormal cell abnormal cell temperature low high abnormal calibration A D converter abnormal digital circuit abnormal Calibration Method zero span calibration Calibration mode automatic semi automatic and manual All are operated using optical switches Either
112. elects the type of equipment and sets the parameters for computation Group G setup Performs the current loop or contact checks T7 2E EPS 7 5 7 43 Entering Parameter Code Selection Display This section briefly describes the password entry procedure for entering the parameter code selection display The password is 1102 it cannot be changed to a different password Switch operation Display Description A o Warm up is complete and the basic panel is now displayed 21 0 Continuously touch the ENT key for at least three seconds PASSno to display PASSno 0000 Touch the ENT key again This allows you to change the leftmost digit that is flashing 1 000 Set the password 1102 If you touch the key the digit that is flashing will be 1 1 000 Touch the gt key to move the position of the digit that is flashing to the right one digit 1 1 00 Touch the key to change the numeric value to 1 1 1 00 Touch the gt key again to move the position of the digit that is flashing to the right one more digit Continuously touch the gt key and the position of the digit that is flashing will move continuously to the right 1 1 Q2 Touch the key to change the numeric value to 2 Continuously touch gt key and the numeric value increases continuously If you touch the ENT key all the digits flash Touch the ENT key again to display A01 on the parameter code se
113. ell 5 6BG3 3 2 9 Finish Polyurethane corrosion resistance coating Weight Insertion length of 0 4 m approx 8 kg JIS 5K 65 approx 13 kg ANSI 150 4 Insertion length of 1 0 m approx 10 kg JIS 5K 65 approx 15 kg ANSI 150 4 Insertion length of 1 5 m approx 12 kg JIS 5K 65 approx 17 kg ANSI 150 4 Insertion length of 2 0 m approx 14 kg JIS 5K 65 approx 19 kg ANSI 150 4 Insertion length of 3 0 m approx 17 kg JIS 5K 65 approx 22 kg ANSI 150 4 Display Function Displays values of the measured oxygen concentration moisture quantity mixture ratio etc Alarm Error Display Displays alarms such as AL 06 or errors such as Err 01 when any such status occurs Calibration Functions Autocalibration Requires the Autocalibration Unit It calibrates automatically at specified intervals Semi auto Calibration Requires the Autocalibration Unit Input calibration started by optical switch or contact then it calibrates automatically afterwards Manual Calibration Calibration by interactively opening closing the valve of calibration gas during operation with optical switch Maintenance Functions Can set new data settings during daily operation and at inspection maintenance time Display data settings calibration data settings test settings current output loop check input output contact check Setup Functions 2 3 2 4 Initial settings should be set to match the plant conditions when in
114. en a check valve is used maximum pressure rating is 300 kPa G pressure at inlet of the auto calibretion unit Air Consumption Approx 1 5 1 min Weight Approx 2 3 kg Calibration gas zero gas span gas flow 0 7 l min at calibration time only AN Note Use instrument air for span calibration gas if no instrument air is available contact YOKOGAWA Model and Codes Suffix code Option code Description ZASE se Standard gas unit S Rc 1 4 Joint FR oe ee With 1 4 NPT adapter Style code GS eee Ler Style B T2 5E EPS IM 11M12A01 05E 2 11 External Dimensions Unit mm 6 hole 180 Reference air outlet Zero gas outlet Span gas inlet Zero gas inlet l 4 Rc1 4 or 4 NPT F Instrument air inlet A HECK REF UT OUT Flow Flow meter meter ZERO span 4 GAS IN GASIN LN Instrument air PA 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 kPaG F2 6E EPS 2 12 IM 11M12A01 05E 2 Specifications 2 2 2 ZR20H Automatic Calibration Unit This automatic calibration unit is applied to supply specified flow of reference gas and calibration gas during automatic calibration to the detector in a system configuration System 3 e Specifications Equipped with the analyzer when automatic calibration is specifie
115. en lower than the hysteresis set value that measurement exceeds the hysteresis set value before the preset delayed time has elapsed So the alarm is not canceled 4 The measured D has fallen below the hysteresis set value and the preset delayed time during measurement has elapsed so the alarm is canceled IM 11M12A01 05E 8 Detailed Data Setting 8 3 3 Alarm Setting Procedure Set the alarm setpoints following Table 8 6 listing parameter codes Table 8 6 Alarm Parameter Codes Oxygen concentration high high alarm setpoint 0 100 O2 Oxygen concentration high alarm setpoint 0 100 O2 Oxygen concentration low alarm setpoint 0 100 O2 Oxygen concentration low low alarm setpoint 0 100 O2 Humidity high high alarm setpoint 0 100 H20 Humidity high alarm setpoint 0 100 H20 Humidity low alarm setpoint 0 100 H20 Humidity low low alarm setpoint 0 100 H20 Mixing ratio high high alarm setpoint 0 1 kg kg Mixing ratio high alarm setpoint 0 1 kg kg Mixing ratio low alarm setpoint 0 1 kg kg Mixing ratio low low alarm setpoint 0 1 kg kg Oxygen concentration alarm hysteresis 0 9 9 O2 Humidity hysteresis 0 9 9 H20 Mixing ratio hysteresis 0 0 1 kg kg Delay alarm action 0 255 seconds Oxygen concentration high high alarm detection 0 Not detected Detected Not detected Detected Not detected Detected Not detected Detected Not detected Detected Not detected Detected Not detected Detec
116. enoid valve remains closed Touch the A key to enter 1 Touch the key The flashing continues Touch the ENT key again to stop the flashing and the solenoid valve will be open to let the calibration gas flow G 1 5 Touch the ENT key once again to switch to the parameter code selection display The solenoid valve will then be closed Basic Touch the gt key together with the ENT key to return to the panel basic panel display display This is not required if you proceed to make another setting The displayed numeric characters indicate the measurement gas concentration T7 10E EPS The symbol S5 indicates that the corresponding keys are being touched and the light characters indicate flashing 7 18 IM 11M12A01 05E 7 9 3 Checking Input Contacts 7 Startup Follow Table 7 11 to check the input contacts The table uses an example with input contact 1 Table 7 11 Checking Input Contacts Switch operation Display Description gt A A01 Display after the password has been entered G01 Touch the A key to switch to Group G G01 Touch the gt key to move the position of the digit that is flashing to the right one digit Touch the A key to enter 2 Touch the ENT key 0 is displayed with the contact open If the contact is closed the display will be 1 one This enables you to check whether or not the wiring connections hav
117. ensor 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 the 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 When replacing the assembly be careful not to allow any flaws on 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 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 tightened it can no longer be used So be sure to replace it 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 Groove in which the contact E7042BS
118. es above are not used in the High temperature Humidity analyzer T10 1 EPS IM 11M12A01 05E 10 Other Functions 10 1 1 Oxygen Concentration 10 1 2 Humidity The oxygen concentration in the process gas is displayed consult Section 9 1 1 earlier in this manual The moisture content contained in air is displayed where the process gas contains water vapors and air refer to Section 9 1 1 earlier in this manual 10 13 Mixing Ratio Where the process gas contains water vapors and air their mixing ratio is displayed refer to Section 9 1 1 earlier in this manual 10 14 Relative Humidity 10 1 5 Dew Point IM 11M12A01 05E The relative humidity U may be obtained using the following theoretical equation JIS Z 8806 U X100 where Water vapor pressure of moist air amp Saturated water vapor Since the gas pressure ratio is equal to the volume ratio the above equation may be expressed mathematically by U P XH X100 where P Gas pressure H Humidity volume ratio The saturated water vapor pressure es is determined by a gas temperature so the relative humidity can be obtained by entering the parameters Use parameter F13 for temperature entry Use parameter F14 for pressure entry The dew point is the temperature at which a water vapor pressure in the moist air is equal to the saturated water vapor pressure The water vapor pressure in the moist air can be obtained from the gas pressure and vo
119. escription 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 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 Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and other natural changes IM 1M12A01 05E vii 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
120. ess varies Specify the probe ZR202G 040 ZR202G 040 External Dimensions ANSI flange 2 10 i Insertion hole 80 minimum Ross Style B T2 1 8 1 EPS K in case of 1 C in case of 2 Unit mm 428 SES Re S55 S229090 SOK KKK RS eee sean DRE SOOO RK KKM HK RY RSR ese SERA 7 C LOS F2 1 3 1 EPS LA Insertion hole Ray 80 minimum JIS flange Flange A B C t D JIS 5K 80 FF SUS304 180 145 4 19 12 40 ANSI Class 150 4B FFSUS304 228 5 190 5 8 219 12 50 IM 11M12A01 05E 2 Specifications 2 2 ZASF Flow Setting Unit and ZR20H Automatic Cali bration Unit 2 2 1 ZASF Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration System 2 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 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 plus approx 50 kPa G or measured gas pressure plus approx 150 kPa G wh
121. fault Setting Calibration mode Manual Calibration procedure Span zero Zero gas oxygen concentration 1 00 Span gas oxygen concentration 21 00 Output hold stabilization time 10 minutes 00 seconds Calibration time 10 minutes 00 seconds Calibration interval 30 days 00 hours Start day and time 9 8 00 YY 01 MM 01 DD 00 00 T9 2 EPS IM 11M12A01 05E 9 Calibration 9 2 2 Calibration 9 2 2 1 Manual Calibration For manual calibration consult Section 7 10 Calibration earlier in this manual 9 2 2 2 Semi automatic Calibration 1 Calibration startup using infrared switches Table 9 3 Semi automatic Calibration Procedure Switch operation Display Brief description gt A ENT b1 1 Change the parameter code to B11 Previous operations omitted gt A SA CAL Touch the ENT key to display SA CAL Semi Auto CAL ENT gt A ENT S PAn Touch the ENT key again to open the span gas solenoid valve pe The span gas then flows SPAN and the currently measured value are alternately 20 84 displayed If the output hold is set the output hold will start at this time gt A ENT Z Ero When the set calibration time elapses the span gas solenoid valve closes automatically 0 89 the zero gas solenoid valve opens and the zero gas flows ZERO and the currently measured value are displayed alternately gt A ENT CAL E nd End when the
122. flow out after these procedures To discharge the gases it is necessary for the needle in the zero gas valves to puncture a hole in the gas cylinder see Section 10 5 3 10 53 Calibration Gas Flow 10 20 lt Preparation before calibration gt 1 To operate the standard gas unit place it on a nearly horizontal surface in order to allow the flow check to indicate the precise flow rate In addition a power supply for driving the span gas air supply pump is required near the unit the length of the power cord attached to the unit is 2 m Select a suitable location for the unit near the installation site of the converter 2 Connect the tube connector port of the standard gas unit to the calibration gas inlet of the detector using a polyethylene resin tube with an outside diameter of 6 mm Be careful to prevent gas leakage 3 Fully open the needle valve mounted on the calibration gas inlet of the detector 4 Enter the oxygen concentration of the sealed gas noted from the cylinder into the converter Also check that the oxygen concentration of the span gas is correctly set 21 vol O for clean air When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a hand held oxygen analyzer to measure the actual oxygen concentration and then enter it IM 11M12A01 05E 10 Other Functions lt Flow of span gas air gt The standard gas unit is used only when manual calibration is employed Therefor
123. from the theoretical value at each oxygen concentration Confirm the theoretical values of the cell voltage in Table 12 3 Although it cannot be generally specified as to what extent the difference from the theoretical value is allowed consider it to be approxi mately 10 mV Table 12 3 Oxygen Concentration and Cell Voltage Oxygen concentration Oxygen concentration O2 Cell voltage mV 1 67 1 21 0 T12 8 EPS 4 Confirm whether deterioration of or damage to the sensor assembly that caused the alarm has occurred abruptly during the current calibration in the following procedure Check the history of the span gas ratio with the parameter codes A50 and A51 Check the history of the zero gas ratio with the parameter codes A60 through A69 The larger the parameter code number the older the displayed data Changes in deterioration of the sensor can be seen 5 If deterioration of the sensor assembly has occurred abruptly it may show that the check valve which prevents moisture in the furnace from getting into the calibration gas tubing has failed If the gas in the furnace gets into the calibration gas tubing it condenses and remains in the gas tubing The sensor assembly is considered to be broken for the reason that the condensation is blown into the sensor assembly by the calibration gas during calibration and so the cell cools quickly 6 If the sensor assembly has been gradually deteriorating check the sensor assem
124. gas outlet Flange Flange ii Ss N PIPING A Fi 156 3 Stop Valve 256 4 49 Model Cod PIPING EERE Specification ZR202G 040 0 JIS 5K 65 FF SUS304 ZR202G 300 F3 24E EPS IM 11M12A01 05E 3 13 8 JIS 10K 65 FF ZR202G LJ L P Flange JIS 10K 65 FF SUS304 L 342 4 Rc1 4 or 1 4NPT Reference air inlet F 1 R ali A i G I Flange PIPING A 2 G1 2 2 1 2NPT etc 156 3 Stop Cable connection port 256 4 Valve 49 Rc1 4 or 1 4NPT Calibration gas inlet flA 33 cn Reference gas outlet Model Code PIPING Weight Specification kg Approx _ 9 JIS 10K 65 FF SUS304 ZR202G 300 F3 25E EPS 9 JIS 10K 80 FF ZR202G LI M P Flange JIS 10K 80 FF SUS304 L 342 4 Re1 4 or 1 4NPT Reference air inlet C ta ll ath ERE 10 Al ES f OO Reference gas outlet PIPING t H B E mi Flange PIPING A J
125. h temperature Humidity Analyzer 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 used to mount the detector Selectable from JIS or ANSI ee standard models N a this part is inserted in the process Select length from 0 4 0 7 1 0 1 5 2 0 2 5 or 3 0 m Calibration gas Cena opening Metal O ring Pipe support U shaped pipe Bolt Loc CN LAMY Lo e gI N Washer or plain washer Figure 6 1 Integrated type High temperature Humidity Analyzer IM 11M12A01 05E 6 1 6 2 ZASF Flow Setting Unit and ZR20H Automatic Cali bration Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve s ZID D Ba ee ces Flowmeter for calibration gas lt F6 2E EPS Flowmeter for reference gas Figure 6 2 ZASF Flow Setting Unit Flowmeter for Flowmeter for Flowmeter for i Span gas Reference gas Zero gas Horizontal Vertical mounting mounting Q LA Span gas flow Reference gas flow Zero gas flow setting valve setting valve setting valve F6 3E EPS Figure 63 ZR20H Automatic Calibration Unit 6 2
126. he ambient tempera ture does not exceed 40 C Otherwise the gas cylinder may explode Store the spare gas cylinders under the same condition 10 22 IM 11M12A01 05E 10 Other Functions 10 6 Methods of Operating Valves in the ZASF Flow Setting Unit The ZA8F Flow Setting Unit is used as the calibration equipment for a system conform ing to System 2 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 ZR20H Auto Calibration Unit 10 61 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 measurement gas pressure plus approx 50 kPa or measured gas pressure plus approx 150 kPa when acheck 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 for the converter 10 62 Operating the Span Gas Flow Setting Valve IM 11M12A01 05E The following description is given assuming that instrument air the same as the refer ence gas is used as the span gas For more details see Section 7 10 2 M
127. he calibration time will be up Figure 8 1 shows the definition of under calibration in the manual calibration IM 11M12A01 05E IM 11M12A01 05E 8 Detailed Data Setting Switch operations Display A ENT b 1 0 m m 8 m 21 00 m OPEn 20 84 v Output hold time during calibration OPEn 0 89 m Z b10 Measured value display ways F8 1E EPS Figure 8 1 Definition of during calibration During semi automatic calibration under calibration is the time starting when a calibration instruction is executed with an infrared switch or a contact input to make a series of calibrations until the preset output stabilization time elapses During automatic calibration under calibration is the time starting when automatic calibration is carried out at the calibration start time until the preset output stabilization time elapses 4 Error appears when Error 1 to Error 4 are being issued 8 22 Preference Order of Output Hold Values The output hold value takes the following preference order Preference order high During error occurrence During calibration During maintenance During warm up 8 2 2E siki For example if the output current is set to 4 mA for under maintenance and no output hold output for during calibration is preset the output is held at 4 mA during the under maintenance
128. he parameter selection display 2 Used to enter data 3 Advances the operation T7 1E EPS The three infrared switches are activated by completely touching the glass surface of the switch To touch any of the keys continuously first touch the surface and then com pletely remove your finger from the surface Then touch it again Infrared switches consist of two elements an infrared emitting element and an infrared receive element Infrared light waves from the element bounce on the operator s finger and are reflected back to the receive element thereby causing the infrared switch to turn on and off depending on the strength of the reflected light waves From these operating principles carefully observe the following IM 11M12A01 05E 7 3 7 4 A CAUTION 1 Be sure to put the equipment case cover back on If this is not done the infrared switch will not reflect the infrared light waves and a dSPErr error will be issued 2 Before placing the equipment in operation be sure to wipe off any moisture or dust on the glass surface if it is wet or dirty Also make sure your fingers are clean and dry before touching the glass surface of the switch 3 If the infrared switches are exposed to direct sunlight they may not operate correctly In such a case change position of the display or install a sun cover IM 11M12A01 05E 7 Startup 742 Display Configuration IM 11M12A01 05E The parameter c
129. hing to the right 030 Touch the A key to enter the number 3 E If you touch the ENT key all the digits flash Touch the ENT key again to stop flashing Touch the ENT key to return to the parameter code selection display Set the humidity reading at 20 mA Touch the gt key to move the position of the digit that is flashing to the right Touch the key to change the number 3 in C13 to 4 Touch the ENT key to display the current set value Touch the gt key to move the position of the digit that is flashing to the right Touch the A key to change the number 2 in C25 to 8 Touch the gt key to move the position of the digit that is flashing to the right Touch the key to change the number 5 in C85 to 0 The number changes from 5 to 6 to 9 to 0 If you touch the ENT key all the digits flash Touch the ENT key again to stop flashing 14 If you touch the ENT key again the parameter code selection display will appear Basic Touch the gt key together with the ENT key to return to the panel basic panel display This is not required if you proceed to display make another setting The displayed numeric characters indicate the humidity of the measurement gas The symbol S5 indicates that the corresponding keys are being touched and the light characters indicate flashing T7701 EPS 7 14 IM 1
130. his 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 cell s robustness is found except for the response time Table 10 3 Cell Robustness and Service Life Cell robustness Cells service life One year min Six months min Three months min One month max T10 3 EPS 10 1 16 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 17 Oxygen Concentration with time constant Humidity with time constant and Mixing Ratio with time constant When the output damping is specified in the mA output range setting the corresponding time constant is also displayed 10 1 18 Maximum Oxygen Concentration Humidity and Mixing Ratio The maximum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed If the setup period elapses the maxi mum 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 19 Minimum Ox
131. imp on terminals appropriate for M4 terminal screws for cable connections 2 The contact output relays are rated 30 V DC 3 A 250 V AC 3 A Connect a load e g pilot lamp and annunciator within these limits IM 11M12A01 05E 5 Wiring 5 5 Wiring for Contact Input The converter can execute specified function when receiving contact signals To use these contact signals proceed wiring as follows Converter Terminal box DI 1 o A D 2 o Contact input 1 Contact input 2 DI C AG o F5 7E EPS Figure 5 14 Contact Input Wiring 5 5 1 Cable Specifications Use a 2 wire or 3 wire cable for this wiring Depending on the number of input s determine which cable to use 5 5 2 Wiring Procedure 1 M4 screws are used for the terminals of the converter Each wire in the cable should be terminated in the corresponding crimp on terminal 2 The ON OFF level of this contact input is identified by the resistance Connect a contact input that satisfies the descriptions in Table 5 2 Table 5 2 Identification of Contact Input ON OFF Closed Open Resistance 200 Q or less 100 kQ or more T5 2E EPS IM 11M12A01 05E 5 7 6 Components 6 Components This chapter describes the names and functions of components for the major equipment of the EXAxt ZR Integrated type Zirconia High temperature Humidity Analyzer 6 1 ZR202G High temperature Humidity Analyzer 6 1 1 Integrated type Hig
132. ing example 2 If the setting for a 4 mA current is 26 H O you must set the maximum 20 mA point at more than 44 H O 26 X 0 8 23 H O Numbers after the decimal point are rounded up Ranges over which oxygen concentrations can be set Outside ranges Maximum humidity for a 20 mA current H20 5 15 25 35 45 55 65 75 Minimum humidity for a 4 mA current H2O F8 1 1 2 EPS Figure B Max and Min Humidity Set Ranges IM 11M12A01 05E 8 3 Mix ratio setting range The minimum mix ratio is set to 0 kg kg or ranges from 0 201 to 0 625 kg kg The maximum mix ratio setting ranges from 0 2 to 1 0 kg kg and must be greater than 1 3 times plus 0 187 the mix ratio set for the minimum Setting example 1 If the setting for a 4 mA current is 0 kg kg you must set the maximum 20 mA point at more than 0 2 kg kg Setting example 2 If the setting for a 4 mA current is 0 201 kg kg you must set the maximum 20 mA point at more than 0 449 kg kg 0 201 X 1 3 0 187 kg kg Numbers after the decimal point are rounded up Ranges over which oxygen concentrations can be set Maximum mixing ratio kg kg at 20 mA Minimum mixing ratio kg kg at 4 mA Figure C
133. ion 1 K9472UF 1 Hood CMPL 11M12A01 05E All Rights Reserved Copyright 2000 Yokogawa Electric Corporation 5 th Edition Jul 2005 YK Customer Model ZR20H Maintenance Integrated type Zirconia Oxygen Analyzer Parts List High Temperature Humidity Analyzer Automatic Calibration Unit ay SPAS rh OC O SPAN IN REF IN ZERO IN SN AY LG Dy WOT te fai SZ Item Part No Qty Description 8 K9473XC 1 Flowmeter YOKOGAWA All Rights Reserved Copyright 2001 Yokogawa Electric Corporation CMPL 11M12A01 12E 1st Edition Feb 2001 YK Yokogawa Electric Corporation 2nd Edition Aug 2001 YK Customer Model ZO21S Maintenance Zirconia Oxygen Analyzer High Temperature Parts List Humidity Analyzer Standard Gas Unit 1 2 Ay ltem Part No Qty Description 1 1 Pump see Table 1 2 E7050BA 1 Zero Gas Cylinder x6 pcs 3 E7050BJ 1 Needle Valve Table 1 Power Pump AC 100V 110 E7050AU 115 AC 200V 220 E7050AV 240 YOKOGAWA meme CMPLIMSDIOE Yokogawa Electric Corporation Revision Record Manual Title Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Manual Number IM 11M12A01 05E Edition Date Remark s Ist 2nd
134. ion and Maintenance Metal O ring Sensor U shaped pipe support Bolts four pots Cy S o VA Filter U shaped pipe pS four 1 8 turn tighten bolts 1 8 turn approximately 45 each F11 3E EPS Figure 11 3 Exploded View of Sensor Assembly 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 11 13 Replacement of the Heater Unit 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 detail 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 IM 11M12A01 05E 11 5 Figure 11 4 Exploded View of Detector IM 11M12A01 05E 11 6 11 Inspection and Maintenance Replacement of heater strut assembly Refer to Figure 11 4 as an aid in the following discussion Remove the cell assembl
135. iption Non CE Mark 24 3 Air Set Changed part numbers and drawing of air set 4 2 1 Piping Parts for System 2 Change part numbers of air set in Table 4 2 Edition 6th Date Sep 2006 Remark s Revised Section 24 3 24 5 44 53 5 32 TAS 79 2 8 2 2 8 2 3 8 24 84 1 84 2 9 2 2 2 10 4 12 2 1 12 2 2 2 12 2 2 3 Air Set Part No K9473XH or K9473XJ Standard Specification Changed descriptions partly Air Set Part No G7004XF or K9473XG Standard Specification Changed descriptions partly Cylinder Regulator Valve Part No G7013XF or G7014XF Standard Specifications Changed descriptions partly and drawing Piping for the Detector with Pressure Compensation Deleted Section Wiring Power and Ground Terminals Added description in Figure 5 5 Wiring for Ground Terminals Added item 4 Changing Set Values Changed description in table 1 Checking calibration Contact Output Changed description in table 7 10 Preference Order of Output Hold Value Deleted or blow back Output Hold Setting Table 8 4 Parameter code C06 maintenance should read calibration Default Values Revised Table 8 5 Output Contact Made some corrections Setting Output Contact Revised Table 8 9 WARNING Deleted second warning Semi automatic Calibration Table 9 3 Added note Table 10 6 Contact related Items in Group E Deleted some codes What
136. isfy a zero gas ratio of 100 30 or a span gas ratio of 0 18 In addition the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement If the sensor becomes no longer operable for example due to breakage investigate the cause and remedy the problem as much as possible to prevent recurrence FUN CAUTION e 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 e 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 minimized e 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 the s
137. isplay Description The set value is displayed after the parameter code selection An example of entering 9 8 is given below The currently set value is 0 0 Touch the gt key to move the position of the digit that is flashing to the digit to be changed Continuously touch the gt key and the position of the digit that is flashing will move continuously to the right Touch the key to set the numeric value 9 Continuously touch the key and the numeric value will change in sequence from 0 to to 2 to3 to 8 to 9 and back to 0 Touch the gt key to move the position of the digit that is flashing to the right Touch the key to set the numeric value 8 After the numeric value appears touch the ENT key If you touch the ENT key again the flashing stops and the current set value will be in effect 7 8 Touch the ENT key once again to return to the parameter code selection display T7 4 5 2E EPS IM 11M12A01 05E 7 Startup 3 If invalid numeric values are entered If an invalid numeric value beyond the input range specified is entered ERR will appear for two seconds after touching the ENT key ERR appears for two seconds and the display returns to the first set value Re enter the numeric value 17 4 5 3E EPS IM 11M12A01 05E 7 9 7 5 Confirmation of Equipment Type Setting This equipment can be used for both
138. ixing RaO ssh sine nn nent ir 10 3 10 1 4 Relative Humidity ss 10 3 10 15 Dew Point dre en er de hd de de an a i 10 3 101 0 Cell Temperature rise aeaa EE aaa AAO AEDE E RE AEA ERIP SETAE REIST 10 4 10 1 7 Process Gas Temperature sseesseessesesesessesesseeresteststtsrestssestnserrrsresese 10 4 10 1 8 Cold Junction Temperature LL 10 4 101 9 Cell Voltage ist inen nanas dis meet durant sd 10 4 10 1 10 Thermocouple Voltage 10 4 101 11 Cold Junction Voltage sicccssnsecte seve teases iene ERER 10 4 10 1 12 Current O tput ccc do mn A ee al a Ae 10 5 10 1 13 Response Times sesientdawiiiined ii E Geass aan 10 5 10 1 14 Internal Resistance of Cell ss 10 5 10 1 15 Robustness of a Cell ss 10 6 10 1 16 Heater On Time Ratio ss 10 6 10 1 17 Oxygen Concentration with time constant Humidity with time constant and Mixing Ratio with time constant 0 0 eeeesceeseceeecesteceeeeeneeenees 10 6 10 1 18 Maximum Oxygen Concentration Humidity and Mixing Ratio 10 6 10 1 19 Minimum Oxygen Concentration Humidity and Mixing Ratio 10 6 10 1 20 Average Oxygen Concentration and Mixing Ratio 10 7 10 1 21 Span gas and Zero gas Correction Ratios 0 0 eee eseseeseerseeseeneeens 10 7 10 1 22 History of Calibration Time ss 10 7 10 123 TUM 24 5 innii iia une A E R A N E AA 10 7 10 124 Software ReVision reine anne Rite 10 7 102 Operational Data Initialization oe eee ceeceeceneeeeceeeseeeeseeseeeaeeeeeeaees 10 8 103 Initializatio
139. l Check the valves in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in the fully closed state IM 11M12A01 05E 12 Troubleshooting 12 3 3 Measurements Sometimes Show Abnormal Values IM 11M12A01 05E lt Causes 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 other 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 There may be a crack in the sensor or leakage at the sensor mounting portion If the indication of the measured value 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 5 There may be leakage in the calibration gas tubing In the case of a negative process inner pressure if
140. l not be measured just as it will not be measured in manual calibration Five minutes maximum Response time mA 10 of analog output span Time Start calibration The response time is obtained after the corrected calibration curve has been found The response time is calculated starting at the point corresponding to 10 of the analog output up to the point at 90 of the analog output span That is this response time is a 10 to 90 response 100 Calibration complete F10 1E EPS Figure 10 1 Functional Drawing of Response Time 10 1 14 Internal Resistance of Cell A new cell sensor indicates its internal resistance of 200 Q maximum As the cell degrades so will the cell s internal resistance increase The degradation of the cell cannot be found only by changes in cell s internal resistance however Those changes in the cell s internal resistance will be a hint to knowing the sensor is degrading The updated values obtained during the calibration are displayed IM 11M12A01 05E 10 5 10 1 15 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 T
141. lculated by oxygen concentration measured in air which include water vapor Note Those values are calcurated by temperature and absolute pressure Then accurate tempera ture and pressure value must be input to the converter Repeatability See Note 1 1 vol H O sample gas pressure 2 kPa or less IM 11M12A01 05E 2 1 Linearity Excluding standard gas tolerance See Note 1 Use oxygen of known concentration in the measuring range as the zero and span calibration gas 2 vol H O Sample gas pressure within 0 49 kPa 3 vol H O Sample gas pressure 2 kPa or less Drift Excluding the first two weeks in use See Note 1 Both zero and span 3 vol H O month Response Time Response of 90 within 5 second Measured after gas is introduced from calibration gas inlet and analog output start changing Notel These tolerances do not apply to the pressure compensated version or where natural convection is used for the reference air 2 12 ZR202G Integrated type Zirconia High temperature Humidity Analyzer Can be operated in the field without opening the cover using optical switches Display 6 digit LCD Switch Three optical switches Output Signal 4 to 20 mA DC one point maximum load resistance 550 Q Digital Communication HART 250 to 550 Q depending on quantity of field devices connected to the loop multi drop mode Note HART is a registered trademark of the HART Communication Foundation Contact Output Signal
142. lection isplay T7 4 8E EPS The symbol S5 indicates that the key is being touched Light characters indicates that the digits are flashing A CAUTION e If no key is touched for at least 20 seconds during password entry the current display will automatically switch to the basic panel display e If no key is touched for at least 10 minutes during parameter code selection the current display will automatically switch to the basic panel display 7 6 IM 11M12A01 05E 7 Startup 744 Selecting Parameter Codes Table Parameter Code Selection Switch operation Display Description A ENT A01 Password has been entered and the parameter code selection display has appeared Character A is flashing indicating that character A can be changed A01 If you touch the gt key once the position of the digit that is flashing will move to the right This allows you to change 0 A 01 Touch the gt key again to move the position of the digit that is flashing to the right one m ore digit This enables you to change numeric character 1 Touch the gt key again to return the position of the digit that is flashing to A Continuously A01 touch the gt key and the position of the digit that is flashing will move continuously to the right b01 If you touch the A key once character A will change to B C01 Touch the A key once to change to C Continuously touch the gt key and the value of the digit th
143. lume ratio pressure ratio as given below e PXH where e Water vapor pressure in moist air P Gas pressure H Humidity volume ratio Use the above equation to find the water vapor in the moist air and use the theoretical equation JIS Z 8806 to obtain the temperature at which that water vapor is equal to the saturated water vapor pressure 10 3 10 1 6 10 1 7 10 1 8 10 1 9 Cell Temperature The cell temperature can be obtained from the thermoelectromotive force and cold junction temperature normally 750 C is displayed Process Gas Temperature A process gas temperature set with parameter code F13 is displayed Cold Junction Temperature This is the internal where the electronics is installed temperature of equipment which compensates for the cold junction temperature for a thermocouple measuring the cell temperature If this temperature exceeds 85 C the electronics may fail If the internal temperature exceeds this take countermeasures to reduce the temperature such as by not exposing the equipment to radiation Cell Voltage 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 oxyge
144. meter F4 11E EPS IM 11M12A01 05E 4 7 5 Wiring 5 Wiring 5 1 General In this Chapter the wiring necessary for connection to the EXAxtZR Integrated type Zirconia High temperature Humidity Analyzer is described A CAUTION Wiring procedure e Never supply current to the equipment or any other device constituting a power circuit in combination with the equipment until all wiring is completed e This product complies with CE marking Where compliance with CE marking is necessary the following wiring procedure is necessary 1 Install an external switch or circuit breaker to the power supply of the equipment 2 Use an external switch or circuit breaker rated 5A and conforming with IEC 947 1 or IEC 947 3 3 It is recommended that the external switch or circuit breaker be mounted in the same room as the equipment 4 The external switch or circuit breaker should be installed within the reach of the operator and marked as the power supply switch of this equipment Wiring should be made according to the following procedure 1 Be sure to connect the shield of the shielded line to FG terminal of the analyzer 2 The most outer sheath of the signal line and the power cable should be stripped off to the minimum necessary length 3 Signal may be affected by noise emission when the signal lines power cable and heater cable are located in the same conduit When using a conduit signal lines should be installed in a separate con
145. mum of four wiring connections as shown below 1 Analog output signal 2 Power and ground 3 Contact output 4 Contact input Contact output 1 ntact output 2 Contact input 1 p Contact outpu oO Contact input 2 TO DI 1 DI 2 DI C DO 1 DO 1 DO 2 DO 2 8 9 10 11 12 13 14 FG AO AO L N G FG O Analog output 100 to 240 V AC 4 20 mA DC 50 or 60 Hz Digital output The protective grounding for the analyzer shall be connected either the protective ground terminal in the equipment or the ground terminal on the case Standard regarding grounding Ground to earth ground resistance 100 or less F5 2E EPS Figure 5 2 Wiring Connection 5 2 IM 11M12A01 05E 5 Wiring 5 13 Mounting of Cable Gland For each wiring inlet connection of the equipment mount the conduit appropriate for the screw size or a cable gland Rc1 4 or 1 4NPT Reference air inlet to N Le Cable gland Rc1 4 or 1 4NPT cE Calibration gas inlet CI 4 G1 2 1 2 NPT or the like Wiring connection F5 3E EPS Figure 5 3 Cable Gland Mounting IM 11M12A01 05E 5 3 5 2 Wiring for Analog Output This wiring is for transmitting 4 to 20 mA DC output signals to a device e g recorder Maintain the load resistance including the wiring resistanc
146. n 2 4 to 21 6 mA 4mA Set value in abnormal state 2 4 to 21 6 T10 6C EPS IM 11M12A01 05E Alarm related Items in Group D Item Tuning Engineering unit 10 Other Functions Default setting Oxygen concentration high high alarm setpoint 0 to 100 O2 100 O2 Oxygen concentration high limit alarm setpoint 0 to 100 O2 100 O2 Oxygen concentration low limit alarm setpoint 0 to 100 O2 0 O2 Oxygen concentration low low alarm setpoint Humidity high high alarm setpoint 0 to 100 0 to 100 O2 0 O2 100 H20 Humidity high alarm setpoint 0 to 100 100 H20 Humidity low alarm setpoint Humidity low low alarm setpoint 0 to 100 0 to 100 H20 0 H20 0 H20 Mixing ratio high high alarm setpoint Oto 1 kg kg 1 kg kg Mixing ratio high alarm setpoint 0 to 1 kg kg 1 kg kg Mixing ratio low alarm setpoint Otol kg kg 0 kg kg Mixing ratio low low alarm setpoint Otol kg kg 0 kg kg Oxygen concentration alarm hysteresis 0 to 9 9 O2 0 1 O2 Humidity alarm hysteresis 0 to 9 9 H20 0 1 H20 Mixing ratio alarm hysteresis 0to0 1 kg kg 0 001 kg kg Delayed alarm action 0 to 255 Seconds 3 seconds Oxygen concentration high high alarm detection Oxygen concentration high limit alarm detection
147. n Procedure ss 10 9 104 Res ta ti iii ne En re rl eine tisane 10 10 10 5 Handling of the ZO21S Standard Gas Unit 10 18 10 5 1 Standard Gas Unit Component Identification 00 0 10 18 10 5 2 Installing Gas Cylinders prena ne aia tarr E A AAE 10 19 10 5 3 Calibration Gas Flow ss 10 20 10 6 Methods of Operating Valves in the ZA8F Flow Setting Unit 10 22 10 6 1 Preparation Before Calibration cece eeeesseeeneeeeeceeeeceeeeeeaeceaeeeneeeeas 10 23 10 6 2 Operating the Span Gas Flow Setting Valve ou ee ceeeeeseceneeeeeeeeee 10 23 10 6 3 Operating the Zero Gas Flow Setting Valve 10 24 10 6 4 Operation After Calibration ss 10 24 IM 1M12A01 05E 11 Inspection and Maintenance sscccssscsssssscssssssssssessesscssessesssscssssscsssesscsscsceees 1 1 1 11 1 Inspection and Maintenance of the Detector o oo eee eeeeeeeeeeeeneeeeees 11 2 11 1 1 Cleaning the Calibration Gas Tube oo eee eeeeseeseecreessetseenaeens 11 2 11 1 2 Replacing the Sensor Assembly 0 0 eee ee eeeeseeeeeeeeseeeneeseesseaeens 11 3 11 1 3 Replacement of the Heater Unit 20 0 cseeseececneeeseensenaeens 11 5 11 1 4 Replacement of O ring ss 11 7 11 1 5 Stopping and Re starting Operation 20 0 eee eee cseeseeeecnseeseenaeens 11 8 11 2 Inspection and Maintenance of the Converter oie eeeeeeeeeeereereeenees 11 9 112 1 Replacing FUSES serie nul sn nt ent daa 11 9 11 3 Replacement of Flowmeter for ZR20H Autocalibration Unit
148. n 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 process gas Pa Oxygen concentration in the reference gas 21 O Table 10 2 Oxygen Concentration Vs Cell Voltage cell temperature 750 C 02 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 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 7 86 14 2 19 2 23 1 26 5 29 5 32 1 02 100 T10 2E EPS m eaa 10 1 10 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 11 Cold Junction Voltage 10 4 This equipment uses temperature measurement ICs that measure the cold junction temperatures The voltage measured by those ICs is displayed IM 11M12A01 05E 10 Other Functions 10 1 12 Current Output The analog output current is displayed 10 1 13 Response Time The cell s response time is obtained in the procedure shown in Figure 10 1 If only either a zero point or span calibration has been carried out the response time wil
149. nducted 3 If the calibration time conflicts with maintenance service or blowback operations calibration will start after completing the maintenance service or blowback opera tions see Section 8 2 1 earlier in this manual 4 If 000 days 00 hours are set for the calibration intervals only the first calibration will be conducted a second or later calibration will not be conducted 5 If a past date is set to the calibration start day no calibration will be conducted Table 9 1 Parameter Codes for Calibration Setting Set Item Zero gas concentration Parameter code Set value Set Zero gas concentration Engineering unit Span gas concentration Set Span gas concentration Calibration mode 0 Manual calibration 1 Semi automatic and manual 2 Automatic semi automatic and manual Output stabilization 0 minutes 0 seconds to 60 minutes 59 seconds MM SS Calibration time 0 minutes 0 seconds to 60 minutes 59 seconds MM SS Calibration period 0 days 0 hours to 255 days 23 hours Date and time Start date and time Calibration procedure 9 2 1 7 Default Values Date and time of first calibration 0 Zero and span 1 Span only 2 Zero only YY MM DD HH MM T9 1 EPS When the analyzer is delivered or if data are initialized the calibration settings are by default as shown in Table 9 2 Table 9 2 Default Settings for Calibration Item De
150. nge K9470BX Unit mm 21 7 Llength Model amp Code Weight kg ZR202A 040 Approx 0 8 ZR202A 070 Approx 1 2 ZR202A 100 Approx 1 6 ZR202A 150 Approx 2 2 ZR202A 200 Approx 2 8 ZR202A 250 Approx 3 4 ZR202A 300 Approx 4 0 F2 16 EPS IM 11M12A01 05E 2 21 3 Installation 3 Installation This chapter describes how to install the following equipment and how to test the insulation resistance 3 1 High temperature Humidity Analyzer 3 2 ZA8F Flow Setting Unit 3 3 ZR20H Automatic Calibration Unit 3 4 Case Assembly for Calibration gas Cylinder E7044KF 3 5 Insulation Resistance Test 3 1 Installation of High temperature Humidity Analyzer 3 1 1 Location The following should be taken into consideration when installing the analyzer 1 Easy and safe access to the analyzer for checking and maintenance work 2 Ambient temperature of no more than 55 C and the terminal box should not be affected by radiant heat 3 No corrosive gases Ay CAUTION A natural convection type analyzer model ZR202G L LI LI C which uses ambient air as reference gas requires that the ambient oxygen concentration be constant 4 No vibration 5 The measured gas satisfies the specifications described in Chapter 2 6 No measured gas pressure fluctuations CAUTION IM 11M12A01 05E e Be sure to select the installation location where the ambien
151. nt 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 2 If dehumidifying is not enough or if foul air is used the measurement accuracy will be adversely affected 9 2 1 5 Calibration Time e When the calibration mode is in manual First set the output stabilization time This indicates the time required from the end of calibration to entering a measurement again This time after calibration the measurement gas enters the sensor to set the time until the output returns to normal The output remains held after completing the calibration operation until the output stabilization time elapses The calibration time set ranges from 00 minutes 00 seconds to 60 minutes 59 seconds For more details consult Section 8 3 Setting Output Hold When the calibration mode is semi automatic set the output stabiliza tion time and calibration time The calibration time is the time required from starting the flow of the calibration gas to reading out the measured value The set calibration time is effective in conducting both zero and span calibrations The calibration time set ranges from 00 minutes 00 seconds to 60 minutes 59 seconds Figure 9 4 shows the relationship between the calibration time and output stabilization time Calibration start contact or switch input _ DP l Span calibration a span gas valve open
152. odes provided for the equipment are used to control the equipment display panels see below By selecting appropriate parameter codes you can conduct calibration and set operation parameters Figure 7 4 shows the configuration of display items The parameter codes are listed in groups of seven which are briefly described in Table 7 2 To enter parameters you first need to enter the password Touch the gt key and ENT key at same time to revert to the main screen Basic panel display Password entry display Group A setup display Group B setup display Parameter code gt Group D setup display selection display Group E setup display Group F setup display Career Cane CITE CITE ere Group G setup display F7 4E EPS Figure 7 4 Display Configuration Table 7 2 Display Functions Display Function and item to be set Basic panel Displays the oxygen concentration in normal operation or displays the detector heater temperature while warming up If an error or alarm arises the corresponding error or alarm number appears Password entry Enters the password for the parameter code selection display Group A setup Displays detailed data such as the cell voltage or temperature Group B setup Sets and performs calibration and blowback Group C setup Sets analog output Group D setup Sets an alarm Group E setup Sets the input and output contacts Group F setup S
153. on describes setting of the analog output range Table 8 1 shows the parameter codes for each setting item and set values Table 8 1 Display Items Parameter code _ Set value Current output 0 Oxygen concentration 1 Humidity 2 Mixing ratio Output mode 0 Linear 1 Logarithm Min oxygen concentration Oxygen concentration reading corresponding to 4 mA Max oxygen concentration Oxygen concentration reading corresponding to 20 mA Min humidity Humidity reading corresponding to 4 mA Max humidity Humidity reading corresponding to 20 mA Min mixing ratio Mixing ratio at 4 mA Max mixing ratio Mixing ratio at 20 mA Output damping coefficient 0 to 255 seconds T8 1 1 EPS A CAUTION When you select logarithmic mode in Section 8 1 3 Output Mode later in this manual the oxygen concentration humidity reading and mixing ratio remain constant at 0 1 O 0 1 H O and 0 01 kg kg respectively IM 11M12A01 05E 8 1 8 1 1 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA Maximum oxygen concentration O2 for a maximum current of 20 mA Set the output items for oxygen concentration reading humidity reading and mixing ratio corresponding to 4 mA and 20 mA When the oxygen concentration was selected with parameter code C01 use parameter codes C11 and C12 for the minimum and maximum settings when the humidity setting was selected with parameter code CO1 use parameter codes C13
154. or 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 increases 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 2 Calibration Procedures A CAUTION Calibration should be made under normal operating conditions if the probe is connected to a dryer the analyzer will undergo calibration under the operating conditions of the dryer To make a precise calibration conduct both zero point and span calibrations 9 2 1 Calibration Setting The following sets forth the required calibration settings 9 2 1 1Mode There are three calibration modes available 1 Manual calibration which allows zero and span calibrations or either one manually in turn 2 Semi automatic calibration which lets calibration start with the touchpanel or a contact input and undergoes a series of calibration operations following p
155. otate the valve shaft loosen the lock nut if the valve shaft has a lock nut and slowly turn it counterclockwise 2 To check the flow rate use an appropriate calibration gas flow meter If the mea surement gas pressure is extremely high adjust the measurement gas pressure to obtain pressures listed in Table 10 9 10 Table 10 9 Measurement gas 50 100 150 200 250 pressure kPa Flow rate ml min 500 430 380 350 320 T10 6 8 EPS 3 Adjust the flow rate After the measured oxygen concentration is stabilized touch the ENT key then all the digits will flash Touch the ENT key again to flash CAL END 4 Close the zero gas flow setting valve to stop the zero gas flow Be sure to tighten the lock nut if valve shaft has a lock nut to prevent any leakage of zero gas into the sensor during measurement When the stabilization time elapses the zero calibration will be complete 10 6 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 24 IM 11M12A01 05E 11 Inspection and Maintenance 11 Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxtZR Zirconia High temperature Humidity Analyzer integrated model to maintain its measuring performance and normal operating condition
156. pecified flow rate Available only in the U S DERAKANE is a registered trademark of the Dow Chemical Company 10 Piping for reference air must be installed to supply reference air constantly at a specified flow rate IM 11M12A01 05E e External Dimensions 2 Specifications Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzers Unit mm L 338 to 351 2123 t Display side L 0 4 0 7 Rc1 4 or 1 4NPT jan 1 0 1 5 2 0 Reference air inlet 2 5 3 0 m N N or ta s Y a Q 9 Rc1 4 or 1 4NPT qi Calibration gas inlet Te 153 to 164 wi H 4 G1 2 2 1 2NPT etc Terminal side 252 to 265 49 Cable connection port 170 C m zA 4 k ge Flange Flange C Flange A B C t 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 OA ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 DIN PN10 DN50 SUS304 165 125 4 18 18 DIN PN10 DN80 SUS304 200 160 8 18 20 o DIN PN10 DN100 SUS304 220 180 8 18 20 D JIS 5K 65 FF SUS304 155 130 4 15 14 JIS 10K 65 FF SUS304 175 140 4 19 18 Flan JIS 10K 80 FF SUS304 185 150 8 19 18 ge JIS 10K 100 FF SUS304 210 175 8 19 18 JPI Class 150
157. r with its power OFF Connect terminal to the crossover wiring and terminal to ground 4 Turn the insulation resistance tester ON and measure the insulation resistance After testing remove the tester and connect a 100 KQ resistance between the cross over wiring and ground to discharge 6 Testing between the heater terminal and ground contact output terminal and ground analog output input terminal and ground can be conducted in the same manner 7 Although contact input terminals are isolated insulation resistance test cannot be conducted because the breakdown voltage of the surge preventing arrester between the terminal and ground is low 8 After conducting all the tests replace the jumper plate as it was Contact input 1 ome WN un Crossover wiring Insulation Contact input 2 resistance OT tester O O O 4 5 6 7 DI 1 DI 2 DI C DO 1 DO 1 DO 2 DO 2 8 9 10 11 12 13 14 L N G FG Remove Crossover wiring jumper plate Insulation Insulation resistance resistance tester tester O O O F3 17E EPS IM 11M12A01 05E 3 9 3 6 Installation of the High Temperature Humidity Ana lyzer with pressure compensation Installation for each flange type Unit mm 1 ANSI Class 150 2 RF ZR202G A P Flange ANSI Class 150 2 RF SUS304 L 34264 Re1 40r1 4NPT Reference air inlet PIPING
158. r the calibration time is up in automatic and semiautomatic calibration Alarm 10 Cold junction temperature alarm Occurs when an equipment internal temperature exceeds 85 C Alarm 11 Thermocouple voltage alarm Generated when thermocouple voltage exceeds 42 1 mV about 1020 C or falls below 5 mV about 170 C Alarm 13 Battery low alarm Internal battery needs replacement T12 2E EPS If an alarm occurs such measures as turning off the heater power are not carried out The alarm is released when the cause for the alarm is eliminated If the analyzer power is turned off after an alarm occurs and then turned on before the cause of the alarm is eliminated the alarm will occur again However alarms 6 7 and 8 alarms related to calibration are not generated unless calibration is executed 12 22 Measures Taken When Alarms Occur 12 2 2 1 Alarms 1 through 3 Oxygen Concentration Humidity and Mixing Ratio Alarms These alarms occur when a measured value exceeds an alarm setpoint or falls below it For more details see Section 8 3 Alarm Setting earlier in this manual 12 2 2 2 Alarm 6 Zero point Calibration Coefficient Alarm In calibration this alarm is generated when the zero correction factor is out of the range of 100 30 refer to Section 9 1 3 Compensation The following can be considered the causes for this 1 The zero gas oxygen concentration does not agree with the value
159. red change the existing output setting as follows Use parameter code C01 for the setting see Table 7 6 When the humidity analyzer is specified in the above setting for the type of detector the analog output will be set to humidity if data initialization is performed Table 7 5 1 cae ee Setting Procedure Display after the password has been entered Change the parameter code to C01 The current set value in this case 0 oxygen concentration is displayed Touch the A key to set the number 1 for humidity setting Touch the ENT key The numeric value will be flashing Touch the ENT key again to stop flashing Touch the ENT key to return to the parameter code selection display T7501 EPS The symbol ae indicates that the corresponding keys are being touched and the light characters indicate flashing 7 12 IM 11M12A01 05E 7 Startup 7 7 2 Output Range Setting IM 11M12A01 05E This section describes how to set the analog output range 1 To provide an oxygen concentration use parameter code C11 to set the minimum oxygen concentration at 4 mA and use parameter code C12 to set the maximum oxygen concentration at 20 mA 2 To provide a humidity output use parameter code C13 to set the minimum humidity at 4 mA and use parameter code C14 to set the maximum humidity at 20 mA 3 To provide a mix ratio use parameter code C15 to set the minimum mix ratio at 4 mA and use par
160. reset calibration periods and stabilization time and 3 Automatic calibration which is carried out automatically following preset calibration periods Calibrations are limited by the following mode selection e When manual calibration is selected Manual calibration only can be conducted This mode does not allow semi automatic calibration with a contact input nor automatic calibration even when its start up time has reached e When semi automatic calibration is selected This mode enables manual and semi automatic calibrations to be conducted The mode however does not allow automatic calibration even when its start up time has reached e When automatic calibration is selected This calibration can be conducted in any mode 9 2 1 2Calibration Procedure Select both span and zero calibrations or span calibration only or zero calibration only Usually select span and zero calibrations 9 2 1 3 Zero gas Concentration Set the oxygen concentration for zero point calibration Enter the oxygen concentration for the zero gas in the cylinder used 9 2 1 4Span gas Concentration Set the oxygen concentration for span calibration If instrument air is used as the span gas enter 21 02 When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a hand held oxygen analyzer to measure the actual oxygen concentration and then enter it 9 6 IM 11M12A01 05E 9 Calibration A CAUTION 1 When instrume
161. ro gas valves onto the gas cylinder First turn the valve regulator of the zero gas valves counterclockwise to completely retract the needle at the top from the gasket surface Maintaining the valve in this position screw the valve mounting into the mouthpiece of the gas cylinder If screw connection is proper you can turn the screw manually Do not use any tool When the gasket comes in contact with the mouthpiece of the gas cylinder and you can no longer turn it manually tighten the lock nut with a wrench 2 Remove the carrying case from the standard gas unit The case is attached to the unit with six screws So loosen the screws and lift them off 3 Slide the gas cylinder through the hole in the back of the unit and connect the tube the piping in the unit to the valve connections Insert each tube at least 10 mm to prevent leakage and secure it using a tube clamp 4 Attach the gas cylinder to the case Extend the valve regulator of the zero gas valves through the hole in the front panel of the unit and secure the bottom of the cylinder with the clamp 5 Take note of the oxygen concentration of the sealed gas indicated on the gas cylinder and replace the carrying case Enter the oxygen concentration of the sealed gas using the parameter code BO1 as a zero gas oxygen concentration Also check that no piping is disconnected Thus the work of installing a gas cylinder is completed However gases in the cylinders cannot immediately
162. s CAUTION When checking the detector carefully observe the following 1 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 2 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 3 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 process gas may leak and then the leaking corrosive gas will cause the built in heater or thermocouple to go open circuit or the detector may corrode 4 Handle the probe with care so that the dust filter mounted screws on the tip of the probe do not hurt your finger s 5 Before opening or closing the terminal box first remove dust sand or the like from the terminal box cover IM 11M12A01 05E 11 1 11 1 Inspection and Maintenance of the Detector 11 1 1 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
163. s representative 12 1 2 2 Error 2 Heater Temperature Failure This error occurs if the detector heater temperature does not rise during warm up or if the temperature falls below 730 C or exceeds 780 C after warm up is completed Causes considered for cases where Error 2 occurs independently are shown below 1 Faulty heater in the probe heater wire breakage 2 Faulty thermocouple in the probe 3 Failure in the converter electronics lt Locating cause of failure and countermeasures gt 1 Turn off the power to the analyzer 2 Remove the probe from the analyzer Also remove all the connectors between the converter and probe Measure the resistance of the heater wire yellow wire from the probe as indicated in Figure 12 2 The heater unit is normal if the resistance is lower than about 902 If the resistance is higher than that value the heater unit may be defective In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit Heater wire Multimeter Q F12 2E EPS Figure 12 2 12 2 IM 11M12A01 05E 12 Troubleshooting 3 Next check the resistance of the thermocouple from the probe Use a multimeter to measure the thermocouple resistance between terminal 3 red cable connected and terminal 4 white cable connected as indicated in Figure 12 3 The thermocouple is normal if the resistance is 50 or less If the value is higher than 5Q the thermocouple
164. s will be canceled when the measured value is less than or more than the preset hysteresis values If both the delay time and hysteresis are set an alarm will be issued if the measured value is in the alarm setting range and the delay time has elapsed When the alarm is reset canceled it is required that the measured value be beyond the preset hysteresis value and that the time is after the preset delayed time Refer to Figure 8 2 for any further alarm output actions The delay time and hysteresis settings are common to all alarm points Alarm range 7 5 High limit alarm setpoint Hysteresis 2 0 SO a a a oe OM Se ee poe ce a a ON coe ps ee Humidity Delay time Delay time Delay time 5 seconds 5 seconds 5 seconds Alarm output ON OFF F8 2E EPS Figure 8 2 Alarm Output Action IM 11M12A01 05E 8 9 8 10 In the example in Figure 8 2 the high limit alarm point is set to 7 5 H O the delayed time is set to five seconds and hysteresis is set to 2 H O Alarm output actions in this figure are expressed as follows 1 Although the measured value A has exceeded the high limit alarm setpoint A falls lower than the high limit alarm setpoint before the preset delayed time of five seconds elapses So no alarm is issued 2 The measured value B exceeds the high limit alarm setpoint and the delayed time has elapsed during that measurement So an alarm results 3 Although the measured value C has fall
165. set calibration time elapses the zero gas solenoid valve then closes automatically The CALEND flashes until the set output stabilization time elapses gt A ENT Basic panel When the output stabilization time elapses the basic panel display then appears display Output holding will be released T9 3E EPS When CAL Err appears a calibration coefficient alarm alarm 6 or 7 may have occurred Press ENT key to return to basic panel display Check the alarm number Refer to Subsection 12 2 2 2 Alarm 6 or Subsection 12 2 2 3 Alarm 7 remove the cause and then recalibrate the instrument The symbol indicates that the key is being touched Light characters indicate that the digits are flashing indicates that both are displayed alternately 2 To start calibration using an input contact follow these steps e Make sure that Calibration start has been selected in the Input contacts display see Section 8 5 earlier in this manual e Apply an input contact to start calibration 3 To stop calibration midway follow these steps 1 Touch the gt key and ENT key together The calibration will stop and the output stabilization time will be set up 2 Touch the gt key once again to return to the basic panel display and the analyzer will be in normal measurement 9 2 2 3 Automatic Calibration No execution operations are required for automatic calibration Automatic calibration starts in
166. shows the infrared switch and the display Table 7 1 shows the three switch keys and functions Figure 7 3 shows the infrared switch and the display 77 YOKOGAWA amp _ 4 Decimal i point D 4 POP Oe CEs SALE o EN EN Bi MmNkgalbbl scftm3 d s h m 1 Data display area 3 Engineering unit display area FI EEFS 2 Infrared switch Figure 7 3 Infrared switch and the display 1 Data display area Displays the humidity set values alarm numbers and error numbers 2 Infrared switch Three switches perform data setting operations 3 Engineering unit display area the percent sign appears when the humidity is dis played 4 Decimal point A decimal point is displayed Table 7 1 Switch and Function Switch Function 1 Moves the position of the digit to the right If you continuously touch the key the position of the digit will move continuously to the right finally returning to the leftmost position after reaching the rightmost position of the digit 2 Selects Yes or No 3 When you touch this key together with the ENT key the previous display then appears or the operation will be cancelled Used to change values If you continuously touch this key the value of the digit will increase continuously e g from 1 to 2 to 3 for numeric data or from A to B to C for alphabetic characters and finally return to its original value ENT 1 Used to change the basic panel display to t
167. sly so can be used to measure humidity of air in driers which are heated by steam or electricity It can also be used in a variety of manufacturing applications with humidifiers as well as with driers for humidity measurement and control It can help improve productivity in these application fields Optional accessories are also available to improve measurement accuracy and provide automate calibration The analyzer is equipped with three infrared switches which enable the user to operate the equipment on site without opening the cabinet An optimal control system can be realized by choosing the most suitable of several equipment versions Some examples of typical system configurations are illustrated following pages 1 1 1 1 lt EXAxt ZR gt System Configuration 1 1 1 System 1 The system configuration determines whether calibration is initiated automatically or manually The three basic system configurations are given below This is the simplest system which consists of an integrated type all in one detector and analyzer This system can be used for monitoring humidity in driers used in food processing or the like No piping is required for the reference gas air which is fed in at the installation site The handheld ZO21S standard gas unit is used for calibration Zero and span gases from the standard gas unit are only fed to the detector through a tube during calibration FAN CAUTION 1 1 2 System 2 1 2 e As
168. st protector See Section 2 1 3 ZA8F Flow setting unit See Section 2 2 1 ZR20H Automatic calibration unit See Section 2 2 2 ZO21S Standard gas unit See Section 2 3 2 1 General Specifications 2 1 1 Standard Specifications High temperature Humidity Analyzer Oxygen concentration in mixed gas which consists of water vapor and air is proportional to the volumetric ratio of oxygen in the air so the volumetric ratio of water vapor can be calculated from the oxygen concentration Measured Objects Water vapor in vol in mixed gases air and water vapor Measured System Zirconia system Measured Range 0 01 to 100 vol O 0 to 100 vol H O or 0 to 1 000 kg kg Output Signal 4 to 20 mA DC maximum load resistance 550 Q Oxygen concentration Any setting in the range of 0 to 5 through 0 to 100 vol O in 1 vol O or partial range Moisture quantity 0 to 25 through 0 to 100 vol H O in 1 vol H O or partial range Mixture ratio 0 to 0 2 through 0 to 1 000 kg kg in 0 001 kg kg or partial range Digital Communication HART 250 to 550 Q depending on quantity of field devices connected to the loop multi drop mode Note HART is a registered trademark of the HART Communication Foundation Display Range Oxygen concentration 0 to 100 vol O Moisture quantity 0 to 100 vol H O Mixture ratio 0 to 1 kg kg Relative humidity 0 to 100 RH Dew point 40 to 370 C Warm up Time Approx 20 min These characteristics are ca
169. stalling the converter Current output data settings alarm data settings contact data settings other settings Display and setting content Display Related Items Oxygen concentration vol O Moisture quantity vol H O mixture ratio kg kg relative humidity RH dew point C cell tempera ture C thermocouple reference junction temperature C maximum minimum average oxygen concentration vol O maximum minimum average moisture quantity vol H O maximum minimum average mixture ratio kg kg cell e mf mV output 1 2 current mA cell response time seconds cell internal resistance V cell condition in four grades heater on time rate calibration record ten times time year month day hour minute Calibration Setting Items Span gas concentration vol O zero gas concentration vol O calibration mode auto semi auto manual calibration type and method zero span calibration zero calibration only span calibration only stabilization time min sec calibration time min sec calibration period day hour starting time year month day hour minute Output Related Items Analog output output mode selection output conditions when warming up maintenance calibrating abnormal oxygen concentration at 4mA 20mA vol O moisture quantity at 4mA 20mA vol H O mixture ratio at 4mA 20mA kg kg time constant preset values when warming up maintenance calibrating abnormal output preset
170. sted in Table 7 12 1 Mode setting There are three calibration modes manual semi automatic and automatic Select the desired mode This section uses manual mode for calibration 2 Oxygen concentration in zero gas Enter the zero gas oxygen concentration for calibration 3 Oxygen concentration in span gas Enter the span gas oxygen concentration for calibration If instrument air is used enter 21 vol O When using the ZO21S Standard Gas Unit for use of the atmo spheric air as a span gas use a hand held oxygen analyzer to measure the actual oxygen concentration and then enter it CAUTION If instrument air is used for the span gas dehumidify the air to a dew point of 20 C and remove any oil mist or dust Incomplete dehumidifying or unclean air will have an adverse effect on the measurement accuracy Table 7 12 Calibration Parameter Codes Set item Parameter code Set value 0 Manual calibration 1 Semi automatic calibration 2 Automatic calibration Zero gas oxygen concentration Span gas oxygen concentration Enter oxygen concentration Enter oxygen concentration T7 12E EPS IM 11M12A01 05E 7 Startup Table 7 13 Calibration Setup Procedure Switch operation Display Description gt A ENT A 01 Display after the password has been entered ENT b01 Set the zero gas concentration Switch the parameter code to B01 Here set 0 98 001 2 00 Touch the
171. t normally perform a steady operation without changing the conditions If the error occurs again check whether or not the reason is applicable to the following and then replace the sensor assembly e A lot of dust and the like may be sticking to the tip of the sensor If dust is found clean and remove the dust see Section 11 1 1 In addition if an error occurs in calibration even after the sensor assembly is replaced the influence of measured gas flow may be suspected Do not let the measured gas flow toward the tip of the detector probe for example by changing the mounting position of the detector 12 6 IM 11M12A01 05E 12 Troubleshooting 12 2 2 5 Alarm 10 Cold Junction Temperature Alarm The equipment incorporates a temperature sensor An alarm is issued when the sensor temperature exceeds 85 C If internal temperature of this equipment exceeds 85 C the electronics may fail lt Locating cause of failure and countermeasures gt This equipment can be used at ambient temperatures up to 55 C If the ambient tempera tures may exceed the limits take appropriate measures such as applying heat insulat ing material to the furnace walls and adding a sun shield to keep out direct sunlight If this alarm occurs even when the ambient temperature is under 55 C the electronics may be defective Contact your local Yokogawa service or sales representative 12 2 2 6 Alarm 11 Thermocouple Voltage Alarm This alarm is generate
172. t temperature is between 20 C and 55 C for the ZR202G Integrated type High temperature Humidity Ana lyzer 3 1 3 12 Probe Insertion A CAUTION 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 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 on the flange gasket Confirm the outside dimensions of the detector in Chapter 3 6 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 1 Do not orient the end of the detector probe upwards 2 If the probe length is 2 5 meters or longer mount the detector vertically no more than a 5 tilt 3 Position the detector probe perpendicular to the measurement gas flow or point the tip downstream Figure 3 1 illustrates an example of the probe insertion Bounds of the probe vertical insertion hole location y Flange corresponds 100 mm to the detector si
173. tart Detection of non combusted gas Selecting action of input contact 1 Action with closed contact Action with open contact Action with closed contact Selecting action of input contact 2 Action with closed contact Action with open contact Action with closed contact Selecting action of output contact 1 Action with open contact normally energized Action with closed contact normally deenergized Action with closed contact Output contact 1 error No action Action No action Output contact 1 high high alarm No action Action No action Output contact 1 high limit alarm No action Action No action Output contact 1 low limit alarm No action Action No action Output contact 1 low low alarm No action Action No action Output contact 1 during maintenance No action Action Action Output contact 1 during calibration No action Action No action Output contact 1 measurement range change No action Action No action Output contact 1 during warm up No action Action Action Output contact 1 calibration gas pressure decrease No action Action No action Output contact 1 detection of non combusted gas No action Action No action T10 6E EPS IM 11M12A01 05E Equipment Setup and Others in Group F
174. ted Not detected Detected Not detected Detected Not detected Detected Note detected Detected Not detected Detected T8 3 3 1 EPS Oxygen concentration high alarm detection Oxygen concentration low alarm detection Oxygen concentration low low alarm detection Humidity high high alarm detection Humidity high alarm detection Humidity low alarm detection Humidity low low alarm detection Mixing ratio high high alarm detection Mixing ratio high alarm detection Mixing ratio low alarm detection Mixing ratio low low alarm detection losl lsl lsi lsl lsl lsi lsi lsi ls lsi lsl A CAUTION Even with alarms set if Not detected has been set in the above alarm detection no alarm is issued Be sure to set Detected in the above alarm detection if you use alarm features IM 11M12A01 05E 8 11 8 34 Default Values When the analyzer is delivered or if data are initialized the alarm set values are by d Table 8 7 Alarm Setting Default Values Set item Oxygen concentration high high alarm setpoint efault as shown in Table 8 7 Oxygen concentration high alarm setpoint 100 O2 100 O2 Oxygen concentration low alarm setpoint 0 O2 Oxygen concentration low low alarm setpoint 0 O2 Humidity high high alarm setpoint 100 H20 Humidity high alarm setpoint 100 H20 Humidity
175. the Oxygen Analyzer and the Humidity Analyzer If you choose optional specification HS at the time of purchase the equipment is set for the Humidity Analyzer Before setting the operating data be sure to check that the desired model has been set Note that if the equipment type setting is changed after operating data are set the operating data that have been set are then initialized and the default settings remain Set the equipment type with parameter code F01 See Table 10 7 later in this manual A CAUTION Note that if the equipment type is changed operation data that have already been set are initialized reverting to the default setting Table 7 3 Equipment Type Setting Switch operation Display Description gt A ENT A 01 Display after the password has been entered gt A ENT F01 Touch the A key to switch to Group F If an unwanted alphabetic character after S gt F has been entered continuously touch the gt key to return to the original a A ENT 0 Touch the ENT key for confirmation If 0 zero is entered the oxygen analyzer 8 is already set If 1 one is entered the humidity analyzer has been set Change the setting following the steps below gt A ENT 0 Continuously touch the A key and the position of the digit will change from 1 to 0 to S 1 to 0 Release the ENT key when 0 is displayed a ENT 0 Touch the ENT key The numeric value will flash V gt m Z j
176. the internal circuits in the converter If an error occurs the converter performs the following 1 Stops the supply of power to the heater in the detector to insure system safety 2 Causes an error indication in the display to start blinking to notify of an error generation Figure 12 1 3 Sends an output contact if the error is set up for Output contact setup for that contact refer to Section 8 4 Output Contact Setup 4 Changes the analog output status to the one set in Output hold setting refer to Section 8 2 Output Hold Setting When the display shown in Figure 12 1 appears pressing the error indication brings up a description of the error Figure 12 2 The content of errors that are displayed include those shown in Table 12 1 Displayed alternately Err 01 Figure 12 1 1 F12 1E EPS Table 12 1 Types of Errors and Reasons for Occurrence Error Type of error Reason for Occurrence Error 1 Cell voltage failure The cell sensor voltage signal input to the converter falls below 50 mV Error 2 Heater temperature failure The heater temperature does not rise during warm up Or it falls below 730 C or exceeds 780 C after warm up is completed Error 3 A D converter failure The A D converter fails in the internal electrical circuit in the converter Error 4 Memory failure Data properly are not written into memory in th
177. ting Unit assises mener 2 11 2 2 2 ZR20H Automatic Calibration Unit ss 2 13 2 3 ZO2IS Standard Gas Unit ss 2 15 224 Other Equipment mines Med ni desta einai aie hae ee 2 16 24 1 Stop Valve part number L9852CB or G7016XH ee eeceeseeeteeteees 2 16 2 4 2 Check Valve part number K9292DN or K9292DS eesse 2 16 DAB CAI DE recense ge he er entevstee daborsndes 2 17 2 44 Zero gas Cylinder part number G7001ZC oe ee eee eseeseeneees 2 19 2 4 5 Pressure Regulator for Gas Cylinder part number G7013XF or G70 14 XB ooo eeeeenseeeneecneeeeaeceeeeenaeees 2 19 2 4 6 Case Assembly for Calibration gas Cylinder part number E7044 KP ss 2 20 2 4 7 Model ZR202A Heater Assembly 2 21 3 Installati n ss ssesessserossssesesresessesssesosresosscocreeseosssioe ressossosrovooiccosessssro ees ressessssosesesses asses Ok 3 1 Installation of High temperature Humidity Analyzer 3 1 IEF Locat mes oair E nn Rene nette 3 1 3 1 2 Probe AO REEE EE 3 2 3 1 3 Installation of the Detector seessssesssessessssssesssssessesserssesseeseesseeseessessees 3 3 3 1 4 Installation of ZH21B Dust Protector wee eeeeseceneeceeeeeneeeneeeneeeens 3 3 3 2 Installation of ZA8F Flow Setting Unit sessssesesseseseeesreresesesserresreresresererses 3 4 3 2 1 lt OCA OM Hein msn nn O O NOTE ts 3 4 IM 11M12A01 05E 32 2 Mounting of ZA8F Flow Setting Unit eeceeneeeeeeseceeeeeneeeaee
178. tio 2 Zero gas ratio 3 Cell voltage mV Zero gas ratio 4 TC voltage mV Zero gas ratio 5 Cold junction voltage mV Zero gas ratio 6 Output current mA Zero gas ratio 7 Cell response time Seconds Zero gas ratio 8 Cell internal resistance Q Zero gas ratio 9 Cell robustness Calibration history 0 YY MM DD HH MM Heater on time ratio Calibration history 1 YY MM DD HH MM Oxygen concentration with time constant O2 Calibration history 2 YY MM DD HH MM Humidity with time time constant H20 Calibration history 3 YY MM DD HH MM Mixing ratio with time time constant kg kg Calibration history 4 YY MM DD HH MM Max oxygen concentration O2 Calibration history 5 YY MM DD HH MM Occurrence of maximum oxygen concentration Min oxygen concentration YY MM DD HH MM O2 Calibration history 6 Calibration history 7 YY MM DD HH MM YY MM DD HH MM Occurrence of minimum oxygen concentration YY MM DD HH MM Calibration history 8 YY MM DD HH MM Average oxygen concentration O2 Calibration history 9 YY MM DD HH MM Maximum humidity H20 Time YY MM DD HH MM Occurrence of max humidity YY MM DD HH MM Software revision Minimum humidity H20 Occurrence of min humidity YY MM DD HH
179. to the O ring the measured gas will leak into the reference gas or vice versa Because of a low oxygen partial pressure between the reference and measurement sides the oxygen concentration reading is high and the humidity reading is low In this case the sensor assembly needs to be reinstalled see Section 11 1 2 In such a case be sure to remove the O ring and replace it with a new one In addition if any crack is found replace the sensor assembly with a new one see Section 11 1 2 earlier in this manual A CAUTION See the cell robustness in function A22 for sensor quality 12 3 2 Measured Value Lower Than True Value 12 10 lt Causes and Countermeasures gt 1 The measuring gas pressure becomes lower If an increment of the measured value due to pressure change cannot be neglected take appropriate measures see Section 11 1 1 1 2 Moisture content in a reference gas changes decreases greatly Changes in the moisture content contained in the instrument air will cause an error of the humidity measurement vol H O or kg kg If this error cannot be ignored use a gas in which the moisture content is constant such as instrument air in almost dry condition as a reference gas 3 The calibration gas zero gas is leaking in the detector If the zero gas is leaking in the detector because of a failure of the valve in the calibra tion gas tubing system the measured value will show a slightly lower value than norma
180. under the average process gas pressure internal pressure of a dryer 2 Moisture content in a reference gas changes increases greatly If air at the analyzer installation site is used for the reference gas a large change of moisture in the air may cause an error in the measured oxygen concentration value vol O If this error cannot be ignored use a gas in which moisture content is constant such as instrument air in almost dry condition as a reference gas 3 Calibration gas span gas is leaking in the sensor If the span gas is leaking in the sensor because of a failure of the valve provided in the calibration gas tubing system the measured value shows a value a little higher than normal Check the valves needle valves check valves solenoid valves for automatic calibration or the like 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 IM 11M12A01 05E 12 9 4 The reference gas is mixing into the measuring gas and vice versa When such mixing occurs since the deference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller the measured value shows a lower value See Section 11 1 2 to check that the sensor has been properly installed An error which does not indicate Error 1 may occur in the sensor If the sensor assembly is loose or if there is any damage
181. utions in this manual when using the product to ensure protection and safety of personnel product and system containing the product iv IM 1M12A01 05E 3 The following safety symbols are used in this manual IM 1M12A01 05E 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 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 attention to information essential for understanding the operation and functions A Tip This symbol gives information that complements the present topic CN SEE ALSO This symbol identifies a source to which to refer Protective Ground Terminal l Function Ground Terminal Do not use this terminal as the protective ground terminal o Alternating current vi E Special descriptions in this manual This manual indicates operation keys displays and drawings on the product as follows e Operation keys displays on the panel Enclosed in Ex MODE key Ex message display BASE L Ex data display 102 lit 102 flashing e Drawing representing flashing Indicated
182. vol H20 9 12 Calibration Gas IM 11M12A01 05E p ene E as russe Oxygen concentration vs Humidity Mixing ratio 5 6 7 H 9 Calibration 1 0 i 0 9 Humidity vol H20 0 8 0 7 Mixing ratio kg kg 0 6 0 5 0 4 0 3 0 2 0 1 0 0 8 9 10 11 1213 14 15 16 17 18 19 20 21 22 Oxygen concentration vol O2 FBE EPS 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 vol O2 with a balance of nitrogen gas N2 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 kg kg Mixing ratio For best accuracy as the span gas use oxygen whose concentration is near the top of the measurement range in a nitrogen mixture 9 3 9 13 9 4 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 p1
183. wire may be broken or about to break In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit A CAUTION e Measure the thermocouple resistance value after the difference between the probe tip temperature and the ambient temperature decreases to 50 C or less If the thermo couple voltage is large accurate measurement cannot be achieved YEL 1 Thermocouple GRN 2 Multimeter m RED 3 Q WHT 4 F12 3E EPS Figure 12 3 4 If the inspection indicates that the thermocouple is normal the electronics may be defective Consult your local Yokogawa service or sales representative 12 1 2 3 Error 3 A D Converter Failure Error 4 Writing to memory Failure e A D Converter Failure It is suspected that a failure has occurred in the A D converter mounted in the converter electronics e Writing to memory Failure It is suspected that a failure has occurred in an operation writing to the memory EEPROM mounted in the converter electronics lt Locating cause the failure and countermeasures gt Turn off the power to the converter once and then restart the converter If the converter operates normally after restarting an error might have occurred due to a temporary drop in the voltage falling below 85 V the least amount of voltage required to operate the converter or a malfunction of the electronics affected by noise Check whether or not there is a failure in
184. y Approx 59 safety valve Primary safety valve Approx 82 k gt Approx 174 Approx 163 IM 11M12A01 05E Part No Outlet G7013XF Rc1 4 G7014XF 1 4 NPT female screw 2 19 2 4 6 Case Assembly for Calibration gas Cylinder part number E7044KF 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 Approx 3 3 kg 10 kg with gas cylinder Note Export of such high pressure filled gas cylinders to most countries is prohibited or restricted unit mm 324 Pressure regulator eos 3XF G7014XF Zero gas cylinder G7001ZC Note E7044KF case assembly has no zero gas cylinder and pressure regulator 2B pipe 260 5 F2 15E EPS 2 20 IM 11M12A01 05E 2 Specifications 2 4 7 Model ZR202A Heater Assembly Suffix code Option code Description ZRODLA pitii paiana Heater Assembly for ZR202G Length 0 4 m 1 070 0 7m 100 im 150 1 5m 200 2m 250 2 5m eee 3m Jig for change A f With Jig EL None Always A T2 2E EPS 1 Suffix code of length should be selected as same as ZR202G installed The heater is made of ceramic do not drop or subject it to pressure stress External Dimensions Jig for cha
185. y CA L If you touch the ENT key again CAL then flashes Cancel If you touch the gt key and ENT key together the display will return to the B10 display If you touch the ENT key again SPAn Y appears Y is flashing If you omit the span calibration touch the gt key and change Y to N If you touch the ENT key the display then jumps to ZERO Y Touch the ENT key to display the calibration gas value in other words the span gas concentration set in Section 7 10 1 Calibration Setup To cancel the above touch the gt key and ENT key together Then the display returns to SPAN Y O P E If you touch the ENT key OPEN and the currently measured value n are displayed alternately Open the Flow Setting Unit span gas flow valve and adjust Ss 20 84 the span gas flow to 600 60 ml min To do this loosen the valve lock nut a and gently turn the valve control shaft counterclockwise Check the calibration gas flowmeter for confirmation If the automatic calibration unit is connected open the span gas solenoid valve and the measured value changes to the span gas value When the display becomes stable proceed to the next step To cancel the above touch the gt key and ENT key together Then the display returns to SPAN Y 2 0 8 4 6 If you touch the ENT key all the digits flash At that point no calibration 7 is conducted yet Z E ro Y If you touch the EN
186. y 6 following Section 11 1 2 earlier in this manual Remove the two screws 15 that tighten the cover 12 and slide it to the flange side Remove the four bolts 10 to remove the converter 16 Then remove the three connectors to which leadwire from the heater and thermocouple is connected 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 heater 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 12Nem 10 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 thermocouple leadwire through the connector 13 Also pass the
187. ygen Concentration Humidity and Mixing Ratio 10 6 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 will 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 IM 11M12A01 05E 10 Other Functions 10 1 20 Average Oxygen Concentration and Mixing Ratio 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 21 Span gas and Zero gas Correction Ratios Span gas and zero gas correction ratios for the past ten calibrations are recorded to enable you to check the 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 z Zero origin Cell Calibration curve
188. ze 4 Type Outside diameter of detector Standard 50 8 mm in diameter Note With dust protector 80 mm in diameter or longer Note horizontal 100 mm D Four hole flange Eight hole flange JIS flange Note l the detector with When the detector with the ZH21B dust protector is used provide a 80 mm dia dust protector or more flange as shown in the above figure 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 Where necessary make a notch in the flange gasket Confirm the outside dimensions of the detector in Chapter 3 6 before installation F3 1E EPS Figure 3 1 Example of Probe Insertion 3 2 IM 11M12A01 05E 3 Installation 3 1 3 Installation of the Detector A CAUTION The cell sensor at the tip of the detector is made of ceramic zirconia Do not drop the detector as impact will damage it e If the detector is mounted horizontally the calibration gas inlet and reference gas inlet should face downwards 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 sur

User`s Manual

Contents

Download Pdf Manuals

Related Search

Related Contents