Home

Model ZR202G Integrated type Zirconia Oxygen Analyzer

1. Unit mm L ae 34244 5 123 gt t Display side 7 i L 0 4 0 7 Rc1 4 or 1 4NPT 1 0 1 5 2 0 Reference gas inlet 2 5 3 0 m N N ok la SI 4 ve J i BEN amp L ee D r N Reference gas outlet 1 PIPING B E ll y PIPING A 4 G1 2 2 1 2NPT etc Terminal side 15643 Stop Cable connection port 170 valve B 256 4 1 49 Rc1 4 or 1 4NPT C Calibration gas inlet A ge Flange C Flange A B C t PIPING ANSI Class 150 2 RF SUS304 152 4 120 6 4 19 19 A ANSI Class 150 3 RF SUS304 190 5 152 4 4 19 24 B A ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 B DIN PN10 DN50 A SUS304 165 125 4 18 18 A DIN PN10 DN80 A SUS304 200 160 8 18 20 B o DIN PN10 DN100 A SUS304 220 180 8 18 20 B 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 SUS304 185 150 8 19 18 B ange JIS 10K 100 FF SUS304 210 175 8 G19 18 B JPI Class 150 4 RF SUS304 229 190 5 8 O19 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 Parts No Q ty Description Fuse A1113EF 1 3 15A Allen wrench L9827AB 1 For lock screw Hood Option code H Unit mm 274 4 D F13 ai Material o
2. ZR202G F ai Item Part No Qty Description 1 K9472UF 1 Hood CMPL 11M12A01 04E 8th Edition Apr 2012 YK Customer Model ZR20H A Integrated type Zirconia Oxygen Analyzer Maintenance High Temperature Humidity Analyzer Parts List Automatic Calibration Unit H S YN Ol QD J WZ y Item Part No Qty Description 8 K9473XC 1 Flowmeter All Rights Reserved Copyright 2001 Yokogawa Electric Corporation YOKOGAWA Subject to change without notice Yokogawa Electric Corporation CMPL 11M12A01 12E 1st Edition Feb 2001 YK 3rd Edition Apr 2011 YK Customer Model ZO21S Zirconia Oxygen Analyzer High Temperature Maintenance Humidity Analyzer Standard Gas Unit Parts List nn Ay Item 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 100 V 110 E7050AU 115 AC 200 V 220 E7050AV 240 All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M3D1 01E YOKOGAWA Subject to chang without notice 1st Edition Jan 2000 YK Yokogawa Electric Corporation 4th Edition Mar 2011 YK Revision Information Title Model ZR202G Integrated type Zi
3. Reference gas inlet Rc1 4 or 1 4NPT Female Zero gas inlet Rc1 4 or 1 4NPT Female 40 66 5 lt gt Check valve Span gas solenoid valve Zero gas solenoid valve Span gas flowmeter Reference gas flowmeter V v ple V Needle valve Zero gas flowmeter Automatic Calibration Unit SPAN IN F3 15E ai To Air set REF IN To Zero gas cylinder ZERO IN F4 11E ai IM 11M12A01 04E 4 6 lt 4 Piping gt 4 4 Piping for the Oxygen Analyzer with Pressure Compensation ZR202c 0 0O 0O O0 P Oxygen Analyzer with pressure compensation may be used in System 2 and System 3 Use this style analyzer whenever the furnace pressure exceeds 5 kPa see Note Even if the fur nace pressure is high the detector can measure by adjusting pressure of the probe with the furnace pressure using instrument air The inside pressure of the probe will be kept identical to the furnace pressure by feeding instrument air at higher pressure than that in the furnace NOTE The process gas pressure should not be subjected to rapid changes Unit mm The detector with pressure compensation is illustrated in Figure 4 12 342 4 m gt 4 C Rc 1 4 or 1 4 NPT Reference gas inlet 1 H O a
4. Table 8 1 Display Item Values set with A00 or F08 Items displayed on the basic panel display 0 Indicates the oxygen concentration 1or2 For humidity analyzers only if 1 or 2 is set for the oxygen analyzer 0 0 is only displayed on the basic panel display 3 Displays an item for the current output If the output damping has been set for the current output values aN CAUTION involving the output damping are displayed If you set 3 in the parameter code A00 or F08 be sure to select Oxygen Concentration in the following mA output setting see Section 8 2 Current Output Setting 8 2 Current Output Setting This section describes setting of the analog output range Table 8 2 shows parameter codes for the set items Table 8 2 Current Output Parameter Codes Set item Parameter code Set value Analog output C01 0 Oxygen concentration 1 4 mA fixed 1 2 4 mA fixed 1 Output mode C03 0 Linear 1 Logarithm Min oxygen concentration C11 Oxygen concentration at 4 mA Max oxygen concentration C12 Oxygen concentration at 20 mA Output damping constant C30 0 to 255 seconds 41 For the oxygen analyzer set 0 zero only for parameter code C01 When it is set the current output is 4 mA fixed regardless of the oxygen concentration IM 11M12A01 04E 8 2 lt 8 Detailed Data Setting gt 8 2 1 Setting Minimum Oxygen Concentration at 4 mA an
5. Span gas Same as Zero gas calibration 5 L ZA8F flow setting unit Calibration gas pressure Zero gas cylinder regulator Calibration gas unit case F1 2E ai Example of System 2 lt 1 Overview gt 1 3 1 1 3 System 3 This example System 3 represents typical applications in large boilers and heating furnaces where is a need to monitor and control oxygen concentration The reference gas and calibration time span gas are clean dry instrument air Zero gas is supplied from a gas cylinder System 3 uses the ZR20H automatic calibration unit with auto switching of the calibration gas A combustible gas detected contact input turns off power to the heater There s also contact output from the converter that can be used to operate a purge gas valve to supply air to the sensor 2 ZR202G Integrated type Zirconia Oxygen Analyzer 1 with automatic calibration unit ZR202G 0 0 0 A 0 O O O A iA Automatic calibration unit 100t0240VAC 1 i ae eave On a Ce Contact input ZRH OL Oe eri riiiiiiiritte gt Analog output contact output Digital output HART T Air Set Reference gas a Instrument air Span gas Calibration gas Zero Kon Calibration gas pressure 3 regulator Zero gas cylinder Calibration gas unit case Note F1 3E ai The installation tempera
6. srrnnnnnnnnnnnnnnnnvnnnnnnnnrnnnrnsnrrsnrrenresnreenr 7 6 7 4 5 Changing Set Values sienanmenstteldsteednlmlendnleidatendln 7 6 7 5 Confirmation of Equipment Type Setting rrnvrnnnvnnnnnvnnnnvnnnnvnnnnvnnnnnnnnnnnnnnn 7 8 7 6 Selection of Measurement Gas rrsrnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 7 9 7 7 Output Range Setting i smivassnnndnnnnnnndnnnnnnndnsannnndnnknn nude nnnn anbe anne nude sann AE ERRARE RRASA 7 9 7 7 1 Minimum Current 4 mA and Maximum Current 20 mA Settings 7 9 7 8 Checking Current LOOp mrrssvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnnensvensvensennsennsennnenr 7 11 7 9 Checking Contact V0 ciiscccccscccecsesscccccescceectciadteneseteecnetineeenesaneestvenideieeaeesies 7 11 7 9 1 Contact Output Check ecccceecceceeeeeeeeeeceeeeeceeseaeeseaeessaeeessaeensaees 7 12 7 9 2 Checking Calibration Contact Output rmarrnrnrnnnrnnnrnrnrnnnrnrnrnrnreenr 7 13 7 9 3 Checking Input Contacts ssnrnrnnnvnnnrnnnrnnnrnrnrnnnrnnnrernrnrnrersreenreenn 7 14 7 10 Calibrationiuusearnsusoonsseasdnieseaeetaasuaneudeeuasasdtandnet 7 15 7 10 1 Calibration SQtup isicascisatisctseateancdsasasesnearcancdentlaateaatuanedaatavedtaantancdaanais 7 15 7 10 2 Manual Callbraton suv nanknen rnansknan nannanknernekivne 7 17 Detailed Data Setting anerepseinnaeemmneniipuvmtnnnsit 8 1 8 1 Setting Display MOM ccccccecsecsecsecsecsecsecseectecsedeeecsecscecseeseesseveseresr
7. 1 Ask Yokogawa service station for additional mounting of ZR20H to the preinstalled ZR202G 2 Select the appropriate reference gas of ZR20H according to the one of ZR202G IM 11M12A01 04E External Dimensions 1 Horizontal Mounting A 2 13 lt 2 Specifications gt Unit mm 84 U DOY ell i Va a S t a te 8 aK vo FI 80 O O O E ED Y H 40 44 MAXI 56 gt gt Zero gas inlet Span gas inlet Rc1 4 or 1 4NPT Female Rc1 4 or 1 4NPT Female Reference gas inlet Zero gas solenoid valve Rc1 4 or 1 4NPT Female 2 Vertical Mounting B KE r amp 184 lt O j e I 1 app H Q K v H e ja NL 66 5 gt 144 wal 180 gt lt 166 5 gt 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 PIPNG INSIDE THE AUTOMATIC CALIBRATION UNIT ZR202G body Calibration gas Reference gas po t t j i Check valve m
8. BASE Ex data display 102 lit 102 flashing Drawing for flashing i i it 2 Indicated by gray characters Flashing lit Wwe e Displays on the LCD display panel Alphanumerics LED Display Alphanumerics LED Display Alphanumerics LED Display A A N n 0 g B b O o 1 i c C P P 2 D d Q q 3 J E E R r 4 uy F F s 5 5 5 G L T E 6 6 H H U y 7 n l v H 8 fa J d w y 9 g K x Y y L L z M n IM 11M12A01 04E vi lt Introduction gt 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 Specifications 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 Zirconia Oxygen 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 operation conditions before conducting analysis Where necessary set the instrument parameters for appropriate operation For details on setting data refer to Chapters 7 to 10 When user changes the operation parameter it is recommended to note down the changed setting data e How to di
9. Table 8 6 Deleted or blow back 8 5 1 Output Contact Made some corrections 8 5 2 Setting Output Contact Table 8 10 Changed descriptions WARNING Deleted second warning 9 2 2 2 Semi automatic Calibration Table 9 3 Added note 10 4 Table 10 6 Contact related Items in Group E Deleted some codes 12 2 1 What is an Alarm Table 12 2 Added Alarms 11 and 13 12 2 2 2Alarm 6 Changed descriptions 12 2 2 3Alarm 7 Changed descriptions p 12 7 and 12 8 Added Sections 12 2 2 6 and 12 2 2 7 CMPL Changed part numbers of Items 4 12 and 13 2 1 2 ZR202G Integrated type Oxygen Analyzer Safety and EMC conforming standard Added Caution 2 1 2 ZR202G Integrated type Oxygen Analyzer Model and Codes Added Note 8 3 Output Hold Setting Table 8 4 Analog Output Hold Setting Added Note 8 3 3 Output Hold Setting Table 8 5 Parameter Codes for Output Holding Added Note 10 4 Reset Table Output related Items in Group C Added Note Apr 2005 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 description Non CE Mark 2 4 5 Air Set Changed part numbers and drawing of air set IM 11M12A01 04E 4th 3rd 2nd Edition 1st 4 2 1 Piping Par
10. 10 4 For the horizontally installed probe whose insertion length is 2 5 m or more use the Probe Protector Be sure to specify ZO21R L 200 H Specify the flange suffix code either C or K 2 The thickness of the flange depends on its dimensions 3 Inconel probe bolts and U shape pipe are used Use this option for high temperature use ranging from 600 to 700 C 4 Specify either CV or SV option code 5 Specify either SCT or PT option code 6 No need to specify the option codes CV and SV since the check valves are provided with the Automatic Calibration Unit Automatic calibration cannot be used when natural convection is selected as reference gas 7 Sun shield hood is still effective even if scratched Hood is necessary for outdoor installation out of sun shield roof 8 Recommended if sample gas contains corrosive gas like chlorine 9 Piping for reference gas must be installed to supply reference gas constantly at a specified flow rate 10 Output signal limits 3 8 to 20 5 mA Specify either C2 or C3 option code IM 11M12A01 04E lt 2 Specifications gt External Dimensions Model ZR202G Integrated type Zirconia Oxyg
11. 12 2 1 What is an Alarm When an alarm is generated the alarm indication blinks in the display to notify of the alarm Figure 12 3 Pressing the alarm indication displays a description of the alarm Alarms include those shown in Table 12 2 Displayed alternately AL 06 gt 21 0 F12 4E ai Figure 12 4 Table 12 2 Types of Alarms and Reasons for Occurrence Alarm Type of alarm Reason for occurrence Alarm 1 Oxygen concentration alarm Occurs when a measured value exceed or falls below concentration alarm the set alarm value refer to Section 8 4 Alarm Setting Alarm6 Zero calibration coefficient alarm Generated when the zero correction ratio is out of the range of 100 30 in automatic and semi automatic calibration refer to Section 9 1 3 Compensation Alarm 7 Span calibration coefficient alarm Generated when the span correction ratio is out of the range of 0 18 in automatic and semi automatic calibration refer to Section 9 1 3 Compensation Alarm 8 EMF stabilization time up Generated when the cell sensor voltage is not stabilized even after the calibration time is up in automatic and semi automatic 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 Batte
12. A immediately 8 Detailed Data Details of key operations and displays Setting 9 Calibration Describes the calibration procedure required in the A course of operation 10 Other Other functions described A Functions 11 Inspection How to conduct maintenance of EXAxt ZR and and procedures for replacement of deteriorated parts O Maintenance 12 Troubleshoot This chapter describes measures to be taken when an A ing abnormal condition occurs CMPL parts list User replaceable parts list A O Read and completely understand before operating the equipment O Read before operating the equipment and refer to it whenever necessary A Recommended to read at least once IM 11M12A01 04E lt Introduction gt Wl For the safe use of this equipment N WARNING EXAxt ZR is very heavy Be sure not to accidentally drop it Handle safely to avoid injury Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment In addition confirm that the power is switched off when connecting power supply Some process gas is dangerous to people When removing this equipment from the process line for maintenance or other reasons protect yourself from potential poisoning by using a protective mask or ventilating the area well N caution The cell Sensor at the tip of the probe is made of ceramic zirconia element Do not drop the equip ment or subject
13. IM 11M12A01 04E lt 12 Troubleshooting gt 12 9 12 3 Measures When Measured Value Shows an Error 12 3 1 The causes that the measured value shows an abnormal value is not always due to instrument failures There are rather many cases where the causes are those that measuring gas itself is in abnormal state or external causes exist which disturb the instrument operation In this section causes of and measures against the cases where measured values show the following phenomena 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 Measured Value Higher Than True Value lt Causes and Measures gt 1 The measuring gas pressure becomes higher The measured oxygen concentration value X vol 0 is expressed as shown below when the measuring gas pressure is higher than that in calibration by Dp kPa X Y 1 Dp 101 30 where Y Measured oxygen concentration value at the same pressure as in calibration vol O Where an increment of the measured value by pressure change cannot be neglected measures must be taken Investigate the following points to perform improvement available in each process Is improvement in facility s aspect available so that pressure change does not occur Is performing calibration available under the average measuring gas pressure internal pressure of a furnace 2
14. SPAN IN v Span gas solenoid valve Span gas flowmeter ann i P 7 de 4 To Air set REF IN Reference gas flowmeter A EFE gt i ll To Zero gas cylinder i V Needle valve ZERO IN Automatic calibration ui Zero gas flowmeter nit F4 11E ai IM 11M12A01 04E 2 14 lt 2 Specifications gt 2 3 ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system configuration based on System 1 It is used in combination with the detector only during calibration e 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 Filled pressure Composition Power Supply Power Consumption Case material Paint Paint Color Piping Weight Span gas Non CE Mark e Model and Codes Suffix code Option code 11 Approx 686 kPa G at 35 C 0 95 to 1 0 vol O N balance 100 110 115 200 220 240V AC 10 50 60 Hz Max 5 VA SPCC Cold rolled steel sheet Epoxy resin baked Mainframe Munsell 2 0 GY3 1 0 5 equivalent Cover Munsell 2 8 GY6 4 0 9 equivalent 6 x 4mm flexible tube connection Approx 3 kg Internal pump draws in air from atmosphere and feeds to detector Description Standard gas
15. User s Manual Model ZR202G Integrated type Zirconia Oxygen Analyzer EXA IM 11M12A01 04E vigilantolant YOKOGAM 9 IM 11M12A01 04E i f 8th Editi Yokogawa Electric Corporation ae lt Introduction gt Introduction The EXAxt ZR Integrated type Zirconia Oxygen Analyzer has been developed for combustion control in various industrial processes There are several version of this analyzer so you can select one that matches your application Optional accessories are also available to improve measurement accuracy and automate calibration An optimal control system can be realized by adding appropriate options This instruction manual describes almost all of the equipment related to the EXAxt ZR You may skip any section s regarding equipment which is not included in your system Regarding the HART Communication Protocol refer to IM 11M12A01 51E IM11M12A01 51E has been published as Model EXAxt ZR series HART protocol Regarding Separate type Zirconia Oxygen Analyzer refer to IM 11M12A01 02E lt Before using the equipment please read any descriptions in this manual related to the equipment and system that 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 eae F z z Specification Installation Operation Maintenance CMPL ZR202G Integrate
16. 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 in stalled as described in Section 10 5 2 Fully clockwise turn the valve regulator by hand 2 Next adjust the flow rate 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 counter clockwise At that time the flow rate also decreases as the inner pressure of the gas cylinder de creases 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 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 calibration twice 4 Stop the zero gas flow Turn the zero gas valve regulator fully clockwise If this valve regulator is not pr
17. Figure 5 4 Wiring for Analog Output 5 2 1 Cable Specifications Use a 2 core shielded cable for wiring 5 2 2 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 cover loosen the lock screw If the screw is not loosened first the cover will be improperly engaged to the body and the terminal box will require replacement When open ing and closing the cover remove any sand particles or dust to avoid gouging the thread After screwing the cover on the equipment body secure it with the lock screw IM 11M12A01 04E 5 4 lt 5 Wiring gt 5 3 Wiring Power and Ground Terminals Wiring for supplying power to the analyzer and grounding the equipment Ground 000000000 Grounding to the earth terminal on the equipment case Equipment case 7 Crimp contact of the grounding line Jumper plate Lock washer Grounding terminal 100 240VAC 50 60Hz F5 5E ai 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 as follows 1 Use a two core or three core cable 2 M4 screws are used for t
18. 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 2 1 00 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 En If you touch the ENT key OPEn and the currently measured value are ENT gt 20 84 displayed alternately Open the Flow Setting Unit span gas flow valve and adjust the span gas flow to 600 60 ml min To do this 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 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 gt A ENT If you touch the ENT key all the digits flash At that point no calibration is R conducted yet The symbol EP indicates that the key is being touched Light characters indicates that the digits are flashing IM 11M12A01 04E 7 18 lt 7 Startup gt Table 7 13 Conducting Calibration Continued Switch operation Display Description gt
19. Moisture content in a reference gas changes increases greatly If air at the detector installation site is used for the reference gas large change of moisture in the air may cause an error in measured oxygen concentration value vol 0 When this error is not ignored use a gas in which moisture content is constant such as instrument air in almost dry condition as a reference gas In addition change of moisture content in exhaust gas after combustion is also considered as a cause of error However normally this error is negligible 3 Calibration gas span gas is mixing into the sensor due to leakage If the span gas is mixing into the sensor due to leakage as a result of failure of the valve provided in the calibration gas tubing system the measured value shows a value a little higher than normal Check valves needle valves check valves solenoid valves for automatic calibration etc in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed states In addition check the tubing joints for leakage 4 The reference gas is mixing into the measuring gas and vice versa Since the difference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller the measured value shows a higher value An error which does not appear as the Error 1 may occur in the sensor Sample gas and or the reference gas may be leaking Visually inspect the sensor If any
20. Oxygen concentration high alarm high high alarm limit values vol O Oxygen concentration low alarm low low alarm limit values vol O Oxy gen concentration alarm hysteresis vol O Oxygen concentration alarm detection alarm delay seconds Selection of contact input 1 and 2 selection of contact output 1 and 2 abnor mal high high alarm high alarm low alarm low low alarm maintenance calibrating range switching warming up calibration gas pressure decrease flameout gas detection answer back of contact input Converter Output Contact Output Contact Input Self diagnosis Calibration lt 2 Specifications gt 2 5 One mA analog output point 4 to 20 mA DC maximum load resistance of 550Q with mA digital output point HART minimum load resistance of 2500 Range Any setting between 0 to 5 through 0 to 100 vol O in 1 vol O and partial range is available Maximum range value minimum range value 1 3 or more For the log output the minimum range value is fixed at 0 1 vol O 4 to 20 mA DC linear or log can be selected Input output isolation Output damping 0 to 255 seconds Hold non hold selection preset value setting possible with hold Two points contact capacity 30V DC 3A 250V AC 3A resistive load One of the output points can be selected to ether normally energized or nor mally de energized status Delayed functions 0 to 255 seconds and hysteresis function 0 to 9 9 vol O can
21. g Reference gas outlet PIPING ii Il Flange 1 PIPING F 2 1 2 NPT or the like Stop valve Wiring connection 49 1 4 or 1 4NPT Calibration gas inlet F4 12E ai 1 Dimension may vary depending on the detector type Ensure that the flange gasket does not block off the reference gas outlet Where necessary make a notch on the flange Figure 4 12 Oxygen Analyzer with Pressure Compensation Ensure that the furnace gas does not flow into the probe Valve operation 1 For safety stop the furnace that the detector is to be installed in If furnace internal pressure is high this is especially dangerous 2 Before starting instrument air flow completely shut the stop valve in front of the reference gas outlet 3 Check that the reference gas outlet is not blocked by a flange gasket or the like IM 11M12A01 04E lt 4 Piping gt 4 7 4 Set the instrument air pressure higher than furnace internal pressure 5 Completely open the stop valve in front of the reference gas outlet and after turning on instru ment air flow start furnace operation As furnace internal pressure rises confirm that instrument air continues to flow and adjust the valve or increase supply pressure if necessary 6 After furnace internal pressure stabilizes adjust flow 7 If furnace operation is stopped stop instrument air flow and completely shut the stop valve in front of the reference gas outlet You may leave reference gas flowing if you w
22. ter code Output contact 1 Operation E10 0 Operated in closed status Normally de energized 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 alarm E21 0 Not operated if a high high alarm occurs 1 Operated if a high high alarm occurs Note 2 High alarm E22 0 Not operated if a high alarm occurs 1 Operated if a high alarm occurs Note 2 Low alarm E23 0 Not operated if a low alarm occurs 1 Operated if a low alarm occurs Note 2 Low low alarm E24 0 Not operated if a low low alarm occurs 1 Operated if a low low alarm occurs Note 2 Maintenance E25 0 Not operated during maintenance 1 Operated during maintenance see Section 8 3 1 Calibration E26 0 Not operated during calibration 1 Operated during calibration see Section 8 3 1 Measurement range E27 0 Not operated when changing ranges change 1 Operated when changing ranges Note 3 Warm up E28 0 Not operated during warming up 1 Operated during warming up Calibration gas E29 0 Not operated while a calibration gas pressure decrease contact is pressure decrease being closed 1 Operated while a calibration gas pressure decrease contact is being closed Note 4 Unburnt gas E32 0 Not operated while a unburnt gas detection contact is being closed detection Operated while a unburnt gas detection contact is being closed Note 5 Note 1 Output contac
23. 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 Nm If they are not uniformly tightened the sensor or heater may be damaged Check with light that there is no gap between sensor flange and probe Replacement of the sensor assembly is now complete Install the detector and restart operation Calibrate the instrument before making a measurement IM 11M12A01 04E 11 4 lt 11 Inspection and Maintenance gt Metal O ring Sensor cell U shaped pipe Dust filter support optional Bolts four g gt 00 gt 9 gt Filter U shaped pipe Washers wT four 1 8 turn tighten bolts 1 8 turn F11 3E ai approximately 45 each Figure 11 3 Exploded View of Sensor Assembly A CAUTION Optional Inconel bolts have a high coefficient of expansion If excess torque is applied while the bolts are being tightened abnormal strain or bolt breakage may result So tighten the bolts following the instructions given above 11 1 3 Replacement of the Heater Assembly This section describes the replacement procedure for the heater assembly 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 assembly reaches high temperatures and is subjected to high voltages So maint
24. A failure of the thermocouple at the detector occurred 2 A failure of the electrical circuits occurred lt Search for cause of failure and Take measures 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 assembly is normal if the resistance is lower than about 900 If the resistance is higher than that value the heater assembly may be defective In this case replace the heater assembly refer to Section 11 1 3 Replacement of the Heater Assembly Heater wire Multimeter Q F12 2E ai 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 50 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 assembly refer to Section 11 1 3 Replacement of the Heater Assembly IM 11M12A01 04E 12 8 lt 12 Troubleshooting gt 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 t
25. AN ENT ZEro If you touch the ENT key again the flashing stops and ZEro Y appears y5 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 Cali bration Setup earlier in this manual To cancel the above touch the gt key and ENT key together then the display returns to ZEro Y If you touch the ENT key OPEn and the currently measured value are displayed alternately Open the Flow Setting Unit zero gas flow valve and adjust the zero gas flow to 600 60 ml min To do this 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 touch 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 m
26. Contact Setup sssessseniea AAN 8 8 8 5 1 Output Contact ceccceccceecceeeeeeceeeeceeeeeeeeeesaceeseneeseneeseaeeeeeeseineesens 8 8 8 5 2 Setting Output Contact 2 eee eeceee eens eeeeeeeeeeeeaeeeeeeeeeeeeireeeeeas 8 9 8 5 3 Default Valties aseisiin ai aiandi nain diiidan iaai 8 10 8 6 Input Contact Settings rnanvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnennnennnvnnnennnennnennnennnennnennnennn 8 11 8 6 1 setting Input Contact uvuuasmnseisansesdsensesdnanider 8 11 8 6 2 Default Valties siisii aiaiai ainada aiaiai naia iaiia 8 11 8 7 Other Setho S saaneina A AARAA AERAR 8 13 8 7 1 Setting the Date and Time mssnanvnnnvnnnvvnnvnnnvnenrnenvernrnnnrnenressresnreenn 8 13 8 7 2 Setting Periods over which Average Values are Calculated and Periods over which Maximum and Minimum Values Are Monitored 8 14 8 7 3 Setting FUels nsnansnunartnitdnideracenakadridniadaadsin 8 15 8 7 4 Setting Purding osanik anan aan aaan 8 19 Cabana 9 1 9 1 Calibration Briefs sicasccisstesseteccelccnentcinitesentcvnestcasneesiel cvtuctcascresusievtesteantresenasnecdes 9 1 9 1 1 Principle of Measurement srnnnnrnnnnvnnnnvnnnnnvnnnvnnnnnnnrnnnvnnnnnnrnnnnrnnn 9 1 9 1 2 Calibration EEE 9 2 9 1 3 OL 0 10 0121 0 151 110 PE 9 2 9 1 4 Characteristic Data from a Sensor Measured During Calibration 9 4 9 2 Calibration ProC QUIS ivsiiiscissinessinceisstixaccnasinnesdecensecnnenessauncisshexenetntannswiidnevanetaan 9 5 9 2 1 Calibration Setti
27. If the thermocouple voltage is large accurate measurement cannot be achieved Thermocouple Multimeter Q F12 3E ai 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 A D Converter Failure It is suspected that a failure has occurred in the A D converter mounted in the converter electronics 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 the failure and take measures 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 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 04E 12 4 lt 12 Troubleshooting gt 12 2 Displays and Measures to Take When Alarms are Generated
28. Oxygen Concentration 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 maximum oxygen concentration that has been displayed so far will be cleared and a new maximum oxygen concentration will be displayed If the setup period of time is changed the current maximum oxygen concentration will be displayed for more details see Section 8 7 2 earlier in this manual 10 1 15 Minimum Oxygen Concentration The minimum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed If the setup period elapses the minimum 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 7 2 earlier in this manual 10 1 16 Average Oxygen Concentration The average oxygen concentration during the periods over which average values are calculated is displayed If the setup period elapses the average oxygen concentration that has been displayed so far will be cleared and a new average oxygen concentration will be displayed If the setup period of time is changed the current average oxygen concentration will be displayed for more details see Section 8 7 2 earlier in this manual 10 1 17 Span and Ze
29. 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 SD indicates that the corresponding keys are being touched and the light characters indicate flashing 7 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 6 earlier in this manual e Apply an input contact to start calibration 3 To stop calibration midway follow these steps Touch the gt key and ENT key together The calibration will stop and the output stabilization time will be set up Touch the gt key once again to return to the basic panel display and the ana lyzer will be in normal measurement 9 2 2 3 Automatic Calibration No execution operations are required for automatic calibration Automatic calibration starts in accord ance with a preset start day and time Calibration is then executed at preset intervals AA CAUTION Before conducting a semi automatic or automatic calibration run the automatic calibration unit before hand to obtain a calibration flow of 600 60 ml min IIM 11M12A01 04E lt 10 Other Functions gt 1 0 1 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 Da
30. 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 i i Connect piping pairs A A9 B B9 C C9 D D9 Vertical mounting Fixing screw pairs D a amp A Horizontal mounting A EL A Gee amp amp fi iO O Yp YP NIP B re k RR v SY Se Ne NY c Zr20h_g0 ai Figure 11 9 Fixing Flowmeter IM 11M12A01 04E lt 12 Troubleshooting gt 12 1 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 1 1 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 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
31. 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 key to change the numeric value to 0 The numeric value will change from 5 to 6 to 9 and back to 0 If you touch the ENT key all the digits flash 020 Touch the ENT key again to stop the flashing 12 Touch the ENT key once again to switch to the parameter code selection display Basic panel display Touch the gt key together with the ENT key to return to the basic panel display This is not required if you proceed to make another setting The displayed nu meric characters indicate the measurement gas concentration The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing IM 11M12A01 04E 7 8 7 9 lt 7 Startup gt 7 1 1 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 6 Checking Current Loop Switch operation Display Description ENT 0 1 Display after the password has been entered 0 1 Touch the A key to switch to Group G 0 0 Touch the ENT key The output current remains preset with the output hold feature Section 2 3 Touch the key to set
32. after calibration However it is recommended that the pressure regulator for the zero gas cylinders be closed because calibration is not required so often IM 11M12A01 04E lt 11 Inspection and Maintenance gt 11 1 11 Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxt ZR Zirconia Oxygen Analyzer to maintain its measuring performance and normal operating conditions A 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 Otherwise the furnace gas may leak and then the leaking corrosive gas will cause the built in heater or thermocouple to disconnect 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
33. alarm action 3 seconds High high alarm detection Not detected High alarm detection Not detected Low alarm detection Not detected Low low alarm detection Not detected 8 5 8 5 1 Output Contact Setup Output Contact Mechanical relays provide contact outputs Be sure to observe relay contact ratings For details see Section 2 1 General Specifications The following sets forth the operation mode of each contact output Output contact 1 you can select open or closed contact when the contact is operated For output contact 2 contact is 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 9 Setting Output Contacts Operating state When no power is applied to this equipment Output contact 1 Open de energized or closed energized selectable Open Output contact 2 Closed de energized only Closed IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 9 8 5 2 Setting Output Contact Set the output contacts following Table 8 10 Table 8 10 Parameter Codes for Output Contact Setting Set item Parame Set value
34. alloy K9473XG Joint 1 4 FNPT Material Zinc alloy with adapter SUS316 Unit mm Panel cut dimensions View A Horizontal Vertical mounting mounting 22 15 I od i 05 40 2 92 27 2 96 5 H to to x Panel Horizontal mounting E Secondary pressure A gauge Panel Vertical mounting Oo fl N i x av H gt Secondary i IA li Approx 122 lt i G7003XF G7004XF Re 1 4 K9473XK K9473XG 1 4NPT connector F22 1 ai IM 11M12A01 04E 2 18 lt 2 Specifications gt 2 4 6 Zero Gas Cylinder part no G7001ZC The gas from this cylinder is used as the calibration zero gas and detector purge gas e Standard Specifications Capacity Filled pressure Composition 140 3 41 9 8 to 12 MPa G 0 95 to 1 0 vol O remaining N Note Export of such high pressure filled gas cylinder to most countries is prohibited or restricted Unit mm te Co 1 N oO y Weight Approx 6 kg F32 ai 2 4 7 Pressure Regulator G7013XF or G7014XF for Gas Cylinder This regulator valve is used with the zero gas cylinders e Standard Specifications Primary Pressure Secondary Pressure Connection Material Max 14 8 MPa G 0 to 0 4 MPa G Inlet W22 14 threads right hand screw Outlet Rc1 4 or 1 4FNPT Brass body Approx 112 Regulator handle Unit
35. and washer Washer 12 gasket t3 0 Gas flow Mounting nut M12 7 SUS316 9 g fe Sy s p Insert length 1 1050 1550 2050 Dimensions of holes on opposing surface F2 3E ai Flange lt 1 gt A B c t D JIS 5K 65 FF SUS304 155 130 4 15 5 40 ANSI Class 150 4 FF SUS304 228 6 190 5 8 19 12 50 Unit mm IM 11M12A01 04E 2 1 0 lt 2 Specifications gt 2 2 ZAS8F Flow Setting Unit and ZR20H Automatic Cali bration Unit 2 2 1 ZA8F 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 flowmeter and flow control valves to control the flow of calibration gas and reference gas Standard Specifications Flowmeter Construction Case Material Painting Tube Connections Reference Gas Pressure Air Consumption Weight NOTE Calibration gas 0 1 to 1 0 l min Reference gas 0 1 to 1 0 l min Dust proof and rainproof construction SPCC Cold rolled steel sheet Baked epoxy resin Dark green Munsell 2 0 GY 3 1 0 5 or equivalent Rc1 4 or 1 4FNPT Clean air supply of sample gas pressure plus approx 50 kPa G or sample gas pressure plus approx 150 kPa G when a check valve is used maxi mum pressure rating is 300 kPa pressure at inlet of the automatic calibra tion unit Approx 1 5 I min Approx 2 kg U
36. box cover 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 sample gas If you become aware of clogging such as when a higher pressure is required to achieve a specified flow rate clean the calibration gas tube To clean the tube follow these steps 1 Remove the detector from the installation assembly 2 Following Section 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 IM 11M12A01 04E 11 2 lt 11 Inspection and Maintenance gt 11 1 2 Exploded view of co
37. chapter later in this manual When there is no error the Basic panel display will appear IM 11M12A01 04E 1 0 1 0 lt 10 Other Functions gt Table 10 6 Resetting Switch operation Display Brief Description A ENT If an error occurs the error number and are displayed alternately as given on the left PASSno Hold down the ENT key for at least three seconds 000 Touch the ENT key again to switch to the password entry display 000 Enter the password 1102 Intermediate switch operations omitted 01 0 1 Change the parameter code to G30 G01 G30 All the digits light Touch the ENT key to execute resetting up The symbol SD indicates that the corresponding keys are being touched and the light characters indicate flashing indicates that the characters are displayed alternately IM 11M12A01 04E lt 10 Other Functions gt 1 0 1 1 A CAUTION Parameters of blank item are not used for Oxygen Analyzer Table 10 7 Parameter Codes Display related Items in Group A Engineering Engineering Code Item unit Code Item unit A00 Selection 0 Oxygen concentration A50 Span correction ratio 0 i 1 Oxygen analyzer 0 0 A51 Span correction ratio 1 2 Oxygen analyzer 0 0 A52 Span correction ratio 2 3
38. comes with six zero gas cylinders including a spare Each gas cyl inder 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 IM 11M12A01 04E lt 10 Other Functions gt 1 0 1 7 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 zero 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
39. crack is found replace the sensor assembly with a new one Note Data such as cell robustness displayed in the detailed data display should also be used for deciding sensor quality as references IM 11M12A01 04E 12 10 lt 12 Troubleshooting gt 12 3 2 Measured Value Lower Than True Value lt Causes and Measures gt 1 The measuring gas pressure becomes lower Where an increment of the measured value due to pressure change cannot be neglected take measures referring to subsection 12 3 1 1 2 Moisture content in a reference gas changes decreases greatly If air at the analyzer installation site is used for the reference gas large change of moisture content in the air may cause an error in measured oxygen concentration value vol 0 When this error is not ignored use a gas in which moisture content is constant such as instrument air in almost dry condition as a reference gas In addition change of moisture content in exhaust gas after combustion is also considered as a cause of error However normally this error is negligible 3 Calibration gas zero gas is mixed into the sensor due to leakage If the zero gas is mixed into the detector due to leakage as a result of failure of the valve provided in the calibration gas tubing system the measured value shows a value a little lower than normal Check valves needle valves check valves solenoid valves for automatic calibration etc in the calibration gas tubing system
40. data in Table 8 16 use the following equations for calculation Find the value of Z in Equations 1 and 2 using Japanese Standard JIS B 8222 If a precise measure ment is not required obtain the value of Z using a graph for the absolute humidity indicated by a dry and wet bulb hygrometer IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 1 5 e For liquid fuel Amount of water vapor in exhaust gas Gw 1 100 1 24 9h w m kg Theoretical amount of air Ao 12 38 x HI 10000 1 36 m kg Low calorific power HI X value 3 37 10000 x Hx 2 55 m kg where HI low calorific power of fuel h Hydrogen in fuel weight percentage w Moisture content in fuel weight percentage Hx Same as numeric value of HI e For gas fuel Amount of water vapor in exhaust gas Gw 1 100 h2 1 2 Yy Cx Hy wv m m Theoretical amount of air Ao 11 2 x HI 10000 m Im Low calorific power HI X value 1 05 10000 x Hx m m where HI low calorific power of fuel CxHy Each hydrocarbon in fuel weight percentage h2 Hydrogen in fuel weight percentage wv Moisture content in fuel weight percentage Hx Same as numeric value of HI e For solid fuel Amount of water vapor in exhaust gas Gw 1 100 1 24 9h w m kg Theoretical amount of air Ao 1 01 x HI 1000 0 56 m kg Low calorific power HI Hh 25 9h w kJ kg X value 1 11 0 106 1000 x Hx m
41. display SS on the left indicates the date January 1 2000 To set June 21 2000 follow the steps below 00 0 i 01 Touch the gt key to move the position of the digit that is flashing to the right 00 0 01 Touch the key to change to 6 00 06 1 Touch the gt key to move the position of the digit that is flashing to the right one digit 00 06 1 Touch the A key to change to 2 Touch the gt key to move the position of the digit that is flashing to the right one digit Let the rightmost character flash and touch the gt key to display the time Continuously touch the gt key then the date and time are alternately displayed Displayed on the left is 7 18 a m Omitted here Touch the key 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 The symbol De indicates that the corresponding keys are being touched and the light characters indicate flashing IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 1 3 8 7 2 Setting Periods over which Average Values are Calculated and Periods over which Maximum and Minimum Values Are Monitored The equipment enables the display of oxygen
42. for Neal m3 combustion Hz CO2 CH4 CmHn O2 Higher Lower Nm m3 HzO No Coke oven gas 5 2 6 9 3 9 3 0 20428 18209 Blast furnace 0 2 0 20 0 3391 3349 Natural gas 2 0 188 4 3 2 1 6 4 2 37883 34074 Propane CsHs 90 CaHio 10 102055 93976 Butane C3Hs 10 CaHio 90 1254961115868 Gases Molecular Formula Oxygen Nitrogen Hydrogen 12767 Carbon monoxide 12642 Carbon dioxide Methane 39750 35820 Ethane 69638 63744 Ethylene 62991 59060 Propane 99070 91255 Butane 128452118623 T8 8E ai IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 18 8 7 3 2 Use the parameter code table below to set fuel values Procedure Table 8 17 Setting Fuel Values Set item Parameter code Setvalue Engineering units Amount of water vapor in F20 0to 5 m3 kg m3 exhaust gas Theoretical amount of air F21 1 to 20 m3 kg m3 X value F22 0 to 19 99 Absolute humidity of the F23 Oto 1 kg kg atmosphere 8 7 3 3 Default Values When the analyzer is delivered or if data are initialized parameter settings are by default as shown in Table 8 18 Table 8 18 Default Settings of Fuel Values Item Default setting 1 00 m3 kg m8 Theoretical amount of air 1 00 m3 kg m3 X value 1 00 Absolute humidity of the atmosphere 0 1000 k
43. for leakage For manual valves check them after confirming that they are in fully closed states 4 Combustible components exist in the sample gas If combustible components exist in the sample gas they burn in the sensor and thus oxygen concentration decreases Check that there are no combustible components 5 Temperature of the sensor cell reaches 750 C or more If the sensor temperature is 750 C or higher this may indicate that sample gas has leaks into the reference gas side corrosion Also check that the thermocouple resistance is no greater than 150 12 3 3 Measurements Sometimes Show Abnormal Values lt Cause and Measure gt 1 Noise may be mixing in with the converter from the detector output wiring Check whether the equipment is 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 Combustible components in the sample gas may be getting into the sensor If the combustible components show signs of dust the abnormality may be improved by mounting a dust filter K9471UA 4 There may be a crack in the sensor or leakage at the sensor mounting portion If the indication of concentration varies in synchronization with the pressure change in the furnace check whether or not there is a cra
44. for two to three seconds and data initialization starts The initialization is complete and the parameter code selection display then appears The symbol DO indicates that the keys are being touched the light characters indicates flashing N WARNING Do not attempt to turn off the equipment power during initialization while USr Go is flashing IM 11M12A01 04E lt 10 Other Functions gt 1 0 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 con trol 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 ifan 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 can cel the error reset the equipment following the steps below or turn the power off and then back on A CAUTION Make sure that before resetting or restarting the power that there is no problem with the equip ment Ifa problem arises again after the resetting turn the power off and troubleshoot the problem by consulting the Troubleshooting
45. gas into the sensor during measurement 10 6 3 Operating the Zero Gas Flow Setting Valve Operate the zero gas flow setting valve during zero calibration in the following procedures 1 When the OPEn and the measured oxygen concentration appear alternately during calibra tion open the zero gas flow setting valve of the flow setting unit and adjust the flow rate to 600 60 ml min To rotate 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 flowmeter If the sample gas pressure is extremely high adjust the sample gas pressure to obtain pressures listed in Table 10 9 10 Table 10 9 Sample gas pressure kPa 50 100 150 200 250 Flow rate ml min 500 430 380 350 320 IM 11M12A01 04E 1 0 20 lt 10 Other Functions gt 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 the valve shaft has a lock nut to prevent any leakage of zero gas into the sensor during measure ment When the stabilization time elapses the zero calibration will be complete 10 6 4 Treatment After Calibration No special treatment of the instrument is needed
46. in the probe heater wire breakage 2 Faulty thermocouple in the probe 3 Failure in the converter electronics lt Search for cause of failure and Take measures 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 assembly is normal if the resistance is lower than about 900 If the resistance is higher than that value the heater assembly may be defective In this case replace the heater assembly refer to Section 11 1 3 Replacement of the Heater Assembly Heater wire Multimeter Q F12 2E ai Figure 12 2 IM 11M12A01 04E lt 12 Troubleshooting gt 12 3 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 wire may be broken or about to break In this case replace the heater assembly refer to Section 11 1 3 Replacement of the Heater Assembly A CAUTION Measure the thermocouple resistance value after the difference between the probe tip temperature and the ambient temperature decreases to 50 C or less
47. inlet should face down ward Unit mm Gasket t1 5 1050 1550 2050 Direction of the sample gas flow Mount the protector so that the notch is on the downstream side of gas flow Calibration gas inlet Reference gas inlet F3104E ai Figure 3 4 Mounting of detector with a probe protector Dust wear protect NOTE When the probe protector is used in the ZR202G with pressure compensation P instrument air leaking from the probe protector may affect the measured value 3 2 Installation of ZA8F Flow Setting Unit 3 2 1 Installation 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 changes of temperature 5 No vibration 6 Little exposure to rays of the sun or rain IM 11M12A01 04E 3 6 lt 3 Installation gt 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 flowmeter works correctly lt Pipe Mounting gt 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The unit weighs approximately 2 to 3 5 kg 2 Mount the flow setting unit on the pipe by tightening the nuts with the U bolt so t
48. m where w Total moisture content in use weight percentage h Hydrogen content weight percentage The average hydrogen content of coal mined in Japan which is a dry ash free type is 5 7 percent Accordingly h may be expressed mathematically by h 5 7 1100 w a 100 x 100 w 100 w1 where a Ash content w1 Moisture content analyzed on a constant humidity basis Hh Higher calorific power of fuel kJ kg HI Low calorific power of fuel kJ kg Hx Same numeric value of HI Figure 8 3 Calculation Formula IM 11M12A01 04E 8 16 lt 8 Detailed Data Setting gt Wet bulb 29 temperature C 0 000 NSR SSRS Dry bulb temperature C F8 4E ai Figure 8 4 Absolute Humidity of Air Absolute humidity kg kg 24 IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 1 7 Table 8 16 Fuel Data For liquid fuel Chemical component Calorific power Theoretical Amount of combustion weight percentage kJ kg amount of gas Nm3 kg air for properties Specific Ash Higher Lower ombustion W content order order Nmkg CO2 H20 S802 N2 Total Kerosene Light oil Heavy No 1 oil class 1 No 2 Heavy oil class 2 No 1 For gas fuel Fuel i i Sroperies Chemical component Calorific power Theoretical compustion amount o A weight percentage kJ Nm3 air
49. mathemati cally expressed by water vapor caused by combustion and water vapor contained in the exhaust gas V water vapor contained in air for combustion actual exhaust gas including water vapor per fuel x 100 Equation 1 Moisture quantity _SwtGwt 4400 G 2 Sw 161xZxmxAo QQ anan Equation 2 Go Gw m 1 Ao 1 61 x Z x m x Ao 7 Gw 1 61 x Z x m x Ao x 100 X Ao lx m where Ao Theoretical amount of air per unit quantity of fuel m3 kg or m3 m3 ann in Table 8 16 G Actual amount of exhaust gas including water vapor per unit quantity of fuel m3 kg or m3 m3 Gw Water vapor contained in exhaust gas per unit quantity of fuel by hydrogen and moisture content in fuel m3 kg orm3 m3 WWW cette MD in Table 8 16 Gw1 Water vapor contained in exhaust gas per unit quantity of fuel moisture content in air m3 kg or m3 m3 Go Theoretical amount of dry exhaust gas per unit quantity of fuel m3 kg or m3 m3 m Air ratio X Fuel coefficient determined depending on low calorific power of fuel m3 kg or m3 m3 3 in Table 8 16 Z Absolute humidity of the atmosphere kg kg Figure 8 4 Fill in the boxes with fuel parameters in Equation 2 above to calculate the moisture content Use Ao Gw and X shown in Table 8 16 If there are no appropriate fuel
50. mm Secondary rimary pressure gauge Pressure gauge W22 Right Stop valve handed screw Approx 59 Approx 163 IM 11M12A01 04E SE Pri safety valve Approx 82 ro Approx 174 p gt Part No Outlet G7013XF Rc1 4 G7014XF 1 4 NPT female screw lt 2 Specifications gt 2 1 9 2 4 8 Case Assembly E7044KF for Calibration gas Cylinder This case is used to store the zero gas cylinders e Standard Specifications Case Paint Baked epoxy resin Jade green Munsell 7 5 BG 4 1 5 Installation 2B pipe mounting Weight Approx 10 kg including gas cylinder Note Export of such high pressure filled gas cylinder to most countries is prohibited or restricted Pressure regulator de 3XF 0 s gt G7014XF gt Aa Zero gas cylinder 3 ety 7 La ASA carts G7001ZC 496 F 158 3 2B mounting pipe Rabe 060 5 P 1 k The oblique line is an opening portion 160 F23 ai Note The zero gas cylinder and the regulator valve are not included in the E7044KF case assembly 2 49 ZR202A Heater Assembly Suffix code Option code Description Heater Assembly for ZR202G Length 1 0 4m 0 7m 1m 1 5m 2m 2 5m 3m Jig for change with Jig
51. 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 B01 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 im mediately 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 5 3 Calibration Gas Flow 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 detec tor using a polyethylene resin tube with an outside diameter of 6 mm Be careful to prevent gas leakage 3 Fully open the stop valve mounted on the calibration gas inlet of the detector 4 Enter the oxygen concentration of the sealed gas noted from the cylinder into
52. range change 3 Calibration start 4 Detection of non combusted gas E02 Selection of input contact 2 O Invalid Invalid 1 Calibration gas pressure decrease 2 Measurement range change 3 Calibration start 4 Detection of non combusted gas E03 Selecting action of input 0 Action with closed contact Action with closed contact 1 1 Action with open contact contact E04 Selecting action of input 0 Action with closed contact Action with closed contact 2 1 Action with open contact contact E10 Selecting action of output O Action with closed contact nor Action with closed contact 1 mally energized contact 1 Action with open contact normally de energized E20 Output contact 1 error 0 No action No action 1 Action E21 Output contact 1 high high 0 No action No action alarm 1 Action E22 Output contact 1 high 0 No action No action alarm 1 Action E23 Output contact 1 low alarm 0 No action No action 1 Action E24 Output contact 1 low low 0 No action No action alarm 1 Action E25 Output contact 1 during 0 No action Action maintenance 1 Action E26 Output contact 1 during 0 No action No action calibration Action E27 Output contact 1 measure 0 No action No action ment range change 1 Action E28 Output contact 1 during 0 No action Action warm up 1 Action E29 Output contact 1 calibra 0 No action No action tion gas pressure decrease 1 Action E32 O
53. ratio data for estimating the combustion efficiency etc check that no air is leaking in beforehand and that the measured value has not been affected by any interference gas CH CO H etc 10 1 2 Cell Temperature This indicates the cell sensor temperature usually indicating 750 C obtainable from the thermoe lectromotive force and cold junction temperature described below 10 1 3 C J 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 tempera ture exceeds 85 C the electronics may fail When the ZR202G is used the maximum C J tempera ture will be 150 C If the internal temperature exceeds this take measures to reduce the temperature such as by not exposing the equipment to radiation 10 1 4 Amount of Water Vapor in Exhaust Gas Calculate the water vapor in the combusted exhaust gas using parameters set in Section 8 7 3 Set ting Fuels Use the following equation for calculation Moisture water vapor amount of water vapor per unit quantity of fuel moisture in air total amount of exhaust gas Gw 1 61xZxAoxm X Aoxm where Gw Amount of water vapor in exhaust gas m kg or m3 m Z Atmospheric absolute humidity kg kg Ao Theoretical air amount m kg or m m m Air ratio X Fuel coefficient Nm kg or m3 m3 For details on param
54. to conduct a calibration 7 10 2 1 Preliminary Before conducting 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 will be a sample gas plus approx 50 kPa or sample gas pressure plus approx 150 kPa when a check valve is used maximum pressure rating is 300 kPa 7 10 2 2 Calibration Implementation 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 13 Conducting Calibration Switch operation Display Description gt A ENT 0 1 Display after the password has been entered gt 7N ENT b 0 Switch the parameter code to B10 D The key operations for this procedure are omitted gt A CAL Touch the ENT key and CAL will be displayed To cancel the above touch the gt key and ENT key together to return to the B10 display If you touch the ENT key again CAL then flashes To cancel the above touch the gt key and ENT key together the display will return to the B10 display ENT G ENT pe gt A ENT S PAn If you touch the ENT key again SPAn Y appears Y is flashing BS ENT ps
55. 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 ZR202G Integrated type Zirconia Oxygen Analyzer with automatic calibration Automatic Calibration Unit rb t amp 100 to 240 VAC ME a a a oe Contact input ZRO0H OL ea gt Analog output contact output Digital output HART A Air Set Reference gas a 4 Instrument air Span gas Calibration gas Zero L Pressure regulator Zero gas cylinder Calibration gas unit case Note The installation temperature limits range for integrated type analyzer is 20 to 55 C acai Figure 4 9 Piping for System 3 IM 11M12A01 04E Horizontal mounting on the ZR202G 214 44 MAX lt gt A Fu Span gas inlet Rc1 4 or 1 4NPT Female Installation of ZR20H Automatic Calibration Unit Display side lt 4 Piping gt Unit mm Terminal box side Zero gas inlet Rc1 4 or 1 4NPT Female Vertical mounting on the ZR202G B 180 44 MAX gt Piping Diagram png 3 ZR202G body Calibration gas Reference gas Span gas inlet Rc1 4 or 1 4NPT Female Reference gas inlet Rc1 4 or 1 4NPT Female 166 5
56. when a check valve is used maximum pressure rating is 300 kPa 2 Check that the oxygen concentration of the zero gas and span gas instrument air 21 vol 0 in the cylinder is set for the converter 10 6 2 Operating the Span Gas Flow Setting Valve The following description is given assuming that instrument air the same as the reference gas is used as the span gas For more details see Section 7 10 2 Manual Calibration 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 counter clockwise To check the flow rate use the calibration flowmeter If the sample gas pressure is extremely high adjust the sample gas pressure to obtain pressures listed in Table 10 8 10 Table 10 8 Sample gas pressure kPa 50 100 150 200 250 Flow rate ml min 500 430 380 350 320 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 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
57. when automatic calibration is specified 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 automatic calibration is to be required after the ZR202G has been installed Ask Yokogawa service station for its mounting Construction Mounting Materials Finish Piping Connection Power Supply Power consumption Dust proof and rainproof construction NEMA4X IP67 excluding flowmeter Mounted on ZR202G no vibration Body Aluminum alloy Piping SUS316 JIS SUS304 JIS Flowmeter MA Methacrylate resin Bracket SUS304 JIS Polyurethane corrosion resistance coating Case Mint green Munsell 5 6 BG3 3 2 9 Cover Mint green Munsell 5 6 BG3 3 2 9 Re 1 4 or 1 4 NPT 24V DC from ZR202G Approx 1 3 W Reference Gas Pressure Sample gas pressure plus Approx 150 kPa 690 kPa max Pressure at Air Consumption Weight Ambient Temperature Ambient Humidity Storage Temperature Model and Codes Model Suffix code Option code Description inlet of automatic calibration unit Approx 1 5 l min Approx 2 kg 20 to 55 C no condensing and freezing 0 to 95 RH 30 to 65 C Automatic calibration unit for ZR202G 1 Gas piping connection Re 1 4 1 4 NPT Instrument air Pressure compensated Mounting Horizontal mounting Vertical mounting Always A
58. 1 MM 01 DD 00 00 IM 11M12A01 04E 9 8 lt 9 Calibration gt 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 Description gt A ENT 1 1 Change the parameter code to b11 Previous operations omitted Touch the ENT key to display SA CAL Semi Auto CAL Touch the ENT key again to open the span gas solenoid valve The span gas then flows SPAn and the currently measured value are alternately displayed If the output hold is set the output hold will start at this time If the set calibration time elapses the span gas solenoid valve closes automatically the zero gas solenoid valve opens and the zero gas flows ZEro and the currently measured value are displayed alternately End If the set calibration time elapses the zero gas solenoid valve then closes automatically The CALEnd flashes until the set output stabiliza tion time elapses Basic panel If the output stabilization time elapses the basic panel display then ap display pears Output holding will be released 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
59. 2 None Always A A Suffix code of length should be selected as same as ZR202G installed 2 Jig part no is K9470BX to order as a parts after purchase Note The heater is made of ceramic do not drop or subject it to pressure stress e External Dimensions Unit mm L length Model amp Code L Weight kg ZR202A 040 552 Approx 0 8 Jigiskchahge gt ZR202A 070 852 Approx 1 2 q ZR202A 100 1152 Approx 1 6 K9470BX ZR202A 150 1652 Approx 2 2 ZR202A 200 2152 Approx 2 8 ZR202A 250 2652 Approx 3 4 ree ZR202A 300 3152 Approx 4 0 IM 11M12A01 04E lt 3 Installation gt 3 1 3 Installation This chapter describes installation of the following equipment 3 1 Model ZR202G Integrated type Zirconia Oxygen Analyzer 3 2 Model ZA8F Flow Setting Unit 3 3 Model ZR20H Automatic Calibration Unit 3 4 Case Assembly E7044KF for Calibration gas Cylinder 3 1 Installation of ZR202G Zirconia Oxygen Analyzer 3 1 1 Installation Location The following should be taken into consideration when installing the probe 1 Easy and safe access to the probe for checking and maintenance work 2 Ambient temperature of not more than 55 C and the terminal box should not be affected by radiant heat 3 A clean environment without any corrosive gases NOTE A natural convection type analyzer model ZR2026 0 0 0O 0 C which uses ambient air as refer ence gas req
60. 4E 3 8 lt 3 Installation gt Horizontal mounting on the ZR202G A Unit mm Display side m Terminal box side m I 7 L AL I oO Tt N Y Zero gas inlet 4048 66 5 Rc1 4 or 1 4NPT Female lt gt gt 166 5 Span gas inlet Reference gas inlet Rc1 4 or 1 4NPT F l Rc1 4 or 1 4NPT Female OLOF Female Vertical mounting on the ZR202G B 166 5 Span gas inlet Rc1 4 or 1 4NPT Female 6 8 Oo t 10 T h N Reference gas inlet Zero gas inlet 180 44 MAX Rc1 4 or 1 4NPT Female 40 40 66 5 Rc1 4 or 1 4NPT Female lt gt lt gt lt gt lt gt F3 15E ai Figure 3 15 Automatic Calibration Unit Mounting IM 11M12A01 04E lt 3 Installation gt 3 9 3 4 Installation of the Case Assembly E7044KF for Calibration Gas Cylinder The case assembly is used to store the G7001ZC zero gas cylinders 3 4 1 Installation Location The following should be taken into consideration 1 Easy access for cylinder replacement 2 Easy access for checking 3 Near to the detector and converter as well as the flow setting unit 4 The temperature of the case should not exceed 40 C due to rays of the sun o
61. 5 use a probe protector Case Aluminum alloy Paint Color Cover Mint green Munsell 5 6BG3 3 2 9 Case Mint green Munsell 5 6BG3 3 2 9 Finish Polyurethane corrosion resistance coating Weight Insertion length of 0 4m approx 8 kg JIS 5K 65 approx 13 kg ANSI 150 4 Insertion length of 1 0m approx 10 kg JIS 5K 65 approx 15 kg ANSI 150 4 Insertion length of 1 5m approx 12 kg JIS 5K 65 approx 17 kg ANSI 150 4 Insertion length of 2 0m approx 14 kg JIS 5K 65 approx 19 kg ANSI 150 4 Insertion length of 3 0m approx 17 kg JIS 5K 65 approx 22 kg ANSI 150 4 IM 11M12A01 04E 2 4 lt 2 Specifications gt Functions Display Function Alarm Error Display Calibration Functions Maintenance Functions Setup Functions Display and setting content Display Related Items Displays values of the measured oxygen concentration etc Displays alarms such as AL 06 or errors such as Err 01 when any such status occurs Auto calibration Requires the Automatic Calibration Unit It calibrates automatically at specified intervals Semi auto Calibration Requires the Automatic Calibration Unit Input cali bration start signal by optical switch or contact then it calibrates automatically afterwards Manual Calibration Calibration with opening closing the valve of calibration gas in operation interactively with the optical switch Can operate updated data settings in daily
62. 6 10 1 16 Average Oxygen Concentration wanrnanrnanrnnnvnrnrnenrnrnrnrnrnrnrnrnveennr 10 6 10 1 17 Span and Zero Correction Ratios rrnrrnnnrnnrnrnrrnrnrrnnrnnnnrnnrnnnnrnnn 10 6 10 1 18 History of Calibration Time rranrronrnonvnonrnrnrnrnrrenrnrnrrrnrnrnrnenrnenneennr 10 7 10119 TMe ieia iaaa nea 10 7 10 1 20 Software Revision ccccccccceeececeeeeeeeeeeeeeeeeeeeeseaeeecaeeesaeeeseneeseas 10 7 10 2 Operational Data Initialization eavrnnnnrnnnnvnnnnvnnnnvnnnnnnnnnnvnnnnvnnnnvnnnnnnnnnnnnn 10 7 10 3 Initialization Procedure rrnnnnnnnnnnnnvnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 10 8 10 4 PROS E E EE E 10 9 10 5 Handling of the ZO21S Standard Gas Unit musversvrnnvennvnnnvennvnnnnnnnvensvennen 10 16 10 5 1 Standard Gas Unit Component Identification eonrenrnnnnnnnn 10 16 10 5 2 Installing Gas Cylinders vu uvunnvanavdnmininrianedeid 10 16 10 5 3 Calibration Gas FOW asierea aiani aaiae ani aaaea 10 17 10 6 Methods of Operating Valves in the ZA8F Flow Setting Unit 10 19 10 6 1 Preparation Before Calibration ccccccccceeeceeeeeeeeeneeseneeteneees 10 19 10 6 2 Operating the Span Gas Flow Setting Valve 00 eects 10 19 10 6 3 Operating the Zero Gas Flow Setting Valve ranrranrnnnrnnnrnnnrnnnn 10 19 10 6 4 Treatment After Calibration ccccceeecceeeeeeeeeeeeeeeeeaeeeeeeeeeneeess 10 20 11 Inspection and Maintena
63. 690 kPa maximum for the ZR20H is obtained Turn the reference gas flow setting valve in the flow setting unit to obtain the flow of 800 to 1000 ml min Turning the valve shaft counterclockwise increases the rate of flow When turning the valve shaft if the valve has a lock nut first loosen the lock nut After completing the valve setup be sure to tighten the lock nut NOTE The calibration gas flow setting will be described later Fully close the needle valve in the flow setting unit 7 3 Supplying Power to Converter A CAUTION To avoid temperature changes around the sensor it is recommended that the power be continuously supplied to the Oxygen Analyzer if it is used in an application where its operations and suspensions are periodically repeated 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 tem perature 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 tem perature and the sample gas temperature After the sensor temperature has stabilized at 750 C the converter is in the measurement mode The display panel then displays the oxygen concentration as in Figure 7 2 This is called the basic panel display Figure 7 1 Display of Sensor Temperature Figure 7 2 Measuremen
64. Analog output selected A53 Span correction ratio 3 A01 Oxygen concentration O A54 Span correction ratio 0 A02 A55 Span correction ratio 3 A03 A56 Span correction ratio 2 A04 A57 Span correction ratio 1 A05 A58 Span correction ratio 2 A06 Air ratio A59 Span correction ratio 1 A07 Cell temperature C A60 Zero correction ratio 0 A08 Cold junction temperature C A61 Zero correction ratio 1 A09 Meas gas temperature C A62 Zero correction ratio 2 A10 Amount of water vapor in exhaust gas A63 Zero correction ratio 3 A11 Cell voltage mV A64 Zero correction ratio 4 A12 TC voltage mV A65 Zero correction ratio 5 A15 Cold junction voltage mV A66 Zero correction ratio 6 A16 Output current mA A67 Zero correction ratio 7 A20 Cell response time Seconds A68 Zero correction ratio 8 A21 Cell internal resistance Q A69 Zero correction ratio 9 A22 Cell robustness A70 Calibration history 0 YY MM DD HH MM A23 Heater on time ratio A71 Calibration history 1 YY MM DD HH MM A24 Oxygen concentration with time constant O A72 Calibration history 2 YY MM DD HH MM A25 A73 Calibration history 3 YY MM DD HH MM A26 A74 Calibration history 4 YY MM DD HH MM A30 Max oxygen concentration O A75 Calibration history 5 YY MM DD HH MM A31 Occurrence of maximum oxygen concen YY MM DD A76 Calibration history 6 YY MM DD tration HH MM HH MM A32 M
65. Group B setup Sets and performs calibration Group C setup Sets analog output Group D setup Sets an alarm Group E setup Sets the input and output contacts Group F setup Selects the type of equipment and sets the parameters for computation Group G setup Performs the current loop or contact checks 7 4 3 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 gt A 0 upi i i i ENT 21 0 Warm up is complete and the basic panel is now displayed PAS Sno Continuously touch the ENT key for at least three seconds to display PASSno 000 Touch the ENT key again This allows you to change the leftmost digit that is flashing 000 Set the password 1102 If you touch the A key the digit that is flashing will be 1 1 00 Touch the gt key to move the position of the digit that is flashing to the right one digit 1 00 Touch the A key to change the numeric value to 1 1 1 0 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 0 Touch the A key to change the numeric value to 2 Continuously touch key and the
66. NTS Fe Let e lUo oln acacia tees cece cases antares i For the safe use of this equipment rsnrnnrnnrnnvnnvrnnvnnvrnnnnnnnnvnnvnnnnnnennennvnnnnnnennernennnnnnnn iii 9 NOTICE aid ae biene vi After Sales Warranty mennnnnnnnnvrnornvnnnnvnnornvnnnnnnnennennnnnnnnnnvnnennnnnnnnnnennnnnnnnnnennennnnnnnennn vii 1 OVE EM 1 1 1 1 lt EXAxt ZR gt System Configuration r rsnvnnnvnnnvnnnvnnnvnnnvnnnnnnnnnnnnnnnnnnnnnnnennnr 1 1 1 1 1 System EEE NE EE 1 1 1 1 2 REE 1 2 1 1 3 SYStEm Snudde E EN 1 3 1 2 lt EXAxt ZR gt System Components rnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 1 4 1 2 1 System Components arnnnvrnsvrnnvnnn vnr vonnvnnnvnnnnnnnnnnrnrennrnsnrernreenrernreennn 1 4 1 2 2 Oxygen Analyzer and Accessories nusnrsrrnnvrrnvrrnnrnnnrnnnrnrnrrenrrrnreennr 1 4 2 Specifications En 2 1 2 1 General Specifications rrrnvnnnnvnnnnvnnnnnnnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 1 2 1 1 Standard Specifications cccccccccceeeceeeeeeeeeceeseeeeeeeeeaeeeeaeeesseeenans 2 1 2 1 2 ZR202G Integrated type Zirconia Oxygen Analyzer 2 2 2 1 3 ZOZ1R Probe Protector nuuueisuinniaidnrgvianladenihnignignigntdnis 2 9 2 2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit 2 10 2 2 1 ZA8F Flow Setting Unit ee eececeeeeeeeeeeseeeeeeeteeeseeeseeeseneeeneeaes 2 10 2 2 2 ZR20H Automatic Calibration Unit 2 12 2 3 20215 Standard Gas Unit 2 seseterveke
67. O Items required for the above system example Pein O To be selected depending on each application For details refer to corresponding chapter Select either 1 2 2 Oxygen Analyzer and Accessories Sample gas temperature 0 to 700 C Mounting Insertion length General use Probe Application Horizontal 0 4 Boiler Fa to Detector Heating furnace vertical 2m ZR202G Vertical 2 5m 1 l Q or more Probe Protector Detector For pulverized coal boiler with gas flow velocity Horizontal 3m ZO21R ZR202G 10 m sec or more venice or less G ra Cement Kiln IT Sample inlet Horizontal 0 4 mone Black liquid recovery boiler to to Detector ZR202G Cement Kiln vertical 2m or Dust Guard 4 6 Vertical 2 5m Protector or more K9471UC F1 4E ai IM 11M12A01 04E 2 2 1 2 1 1 lt 2 Specifications gt 2 1 Specifications This chapter describes the specifications for the following ZR202G General use Integrated type Zirconia Oxygen Analyzer See Section 2 1 2 ZO21R L Probe Protector See Section 2 1 3 ZA8F Flow Setting Unit See Section 2 2 1 ZR20H Automatic Calibration Unit See Section 2 2 2 ZO215 Standard Gas Unit See Section 2 3 K9471UA Dust Filter for Oxygen Analyzer See Section 2 4 General Specifications Standard Specifications Measured Object Oxygen concentration in combustion exhaust gas and mixed gas excluding inflam mable gases May not be applicable corrosive gas such as ammonia chlorine is
68. 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 High alarm setpoint Hysteresis 2 0 Oxygen concentration Delayed time Delayed time Delayed time 5 seconds 5 seconds 5 seconds Alarm output ON OFF F8 2E ai Figure 8 2 Alarm Output Action IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 7 In the example in Figure 8 2 the high alarm point is set to 7 5 O the delayed time is set to five sec onds and hysteresis is set to 2 O Alarm output actions in this figure are expressed as follows 1 Although oxygen concentration measurement A has exceeded the high alarm setpoint A falls lower than the high alarm setpoint before the preset delayed time of five seconds elapses So no alarm is issued 2 Oxygen concentration measurement B exceeds the high alarm setpoint and the delayed time has elapsed during that measurement So an alarm results 3 Although oxygen concentration measurement C has fallen 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 Oxygen concentration measurement D has fallen below the hysteresis set value and the preset delayed time during measurement has elapsed so the alarm is canceled 8 4 3 Alarm Setting Set the alarm setpoints following Tab
69. The contact output relays are rated 30 V DC 3A 250 V AC 3A Connect a load e g pilot lamp and annunciator within these limits 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 0 RE DI 2 o PT DI C oc o ne Contact input 2 F5 7E ai Contact input 1 Figure 5 14 Contact Input Wiring 5 5 1 Cable Specifications Use a 2 core or 3 core cable for this wiring Depending on the number of input s determine which cable to use IM 11M12A01 04E 5 6 lt 5 Wiring gt 5 5 2 Wiring Procedure 1 M4 screws are used for the terminal of the converter Each cable should be equipped with the corresponding crimp contact 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 IM 11M12A01 04E lt 6 Components gt 6 1 6 Components This chapter describes the names and functions of components for the major equipment of the EX Axt ZR Integrated type Zirconia Oxygen Analyzer 6 1 ZR202G Zirconia Oxygen Analyzer 6 1 1 Integrated type Zirconia Oxygen Analyzer Terminal box Non explosion proof JIS C0920 equivalent to IP44D Equivalent t
70. a hint to knowing the sensor is degrading The updated values obtained during the calibration are displayed 10 1 11 Robustness of a Cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed as one of four time periods during which the cell may still be used 1 more than a year 2 more than six months 3 more than three months 4 less than one month The above four time periods are tentative and only used for preventive maintenance not for warranty of the performance This cell s robustness can be found by a total evaluation of data involving the response time the cell s internal resistance and calibration factor However if a zero or span calibration was not made the response time cannot be measured In such a case the response time is not used as a factor in evalu ating the cell s robustness Table 10 3 Cell Robustness and Service Life Cell robustness Cells service life 5 One year min 3 Six months min 2 Three months min 1 One month max IM 11M12A01 04E 1 0 6 lt 10 Other Functions gt 10 1 12 Heater On Time Ratio The probe sensor is heated to and maintained at 750 C When the sample gas temperature is high the amount of heater ON time decreases 10 1 13 Oxygen Concentration with time constant When the output damping is specified in the mA output range setting the corresponding time constant is also displayed 10 1 14 Maximum
71. a series of calibrations until the preset output stabilization time elapses In an automatic calibration during 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 IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 5 8 3 2 8 3 3 8 3 4 Preference Order of Output Hold Value The output hold value takes the following preference order During error occurrence During calibration Preference order high During maintenance During warm up 8 3 2E siki For example if the output current is set to 4 mA during maintenance and without hold output during calibration is preset the output is held at 4 mA in the maintenance display However the output hold is released at the time of starting the calibration and the output will be held again at 4 mA after completing the calibration and when the output stabilization time elapses Output Hold Setting Table 8 5 lists parameter codes with set values for individual set items Table 8 5 Parameter Codes for Output Holding Set items Parameter code Set value During warm up C04 0 4mA 1 20 mA 2 Holds Set value During maintenance C05 0 Without hold feature 1 Last measured value 2 Holds set values During calibration C06 0 Without hold feature 1 Last measured
72. alid At that point the relationship as in Figure 9 1 is effected between the oxygen concentration of the measure ment gas in contact with the positive electrode and the electromotive force of the sensor cell where a comparison gas of air is used on the negative electrode side IM 11M12A01 04E lt 9 Calibration gt N O i 1 1 1 1 1 1 1 1 l 1 1 4 1 ead EO 100 4 c 0 ni 1 1 1 1 1 y I 1 l 4 bites 1 1 1 I i f calibration 4 I 1 l I 1 l 1 Tat 1 i 1 1 E 1 1 1 UG Cell voltage aa mV 1 I o a lt Q xs Q 1a lor a 3 N Ea 1 o ii Q o Jo gan 1 1 1 1 1 1 1 ol 1 1 1 1 1 1 1 1 4 Oo N Oo 1 1 1 1 1 1 1 1 1 1 1 1 i 1 i 1 4 Oxygen concentration vol 02 F9 1E ai Figure 9 1 Oxygen Concentration in a Measurement Gas vs Cell Voltage 21 vol 0 Equivalent The measurement principles of a zirconia oxygen analyzer have been described above However the relationship between oxygen concentration and the electromotive force of a cell is only theoretical Usually in practice a sensor shows a slight deviation from the theoretical value This is the reason why calibration is necessary To meet this requirement an analyzer calibration is conducted so that a calibration curve is obtained which corrects the deviation from the theoretical ce
73. alue of 2000 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 11 IM 11M12A01 04E 12 6 lt 12 Troubleshooting gt 12 2 2 3 Alarm 7 Span Calibration Coefficient Alarm In calibration this alarm is generated when the span gas correction 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 cell assembly is damaged and the cell voltage is abnormal lt Search for cause of failure and Take measures 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 out re calibration it is suspected that improper calibration conditions were the cause of the alarm i
74. alve condensed water may be produced 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 04E 4 2 lt 4 Piping gt 4 1 1 Piping Parts for System 1 Check that the parts listed in Table 4 1 are provided Table 4 1 Piping Parts Equipment Piping location Parts Name Description Oxygen Analyzer Calibration gas inlet Stop valve L9852CB or G7016XH recommended by YOKOGAWA Nipple Rc1 4 or 1 4 NPT General parts Joint for tube connection Rc1 4 1 4NPT fora General parts 6x4mm soft tube Reference gas inlet Sealed up when piping is required refer to Section 4 1 3 Note Parts with marking are used when required General parts can be found on the local market 4 1 2 Piping for the Calibration Gas When carrying out calibration connect the piping 6 0 D x 4 1 D mm tube from the standard gas unit to the calibration gas inlet of the oxygen analyzer Mount the stop valve of a quality specified by YOKOGAWA through a nipple found on the local market as illustrated in Figure 4 2 and mount a joint also found on the local market at the stop valve tip The stop valve may be mounted on the equipment when the oxygen analyzer is shipped Note Mount the stop valve in the vicinity of the equipment Stop valve Tube connectio
75. an 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 anumber on four levels IIM 11M12A01 04E lt 9 Calibration gt 9 5 9 2 Calibration Procedures A CAUTION Calibration should be made under normal operating conditions if the probe is connected to a furnace the analyzer will undergo calibration under the operating conditions of the furnace To make a precise calibration conduct both zero and span calibrations 9 2 1 Calibration Setting The following sets forth the required calibration settings 9 2 1 1 Mode 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 touch panel or a contact input and undergoes a series of calibration operations following preset calibration periods and stabilization time 3 Automatic calibration which is carried out automatically following preset calibration periods Calibrations are limited by the following mode selection 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 W
76. anual 7 7 1 Minimum Current 4 mA and Maximum Current 20 mA Settings Use the parameter codes C11 to set the oxygen concentration at 4 mA and C12 to set the oxygen concentration at 20 mA The following shows where 10 O is set at 4 mA and 20 O at 20 mA IM 11M12A01 04E 7 10 lt 7 Startup gt Table 7 5 Minimum and Maximum Value Setting Procedure Switch operation Display Description gt A ENT 01 Display after the password has been entered ENT 01 Set the oxygen concentration at 4 mA Change the parameter code to C11 Touch the key to switch to Group C D 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 numeric value 1 ENT p 00 Touch the ENT key to display the current set value 0 O has been set ENT 000 Touch the gt key to move the position of the digit that is flashing to the right 010 Touch the key to change the numeric value to 1 If you touch the ENT key all the digits flash Touch the ENT key again to stop the flashing Touch the ENT key once again and the display will switch to the parameter code selection display Set the oxygen concentration at 20 mA Touch the gt key to move the position of the digit that is flashing to the right Touch the key to enter the numeric value 2
77. ated type Zirconia Oxygen Analyzer 2 100 to 240 VAC beets Contact input EEE gt Analog output contact output Digital output HART Calibration gas 100 110 115 200 220 240 V AC Z0218 Standard gas unit F11Eai Figure 1 1 Example of System 1 IM 11M12A01 04E 1 2 lt 1 Overview gt A CAUTION As this system uses ambient air for the reference gas measuring accuracy will be affected by the installation location e Astop valve should be connected to the calibration gas inlet of the equipment The valve should be fully closed unless calibration is in progress 1 1 2 System 2 This system is for monitoring and controlling oxygen concentration in the combustion gases of a large size boiler or heating furnace Instrument air clean and dry air of oxygen concentration 21 is used as the reference gas and the span gas for calibration Zero gas is fed from a cylinder during calibration The gas flow is controlled by the ZA8F flow setting unit for manual valve operation Ea A ZR202G Integrated type Zirconia Oxygen Analyzer Stop valve or Check valve Figure 1 2 IM 11M12A01 04E Q i ii i 100 to 240 VAC i Contact input aes gt Analog output contact output Digital output HART Flowmeter Needle Reference gas valve Air Set PP Ee YA Calibration gas _ a a Instrument air
78. ation 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 initiali zation Table 10 4 lists the initialization items by a parameter 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 Data in Group C F34 Data in Group D F35 Data in Group E F36 Data in Group F A CAUTION When Data in Group F are initialized by the parameter code of F36 FO1 and F02 and F08 and F10 cannot be initialized IM 11M12A01 04E 1 0 8 lt 10 Other Functions gt 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 A ENT F 0 Enter the parameter code for the item to be initialized The following show an example of entering F30 Previous needed operations are omitted 000 Touch the ENT key to switch to the password entry display SD 000 Enter the password 1255 for initialization Ihr ag da Isr After you enter the password and then touch the ENT key all the digits flash Touch the ENT key again to display USr Go Touch the ENT key once more All the digits then flash
79. ay after the password has been entered ENT 0 1 Touch the key to switch to Group G gt A G 1 Touch the gt key to move the position of the digit that is flashing to the right one digit G 1 Touch the A key to enter 1 gt Touch the ENT key to have 0 zero flash The contact is then open Touch the A key to set 1 one Touch the ENT key The flashing continues Touch the ENT key again to stop the flashing and the contact will be closed G 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 settin display q you p 9 The displayed numeric characters indicate the measurement gas concentration The symbol ao indicates that the key is being touched Light characters indicates that the digits are flashing A CAUTION 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 lat
80. be added to high low alarms The following functions are programmable for contact outputs 1 Abnormal 2 High high alarm 3 High alarm 4 Low low alarm 5 Low alarm 6 Maintenance 7 Calibration 8 Range switching answer back 9 Warm up 10 Calibration gas pressure decrease an swer back of contact input 11 Flameout gas detection answer back of 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 Abnormal cell abnormal cell temperature low high abnormal calibration A D converter abnormal digital circuit abnormal Method zero span calibration Calibration mode Auto semi auto and manual All are operated using opti cal switches Either zero or span can be skipped Zero calibration gas concentration setting range 0 3 to 100 vol O in 0 01 vol 0 Span calibration gas concentration setting range 4 5 to 100 vol O in 0 01 vol 0 Use nitrogen balanced mixed gas containing 0 to 10 vol O scale of oxy gen for standard zero gas and 80 to 100 vol O scale of oxygen for stand ard span gas Calibration period date time setting maximum 255 days IM 11M12A01 04E 2 6 Model and Codes Model lt 2 Specifications gt Suff
81. ck 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 furnace inner pressure if the indication of concentration varies with the pressure change in the furnace check whether or not there is leakage in the calibration gas tubing IM 11M12A01 04E Customer Model ZR202G Maintenance Zirconia Oxygen Analyzer Parts List Integrated type 11 12 FO4E ai Item Part No Qty Description 1 K9471UA 1 Dust Filter Option 2 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 7 E7042UD 1 Cell Assembly 8 E7042BS 1 Contact 9 K9470BJ 1 Metal O ring 10 E7042AY 1 Filter Assembly 11 Bolts and Washeres K9470ZF 1 G7109YC X4 E7042DW X4 K9470ZG 1 K9470BK X4 E7042DW X4 for Option code C 12 Calibration Tube Assembly K9470ZK 1 Cal Gas Tube Assembly K9470ZL 1 Cal Gas Tube Assembly for Option code C 13 ZR202A 000 0 A 1 Heater Assembly All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M12A01 04E YOKOGAWA Subject to change without notice 1st Edition Aug 2000 YK Yokogawa Electric Corporation 8th Edition Apr 2012 YK Hood for ZR202G
82. ck that the parts listed in Table 4 2 are provided Table 4 2 Piping Parts Equipment Piping location Parts Name Description Oxygen Analyzer Calibration gas inlet Stop valve or check valve Stop valve L9852CB or G7016XH recommended by YOKOGAWA Check valve K9292DN or K9292DS provided by YOKOGAWA Nipple Rc1 4 or 1 4 NPT General parts Zero gas cylinder User s scope Pressure Regulator G7013XF or G7014XF recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts Reference gas inlet Air set G7003XF K9473XK or G7004XF K9473XG recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts 4 2 2 Note Parts with marking are used when required General parts can be found on the local market Piping for the Calibration Gas This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit and be tween the ZA8F flow setting unit and the ZR202G analyzer The cylinder should be placed in a case assembly E7044KF or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature may not exceed 40 C Mount the pressure regulator recommended by YOKOGAWA on the cylinder Mount the stop valve or the check valve recommended by YOKOGAWA through the nipple found on the local market at the calibration gas inlet of the equipment as illustrated in Figure 4 8 The stop valve or the check valve may have been mounted on the equ
83. concentration average values and maximum 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 8 7 2 1 Procedure Use the parameter code table below to set the average maximum and minimum oxygen concentra tion 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 Parameter Codes for Average Maximum and Minimum Values Table 8 15 Set item Parameter code Set range Units Periods over which average values F11 1 to 255 Hours are calculated Periods over which maximum F12 1 to 255 Hours and minimum values are monitored 8 7 2 2 Default Value When the analyzer is delivered or if data are initialized periods over which average values are calcu lated are set to one hour and periods over which maximum and minimum values are monitored are set to 24 hours IM 11M12A01 04E 8 14 lt 8 Detailed Data Setting gt 8 7 3 Setting Fuels 8 7 3 1 Input Parameters The analyzer calculates the moisture content contained in exhaust gases The following sets forth the fuel parameters necessary for calculation and their entries The moisture quantity may be
84. d a second or later calibration will not be conducted 5 Ifa past date is set to the calibration start day no calibration will be conducted Table 9 1 Parameter Codes for Calibration Setting Set Item ledd dag Set value ger ring Zero gas concentration B01 Set Zero gas concentration 0 Span gas concentration B02 Set Span gas concentration 0 Calibration mode B03 0 Manual calibration 1 Semi automatic and manual 2 Automatic semi automatic and manual Hold Output stabilization time B04 0 minutes 0 seconds to 60 minutes 59 seconds MM SS Calibration time B05 0 minutes 0 seconds to 60 minutes 59 seconds MM SS Calibration interval B06 0 days 0 hours to 255 days 23 hours Date and time Start date and time BO7 Date and time of first calibration YY MM DD HH MM Calibration procedure B08 0 Zero and span 1 Span only 2 Zero only 9 2 1 7 Default Values 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 Default Setting Calibration mode Manual Calibration procedure Span zero Zero gas oxygen concentration 1 00 Span gas oxygen concentration 21 00 Hold Output stabilization time 10 minutes 00 seconds Calibration time 10 minutes 00 seconds Calibration interval 30 days 00 hours Start date and time 00 YY 0
85. d Maximum Oxygen Concentration at 20 mA Set the oxygen concentration values at 4 mA and 20 mA 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 greater than 1 3 times the concentration of oxygen set for the minimum If it does not fall within this input range setting the setting will be invalid and the previous set values will remain 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 13 0 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 75 1 3 Numbers after the decimal point are rounded up N caution When you select logarithmic mode the minimum output remains constant at 0 1 O and the parameter C11 display remains unchanged 8 2 2 Entering Output Damping Constants If a measured value adversely affected by a rapid change in the sample gas oxygen concentration is used for the control means frequent on off actions of the output will result To avoid this the converter allows the setting of output damping constants ranging from 0 to 255 seconds 8 2 3 Selection of Output Mode You can select a linear or logarithmic output mode The former provides linear characteristics between the ana
86. d the ZR20H Automatic Calibration Unit please note that the supplying airflow pressure will vary depending on the furnace pressure IM 11M12A01 04E 4 8 lt 4 Piping gt 4 4 1 Piping Parts for Oxygen Analyzer with Pressure Compensation Check that the parts listed in Table 4 3 are provided Table 4 3 Piping Parts Equipment Piping location Parts Name Description Oxygen Analyzer Calibration gas inlet Check valve or stop Stop valve L9852CB or G7016XH with pressure valve recommended by YOKOGAWA compensation Check valve K9292DN or K9292DS provided by YOKOGAWA Nipple Rc1 4 or 1 4 NPT General parts Zero gas cylinder User s scope Pressure regulator G7013XF or G7014XF recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts Reference gas inlet Note Use parts with marking as required General parts can be found on the local market Air set G7003XF K9473XK or G7004XF K9473XG recommended by YOKOGAWA Joint for tube connection 4 4 2 Piping for the Calibration Gas Calibration gas piping is basically identical to that of System 2 See Section 4 2 2 4 4 3 Piping for the Reference Gas Rc1 4 or 1 4 NPT General parts Reference gas piping is basically identical to that of for System 2 See Section 4 2 3 IM 11M12A01 04E 5 1 lt 5 Wiring gt 5 This Wiring chapter describes wiring procedures necessa
87. d type Oxygen Analyzer O O O O O ZO21R Probe Protector O O ZA8F Flow Setting Unit for manual calibration use O O O ZR20H Automatic Calibration Unit O O O O Case Assembly for calibration O O gas cylinder Part No E7044KF Check valve Part No K9292DN O O K9292DS Dust Filter for the detector Part No K9471UA O O O Dust Guard Protector Part No K9471UC O O ZO21S_ Standard Gas Unit O O O O CMPL Customer Maintenance Parts List Media No IM 11M12A01 04E CD 8th Edition Aug 2015 YK IM 11M12A01 04E All Rights Reserved Copyright 2000 Yokogawa Electric Corporation lt Introduction gt This manual consists of twelve chapters Please refer to the reference chapters for installation opera tion and maintenance Relates to Chapter Outline F 5 F Installation Operation Maintenance 1 Overview Equipment models and system configuration examples O A O 2 Specifications Standard specification model code or part number O O dimension drawing for each equipment 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 A output signal wiring or others 6 Components Major parts and functions are described A O O 7 Startup Basic procedure to start operation of EXAxt ZR Chapter 7enables you to operate the equipment
88. e right one digit ENT 000 90 Touch the key to change the numeric value to 9 ENT 000 90 Touch the gt key to move the position of the digit that is flashing to the right one digit 000 9 Touch the key to change the numeric value to 8 Touch the ENT key to have all the digits flash 000 98 Touch the ENT key again to stop the flashing 01 Touch the ENT key once again to switch to the parameter code selection display Set the span gas concentration by above procedure set 21 Next set the calibration mode Switch the parameter code to B03 Touch the ENT key to display the currently set value If itis 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 03 Touch the ENT key again to stop the flashing Touch the ENT key once again to switch to the parameter code selection display Basic panel display Touch the gt key together with the ENT key to return to the basic panel display This is not required if you proceed to make another setting The displayed numeric characters indicate the measurement gas con centration The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing IM 11M12A01 04E lt 7 Startup gt 7 1 7 7 10 2 Manual Calibration The following describes how
89. e during calibration 2 4 to 21 6 mA 4mA C34 Set value in abnormal state 2 4 to 21 6 mA 3 4 mA Note C07 and C34 is not displayed when option code C2 or C3 NAMUR NE 43 compliant is specified Alarm related Items in Group D Code Item Tuning Engineering unit Default setting D01 Oxygen concentration 0 to 100 O 100 O high high alarm setpoint D02 Oxygen concentration 0 to 100 O 100 O high alarm setpoint DO3 Oxygen concentration 0 to 100 O 0 O low alarm setpoint D04 Oxygen concentration 0 to 100 O 0 O low low alarm setpoint D30 Oxygen concentration 0 to 9 9 O 0 1 O alarm hysteresis D33 Delayed alarm action 0 to 255 Seconds 3 seconds D41 Oxygen concentration 0 Not detected Not detected high high alarm detection 1 Detection D42 Oxygen concentration 0 Not detected Not detected high alarm detection 1 Detection D43 Oxygen concentration 0 Not detected Not detected low alarm detection 1 Detection D44 Oxygen concentration 0 Not detected Not detected low low alarm detection 1 Detection IM 11M12A01 04E 10 14 lt 10 Other Functions gt Contact related Items in Group E Code Item Tuning Engineering unit Default setting E01 Selection of input contact 1 0 Invalid Invalid 1 Calibration gas pressure decrease 2 Measurement
90. e 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 Elec tric 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 Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the nearest sales office described in this instruc tion manual IM 11M12A01 04E lt CONTENTS gt Toc 1 Model ZR202G Integrated type Zirconia Oxygen Analyzer IM 11M12A01 04E 8th Edition CONTE
91. 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 the parameter selection display 2 Used to enter data 3 Advances the operation 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 completely remove your finger from the surface Then touch it again Infrared switches consist of two elements an infrared emitting element and an infrared acceptance el ement Infrared light waves from the element bounces on the operator s finger and are reflected back to the acceptance element thereby causing the infrared switch to turn on and off depending on the strength of the reflected light waves From this operating principles carefully observe the following IM 11M12A01 04E 7 4 lt 7 Startup gt 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 Ifthe infrared switches are exposed to direct sunlight they may not op
92. easured 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 3 When the preset output hold time is up the calibration is complete 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 panel If you touch the gt key and ENT key together then the basic panel display display appears The above display is a result of switch operations The symbol SD indicates the keys are being touched and the light characters indicate flashing indicates that the characters are displayed alternately IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 1 8 Detailed Data Setting 8 1 Setting Display Item Display items are defined as items displayed on the basic panel display Parameter code A00 or F08 is used to set the display items as shown in Table 8 1 The oxygen concentration is set at the factory before shipment In addition if the data initialization is performed the oxygen concentration will be set
93. echadcandet ccgans socccuadshsacasacacieke 12 4 IM 11M12A01 04E Toc 6 lt CONTENTS gt 12 3 Measures When Measured Value Shows an Error ssernnvnnnvnnnvnnnvnnnvnnnvnnnennn 12 9 12 3 1 Measured Value Higher Than True Value 12 9 12 3 2 Measured Value Lower Than True Value n se 12 10 12 3 3 Measurements Sometimes Show Abnormal Values rrxvrrnnr0 12 10 Customer Maintenance Parts List rrnnnnnnnnnvvrnnnnvnnnnvennnnvnnn CMPL 11M12A01 04E Customer Maintenance Parts List rrrnnnnnnnvvrnnnnvnnnnvennnnvnn CMPL 11M12A01 12E Customer Maintenance Parts List rrnrnnnvnnnnvnnnvrnnvennnvennvnnnee CMPL 11M3D1 01E Revision Information IM 11M12A01 04E lt 1 Overview gt 1 1 1 1 1 Overview The EXAxt ZR Integrated type Zirconia Oxygen Analyzer is used to monitor and control the oxygen concentration in combustion gases in boilers and industrial furnaces for wide application in industries which consume considerable energy such as steel electric power oil and petrochemical ceramics pulp and paper food or textiles as well as incinerators and medium small boilers It can help conserve energy in these industries The EXAxt ZR also contributes to preservation of the earth s environment in preventing global warming and air pollution by controlling complete combustion to reduce CO2 SOx and NOx The EXAxt ZR Integrated type Zirconia Oxygen Analyzer integrates both probe and converter The analyzers need not
94. ed when they are set to be detected with parameter codes D43 and D44 and if the measured values are lower than the preset oxygen concen tration values specified with D03 and D04 The oxygen alarm set values can range from 0 to 100 O 8 42 Alarm Output Actions If the measured values of the oxygen concentration fluctuate between normal steady state values and alarm setting there may be a lot of alarm output issuing and canceling To avoid this set the delay time and allow for hysteresis for alarm canceling under the alarm output conditions as Figure 8 2 shows When the delay time is set an alarm will not be issued so quickly even if 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 there will be a similar delay each time the measured value returns to the steady state from the alarm setpoint range canceling the alarm status If hysteresis is set alarms 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 setpoint 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 preset delay time
95. el ZO021R L 200 0 B for enhance forth gt The detector is used with a probe protector to support the probe ZR202G when the probe length is 2 5m or more and mounted horizontally 1 Put a gasket provided by the user between the flanges and mount the probe protector in the probe insertion hole 2 Make sure that the sensor assembly mounting screws four bolts at the probe tip are not loose 3 Mount the detector so that the calibration reference gas inlet faces downward Unit mm Direction of the sample gas flow Gasket t1 5 Detector top Calibration gas inlet Reference gas inlet F3103E ai Figure 3 3 Probe protector supporting the mounting strength IM 11M12A01 04E lt 3 Installation gt 3 5 lt Detector with a probe protector Model ZO21R L ONMN O B for dust wear protect gt The detector is used with a probe protector to prevent the sensor from being worn by dust particles when there is a high concentration of dust and gas flow exceeds 10 m sec fine carbon boiler or flu id bed furnace 1 Put the gasket that is provided by user between the flanges and mount the probe protector in the probe insertion hole The probe protector should be installed so that the notch comes to the downstream of the sample gas flow 2 Make sure that the sensor assembly mounting screws four bolts at the probe tip are not loose 3 Where the detector is mounted horizontally the calibration reference gas
96. en Analyzers Unit mm L 338 to 351 123 lt gt lt gt p 7 t 2 Display side LE OA OG Rc1 4 or 1 4NPT A 1 0 1 5 2 0 Reference gas inlet E 2 5 3 0 m Q N gi N re Yy Ve J D e Q EE GM D 4 G1 2 2 1 2NPT etc Terminal side Le 252 to 265 p49 Cable connection port ig 170 gt Re1 4 or 1 4NPT Calibration gas inlet c g AIN 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 BA ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 DIN PN10 DN50 A SUS304 165 125 4 18 18 DIN PN10 DN80 A SUS304 200 160 8 18 20 o DIN PN10 DN100 A SUS304 220 180 8 18 20 Q JIS 5K 65 FF SUS304 155 130 4 15 14 JIS 10K 65 FF SUS304 175 140 4 19 18 Flange JIS 10K 80 FF SUS304 185 150 8 19 18 9 JIS 10K 100 FF SUS304 210 175 8 19 18 JPI Class 150 4 RF SUS304 229 190 5 8 19 24 JPI Class 150 3 RF SUS304 190 152 4 4 19 24 F11 01 ai Westinghouse 155 127 4 11 5 14 e Standard Accessories Item Parts No Q ty Description Fuse A1113EF 1 3 15A Allen wrench L9827AB 1 For lock screw IM 11M12A01 04E 2 8 lt 2 Specifications gt Model ZR202G P Integrated type Zirconia Oxygen Analyzer with pressure compensation
97. enance services should be performed after the power is off and the heater assembly temperature has returned to normal room temperature For details refer to IM11M12A01 21E Heater Assembly NOTE If the heater assembly can not be removed because a screw has fused to its thread one of our service representatives can fix it IM 11M12A01 04E lt 11 Inspection and Maintenance gt 11 5 Figure 11 4 Exploded View of Detector 11 6 lt 11 Inspection and Maintenance gt Replacement of heater assembly Refer to Figure 11 4 as an aid in the following discussion Remove U shaped pipe support 4 U shaped pipe Filter and the sensor cell following Section 11 1 2 earlier in this manual Remove the two screws 15 that tighten the cover 2 and slide it to the flange side Remove the four bolts 0 to remove the converter 16 Then remove the three connectors to which leadwire from the heater and thermocouple is connected Loosen screw until heater assembly 3 plate can be removed There s no need to remove O ring which prevents screw 9 from dropping out Pull out connector 43 Loosen and remove the screw with a special wrench part no K9470BX or equivalent and then remove the heater assembly 3 from the detector 4 To reassemble the heater assembly reverse the above procedure Insert the heater assembly 3 into the detector 4 while inserting the calibration pipe in the detector into the heater
98. ent with platinum electrodes on both sides is heated up in contact with gases having different oxygen partial pressures on each side the element shows the action of the concentration cell In other words the electrode in contact with a gas with a higher oxygen partial pressure acts as a negative electrode As the gas comes in contact with the zirconia element in this negative electrode oxygen molecules in the gas acquire electrons and become ions Moving in the zirconia element they eventually arrive at the positive electrode on the opposite side There the electrons are released and the ions return to the oxygen molecules This reaction is indicat ed as follows Negative electrode O 4e gt 2 O gt Positive electrode 2 O gt O 4e The electromotive force E mV between the two electrodes generated by the reaction is governed by Nernst s equation as follows E RT AF In PX Paiuunrike nike kender dende Equation 1 where R Gas constant T Absolute temperature n 4 F Faraday s constant Px Oxygen concentration in a gas in contact with the negative zirconia electrode Pa Oxygen concentration in a gas in contact with the positive zirconia electrode Assuming the zirconia element is heated up to 750 C then we obtain equation 2 below E 50 74 log PX Pa rranrnonrnonrnrnrnnnrernvennrernrernrernrernreennr Equation 2 With this analyzer the sensor zirconia element is heated up to 750 C so Equation 2 is v
99. envnnnrnnnrnnnrnenrrenrnenreennr 5 4 5 4 Wiring for Contact Output rs rrsvrnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnnnnnvnnnvnnnnnnsvnnsennsennnenr 5 5 5 4 1 Cable Specifications onnensa idii 5 5 5 4 2 Wiring POCE TUNG areas aa E dd iset 5 5 5 5 Wiring for Contact Input rrrnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnnnnnnnnnnnnnnnnnennennnennnenn 5 5 5 5 1 Cable Specifications n nisrani Eiaa 5 5 5 5 2 Wiring Procedure msnanrnrnrnrnrnrnrnrnrnrnrnrnrernrernvernreenrernresnresnreenresnreennn 5 6 Components 2 sjudessesesenbnosbeeeneendmiin eesddneie 6 1 6 1 ZR202G Zirconia Oxygen Analyzer msennvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnennnnnnsennennsnnnnenr 6 1 6 1 1 Integrated type Zirconia Oxygen Analyzer s es 6 1 6 2 ZA8F Flow Setting Unit ZR20H Automatic Calibration Unit 0 6 2 OE al ARE E E T se aue tends E 7 1 7 1 Checking Piping and Wiring Connections m rrsvrnnvnnnvnnnvnnnvnnnnnnnnnnnennnnnnnnnnnr 7 2 7 2 WAV OS Ot ii EE NE A Aa AE Ea ea AEE aukana aAA 7 2 7 3 Supplying Power to Converter rssrnnnvnnnvnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 7 2 7 4 Operation of Infrared Switch anrrnnnnnnnnrnnnnvnnnnvnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 7 3 7 4 1 Display and Switche S earra eraann RE IRR EEEE AERA TENRA 7 3 7 4 2 Display Configuratio sssaaa AA 7 4 7 4 3 Entering Parameter Code Selection Display rrrrvrrrvnrnvvrnvnrnvnnnnnnn 7 5 7 4 4 Selecting Parameter Codes
100. er in this manual IM 11M12A01 04E lt 7 Startup gt 7 1 3 7 9 2 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 9 The table uses an example with a zero gas solenoid valve Table 7 9 Checking Calibration Contact Output Switch operation Display Description gt A ENT 0 1 Display after the password has been entered ENT 0 1 Touch the A key to switch to Group G aad G 1 Touch the gt key to move the position of the digit that is flashing to the right one digit G 1 Touch the A key to enter 1 We G 1 Touch the gt key to move the position of the digit that is flashing to the right one digit G 1 Touch the key to enter 5 gt Touch the ENT key to have 0 flash The solenoid valve remains closed Touch the key to enter 1 MM Touch the ENT 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 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 basic panel display pane
101. er or not the reason is applicable to the following and then replace the sensor assembly e Alot 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 IM 11M12A01 04E lt 12 Troubleshooting gt 12 7 In addition if an error occurs in calibration even after the cell assembly is replaced the influence of sample gas flow may be suspected Do not let the sample gas flow toward the tip of the detector probe for example by changing the mounting position of the detector 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 Search for cause of failure and Take measures gt This equipment can be used at ambient temperatures up to 55 C If the ambient temperatures may exceed the limits take appropriate measures such as applying heat insulating 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 generated when the emf voltage of thermocouple falls below 5 mV about 170 C or exceeds 42 1 mV about 1020 C 1
102. erate correctly In such a case change position of the display or install a sun cover 7 42 Display Configuration The parameter codes 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 refer to See 7 4 3 Touch the gt key and ENT key at same time to revert to the main screen Basic panel display Password entry display eee Group A setup display Group B setup display 3 Group C setup display Parameter code gt Group D setup display selection display Group E setup display Group F setup display Group G setup display F7 4E ai Figure 7 4 Display Configuration IM 11M12A01 04E lt 7 Startup gt 7 5 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
103. ered to be the causes for the cell voltage falling below 50 mV 1 Continuity failure between the cell assembly electrode and the contact 2 Damage or deterioration of the cell assembly 1 2 3 Improper connection between the sensor and the electronics 4 Wiring failure inside the detector 5 5 Abnormality in the converter electronics lt Locating the failure and Take measures gt 1 Turn off the power to the equipment 2 Remove the cell assembly from the probe Check for dirty or corroded sensor parts including electrode and contact 3 If the contact part is normal the cell assembly may be damaged or deteriorated Replace the cell 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 connected 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 sales 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
104. ero correction ratio 9 A22 Cell robustness A70 Calibration history 0 YY MM DD HH MM A23 Heater on time ratio A71 Calibration history 1 YY MM DD HH MM A24 Oxygen concentration with time O A72 Calibration history 2 YY MM DD constant HH MM A25 A73 Calibration history 3 YY MM DD HH MM A26 A74 Calibration history 4 YY MM DD HH MM A30 Max oxygen concentration O A75 Calibration history 5 YY MM DD HH MM A31 Occurrence of maximum oxygen YY MM DD A76 Calibration history 6 YY MM DD concentration HH MM HH MM A32 Min oxygen concentration O A77 Calibration history 7 YY MM DD HH MM A33 Occurrence of minimum oxygen YY MM DD A78 Calibration history 8 YY MM DD concentration HH MM HH MM A34 Average oxygen concentration O A79 Calibration history 9 YY MM DD HH MM A35 A80 Time YY MM DD HH MM A36 A90 Software revision Note The blank parameter codes above are not used in the oxygen analyzer IM 11M12A01 04E lt 10 Other Functions gt 1 0 3 10 1 1 Air Ratio Air ratio is defined as the ratio of the amount of air theoretically required to completely burn all the fuel to the amount of air actually supplied For this equipment the air ratio will be obtained in a simplified way by measuring the oxygen concen tration in the exhaust gas The air ratio may be expressed mathematically by 1 21 oxygen concentration xal m If you use the air
105. eseeeseeests 8 1 8 2 Current Output Setting rrrnrnnnvnnnvnnnvnnnvnnnvnnnvnnnnnnnnnnnvnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 8 1 8 2 1 Setting Minimum Oxygen Concentration at 4 mA and Maximum Oxygen Concentration at 20 MA srrnnvnnnvnnnvrnnvrnnvrnnnrnnnrrnnrernrennresnreenrernreennn 8 2 8 2 2 Entering Output Damping Constants rnrsvvrnvnnnvnnnvvrnvvrnvvrnvrrnvnrnnenn 8 2 8 2 3 Selection of Output Mode rnnnrnnnnnnnnnnnnnrnnnnnnnrnvnnnnnnnnnnnenrnnnnrnnnnrnnn 8 2 8 2 4 Default Values gene 8 2 IM 11M12A01 04E Toc 4 10 IM 11M12A01 04E lt CONTENTS gt 8 3 Output Hold Setting iccccecacecececacecscecacecececaceence case cece cece ence ence cece cece cece ence ende sen eden 8 3 8 3 1 Definition of Equipment Status mrrrnnrrnrrrnnnrrnnnrenrnrnnrnnnnrnnnnnnnnnnennn 8 3 8 3 2 Preference Order of Output Hold Value ccscceeeteeeeseeeeseetens 8 5 8 3 3 Output Hold Setting ee cceeeeeneeeeeeeeeeeeeeeeeaeeeeeeeeeeeseeeeeeeeas 8 5 8 3 4 Default Values uanuunmesananmamasanmomarten barer 8 5 8 4 Setting Oxygen Concentration AlarmsS rxs rssvrnnvnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 8 6 8 4 1 Alarmi VAIS ocana aaa nananana aeaaaee adani 8 6 8 4 2 Alarm Output ACtiOns enni crenandirand naa 8 6 8 4 3 Alarm Setting eeececceeceeeeeeeeeeeeeeeeesneeseeesneesaeesneesieesieesieesieesieesieeseees 8 7 8 4 4 Default Values si ssania naanin anadan anaia itani taadaa enal 8 8 8 5 Output
106. eters see Section 8 7 3 Setting Fuels earlier in this manual IM 11M12A01 04E 1 0 4 lt 10 Other Functions gt 10 1 5 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 volt age approximates the ideal value corresponding to the measured oxygen concentration the sensor will be assumed to be normal The ideal value of the cell voltage E when the oxygen concentration measurement temperature is controlled at 750 C may be expressed mathematically by E 50 74 log Px Pa mV where Px Oxygen concentration in the sample gas Pa Oxygen concentration in the reference gas 21 vol 0 Table 10 2 shows oxygen concentration versus cell voltage 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 9 102 56 93 62 87 28 82 36 78 35 74 95 72 01 69 41 2 3 4 5 6 7 8 9 51 82 42 88 36 54 31 62 27 61 24 21 21 27 18 67 02 10 21 0 30 40 50 60 70 80 90 mv 16 35 0 7 86 14 2 19 2 23 1 26 5 29 5 32 1 02 100 T10 2E ai mv 34 4 10 1 6 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 t
107. f HOOD Aluminum Food Weight Approx 800g IM 11M12A01 04E 2 9 lt 2 Specifications gt 2 1 3 ZO21R Probe Protector This probe protector is required for the general use detector when it is used for oxygen concentration measurements in powdered coal boilers or in fluidized furnaces to prevent abrasion due to dust parti cles when gas flow exceeds 10 m sec When probe length of the ZR202G is 2 5 m or more and mounted horizontally be sure to select a probe protector ZO21R L 200 L B to support the probe Insertion Length 1 05 m 1 55 m 2 05 m Flange JIS 5K 65A FF equivalent ANSI Class 150 4 FF without serration equiva lent However flange thickness is different Material SUS316 JIS SUS304 JIS Flange Weight 1 05m Approx 6 10 kg JIS ANSI 1 55 m Approx 9 13 kg JIS ANSI 2 05 m Approx 12 16 kg JIS ANSI Installation Bolts nuts and washers are provided for detector probe adapter and pro cess side flange e Model and Codes Suffix code Option code Description Flange 1 ZO21R L es mmmm gt Probe Protector 0 to 700 C Insertion 100 1 05 m 3 5 ft length 150 1 55 m 5 1 ft 2 22 2222 2 05 m 6 8 ft JIS 5K 65 FF SUS304 ANSI Class 150 4 FF SUS3044 Style code Style B 1 Thickness of flange depends on dimensions of flange External Dimension Flange lt 1 gt with bolts nuts
108. g kg Amount of water vapor in exhaust gas 8 7 4 Setting Purging 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 calibra tion 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 Phiri F8 5 ai Figure 8 5 Display during Purging 8 7 4 1 Procedure Use the parameter code table below to set the purging time The allowable input ranges from 0 to 60 minutes Table 8 19 Purging Time Set item Parameter code Set range Units Purging time F15 0 to 60 minutes 8 7 4 2 Default Value When the analyzer is delivered or if data are initialized purging time is set to 0 minutes IM 11M12A01 04E lt 9 Calibration gt 9 1 9 9 1 9 1 1 Calibration Calibration Briefs Principle of Measurement This section sets forth the principles of measurement with a zirconia oxygen analyzer before detailing calibration Asolid electrolyte such as zirconia allows the conductivity of oxygen ions at high temperatures There fore when a zirconia plated elem
109. g the first two weeks in use Excluding the case where the reference gas is by natural convection Both zero and span 2 Maximum value of set range month Response Time Response of 90 within 5 seconds Measured after gas is introduced from calibration gas inlet and analog output starts changing Installation Altitude 2000 m or less Category based on IEC 61010 II Note Pollution degree based on IEC 61010 2 Note Note Installation category called over voltage category specifies impulse withstand voltage Category II is for electrical equipment Pollution degree indicates the degree of existence of solid liquid gas or other inclusions which may reduce dielectric strength Degree 2 is the normal indoor environment Safety and EMC conforming standards ZR202G Safety EN 61010 1 CAN CSA C22 2 No 61010 1 UL Std No 61010 1 EMC EN 61326 1 Class A Table 2 For use in industrial locations EN 61326 2 3 EN 61000 3 2 Influence of immunity environment Criteria A 20 of F S EMC Regulatory Arrangement in Australia and New Zealand Korea Electromagnetic Conformity Standard A CAUTION This instrument is a Class A product and it is designed for use in the industrial environment Please use this instrument in the industrial environment only 2 1 2 ZR202G Integrated type Zirconia Oxygen Analyzer Can be operated in the field without opening the cover using optical switches Display 6 digit LCD Switch Three optical swi
110. hat the metal fitting is firmly attached to the pipe F3401E ai Figure 3 12 Pipe Mounting lt Wall Mounting gt 1 Make a hole in the wall as illustrated in Figure 3 13 Vj 14 Unit mm 4 Ne hole or M5 screw F3 13E ai Figure 3 13 Mounting holes IM 11M12A01 04E lt 3 Installation gt 3 7 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 ai Figure 3 14 Wall mounting 3 3 Installation of ZR20H Automatic Calibration Unit 3 3 1 Installation 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 ZR202G 0 0 0 0 Aor Bis shipped with automatic calibration unit attached The automatic calibration unit includes flowmeters and solenoid valves so as to ensure reliable and accurate operation Flowmeter should be mounted vertically The associated probe is designed for horizontal or vertical mounting If you buy the automatic calibration unit afterward and need to install it or replace it contact our ser vice representative IM 11M12A01 0
111. he detector keep on following air at 600 ml min into the calibration gas pipe lt Restarting Operation gt When restarting operation be sure to flow air for 5 10 minutes at 600 ml min into the calibration gas pipe before supplying the power to converter IM 11M12A01 04E 11 8 lt 11 Inspection and Maintenance gt 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 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 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 ai F11 6E 2 Figure 11 5 Cover of Display 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 con
112. he terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections 5 3 2 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 04E lt 5 Wiring gt 5 5 5 4 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 alarm or high alarm Do the contact output wiring according to the following requirements Analyzer Terminal box Annunciator or the like 1 Output Q 2 Output Q F5 6E ai Figure 5 6 Contact Output Wiring 5 4 1 Cable Specifications The number of cores varies depending on the number of contacts used 5 4 2 Wiring Procedure 1 M4 screws are used for the terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections 2
113. he thermocouple voltage is large accurate measurement cannot be achieved Thermocouple Multimeter Q F12 3E ai 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 calibration and purge 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 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 range 30 to 70 C then battery life is typically 1 year
114. he thermocouple volt age including the voltage corresponding to the cold junction temperature are displayed 10 1 7 Cold Junction Voltage This equipment uses temperature measurement ICs that measure the cold junction temperatures The voltage measured by those ICs is displayed 10 1 8 Current Output The analog output current is displayed IM 11M12A01 04E lt 10 Other Functions gt 1 0 5 10 1 9 Response Time The cell s response time is obtained in the procedure shown in Figure 10 1 If only either zero or span calibration has been carried out the response time will not be measured just as it will not be measured in manual calibration Five minutes maximum mA 10 of analog output span E E Start calibration Calibration complete 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 F10 1E ai Figure 10 1 Typical Response Time characteristics 10 1 10 Cell s Internal Resistance Anew 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
115. he zero correction ratio exceeds the range of 100 30 or the span correction ratio becomes larger than 0 18 calibration of the sensor becomes impossible IIM 11M12A01 04E lt 9 Calibration gt 9 3 81 92 ez e2 I Zero origin Calibration curve Cell before correction electromotive force mV et f Corrected calibration curve theoretical calibration curve Span origin 21 0 pi p2 0 51 Span gas concentration Zero gas concentration Oxygen concentration vol 02 Zero correction ratio B A x 100 Correctable range 100 30 Span correction ratio C A x 100 Correctable range 0 18 F9 2E ai Figure 9 2 Calculation of a Two point Calibration Curve and Correction Ratios Using Zero and Span Gases Figure 9 3 shows a one point calibration using only a span gas In this case only the cell electromo tive force for a span gas with oxygen concentration p1 is measured The cell electromotive force for the zero gas is carried over from a previous measurement to obtain the calibration curve The principle of calibration using only a span gas also applies to the one point calibration method using a zero gas only 81 92 I Zero origin ez Cell electromotive force mV Previous Zero gas data ei Corrected calibration curve theoretical calibration curve es ef 0 Span origin 21 0 pi 0 51 Span gas concentration Oxygen concentration vol 02 Zero correction ratio B A x 100 Correctable ra
116. hen 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 When Automatic calibration is selected This calibration can be conducted in any mode 9 2 1 2 Calibration 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 calibration Enter the oxygen concentration for the zero gas in the cylinder used IM 11M12A01 04E 9 6 lt 9 Calibration gt 9 2 1 4 Span gas Concentration Set the oxygen concentration for span calibration If instrument air is used as the span gas enter 21 OQ 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 A CAUTION 1 When instrument air is used for the span calibration remove the moisture from the instrument air at a dew point temperature of 20 C and also remove any oily mist and dust from that air 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 When the calibration mode is in manual First set the hold output stabilization time T
117. his 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 hold output stabilization time elapses The calibra tion 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 in semi automatic set the hold output stabilization 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 calibra tion time is effective in conducting both zero and span calibrations The calibration time set rang es from 00 minutes 00 seconds to 60 minutes 59 seconds Figure 9 4 shows the relationship between the calibration time and hold output stabilization time Calibration start o oS o contact or switch input 1 Span calibration lee eee span gas valve open Calibration time Zero calibration O ee ee zero gas valve open Calibration time Analog output status ee Hold output stabilization Li time i Li Analog output remains hold when output remains hold F9 4E ai Figure 9 4 Calibration and Hold Output stabilization Time Settings When the calibration mode is in automatic IIM 11M12A01 04E In addition t
118. ht angles to the sample gas flow or the probe tip 100mm Flange matches With dust filter 51 mm in diameter Note should point downstream vertical Bounds of the probe 1 insertion hole location Type Outside diameter of detector Standard 50 8 mm in diameter Note the detector size With probe protector 60 5 mm in diameter Note horizontal 100mm Four hole flange Eight hole flange F3101E ai Note When using the detector with pressure compensation ensure that the flange gasket does not block the reference gas 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 Figure 3 1 Illustrates an example of the probe insertion hole 3 1 3 Installation of the Probe N caution IM 11M12A01 04E The cell Sensor at the tip of the detector is made of ceramic zirconia Do not drop the detector as impact will damage it Agasket 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 sample gas lt 3 Installation gt 3 3 The following should be taken into consideration when mounting the general use detector lt General use detector gt 1 Make sure that the cell mounting screws four bolts at the probe tip are not loose If a dust filter see Secti
119. in oxygen concentration Oz A77 Calibration history 7 YY MM DD HH MM A33 Occurrence of minimum oxygen concen YY MM DD A78 Calibration history 8 YY MM DD tration HH MM HH MM A34 Average oxygen concentration O A79 Calibration history 9 YY MM DD HH MM A35 A80 Time YY MM DD HH MM A36 A90 Software revision Note1 indicates that both are displayed alternately Note2 Parameter codes with no items in the above table are not used in the oxygen analyzer IM 11M12A01 04E 10 12 lt 10 Other Functions gt Calibration related Items in Group B Code Item Tuning Engineering unit Default setting BO1 Zero gas concentration 0 3 to 100 O 1 O B02 Span gas concentration 4 5 to 100 O 21 O B03 Calibration mode 0 Manual calibration Manual calibration 1 Semi automatic and manual calibration 2 Automatic semi automatic and manual calibration B04 Hold Output stabilization 0 minutes 0 seconds to 60 minutes MM SS 10 minutes 0 sec time 59 seconds onds B05 Calibration time 0 minutes 0 seconds to 60 minutes MM SS 10 minutes 0 59 seconds seconds B06 Calibration interval 0 days 0 hours to 255 days 23 hours DD HH 30 days 0 hours BO7 Calibration start date and YY MM DD HH MM 00 01 01 00 00 time B08 Calibration procedure 0 Zero and span Zero and span 1 Span only 2 Zero only B09 Calibration concentrat
120. input 2 l l l 1 2 3 4 5 6 7 i DI 1 DI 2 DI C DO 1 DO 1 DO 2 DO 2 8 9 10 11 12 13 14 I FG AO AO L N G FG o i I LE I odel I d I I ry l Analog output 100 to 240 V AC I 4 20 mA DC 50 or 60 Hz Digital output F28 EPS 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 1000 or less Figure 5 2 Wiring Connection IM 11M12A01 04E lt 5 Wiring gt 5 3 5 1 3 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 gas inlet e g gE l ee KS Calibration gas inlet cl FIC 4 G1 2 2 1 2NPT etc Cable connection port F5 3E ai Cable gland Figure 5 3 Cable Gland Mounting 5 2 Wiring for Analog Output This wiring is for transmitting 4 to 20mA DC output signals to a device e g recorder Maintain the load resistance including the wiring resistance of 5500 or less Analyzer Receiver F5 4E ai
121. ion Display only O measurement B10 Manual calibration imple mentation B11 Semi automatic calibration implementation IM 11M12A01 04E Output related Items in Group C lt 10 Other Functions gt 10 13 Code Item Tuning Engineering unit Default setting C01 Analog output 0 Oxygen concentration Oxygen 1 Amount of moisture content concentration 2 Mixed ratio C03 Output mode 0 Linear Linear 1 Logarithm C04 Output during warm up 0 Held at 4 mA 1 Held at 20 mA 2 Set value remains held Held at 4 mA C05 Output during maintenance 0 Not held Held output just 1 Held output just before mainte befor e maintenance nance service Je 2 Set value remains held C06 Output during calibration 0 Not held Held output just 1 Held output just before calibration before calibration 2 Set value remains held C07 Output during error occur 0 Not held Held output at a rence 1 Held output just before abnormal preset value state occurs 2 Set value remains held C11 Min oxygen concentration See Section 8 2 O 0 O C12 Max oxygen concentration See Section 8 2 O 25 O C30 Output damping constant 0 to 255 Seconds 0 second C31 Set value during warm up 2 4 to 21 6 mA 4mA C32 Set value during mainte 2 4 to 21 6 mA 4mA nance C33 Set valu
122. ion of the digit will change from 1 to 0 to 1 to 0 Release the ENT key when 0 is displayed Touch the ENT key The numeric value will flash Touch the ENT key again to stop the numeric value from flashing 0 1 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 display This is not required if you proceed to make another setting The displayed nu meric characters indicate the measurement gas concentration The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing IM 11M12A01 04E lt 7 Startup gt 7 9 7 6 Selection of Measurement Gas Combustion gases contain moisture created by burning hydrogen in the fuel If this moisture is re moved the oxygen concentration might be higher than before You can select whether the oxygen concentration in a wet gas is to be measured directly or compensated for its dry gas value before use Use the parameter code F02 to set the measurement gas For details on the parameter code see Table 10 7 later in this manual Table 7 4 Setting Measurement Gas Switch operation Display Description gt A ENT 0 1 Display after the password has been entered A ENT 0 1 Touch the A key to switch to Group F If an unwanted alphabetic character after F K has been entered co
123. ipment when shipped Connect the flow setting unit and the analyzer to a 6mm O D x 4mm I D or nominal size 1 4 inches or larger stainless steel pipe IM 11M12A01 04E 4 4 lt 4 Piping gt Piping for the reference gas 6mm 0 D by 4mm I D stainless steel pipe Piping for the calibration gas 6mm 0 D by 4mm 1 D stainless steel pipe Stop valve or check valve F4 8E ai Figure 4 8 Piping for the Calibration Gas Inlet 4 2 3 Piping for the Reference Gas Reference gas piping is required between the air source instrument air 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 6mm 0 D x 4mm I D or nominal size 1 4 inches stainless steel pipe between the flow setting unit and the analyzer 4 3 Piping for System 3 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 a individual needle valve After installation and wiring check zero gas calibration contact output see Sec 7 9 2 and adjust zero gas regulator and calibration gas needle
124. ish N caution e Use suitable cable glands to completely seal the detector As far as possible do not stop the instrument air flow to prevent the sample gas from entering the detector and damaging the zirco nia cell Connect the stop valve which is at the calibration gas inlet directly to the equipment If piping connections are made between the detector and the needle valve condensation will result inside the piping and cause the sensor to be damaged when the calibration gas is intro duced Figure 4 13 illustrates an example of System 2 using the analyzer with pressure compensation Supplying the air pressure flow may vary depending on the furnace pressure It is recommended to use a flow gauge and an air set meeting the furnace pressure ZR202G Integrated type Zirconia Oxygen Analyzer 1 with pressure compensation Q Stop valve i 100 to 240 VAC or p kenseeeessseee Contact input Check valve ds gt Analog output contact output Digital output HART Flowmeter Ne Reference gas 3 sky k Air Set Calibration gas gt _ _ Vv Instrument air Span gas Same as Zero gas calibration ZA8F flow setting unit Pressure regulator Zero gas cylinder Calibration gas unit case F1 2E ai Figure 4 13 Illustrates an example of System 2 using the analyzer with pressure compensa tion N caution e When using the ZA8F Flow Setting Unit an
125. it to pressure stress Do NOT allow the sensor probe tip to make contact with anything when installing the analyzer Avoid water dropping directly on the probe sensor of the analyzer when installing it 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 sample gas may damage the sensor The probe especially at the tip becomes very hot Be sure to handle it with gloves 1 About This Manual The contents of this manual shall not be reproduced or copied in part or in whole without per mission This manual explains the functions contained in this product but does not warrant that those will suit the particular purpose of the user 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 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 If the product is used in a manner not specified in this manual the safety of this product may be impaired IM 11M12A01 04E iv lt Introduction gt 2 Safety and Modification Precautions E Follow the safety precaution
126. ix code Option code Description ZR202G Integrated type Zirconia Oxygen Analyzer 0 4m 0 7m 1 0m 1 5m 2 0m 2 5m 1 3 0m 1 Wetted material SUS316 Stainless steel with Inconel calibration gas tube 8 Flange 2 Auto Calibration Reference gas ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 A SUS304 DIN PN10 DN80 A SUS304 DIN PN10 DN100 A SUS304 JIS 5K 65 FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Westinghouse Not required Horizontal mounting 6 Vertical mounting 6 Natural convection External connection Instrument air 9 Pressure compensated 9 Gas Thread Rc 1 4 1 4 NPT Female Connection box thread G1 2 Pg13 5 M20x1 5 mm 1 2NPT Instruction manual Japanese English Chinese Always A Options Valves Inconel bolt 3 Check valve 4 Stop valve 4 Hood 7 Dust Filter Dust Guard Protector Tag plates NAMUR NE43 compliant Stainless steel tag plate 5 Printed tag plate 5 Failure alarm down scale Output status at CPU failure and hardware error is 3 6 mA or less 10 Failure alarm up scale Output status at CPU failure and hardware error is 21 0 mA or more
127. l This is not required if you proceed to make another setting display q you p g The displayed numeric characters indicate the measurement gas concentration The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing IM 11M12A01 04E 7 14 lt 7 Startup gt 7 9 3 Checking Input Contacts Follow Table 7 10 to check the input contacts The table uses an example with input contact 1 Table 7 10 Checking Input Contacts Switch operation Display Description gt A ENT 0 1 Display after the password has been entered ENT 0 1 Touch the key to switch to Group G D ENT G 1 Touch the gt key to move the position of the digit that is flashing to the right one digit ENT G 1 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 have been prop erly made or not 2 1 Touch the ENT 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 display The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing IM 11M12A01 04E lt 7 Startup gt 7 1 5 7 10 Calibration The converter is calibrated in s
128. le 8 7 listing parameter codes Table 8 7 Parameter Codes for Oxygen Concentration Alarms Set item Parameter code Set value Oxygen concentration DO1 0 100 O high high alarm setpoint Oxygen concentration D02 0 100 O high alarm setpoint Oxygen concentration D03 0 100 O low alarm setpoint Oxygen concentration D04 0 100 O low low alarm setpoint Oxygen concentration D30 0 9 9 O alarm hysteresis Delayed alarm action D33 0 255 seconds Oxygen concentration D41 0 Not detected high high alarm detection 1 Detected Oxygen concentration D42 0 Not detected high alarm detection 1 Detected Oxygen concentration D43 0 Not detected low alarm detection 1 Detected Oxygen concentration D44 0 Not detected low low alarm detection 1 Detected 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 04E 8 8 lt 8 Detailed Data Setting gt 8 4 4 Default Values When the analyzer is delivered or if data are initialized the default alarm set values are as shown in Table 8 8 Table 8 8 Alarm Setting Default Values Set item Set value High high alarm setpoint 100 O High alarm setpoint 100 O Low alarm setpoint 0 O Low low alarm setpoint 0 O Alarm hysteresis 0 1 O Delayed
129. 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 e Standard Specifications Connection Rc1 4 or 1 4FNPT Material SUS304 JIS Pressure Between 150 kPa G or more 350 kPa G or less Weight Approx 90 g Part No Description K9292DN Joint Re 1 4 Material SUS304 JIS K9292DS Joint 1 4 NPT Material SUS304 JIS K9292DN Rc 1 4 A R 1 4 B Unit mm K9292DS 1 4FNPT A 1 4NPT Male B Approx 19 _ gt IM 11M12A01 04E Approx 54 F30 EPS lt 2 Specifications gt 2 17 2 4 5 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases Standard Specifications e Part no G7003XF or K9473XK Primary Pressure Max 1 MPa G Secondary Pressure 0 02 to 0 2 MPa G Connection Rc1 4 or 1 4FNPT with joint adapter Weight Approx 1 kg Part No Description G7003XF Joint RC 1 4 Material Zinc alloy K9473XK Joint 1 4 FNPT Material Zinc alloy with adapter SUS316 e Part no G7004XF or K9473XG Primary Pressure Secondary Pressure Max 1 MPa G 0 02 to 0 5 MPa G Connection Rc1 4 or 1 4 FNPT with joint adapter Weight Approx 1kg Part No Description G7004XF Joint RC 1 4 Material Zinc
130. ll electromotive force Calibration Gas A gas with a known oxygen concentration is used for calibration Normal calibration is performed using two different gases a zero gas of low oxygen concentration and a span gas of high oxygen concentra tion 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 0 with a balance of nitrogen gas N The span gas widely used is clean air at a dew point temperature below 20 C and free of oily mist or dust as in instrument air 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 electromotive forces for a span gas with an oxygen concentration p1 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 sample gas is determined from this calibration curve In addition the calibration curve corrected by calibration is compared with the theoretical calibration curve for determining the zero correction ratio represented by B A x 100 on the basis of A B and C shown in Figure 9 2 and a span correction ratio of C A x 100 If t
131. log output signal and oxygen concentration 8 2 4 Default Values When the analyzer is delivered or data are initialized the output current settings are by default as shown in Table 8 3 Table 8 3 Output Current Default Values Item Default setting Min oxygen concentration 0 O Max oxygen concentration 25 O Output damping constant 0 seconds Output mode Linear N caution e When you select logarithmic mode the minimum output remains constant at 0 1 O and the parameter C11 display remains unchanged IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 3 8 3 Output Hold Setting The output hold functions retain an analog output signal at a preset value during the equipment s warm up time or calibration or if an error arises Table 8 4 shows the analog outputs that can be retained and the individual states Table 8 4 Analog Output Hold Setting Equipment status During warm up During mainte During calibra Error occurrence nance tion 1 Output hold values available 4mA O 20 mA O Without hold feature Retains output from just before occurrence Set value 2 4 to 21 6 O o O o mA O The output hold functions are available The output hold functions on error occurrence are unavailable when option code C2 or C3 NAMER NE 43 compliant is specified 8 3 1 Definition of Equipment Status 1 During warm up Du
132. ly specified as to what extent the difference from the theoretical value is allowed consider it to be approximately 10 mV Table 12 3 Oxygen Concentration and Cell Voltage Oxygen concentration Oxygen concentration O Cell voltage mV 1 67 1 21 0 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 correction ratio with the parameter codes A50 through A59 Check the history of the zero gas correction 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 cell 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 cell assembly is considered to be broken for the reason that the condensation is blown into the cell assembly by the calibration gas during calibration and so the cell cools quickly 6 If the cell assembly has been gradually deteriorating check the cell assembly status in the following procedure a Display Cell resistance by specifying the parameter code A21 A new cell will show a cell resistance v
133. mponents Calibration gas tube Rod with outside diameter of 2 to 2 5 mm F11 1E ai Figure 11 1 Cleaning the Calibration Gas Tube Replacing the Sensor Assembly The performance of the sensor cell deteriorates as its surface becomes soiled during operation Therefore you have to replace the sensor when its life expectancy expires for example when it can no longer satisfy a zero correction ratio of 100 30 or a span correction ratio of 0 18 In addition the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement If the sensor becomes no longer operable for example due to breakage investigate the cause and remedy the problem as much as possible to prevent recurrence N caution Ifthe sensor assembly is to be replaced allow enough time for the detector to cool down from its high temperature Otherwise you may get burned Ifthe 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 shar
134. ms have been set off IM 11M12A01 04E lt 8 Detailed Data Setting gt 8 11 8 6 Input Contact Settings The converter input contacts execute set functions by accepting a remote contact signal Table 8 12 shows the functions executed by a remote contact signal Table 8 12 Input Contact Functions Set item Function Calibration gas pressure While a contact signal is on neither semi automatic nor automatic calibrations decrease can be made Measuring range change While contact input is on the analog output range is switched to 0 25 0 Calibration start If a contact signal is applied semi automatic calibration starts only if the semi automatic or automatic mode has been setup Contact signal must be applied for at least one second Even though a continuous contact signal is applied a second calibration cannot be made If you want to make a second calibration turn the contact signal off and then back on Unburnt gas detection If a contact signal is on the heater power will be switched off An one to 11 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 ana lyzer A CAUTION Measurement range switching function by an external contact input is available for analog output 1 only and the range is fixed to 0 25 0 T
135. n joint F4 2E ai Figure 4 2 Piping for the Calibration Gas Inlet 4 1 3 Piping for the Reference Gas e Normally no piping is required for the reference gas inlet when the equipment applies natural convection for reference gas models ZR202G L L L1 L C Leave the plug as it is If the air around the probe is polluted and the necessary oxygen concentration 21 vol 0 cannot be obtained make instrument air piping as in Section 4 2 System 2 When the equipment uses instrument air for the reference gas piping is required as described in Section 4 2 System 2 models ZR2026 0 0O 0O O E or P IM 11M12A01 04E lt 4 Piping gt 4 3 4 2 4 2 1 Piping for System 2 Piping in System 2 is illustrated in Figure 4 7 Stop valve or Check valve gt Analog output contact output Digital output HART Needle Flowmeter valve Reference gas py Air Set Calibrati alibration gas 7 sy Instrument air Span gas Same as Zero gas calibration K Kae ZA8F flow setting unit Pressure regulator Zero gas cylinder Calibration gas unit case F1 2E al Figure 4 7 Piping for System 2 System 2 illustrated in Figure 4 7 requires piping as follows e Mount the check valve or the stop valve through a nipple to the calibration gas inlet of the equipment Piping Parts for System 2 Che
136. n Gas usrnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnsvnnnvnnnrnnnnenn 4 3 4 2 3 Piping for the Reference Gas rrmnrrnnnvnnnvnnnvnnnvnnnvennvenrvnrsvnnsrnnsreennenn 4 4 4 3 Piping for System 3 lt cs cc ccectceccestenctcesteesteestenstensteesteestenstenstenstenstensteestensteestes 4 4 4 4 Piping for the Oxygen Analyzer with Pressure Compensation 4 6 4 4 1 Piping Parts for Oxygen Analyzer with Pressure Compensation 4 8 4 4 2 Piping for the Calibration Gas usrnnnvnnnvnnnvvnnvvnnvnnnvvnnvnnsvnnsrnnsrernnnnn 4 8 4 4 3 Piping for the Reference Gas rrmnsrnnnvnnnvnnnvnnnvennvenvnnnvnnnvnnsvensvnennnn 4 8 WINING EEE EE 5 1 5 1 GMO lal A A A A 5 1 5 1 1 Terminals for the External Wiring reonrnonrnonrnonrnrnrnrnrnnnrennrnenrernreennr 5 2 5 1 2 KA Ao E T E TEN TET 5 2 5 13 Mounting of Cable Glando asisssiraissiasinsidan inaina anina aR nN 5 3 5 2 Wiring for Analog Output assnsessensennennennunnunnunnunnunnunnunnunnunnunnunnnnnnnnnnnnnnnnnnnnnne 5 3 5 2 1 Cable Specifications cc ccceccceeeeceeeeeeeeceeseceeeeaeeseaeeeeaeeeeaeeesseeenees 5 3 5 2 2 Wiring Procedure uuuhvndmiv ud iavdisvdidne id kin sdadednie 5 3 5 3 Wiring Power and Ground Terminals rsernnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnennsennnen 5 4 5 3 1 Wiring for Power Line arnanrnonrnrnvnrnrnrnvernrnrnvernrernrernrernrernreenrernreenen 5 4 lt CONTENTS gt Toc 3 5 3 2 Wiring for Ground Terminals eanrronrnonrnonrnnnrn
137. n the preceding calibration 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 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 Search for cause of failure and Take measures 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 out normally perform a steady operation without changing the conditions If the error occurs again check wheth
138. nce nnenvvnnnnnnnnnnnnnvvnnnnnnnnnnnnnnnnnnnnnnnnnnnnennennr 11 1 11 1 Inspection and Maintenance of the Detector rrrnnnvnnnnvnnnnvnnnnvnnnnnnnnnnnnnnn 11 1 11 1 1 Cleaning the Calibration Gas Tube rrmrrrnanvnnnrnnnvnnnrvrnrnrnrnrnrernreenn 11 1 11 1 2 Replacing the Sensor Assembly rrranrnanrnonrnnnvnnnrnnnrnrnrnrnrernrrenveennr 11 2 11 1 3 Replacement of the Heater Assembly rannnanvnonrnonrnonvnenrnrnrnenrnnn 11 4 11 1 4 Replacement of Dust Filter rrrrrrrnrnnrnrnnrnrrrnnnrrnrnrnnrnrnrrnnnnnnnnennnn 11 6 11 1 5 Replacement of O ring rranrnonrnrnrnrn venn vnnnrnrnvnnnrnenrnrnreenrernrernreenneennn 11 6 11 1 6 Stopping and Re starting Operation mraerrnrnnrnrrrrrnrrrnnrrnrnrnnrnnnnn 11 6 11 2 Inspection and Maintenance of the Converter rrnnnvnnnnvnnnnvrnnnvnnnnnvnnnnnnnnn 11 8 11 2 1 Replacing FUs sS ineimneimnerrineiiyinstnsiinstisiiknesiiaifeiibniekaidedn 11 8 11 3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit 11 10 12 Troubleshoofng icici ccctec ie cate eee eerie hue 12 1 12 1 Displays and Measures to Take When Errors OCCUD unsvnnnvnnnvnnnvnnnvnnnennnennn 12 1 12 1 1 What iS at Emor uyutaensdassdansdanndenadaandnnaddendeine 12 1 12 1 2 Measures to Take When an Error Occurs rranrnonrnrnrvenrnrnrnrnrnrnreennr 12 2 12 2 Displays and Measures to Take When Alarms are Generated rxsvrnnern 12 4 12 2 1 What 1S an Alan osiinsa cazanachcdean
139. nds and the display returns to the first set value Re enter the numeric value IM 11M12A01 04E 7 8 lt 7 Startup gt 7 5 Confirmation of Equipment Type Setting This equipment can be used for both 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 param eter code F01 See Table 10 7 later in this manual Ax 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 Converter Type Setting Procedure Switch operation Display Description gt ENT 0 1 Display after the password has been entered 0 1 Touch the key to switch to Group F If an unwanted alphabetic character after F has been entered continuously touch the key to return to the original Touch the ENT key for confirmation If 0 zero is entered the oxygen analyzer is already set If 1 one is entered the humidity analyzer has been set Change the setting following the steps below Continuously touch the A key and the posit
140. nectors 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 TVER kr F11 7E ai F11 8E ai Figure 11 7 Locations of Connectors Figure 11 8 Location of Fuse IM 11M12A01 04E lt 11 Inspection and Maintenance gt 11 9 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 250 V Maximum rated current 3 15A Type Time lag fuse Standards UL CSA and VDE approved Partnumber A1113EF IM 11M12A01 04E 1 1 1 0 lt 11 Inspection and Maintenance gt 11 3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit 1 Remove pipe holding piping fitting 2 Remove bolts holding flowmeter and replace it A 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
141. ng cecceeeeeeeeeeeeeeeneeeneeeeeeeeeeeeeeeeaeeeeeereeeeas 9 5 9 2 2 Calibraton EEE 9 8 Other FUnchons u uusunere invert ikanenedsreiigsdndneidsdedat 10 1 10 1 Detailed Display asiasia niana AE EAE AARAA TARAA AARS 10 1 10 1 1 All RAO cuna AEAEE AERE 10 3 10 1 2 Cell Temperature ccecccececceseeeeseeeeeeaeeeeeeeeeeeeseaeesseeeeneeeseaeeesaees 10 3 10 1 3 C J Temperatures s ic cada tcaedadeainaiianancii need 10 3 10 1 4 Amount of Water Vapor in Exhaust Gas rmernrnrrnrorrnrrrrrrrnrnrnnrnnn 10 3 10 1 5 OL AV LK TO gt AAEE 10 4 10 1 6 Thermocouple Voltage m uemmmverieveismndinmin 10 4 10 1 7 Cold Junction Voltage arnrnrnnnrnnnvnnnvnnnrnnnvnnnvnnnrnnnvnnnrnenrnsnrnenrnsnreenn 10 4 10 1 8 Current Output stanisa lasanan niian aaia aiaiai 10 4 10 1 9 RESPONSE TIME eccceeecceeeeeeeeeeeeceeeeceeeeaeeeeaeeseaeeeseeeeseaeeseaeenseeess 10 5 10 1 10 Cell s Internal Resistance rrnrnnnrnnnvnnnvnrnrnnnrernrrrnrernrernrernrernreennr 10 5 10 1 11 Robustness ofa Cell rrranrnonrnonrnonrnrnrnrnvnrnrnrnrnrnrrrnrnnnrrrnrrenrnenreennr 10 5 10 1 12 Heater On Time Ratio mrrnrnnrnrnnrnrrrrnnrrnnnrnnrnrnnrnnnrrnnnerrnnenrnnenennn 10 6 10 1 13 Oxygen Concentration with time constant cece eeeeeeeeeeee 10 6 10 1 14 Maximum Oxygen Concentration sranrnanrnonvnenrnrnrnnnrnnnrnrnrnnnveennr 10 6 10 1 15 Minimum Oxygen Concentration arranrnanvnonrnenrnenvnnnrnrnrrnnrrrnveennr 10
142. ng 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 is placed F11 2E ai Figure 11 2 Installing the Contact 2 Next make sure that the O ring groove on the flange surface of the sensor cell is clean Install the metal O ring in that O ring groove and then insert the sensor cell 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 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
143. nge 100 30 Span correction ratio C A x 100 Correctable range 0 18 F9 3E ai Figure 9 3 Calculation of a One point Calibration Curve and Correction Ratios Using a Span Gas IM 11M12A01 04E 9 4 lt 9 Calibration gt 9 1 4 Characteristic Data from a Sensor Measured During Calibration During calibration calibration data and sensor status data listed below are acquired However if the calibration is not properly conducted an error occurs in automatic or semi automatic calibration these data are not collected in the current calibration These data can be observed 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 ratio Recorded the past ten span correction ratios 2 Record of zero correction ratio Recorded the past ten zero correction ratios 3 Response time You can monitor the response time provided that a two point calibration has been done in semi automatic or automatic calibration 4 Cell s internal resistance The cell s internal resistance gradually increases as the cell sensor deteriorates You can mon itor 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 sp
144. nstallation of ZA8F Flow Setting Unit nssenavennvennvennvnnnvnnnvennvnnnvensvennvnnnennen 3 5 3 2 1 installation Location un idviknhihvnnndenmeklnddetirii 3 5 3 2 2 Mounting of ZA8F Flow Setting Unit cee eeeeeeeeeeeeeeeteeeeeeeeees 3 6 3 3 Installation of ZR20H Automatic Calibration Unit sseersvernvrnnvennvennvennvennenn 3 7 3 3 1 Installation Location ai 2s csien cian eon anenapndylenaeain 3 7 3 3 2 Mounting of ZR20H Automatic Calibration Unit eee 3 7 3 4 Installation of the Case Assembly E7044KF for Calibration Gas Cylinder3 9 3 4 1 Installation LOCATON wc hv mrir ridgr rigrnrrvrrirriru drive 3 9 3 4 2 Mounting a ass drar hehe oe NE 3 9 3 5 Insulation Resistance Test rrnsnrnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnennnennnennnennn 3 10 PIPINO 4444 4 1 4 1 Piping for System 1 mnivrnevnssvansvnnsvannennnvnnnvnnnvnnnennnvnnnennnvnnnennnvannennnvnnnen nen nnen nen 4 1 4 1 1 Piping Parts for System 1 srnanrnnnvnnnvnnnvnnnvnnnvvnnvensvensvensvnnsrnssrnssvessnen 4 2 4 1 2 Piping for the Calibration Gas usrnrnvnnnvnnnvvnnvnnnvennvnnnvnnsvennvennrnnnnen 4 2 4 1 3 Piping for the Reference Gas rrmnsrnnnvnnnvnnnvvnnvnnnvennvennvensvnnsrensrnennenn 4 2 4 2 Piping for System 2 siccsdesseee tee icesendiee dienes iee tee divaee div ee diene dreven vern keen den 4 3 4 2 1 Piping Parts for System 2 cca d ecceesteceecesecueccueeceee shh dlanegestedtagesaeasegeeneaens 4 3 4 2 2 Piping for the Calibratio
145. ntinuously touch the A key to return to the original A FO Touch the gt key to move the position of the digit that is flashing to the right FO Touch the key to change the numeric value to 2 If an unwanted numeric value has been entered continuously touch the A key to return to the original Touch the ENT key for confirmation If 0 zero is entered the oxygen concen tration in a wet gas is already set If the oxygen concentration in a dry gas is to be entered follow the steps below to set 1 one Continuously touch the A key and the position of the digit will change from 1 to 0 to 1 to 0 Release the ENT key when 1 one is displayed Touch the ENT key The numeric value will flash Touch the ENT key again to stop the value from flashing 03 Touch the ENT key once again and the display will change to the parameter code selection panel Basic Touch the gt key together with the ENT key to return to the basic panel display panel display This is not required if you proceed to make another setting The displayed nu meric characters indicate the measurement gas concentration The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing 7 7 Output Range Setting This section sets forth analog output range settings For details consult Section 8 2 Current Output Settings later in this m
146. ntk vekket venn ekke pant pakke pk punt oki ent 2 14 2 4 Other EqQuipime nt visscsceiscccisecccssecetecicnsecesusn cenvercastetecancatuacnascreseeresuecstantusdexsanees 2 15 2 4 1 Dust Filter for Oxygen Analyzer part no K9471UA eee eee 2 15 2 4 2 Dust Guard Protector part no K9471UC nrranrnonrnenrnenrnenrrenrrennr 2 15 2 4 3 Stop Valve part no L9852CB or G7016XH ssrnrnrnrnrnnnrnnnrnnnreenr 2 16 2 4 4 Check Valve part no K9292DN or K9292DS eenvnrnvnenrnrnrnenreenr 2 16 2 4 5 ANES c 2 17 2 4 6 Zero Gas Cylinder part no G7001ZC srnnnvnnnvnnnvnnnvnnnvvnnvnnnvrnnnnnn 2 18 24 7 Pressure Regulator G7013XF or G7014XF for Gas Cylinder 2 18 24 8 Case Assembly E7044KF for Calibration gas Cylinder 2 19 24 9 ZR202A Heater Assembly rrnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnvnnnrnnnvnnnvnnnnnn 2 19 IM 11M12A01 04E Toc 2 5 IM 11M12A01 04E lt CONTENTS gt Installati n eae ee ee ee eee ee ence 3 1 3 1 Installation of ZR202G Zirconia Oxygen Analyzer nernnnnnnvnnnvnnnvnnnvnnnvnnnvnnnenr 3 1 3 1 1 Installation Location 0 0 eeeeeeeeeeeeeeeeee tere enee tere seee tee teetieeteetieetieeteee 3 1 3 1 2 Probe Insertion Hole ai anarmitaime nden nindrietedtd eid 3 2 3 1 3 Installation of the Probe ecreis inniinn 3 2 3 1 4 Installation of the Dust Filter K9471UA Dust Guard Protector K9471UC Probe Protector ZO21R musnnnnvnnnvnnnvnnnvvnnvnnnvnrrvernnen 3 3 3 2 I
147. 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 selection display The symbol SD indicates that the key is being touched Light characters indicate 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 auto matically switch to the basic panel display 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 IM 11M12A01 04E 7 6 lt 7 Startup gt 7 4 4 Selecting Parameter Codes Switch operation Display Description gt 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 AO Touch the gt key again to move the position of the digit that is flashing to the right one more 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 Con tinuously touch the gt key and the position of the digit that is flashing will move continuously to the right If y
148. o 95 RH non condensing Ratings 100 to 240 VAC Acceptable range 85 to 264 V AC Power Supply Frequency Ratings 50 60 Hz Power Consumption Acceptable range 45 to 66 Hz Max 300 W approx 100 W for ordinary use Reference Gas System Natural Convection Instrument Air Pressure Compensation Instrument Air System excluding Natural Convection Pressure 200 kPa the pressure inside the furnace It is recommended to use air which is dehumidified by cooling to dew point 20 C or less and dust or oil mist are removed Consumption Approx 1NI min Material in Contact with Gas SUS 316 JIS Zirconia SUS 304 JIS flange Hastelloy B Inconel Construction Gas Connection Wiring Connection Installation Probe Mounting Angle 600 601 Heater and thermocouple replaceable construction Non explosion proof JIS C0920 equivalent to IP44D Equivalent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version Re 1 4 or 1 4 FNPT G1 2 Pg13 5 M20 by 1 5mm 1 2 NPT select one type 4 pieces Flange mounting Horizontal to vertically downward When the probe insertion length is 2 m or less installing at angles from hori zontal to vertically downward is available When the probe insertion length is 2 5m or more mount vertically downward within 5 and if installing at angles from horizontal to vertically downward within
149. o 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 ANSI DIN or JPI standard models s p this part is inserted in the furnace ME Selectable of length from 0 4 0 7 1 0 1 5 2 0 2 5 or 3 0m Dust filter mounting screw Calibration gas ipe openin Contact pips op g Metal O ring Pipe support U shaped pipe Probe s NN Filter Washer Figure 6 1 Integrated type Zirconia Oxygen Analyzer IM 11M12A01 04E 6 2 lt 6 Components gt 6 2 ZA8F Flow Setting Unit ZR20H Automatic Calibra tion Unit Reference gas flow setting valve Span gas flow setting valve SV Zero gas O S flow setting valve Ny Ss Z y gt S Flowmeter for reference gas Flowmeter for calibration gas lt Figure 6 2 ZA8F Flow Setting Unit F6 4E ai Horizontal mounting Vertical mounting Flowmeter for Flowmeter for Span gas Reference gas Flowmeter for Flowmeter for Flowmeter for Span gas Reference gas Zero gas z ETT wae Kan Np IN N 1 Flowmeter for Zero gas OH Span gas Span gas O O flow setting flow setting SPAN REF IN ZERO IN valve valve SPAN IN REF N AAR AN 28008 S NY Ww WS ND flow setting valve Reference gas Span gas Reference gas flow setting valve flow set
150. o conduct a semi automatic calibration be sure to set the Calibration setup mode to Semi au tomatic or Automatic 8 6 1 Setting Input Contact To set the input contacts follow the parameter codes given in Table 8 13 Table 8 13 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 Input contact 2 function E02 Invalid Calibration gas pressure decrease Measuring range change Calibration Unburnt gas detection Input contact 1 action E03 Operated when closed Operated when open Input contact 2 action E04 Operated when closed O O0O BR WOl MI A l O R Ol M gt O Operated when open 8 6 2 Default Values When the analyzer is delivered or if data are initialized the input contacts are all open IM 11M12A01 04E 8 12 lt 8 Detailed Data Setting gt 8 7 Other Settings 8 7 1 Setting the Date and Time 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 14 Data and time Settings Switch operation Display Description gt A ENT F 0 Select the parameter code F10 ENT 0 0 1 i 0 1 If you touch the ENT key the current date will be displayed The
151. o the above hold 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 respec tively After the first calibration is carried out the next calibration will be executed according to the preset calibration intervals lt 9 Calibration gt 9 2 1 6 Setting When setting calibration timing requirements bear the following precautions in mind CAUTION 1 If the calibration interval is shorter than the sum of hold output stabilization time plus calibra tion 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 Forthe same reason if the calibration start time conflicts with manual calibration or semi auto matic calibration the current calibration will not be conducted 3 Ifthe calibration time conflicts with maintenance service operation calibration will start after com pleting the maintenance service operation see Section 8 3 1 earlier in this manual 4 19000 days 00 hours are set for the calibration intervals only the first calibration will be conduct e
152. o unused cable connection gland s of the equipment The cables indicated in Table 5 1 are used for wiring 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 converter Name Need for shields Number of wires L N Power supply 20r3 AO AO Analog output oO 2 DO 1 DO 2 Contact output 2to4 DI 1 DI 2 DI C Contact input 3 When the case is used for protective grounding use a 2 wire cable WARNING Cables that withstand temperatures of at least 80 C should be used for wiring IM 11M12A01 04E 5 2 lt 5 Wiring gt A NOTE e Select an appropriate cable O D for the cable gland size e Protective grounding should have the grounding resistance of 1000 or less 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 DI 1 2 C DO1 DO2 000000000 000000Q92 FG A0 L N O Oo Figure 5 1 Terminals for External Wiring 5 1 2 Wiring Make the following wiring for the equipment It requires a maximum of four wiring connections as shown below 1 Analog output signal 2 Power and ground 3 Contact output 4 Contact input Model ZR202G Integrated type Zirconia Oxygen Analyzer Contact input 1 Contact output 1 Contact output 2 Contact
153. on 2 4 1 is used make sure it is properly attached to the detector Refer to Section 3 1 4 for installation of the dust filter 2 Where the detector is mounted horizontally the calibration gas inlet and the reference gas inlet should face downward 3 1 4 Installation of the Dust Filter K9471UA Dust Guard Protector K9471UC Probe Protector ZO21R A CAUTION e The dust filter is used to protect the Zirconia sensor from corrosive dust or a high concentration of dust such as in utility boilers and concrete kilns If a filter is used in combustion systems other than these it may have adverse effects such as response delay The combustion conditions should be examined carefully before using a filter e The dust filter requires gas flow of 1 m sec or faster at the front surface of the filter When you specify option code F1 the detector is shipped with the dust filter mounted Follow this procedure when replacing the filter in the detector It is recommended that you read Chap ter 11 prior to filter mounting for it is necessary to be familiar with the detector s construction especial ly the sensor assembly 1 Mount the dust filter by putting it on the end of the detector and screw the dust filter clockwise Put a hook pin wrench K9471UX 52 to 55 in diameter into the hole on the dust filter to fasten or remove it Apply a heat resistant coating see Note 1 to the threads on the detector Where mounting dust filter afte
154. operation and checking Display data settings calibration data settings test settings current output loop check input output contact check Initial settings suit for the plant conditions when installing the converter Current output data settings alarm data settings contact data settings other settings Oxygen concentration vol O Output current value mA air ratio mois ture quantity in hot gases vol H O Cell temperature C thermocouple reference junction temperature C maximum minimum average oxygen concentration vol O cell e m f MV cell internal resistance Q 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 0 Output Related Items Alarm Related Items Contact Related Items IM 11M12A01 04E calibration mode auto semi auto manual calibration type and method zero span calibration zero calibration only span calibration only stabiliza tion time min sec calibration time min sec calibration period day hour starting time year month day hour minute Analog output output mode selection output conditions when warming up maintenance calibrating abnormal 4 mA 20 mA point oxygen concentration vol 0 time constant preset values when warming up maintenance cali brating abnormal output preset values on abnormal
155. operly adjusted the needle valve will not close completely and a cylinder gas may leak When the output stabilization time elapses the calibration is complete lt Treatment after completion of calibration gt 1 Fully close the stop valve mounted on the calibration gas inlet of the detector 2 Remove the tube connecting the detector to the standard gas unit N WARNING Store the standard gas unit with the gas cylinder mounted where the ambient temperature does not exceed 40 C Otherwise the gas cylinder may explode Store the spare gas cylinders under the same condition IM 11M12A01 04E lt 10 Other Functions gt 1 0 1 9 10 6 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F Flow Setting Unit is used as the calibration equipment for a system conforming to System 2 Calibration in such a system is to be manually operated So you have to operate the valve of the Flow Setting Unit each time calibration is made starting and stopping the calibration gas flow and adjusting the flow rate For the operation of the converter refer to Section 7 10 10 6 1 Preparation Before Calibration To operate the ZA8F Flow Setting Unit prepare for calibration as follows 1 Check for a complete closing of the zero gas flow setting valve in the unit and open the regulator valve for the zero gas cylinder until the secondary pressure is sample gas pressure plus approx 50 kPa or sample gas pressure plus approx 150 kPa
156. or calibration If instrument air is used enter 21 vol O 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 A 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 11 Calibration Parameter Codes Set item Parameter code Set value Calibration mode B03 0 Manual calibration 1 Semi automatic calibration 2 Automatic calibration Zero gas oxygen concentration B01 Enter oxygen concentration Span gas oxygen concentration B02 Enter oxygen concentration IM 11M12A01 04E 7 16 lt 7 Startup gt Table 7 12 Switch operation Display Calibration Setup Procedure Description gt ENT 01 Display after the password has been entered gt ENT 01 Set the zero gas concentration Switch the parameter code to B01 Here set 0 98 ENT SD 01 00 Touch the ENT key to display the currently set value ENT 001 00 Touch the gt key to move the position of the digit that is flashing to 1 ENT 000 00 Touch the key to change to 0 ENT 000 00 Touch the gt key to move the position of the digit that is flashing to th
157. ou touch the A key once character A will change to B Touch the key once to change to C Continuously touch the A key and the value of the digit that is flashing will increase continuously from D to E to F to G toA Numeric values will change from 0 to 1 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 After you select the desired character touch the ENT key The set data will be displayed The symbol SD indicates that the key is being touched Light characters indicates that the digits are flashing 7 4 5 Changing Set Values 1 Selecting numeric values from among preset values Switch operation Display Description gt A ENT 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 key once to change the current value from 0 to 1 Touch the 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 A key and the numeric values will change continuously IM 11M12A01 04E Display the desired numeric value and touch the ENT key The dis
158. p protrusions on the groove The contact s resistance should be minimized e Use cell assemblies manufactured in or after Sept 2000 the serial number on the side of the cell assembly should be 0J000 or later for example 0K123 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 sensor assembly Normally replace the sensor cell 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 sample gas will not be sealed IM 11M12A01 04E lt 11 Inspection and Maintenance gt 11 3 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 amo
159. play will then return to the parameter code selection lt 7 Startup gt 7 7 2 Entering numeric values such as oxygen concentration values and factors Switch operation Display Description A ENT 0 0 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 ENT 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 A key and the numeric value will change in sequence from 0 to 1 to 2 to 3 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 Where the correct numeric value is displayed touch the ENT key If you touch the ENT key again the flashing stops and the current set value will be in effect Touch the ENT key once again to return to the parameter code selection display 3 If invalid numeric values are entered Switch operation Display Description gt A ENT If an invalid numeric value beyond the input range specified is entered Err will appear for two seconds after touching the ENT key 4 Err 0 0 Err appears for two seco
160. present check with YOKOGAWA Measured System Oxygen Concentration Output Signal Measurement Range Zirconia system 0 01 to 100 vol O 4 to 20 mA DC maximum load resistance 5500 Any setting in the range of 0 to 5 through 0 to 100 vol O in 1 vol 0 or partial range Digital Communication HART 250 to 550Q depending on number of field devices connected to the loop multi drop mode Note HART is a registered trademark of the HART Communication Foundation Display Range Warm up Time Repeatability Linearity 0 to 100 vol O Approx 20 min Excluding the case where the reference gas is by natural convection 0 5 Maximum value of set range less than 0 to 25 vol O range 1 Maximum value of set range 0 to 25 vol O or more and up to 0 to 100 vol O range Excluding standard gas tolerance Excluding the case where the reference gas is by natural convection Use oxygen of known concentration with in the measuring range as the zero and span calibration gases 1 Maximum value of set range less than 0 to 25 vol O range Sample gas pressure within 4 9 kPa 3 Maximum value of set range 0 to 25 vol O or more and less than 0 to 50 vol O range Sample gas pressure within 0 49 kPa 5 Maximum value of set range 0 to 50 vol 0 or more and up to 0 to 100 vol O range Sample gas pressure within 0 49 kPa IM 11M12A01 04E lt 2 Specifications gt Drift Excludin
161. r having once removed it from the detector reapply the heat re sistant coating Note 1 As the detector is heated to 700 C it is recommended to use the heat resistant coating on the threads to prevent seizing up Name of heat resistant coating material Never Seez Nickel Special Carborundum filter SiC Detector Ps 51 Attach the filter unit to the tip of the detector by screwing it clockwise Increasing of insertion length F31 EPS Figure 3 2 1 Installation of the dust filter IM 11M12A01 04E 3 4 lt 3 Installation gt lt Procedures for installing the dust guard protector K9471UC gt The ZR202G is shipped with the dust guard protector when the option code F2 is specified in case of ordering the detector The protector should be used when preventing dusts and water drops from lowering the detector performance is desired Screw the protector on the top of the detector so as to cover the top When attaching or detaching the protector perform by hooking holes of its side with a hook pin wrench for 052 55 hole Pin diameter 4 5 mm P N K9471UX or the like or by pass a screw driver through the holes When re attaching the protector after detaching it apply the Never Seez Nickel Special to it Increasing of insertion length i 100 R 8 7 122 F11 1 ai Figure 3 2 2 Installation of the dust guard protector lt Detector with a probe protector Mod
162. r radiated heat 5 No vibration 3 4 2 Mounting Mount case assembly on a pipe nominal JIS 50 A as follows 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the case assembly The sum of the case assembly and the calibration gas cylinder weighs approxi mately 4 2 kg 2 Mount the case assembly 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 ai Figure 3 16 Pipe Mounting IM 11M12A01 04E 3 10 lt 3 Installation gt 3 5 Insulation Resistance Test Even if the testing voltage is not so great that it causes dielectric breakdown testing may cause deteri oration in insulation and a possible safety hazard Therefore conduct this test only when it is neces sary 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 confirm that insulation resistance is 20 MQ or more Remove wiring from the converter and the detector 1 2 3 IM 11M12A01 04E Remove the jumper plate located between terminal G and the protective grounding terminal Connect crossover wiring between L and N Connect an insulation resistance tester with its power OFF Connect terminal to the crosso ver wiring and terminal to ground Turn the insulation resistance tes
163. rconia Oxygen Analyzer Manual No IM 11M12A01 04E 8th 7th 6th 5th Aug 2015 Revised section 2 1 1 Some spell error corrections and addtion of specification description 2 1 2 ZR202G Integrated type Zirconia Oxygen Analyzer Deleted the C tick Safety and EMC conforming standards 2 4 3 Stop Valve Changed of the weight and dimensions 2 4 4 Check Valve Changed of the weight 5 1 General Table 5 1 Deleted cable type General Added WARNING CMPL Customer Maintenance Parts List CMPL 11M12A01 04E is updated to 8th edition Mar 2012 Revised and Corrected over all Sep 2006 Revised Section 2 4 5 Air Set Part No K9473XH or K9473XJ Standard Specification Changed descriptions partly Air Set Part No G7004XF or K9473XG Standard Specification Changed descriptions partly 24 7 Cylinder Regulator Valve Part No G7013XF or G7014XF Standard Specifications Changed descriptions partly and drawing 5 3 Wiring Power and Ground Terminals Added description in Figure 5 5 5 3 2 Wiring for Ground Terminals Added item 4 74 5 Changing Set Values Changed description in table 1 7 9 2 Checking Calibration Contact Output Changed description in table 7 10 8 3 2 Preference Order of Output Hold Value Deleted or blow back 8 3 3 Output Hold Setting Table 8 5 Parameter code C06 maintenance should read calibration 8 3 4 Default Values
164. ring warm up is the time required after applying power until the sensor temperature stabi lizes 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 During maintenance During 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 During 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 calibrations is complete and the preset output stabilization time has elapsed the calibration time will be up Figure 8 1 shows the definition of during calibration in the manual calibration IM 11M12A01 04E 8 4 lt 8 Detailed Data Setting gt Display b10 CAL SPAn 21 00 OPEn 20 84 ZEro 0 98 x OPEn 0 89 Figure 8 1 p Definition of During Calibration Output hold time during calibration 10 Measured value display In a semi automatic calibration during calibration is the time starting when a calibration in struction is executed with an infrared switch or a contact input to make
165. ro Correction Ratios Span and zero 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 Zero origin ez Cell Calibration curve before correction ed Previous force m Zero gas data e1 F 7 Corrected calibration curve theoretical calibration curve es ef 0 Span origin 21 0 pi 0 51 Span gas concentration Oxygen concentration vol 02 Zero correction ratio B A x 100 Correctable range 100 30 Span correction ratio C A x 100 Correctable range 0 18 F10 2E ai Figure 10 2 IM 11M12A01 04E lt 10 Other Functions gt 1 0 7 10 1 18 History of Calibration Time The calibration conducted dates and times for the past ten calibrations are stored in memory 10 1 19 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 gt 15 06 F10 3E ai Figure 10 3 Date and time Display 10 1 20 Software Revision The revision number of the software installed is displayed 10 2 Operational Data Initialization Individual set data initializ
166. ry for the EXAxt ZR Integrated type Zirconia Oxy gen Analyzer 5 1 ca General UTION Never supply current to the equipment or any other device constituting a power circuit in combi nation with the equipment until all wiring is completed This product complies with CE marking Where a performance suit for CE marking is necessary the following wiring procedure is necessary Install an external switch or circuit breaker to the power supply of the equipment Use an external switch or circuit breaker rated 5A and conforms to IEC 947 1 or IEC 947 3 Itis recommended that the external switch or circuit breaker be mounted in the same room as the equipment 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 procedure Wiring should be made according to the following procedure 1 2 Note Be sure to connect the shield of the shielded line to FG terminal of the analyzer The most outer sheath of the signal line and the power cable should be stripped off to the mini mum necessary length Signal will 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 the sepa rate conduit from power and heater cables Be sure to ground the metal conduit Mount the attached two blind plugs t
167. ry low alarm Internal battery needs replacement If an alarm is generated such measures as turning off the heater power are not carried out The alarm is released when the cause for the alarm is eliminated However Alarm 10 and or Alarm 11 may be generated at the same time as Error 2 heater temperature error In such a case the measure taken for this error has priority If the converter power is turned off after an alarm is generated and restarted before the cause of the alarm has been eliminated the alarm will be generated again However Alarms 6 7 and 8 alarms related to calibration are not generated unless calibration is executed 12 2 2 Measures Taken When Alarms are Generated 12 2 2 1 Alarm 1 Oxygen Concentration Alarm This alarm is generated when a measured value exceeds an alarm set point or falls below it For details on the oxygen concentration alarm see Section 8 4 Setting Oxygen Concentration Alarms in the chapter on operation 12 2 2 2 Alarm 6 Zero Calibration Coefficient Alarm In calibration this alarm is generated when the zero correction ratio 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 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 ou
168. s in this manual when using the product to ensure protection and safety of personnel product and system containing the product m The following safety symbols and wordings are used on the product as well as in this manual 3 The following safety symbols are used in this manual Throughout this user s manual you will find several different types of symbols are used to identify different sections of text This section describes these icons N WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices A IMPORTANT Indicates that operating the hardware or software in this manner may damage it or lead to system failure A NOTE Draws attention to information essential for understanding the operation and features TIP Identifies additional information SEE ALSO Identifies a source to be referred to Clicking a reference displayed in green can call up its source while clicking a reference displayed in black cannot IM 11M12A01 04E lt Introduction gt 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
169. section in the heater assembly 23 as well as in the bracket hole Coat the screw with grease Never Seez G7067ZA and tighten the screw 8 with a special tool part no K9470BX or equivalent with a tightening torque of 12N m 10 Next to install the O rings 22 on the calibration gas and reference gas pipes disassemble the connector 43 in the following procedure First remove the screw 25 and then remove the plate 47 and two caps 0 If the O ring 2 remains in the hole pull them out from the back Pass the heater and thermocouple leadwire through the connector 3 Also pass the calibration gas and reference gas pipes through the opening of the connector 3 If the O ring 2 fails replace it with a new one Push the two caps 9 into the associated opening of the connector 3 Insert the plate 47 aligning it with the groove of the cap 20 and tighten it with the screw 05 If you attempt to insert the calibration gas and reference gas pipes into the connector 3 without disassembling the connector 3 the O ring may be damaged Tighten screw in the heater assembly 3 until connector 3 can t move Reassemble in reverse order to the above disassembly procedure When installing the cell assembly replace the metal O ring 7 with a new one 11 1 4 Replacement of Dust Filter Set the dust filter in place using a special pin spanner with a pin 4 5 mm in diameter part no K9471UX or equivalent If a dust filter that has alread
170. sed instrument air for span calibration gas if without instrument air is used contact YOKOGAWA Model and Codes Option code Description TEET Flow setting unit IM 11M12A01 04E Rc 1 4 s mdessask e With 1 4 NPT adapter lt 2 Specifications gt 2 11 External Dimensions REFERENCE CHECK il REFERENCE SPAN ZERO Calibration gas outlet Reference gas outlet Unit mm inch 2B mounting pipe fv Zero gas inlet IDX Piping connection port A Model Piping connection port A ZA8F J C 5 Rc1 4 ZA8F A C 5 1 4NPT Instrument air inlet Weight Approx 2 3 kg PIPNG INSIDE THE FLOW SETTING UNIT A A CHECK REF OUT OUT i Flowmeter Flowmeter wo 0 0 amp EG i AIR IN 1 i ZERO SPAN ME Instrument air GAS IN GAS IN Hr Approx 1 5 l min Air Set Air pressure without check valve sample gas pressure approx 50 kPaG with check valve sample gas pressure approx 150 kPaG F2 6E ai IM 11M12A01 04E 2 12 lt 2 Specifications gt 2 22 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
171. set up for Output contact setup for that contact refer to Section 8 5 Output Contact Setup 4 Changes the analog output status to the one set in Output hold setting refer to Section 8 3 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 F12 1E ai Types of Errors and Reasons for Occurrence Reason for Occurrence The cell sensor voltage signal input to the converter falls below 50 mV The heater temperature does not rise during warm up or it falls below 730 C or exceeds 780 C after warm up is completed The A D converter fails in the internal electrical circuit in the converter Err 01 Figure 12 1 Table 12 1 Error Type of error Error 1 Cell voltage failure Error 2 Heater temperature failure Error 3 A D converter failure Error 4 Memory failure Data properly are not written into memory in the internal electrical circuit in the converter IM 11M12A01 04E 12 2 lt 12 Troubleshooting gt 12 1 2 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 consid
172. spose the batteries This is an explanation about the new EU Battery Directive DIRECTIVE 2006 66 EC This directive is only valid in the EU Batteries are included in this product Batteries incorporated into this product cannot be removed by yourself Dispose them together with this product When you dispose this product in the EU contact your local Yokogawa Europe B V office Do not dispose them as domestic household waste Battery type silver oxide battery Notice The symbol see above means they shall be sorted out and collected as ordained in ANNEX II in DIRECTIVE 2006 66 EC IM 11M12A01 04E lt Introduction gt vii 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 description of the problem Any diagrams or data explaining the problem would also be appreciated If we replace the product with a new one we won t provide you with a repair report Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the customer site is located outside of the service area a fee for dispatching the maintenanc
173. sure of ZA8F with check valve changed 10 6 1 Reference gas pressure of ZA8F with check valve changed 11 1 Added Filter to 11 1 Inspection and Maintenance of the ZR202G Detector 12 2 1 Corrected explanation of Alarm 10 Added Filter to CMPL11M12A01 04E and added ZR20H Automatic Calibration Unit to CMPL 11M12A01 12E Date Remark s Oct 2000 Newly published IM 11M12A01 04E
174. t 2 remains closed Note 2 The oxygen concentration alarm must be preset see Section 8 4 Note 3 Range change answer back signal For this action the range change must be preset during the setting of input contacts see Section 8 6 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 N 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 temper ature abnormal occurs IM 11M12A01 04E 8 10 lt 8 Detailed Data Setting gt 8 5 3 Default Values When the analyzer is delivered or if data are initialized output contacts are by default as shown in Table 8 11 Table 8 11 Output Contact Default Settings Item Output contact 1 Output contact 2 High high alarm High alarm Low alarm Low low alarm Error O Warm up O Output range change Calibration Maintenance O High limit temperature alarm Calibration gas pressure decrease Unburnt gas detection Operating contact status Open Closed fixed O Present NOTE The above blank boxes indicate the ite
175. t Guard Protector part no K9471UC Unit mm Detector gt Increasing of insertion length F31 EPS Recommended to be used when sample gas is likely to flow directly into the cell due to its flow direc tion in the stack or the like flammable dust may go into the cell or water drops are likely to fall and remain in the cell during downtime or the like due to the installation position Material Weight SUS316 Approx 0 3 kg Increasing of insertion length D 100 50 8 B 122 F11 1 ai Unit mm IM 11M12A01 04E 2 1 6 lt 2 Specifications gt 2 4 3 Stop Valve part no L9852CB or G7016XH This valve is mounted on the calibration gas line in the system to allow for one touch calibration This is applied to a system configuration System 1 e Standard Specification Connection Re 1 4 or 1 4 FNPT Material SUS 316 JIS Weight Approx 150 g Part No Description L9852CB Joint Re 1 4 Material SUS316 JIS G7016XH Joint 1 4 NPT Material SUS316 JIS Rc1 4 or 1 4NPT 48 8 Full open length 40 F15 ai 2 4 4 Check Valve part no 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 sample gas from entering the calibration gas
176. t Mode Display While Warming Up IM 11M12A01 04E lt 7 Startup gt 7 3 7 4 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 shows the infrared switch and the display Table 7 1 shows the three switch keys and functions YOKOGAWA 4 Decimal point ee LIL e e e e uMmNkgalbbl scftm3 d s h m 1 Data display area 3 Engineering unit display area 2 Infrared switch F7 3E ai Figure 7 3 Infrared switch and the display 1 Data display area Displays the oxygen concentration 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 oxygen concentration is dis played 4 Decimal point A decimal point is displayed Table 7 1 Switch and Function Switch Function gt 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 A Used to change values If you continuously touch this key the value of the digit will increase continuously
177. t of the specified flow 600 60 ml min 3 The sensor assembly is damaged and so cell voltage is not normal IM 11M12A01 04E lt 12 Troubleshooting gt 12 5 lt Search for cause of failure and Take measures gt 1 Confirm the following and carry out calibration again If the items are not within their proper states 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 calibration 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 sensor 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 from the theoretical value at each oxygen concentration Confirm the theoretical values of the cell voltage in Table 12 3 Although it cannot be general
178. ta J N NOTE Refer to Section 8 1 Setting Display Item for parameter code A00 IM 11M12A01 04E 1 0 2 lt 10 Other Functions gt Table 10 1 Parameter Codes for Detailed Operation Data Code Item Engineering Code Item Engineering unit unit A00 Selection 0 Oxygen concentration A50 Span correction ratio 0 pan 1 Oxygen analyzer 0 0 A51 Span correction ratio 1 2 Oxygen analyzer 0 0 A52 Span correction ratio 2 3 Analog output select A53 Span correction ratio 3 ed A01 Oxygen concentration O A54 Span correction ratio 4 A02 A55 Span correction ratio 5 A03 A56 Span correction ratio 6 A04 A57 Span correction ratio 7 A05 A58 Span correction ratio 8 A06 Air ratio A59 Span correction ratio 9 A07 Cell temperature C A60 Zero correction ratio 0 A08 Cold junction temperature C A61 Zero correction ratio 1 A09 Meas gas temperature C A62 Zero correction ratio 2 A10 Amount of water vapor in exhaust gas A63 Zero correction ratio 3 A11 Cell voltage mV A64 Zero correction ratio 4 A12 TC voltage mV A65 Zero correction ratio 5 A15 Cold junction voltage mV A66 Zero correction ratio 6 A16 Output current mA A67 Zero correction ratio 7 A20 Cell response time Seconds A68 Zero correction ratio 8 A21 Cell internal resistance Q A69 Z
179. ta in group E F36 Initializing data in group F Inspection related Items in Group G Code Item Tuning Engineering unit Default setting G01 mA output loop 4 to 20 mA G11 Output contact 1 0 Open G12 Output contact 2 0 Open G15 Automatic calibration 0 Off solenoid valve zero 1 On G16 Automatic calibration 0 Off Off solenoid valve span 1 On G21 Input1 contact 0 Open 1 Closed G22 Input2 contact 0 Open 1 Closed G30 Reset IM 11M12A01 04E 1 0 1 6 lt 10 Other Functions gt 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 Oper ate the ZO21S Standard Gas Unit for calibrating a system classified as System 1 according to the procedures that follow 10 5 1 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 NI 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 Foa el Figure 10 4 Standard Gas Unit Component Identification 10 5 2 Installing Gas Cylinders Each ZO21S Standard Gas Unit
180. tches 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 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 tempera ture measures more than 600 C High temperature service greater than 700 C is not available Sample Gas Pressure 5 to 250 kPa When the pressure in the furnace exceeds 3 kPa it is rec ommended to compensate the pressure When the pressure in the furnace exceeds 5 kPa you must perform pressure compensation No pressure fluctuation in the furnace be allowed Note When the detector is used in conjunction with a check valve and the ZA8F Flow Setting Unit the maximum pressure of sample gas is 150 kPa When with a check valve and the ZR20H Automatic Calibration Unit it is 200 kPa If the pressure of your sample gas exceeds these limits consult with Yokogawa IM 11M12A01 04E Probe Length Probe Material Ambient Temperature Storage Temperature Humidity Range Power Supply Voltage lt 2 Specifications gt 0 4 0 7 1 0 1 5 2 0 2 5 3 0m SUS 316 JIS 20 to 55 C 5 to 70 C on the case surface 30 to 70 C 0 t
181. ter ON and measure the insulation resistance After testing remove the tester and connect a 100 KQ resistance between the crossover wiring and ground to discharge Testing between the heater terminal and ground contact output terminal and ground analog output input terminal and the ground can be conducted in the same manner Although contact input terminals are isolated insulation resistance test cannot be conducted be cause the breakdown voltage of the surge preventing arrester between the terminal and ground is low After conducting all the tests replace the jumper plate as it was Contact input 1 CO Crossover wiring Insulation resistance tester O Contact input 2 Crossover wiring jumper D plate Insulation Insulation resistance resistance tester tester O O O O F3 17E ai lt 4 Piping gt 4 1 4 Piping This chapter describes piping procedures in the three typical system configurations for EXAxt ZR Integrated type Zirconia Oxygen Analyzer Ensure that each check valve stop valve and joints used for piping are not leaking Especially when there is any leakage at piping and joints for the calibration gas it may cause clogging of the piping or incorrect calibration Be sure to conduct leakage test after setting the piping e Basically apply instrument air dehumidified to the dew point 20 C or lo
182. 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 lt Flow of span gas air gt The standard gas unit is used only when manual calibration is employed Therefore the timing for flowing span gas air is included in the manual calibration flowchart de scribed in Section 7 10 2 2 earlier in this manual For operation of the converter see Section 7 10 2 2 1 When the OPEn and the measured oxygen concentration are alternately displayed during calibration plug the power cord into the power supply socket to start the pump of the standard gas unit IM 11M12A01 04E 1 0 1 8 lt 10 Other Functions gt 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 loos en the lock nut and turn it using a flat blade screwdriver Turning the valve shaft counterclock wise 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
183. the numeric value 1 to set a 10 mA output Touch the ENT key to have all the digits flash 1 0 0 Touch the ENT key again to stop the flashing A 10 mA output is then issued 0 1 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 to return to the basic panel display panel display The symbol Na indicates that the key is being touched Light characters indicates that the digits are flashing Checking Contact I O Conduct a contact input and output check as well as an operation check of the solenoid valves for the optional automatic calibration unit Table 7 7 Parameter Codes for Checking Contact I O Check item Parameter code Set value and contact action Contact output 1 G11 0 Open 1 Closed Contact output 2 G12 0 Open 1 Closed Automatic calibration solenoid valve G15 o Off zero gas 1 On Automatic calibration solenoid valve G16 o Off span gas 1 On Contact input 1 G21 0 Open 1 Closed Contact input 2 G22 0 Open 1 Closed IM 11M12A01 04E 7 12 lt 7 Startup gt 7 9 1 Contact Output Check Follow Table 7 8 to check the contact output The table uses an example with contact output 1 Table 7 8 Checking Contact Output Switch operation Display Description gt A ENT 0 1 Displ
184. ting valve flow setting valve F6 3E ai ZERO IN Figure 6 3 ZR20H Automatic Calibration Unit IM 11M12A01 04E lt 7 Startup gt 7 1 7 Startup The following describes the minimum operating requirements from supplying power to the convert er to analog output confirmation to manual calibration Check piping and wiring connections Set output ranges Check current loop Set up valves Supply power Check contact action Confirm converter Gane type setting alibrate analyzer Set detailed data hi Select gas to be measured Place in normal operation F7 0E ai Figure 7 1 Startup Procedure For system tuning by HART communication refer to the IM 11M12A01 51E HART Communication Protocol IM 11M12A01 04E 7 2 lt 7 Startup gt 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 in the following procedures 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 the air pressure of sample gas pressure plus approx 50 kPa plus approx 150 kPa for with check valve 300 kPa maximum for the ZA8F
185. ts for System 2 Change part numbers of air set in Table 4 2 4 4 1 Piping Parts fora System using Detector with Pressure Compensation Changed part numbers of air set in Table 4 3 Jul 2003 Revised section Notation of flange specification unified Dust guard protector G7004XF K9473XG Air set added CMPL 11M12A01 04E Cell assembly parts no changed revised to 5th edition Sept 2001 Revised section 1 2 Model ZR202A Heater Assembly added 2 2 1 ZA8F Flow Setting Unit error corrected 2 7 8 Model ZR202A Heater Assembly added 8 6 Table 8 12 Input Contact Functions changed 11 1 3 Reference document added to Replacement of the Heater Assembly Heater Assembly added to CMPL 11M12A01 04E CMPL 11M12A01 04E Model ZR20H changed Mar 2001 Revised Section 1 1 3 Explanation changed in System 3 example 1 2 1 ZR20H added to list of Equipment Models 2 1 2 Some changes to ZR202G Integrated type in MS code table and notes added 22 Reference gas pressure of ZA8F with check valve changed detailed explanation added to ZR20H Automatic Calibration Unit 3 3 Added detail to 3 3 Installation of ZR20H Automatic Calibration Unit 3 5 Corrected errors in Insulation Resistance Test Wiring Diagram 4 3 Added explanation for piping to System 3 example 6 1 Added Filter to 6 1 ZR202G Detector 6 2 Added Names and Functions to 6 2 ZR20H Automatic Calibration Unit 7 1 Air set secondary pressure with check valve changed 7 10 2 Reference gas pres
186. ture limits range for integrated type analyzer is 20 to 55 C Shield cable Use shielded signal cables and connect the shields to the FG terminal of the converter 2 Select the desired probe from the Probe Configuration table on page 1 4 3 When a zirconia oxygen analyzer is used 100 N gas cannot be used as the zero gas Use approx 1 vol O gas N based Figure 1 3 Example of System 3 IM 11M12A01 04E 1 4 lt 1 Overview gt 1 2 lt EXAxt ZR gt System Components 1 2 1 System Components Integrated type System configuration System Components y p Example 1 Example 2 Example 3 ZR202G Integrated type Zirconia Oxygen Analyzers ZO21R Probe Protector for Zirconia Oxygen Analyzers K9471UA Dust Filter for Oxygen Analyzer K9471UC Dust Guard Protector ZO21S Standard Gas Unit ZA8F Flow Setting Unit for manual calibration O O O O O O O O O ZR20H Automatic Calibration Unit for Integrated type Analyzer o L9852CB G7016XH Stop Valve for Calibration gas line e 9 K9292DN K9292DS Check Valve for Calibration gas line 9 G7003XF K9473XK G7004XF K9473XG Air Set e e G7001ZC Zero gas Cylinder e e G7013XF G7014XF Pressure Regulator for Gas Cylinder o o E7044KF Case Assembly for Calibration gas Cylinder e e ZR202A Heater Assembly Spare Parts for ZR202G O O
187. uch a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases There are three types of calibration procedures available 1 Manual calibration conducting zero and span calibrations or either of these calibrations in turn 2 Semi automatic calibration which uses the infrared switches or a contact input signal and con ducts 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 ZR20H 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 Set the following three items before carrying out a calibration Parameter codes for these set items are listed in Table 7 11 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 f
188. uires that the ambient oxygen concentration be constant Automatic calibration cannot be used when natural convection is selected as reference gas 4 No vibration 5 The sample gas satisfies the specifications described in Chapter 2 6 No sample gas pressure fluctuations A CAUTION The ambient temperature of the ZR202G Integrated type Zirconia Oxygen Analyzer should be between 20 C and 55 C IM 11M12A01 04E 3 2 lt 3 Installation gt 3 1 2 Probe Insertion Hole N 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 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 gas outlet on the detector flange If the flange gasket blocks the outlet the detector cannot conduct pressure compensation Where necessary make a notch on the flange gasket 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 mount the probe with the tip higher than the probe base 2 If the probe length is 2 5 m or more the detector should be mounted vertically no more than a 5 tilt 3 The detector probe should be mounted at rig
189. unit Panel 200 V AC 50 60 Hz 220 V AC 50 60 Hz 240 V AC 50 60 Hz 100 V AC 50 60 Hz 110 V AC 50 60 Hz 115 V AC 50 60 Hz Japanese version English version Style code External Dimensions Style A 1600 Zero gas cylinder 6 cylinder E7050BA IM 11M12A01 04E Hfe of g y aml far nl I NSA ol 2 Flow checker AN i QI 8 Span gas valve I Zero gas valve a q q Y 3 Gas outlet 1 354 g F24 ai 2 15 lt 2 Specifications gt 2 4 2 4 1 Other Equipment Dust Filter for Oxygen Analyzer part no K9471UA This filter is used to protect the detector sensor from corrosive dust components or from a high con centration of dust when the oxygen concentration in utility boilers or concrete kilns are to be meas ured This filter requires the measuring gas flow of 1 m sec or faster to replace gas inside zirconia sensor e Standard specifications Applicable detector Standard type detector for general use the sample gas flow should be approximately perpendicular to the probe Mesh 30 microns Material Carborundum Filter SUS316 JIS Weight Approx 0 2 kg Part No Description K9471UA Filter K9471UX Tool Carborundum filter SiC 51 Attach the filter unit to the tip of the detector by screwing it clockwise 2 42 Dus
190. use a sampling device and allow direct installation of the probe in the wall of a flue or furnace to measure the concentration of oxygen in the stack gas of the temperature up to 700 C The probe uses a high reliability Zirconia sensor and a heater assembly that can be replaced on site The analyzer is equipped with three infrared switches which enable the user to operate the equipment without opening the cover on site Analyzer calibration can also be fully automated and the automatic calibration unit is provided Choose the equipment which best suits your needs so that an optimal combustion control system can be obtained Some examples of typical system configuration are illustrated below lt EXAxt ZR gt System Configuration The system configuration should be determined by the conditions e g whether the calibration is to be automated and whether flammable gas is present and requires safety precautions The system configuration can be classified into three basic patterns as follows System 1 This is the simplest system consisting of an integrated type analyzer This system can be implemented for monitoring oxygen concentration in the combustion gases boiler No piping is required for the reference gas air which is fed in at the installation site The ZO21S standard gas unit is used for calibration Zero gas from this unit and span gas air is sent to the probe through a tube which is connected during calibration ZR202G Integr
191. utput contact 1 detection 0 No action No action of non combusted gas 1 Action IM 11M12A01 04E Equipment Setup and Others in Group F 10 15 lt 10 Other Functions gt Code Item Tuning Engineering unit Default setting F01 Equipment setup 0 Oxygen analyzer Oxygen analyzer 1 Humidity analyzer F02 Selection of measurement O Wet Wet gas 1 Dry F04 Selection of temperature 0 degree C degree C units 1 degree F F05 Selection of pressure units 0 kPa kPa 1 psi F08 Selection of display items O Oxygen concentration Oxygen concentra 1 Amount of moisture quantity tion 2 Mixed ratio 3 Item selected with analog output F10 Date YY MM DD HH MM F11 Period over which average 1 to 255 hours Hours One hour values are calculated F12 Period over which max 1 to 255 hours Hours 24 hours and min values are mon itored F15 Purging time 0 to 60 minutes Minutes F20 Amount of water vapor in 0to 5 m kg m3 1 0 m3 kg m3 exhaust gas F21 Theoretical amount of air 0 to 20 m 3 kg m3 1 0 m3 kg m3 F22 X value 0 to 19 99 1 F23 Absolute humidity of the 0 to 1 kg kg 0 1 kg kg atmosphere F30 Initializing all data F31 Initializing data in group A F32 Initializing data in group B F33 Initializing data in group C F34 Initializing data in group D F35 Initializing da
192. value 2 Holds set values During error occurrence C07 0 Without hold feature 1 Last measured value 2 Holds set values Note C07 is not displayed when option code C2 or C3 NAMUR NE 43 compliant is specified Default Values When the analyzer is delivered or if data are initialized output holding is by default as shown in Table 8 6 Table 8 6 Output Hold Default Values Status Output hold min and max values Preset value During warm up 4mA 4mA Under maintenance Holds output at value just before maintenance started 4mA Under calibration or blow back Holds output at value just before starting calibration 4mA On Error occurrence Holds output at a preset value 3 4mA IM 11M12A01 04E 8 6 lt 8 Detailed Data Setting gt 8 4 Setting Oxygen Concentration Alarms The analyzer enables the setting of four alarms high high high low and low low alarms depending upon the oxygen concentration The following section sets forth the alarm operations and setting procedures 8 4 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 with parameter codes D41 and D42 and if the measured values exceed the preset oxygen concentration values specified with D011 and D02 The oxygen alarm set values can range from 0 to 100 0 2 Low and low low alarm values Low alarms and low low alarms are issu
193. wer removed any dust oil mist and the like for the reference gas when piping e When the instrument applies natural convection for reference gas Model ZR202G 0 O O H C ambient air near the probe is used for reference gas therefore the accuracy of analysis will be affected by ambient humidity changes or the like If more accurate analysis is necessary use instrument air dehumidified to the dew point 20 C or lower removed any dust oil mist and the like for reference gas Stable analyzing can be conducted when using instrument air 4 1 Piping for System 1 The piping in System 1 is illustrated in Figure 4 1 AI 2ZR202G Integrated type Zirconia Oxygen Analyzer m A A Stop valve X Hi i 100 to 240 V AC dmsemnrnnsnsnneren Contact input gt Analog output contact output Digital output HART Calibration gas 100 110 115 200 220 240 V AC Z0218 Standard gas unit FAE Figure 4 1 Piping for 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 1 D 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 The stop valve should be connected directly to the equipment If any piping is present between the analyzer and the stop v
194. y been replaced once is used again apply grease Never Seez G7067ZA to the threads of the dust filter 11 1 5 Replacement of O ring The detector uses three different types of O rings 4 and 3 One O ring alone 44 or two O rings 2 and 02 are used For a pressure compensating model two O rings are used for individual uses Two O rings and 22 are used for reference gas sealing and require periodic replacement 11 1 6 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 IM 11M12A01 04E lt 11 Inspection and Maintenance gt 11 7 A CAUTION When operating an instrument such as boiler or industrial furnace is stopped with the zirconia oxygen analyzer operation moisture can condensate on the sensor portion and dusts may stick to it If operation is restarted in this condition the sensor which is heated up to 750 C firmly fixes 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 be used 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 gas to the sensor If impossible to do the above remove the detector 2 If unavoidably impossible to supply the power and removing t

Model ZR202G Integrated type Zirconia Oxygen Analyzer

Contents

Download Pdf Manuals

Related Search

Related Contents