Model ZP, In-Situ Oxygen Sensor Instruction Manual
Contents
1. PCC III Z Option Board P N 190371 opio Zero Cross E 2 coupler detector R 39 H 120 Vac Pm n 60Hz i H C ya A S opo eater Control CPU AND i f gt coupler connector ai RESET Phase Angle i J Law Al Modulated J LU 42 N Watchdog ZP xx Oxygen Probe Timer O f p far A Isolated Line Voltage a rb Isolated Low Voltage 7 9 25Vd YO Q L e ee Heater 3 ti a 1 GN wate AID Converter M 43 3 Type R TIC couplers 3 channel Ta ID Yar p 16 bit 150 mV FS Laf DS1 H 45 5 ZrO Cell CPU OK ji wa cy Sellimeedence ft s Ww vou KT Test Relay K 1g DS2 s TEMP j Optional Flue Gas g 47 1 A Temperature Sensor l poo z TYPE J T C Yr i Las e NY Cal Data DS3 3 EEPROM Diagnostic H BS amp Code CJC Temp JET Isolated Power Supply Note Some wiring is omitted for clarity Sensor Ka Refer to the Installation Section for complete i field wiring details Fig x x Functional Block Diagram of Z Option Board with ZP Oxygen Probe Z board diagnostic LED s DS1 blinks to show that the Z board microprocessor is functioning DS2 is ON when the Cell is at operating temperature and blinks while warming up DS3 is OFF when the ZP is ope2. ZP 20 Oxygen Sensor and PCC III Zxx0 Controller Unit System Overview Monitoring flue gas oxygen levels minimizes fuel expense and insures safe combustion for all combustion processes For Low NOx Burners that utilize Flue Gas Recirculation FGR windbox oxygen monitoring provides accurate feedback of the FGR air ratio for stable NOx control A model ZP Oxygen Analyzer System consists of ZP Oxygen Sensor 190130 connecting cable type Z PCC III I O expansion option board and a PCC II Controller see above The Z plug in option board is mounted inside the PCC III controller and can be factory or field installed The PCC III can accept up to two Z option boards and therefore two ZP Oxygen Sensors The Model ZP detector is an in situ direct insertion Zirconium Oxide element with proven accuracy and long term stability The Heater is a reliable ceramic element The detector uses ambient air instead of plant compressed air for it s reference so it is immune to damage caused by water and oil in compressed air systems The ZP is suitable for use in processes fired by gas all grades of oil and process off gasses A standard 3 flange is used to mount the ZP probe The sample gas filter can be cleaned without removing the probe from the stack The Detector can be repaired or replaced without removing the probe from the stack The ZP Oxygen Probe is directly wired to the PCC III Controller eliminates a field mounted
3. 1 4 Compression RNN TSS RRS EQ SAS NN RSs S WV n aaa gt s son RRS EE SQQQQMn asosqon RSs EV SsQ SA B8Son RRS EQ AABO8S os R amp S S S WSR RV nn RV i RV a RV nr RV 7 RV w Sas L 1 3 1 3 1 3 Minimum p Stack R Exposed _ Length Stack Width Nipple Length 6 0 500 F Site sete 9 500 750 F Insulation 12 750 1000 F Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 6 Check Flange Temperature The ZP Detector flange temperature must be less than 260 F in order to prevent long term damage to the calibration gas and ambient air elastomer seals within the Detector head After the ZP is bolted to the duct mounting flange the burner should be operated for enough time for the ZP Detector flange temperature to stabilize typ 20 40 min Observe the temperature sensitive label on the Detector flange see below 9 Sa 780 oa 2700 27 G Temperature Temperature Under 260 Deg F Above 260 Deg F Temperature Sensitive Labels If the duct is insulated and the nipple and flange are not insulated and the proper nipple length is used see chart in Installation sketch the Detector flange temperature will not exceed 260 F If the Detector temperature exceeds 260 F use one or all of the following to lower the temperature Reduce duct Radiant h
4. Wiring The PCC IIl and ZP 120 Vac power supplies should only be turned off for ZP maintenance or for extended Boiler shutdowns The 120 Vac power should NOT be turned off every time the burner is shut down Excessive power cycling can shorten the life of the ZP detector Provide a service loop in the flex conduit at the Detector to allow removal disconnecting the wiring Note The Terminal Screws in the Detector head are M4x0 7 metric screws The ZP Sensor and the Z option board are factory calibrated as a matched pair The Sensor and Z board are marked with the same serial number Install and wire the ZP Sensor and PCC III Z board as a matched pair PCC Ill Z Option Board P N 190130 7 Wire Cable 120 Vac H x 39 Internal note 1 3 Amp 70W 60 Hz N x 40 Fuse ZP xx Oxygen Probe G x41 RAG x 42 wO Heater note 2 NO SEAS x 43 Type R Green BAG note 3 yp j TypeRTIC gt x 44 TIC Wire Cable R4 E S Gray B ZrO Cell x 45 Cable R x 46 a note 4 note 5 Xar TYPEJ wt TIG WIRE lt TYPEJTIC gt y X 48 R Optional Flue Gas note 6 note 7 Temperature Sensor PIN 104087 Notes 1 Run all wires in one conduit 500 ft maximum wiring length Avoid
5. 41 High Cal was gt 0 75 difference from last calibration Check Cal Gas value 42 mV decade slope was out of range Auto Cal aborted Check cal gas values and cell impedance 43 Cell Offset was out of range Auto Cal aborted Check cal gas values and cell impedance 44 Calibration Cell Temperature is out of range Auto Cal aborted 45 Cal Gas pressure switch is ON after closing High Cal Gas valve Check solenoid vale and pressure switch operation 46 ENABLE Input turned OFF during Auto Cal Auto Cal aborted Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 18 Handling Operation and Maintenance Handling Precautions CAUTION The ZP flange and tip external surface temperatures approach 200 F when outside the stack or duct When installed Flue gas Temperatures can substantially increase the ZP surface temperatures Always wear protective gloves to avoid burns The Zirconium Cell Cell Heater and dust filters are all ceramic and can be damaged if dropped Do not drop the ZP Sensor assembly or ZP Detector Package with cushioning before shipping Liquid water should not be allowed to come in contact with the Cell Water vapor is not a concern Liquid water that contacts a hot cell or heater can crack the element and destroy it Calibration gas must be dry and tubing must slope down to prevent trapping condensation Condensation can for water drops observe start up shutdown procedures below Operation Inte
6. RETENTIVE BYTES 0 DATA BYTES 5 NAME AABO SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A or D MASTER BLOCK 1 2 Parameter Description Default Max Min Code Notes 1 AUX OUT CH 0 x 0 3 3 Notes 1 This is NOT a normal Block Input This Input is the Master Block that will be used as the Source for the auxiliary output signals There is no Input Type mis match error checking because the Master Block output value is not used by the AABO 2 If the Input Block ie Master Block does not have any Auxiliary Block Outputs then the AABO Block Output The Input current value ie Master Block Output An error message is generated when you attempt to leave S M mode The PCC III will not leave S M mode until a proper Master Block is assigned 3 The scaling function and quantity of auxiliary output channels is determined by the Master Block F94 DABO Discrete Auxiliary Block Output Function DABO allows the ZAIN Discrete Auxiliary Block Outputs to be connected to other Blockware Inputs The Input of the DABO must be soft wired to a ZAIN Block Parameter 1 is used to select the ZAIN Auxiliary Output signal that will become the Output signal of this DABO Block See the ZAIN Block description for a list of the available Auxiliary Outputs and for the scaling of each Aux Output DABO ch 1 1 when the ZP Sensor and Z board are operating Normally If he AABO Diagnostic Code equals 1 6 8 10 15 30 or 50 52 or if a Calibr
7. amp Extractive A portable oxygen analyzer or an EPA CEM oxygen analyzer extracts a sample of the flue gas from the duct and transports it to a measurement device that is located outside of the duct Since the temperature of the connecting tubing and or the external measurement cell is below the dew point that is condensation temperature of the water vapor in the flue gas sample the water vapor in the flue gas condenses This is know as a Dry oxygen measurement because the condensed water occupies a negligible percentage of the total volume of the flue gas Effectively a portable or other extractive Dry oxygen analyzer measures Oxygen as a percentage of all of the Dry flue gas component gasses O2 N2 CO2 CO Therefore a Dry Oxygen measurement will always be higher than a Wet Oxygen measurement of the same flue gas Approximate Correction Factors Natural Gas Wet 0 888 Dry OR Dry 1 125 Wet 2 thru 6 oils Wet 0 930 Dry OR Dry 1 075 Wet Coal wood and solid fuels Varies widely based on the moisture content of the fuel as burned Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 20 Diagnostic Codes The Diagnostic Codes and remedies are listed on pages 16 and 18 The Codes can be displayed as follows The PCC III Z option board has a Diagnostic Code LED that blinks for Codes 1 through 10 Remove the PCC III front door to view the Diagnostic LED Count the number of ti
8. detector has been overheated and the viton seal is leaking Replace Detector or return to the factory for replacement Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 23 Parts Contact your local representative for price and availability of parts Oxygen Sensor Exploded View Item Description Rainproof Detector Cover Optional O Ring for Detector Cover Terminal Screw M4x0 7 metric thread Detector Cable Conduit Gland Socket Head Cap Screw 10 32 SS Calibration Gas Port Temperature Sensitive Label 260 deg F CO N OQ on AI Co po gt O Ring for Detector Flange Replacement Cell with Heater and Thermocouple Filter Assembly Oxygen Probe Full Faced 4 Bolt 125 3 Flange Gasket Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 24
9. it must be replaced The general Installation procedure is Select a stack location Mount a pipe nipple and 3 125 flat faced flange on the duct nipple amp flange supplied by others Mount the ZP Sensor on the flange Check the Flange Temperature Run calibration gas tubing to floor level Mount the PCC III controller Run conduit from the PCC III to the ZP with flexible service loop at the ZP Pull 190130 cable through the conduit and terminate the wiring Location Locate the end of the probe in the middle one third of the flue gas stream as shown below and approximately perpendicular to the flue gas flow The location must be upstream of any ambient air infiltration and thus oxygen caused by stack leaks The probe should be located in an area free from any abrupt variations in flue gas pressure or temperature and flow stagnation pockets The probe should be mounted in an area of uniform flue gas flow The Probe should not be subjected to excessive vibration The standard ZP is designed for indoor use If located outdoors purchase and install the optional Rain Cover The detector uses ambient air as a reference air containing abnormal oxygen levels causes measuring errors Make sure that flue gas is not leaking out in the vicinity of the probe The ZP probe must always be horizontal or pitched down away from the detector to prevent accumulation of condensed flue gas water at the Detector Flue gas contains a substanti
10. listing of these codes see the tables below Code Description Comments Possible Causes 0 Normal Operation 1 CPU board is not communicating with Z Option Board Does the PCC III BlockWare include a ZAIN block if not correct the PCC III BlockWare Does ZAIN Block Option Slot Parameter match the actual Z Option Board location Slot 1 vs Slot 2 Check CPU Option Board connector pin alignment If no other problem found replace Z Option Board 2 Z Option Board A D converter is bad Replace Z Option Board 3 Cell T C Wire Open Check connections and T C field wiring continuity Repair field wiring Check T C continuity inside the Detector If open replace detector 4 Cell T C Wiring Reversed Correct field wiring Black T C wire is positive Red T C wire is negative 5 Cell T C Wiring Shorted Wait 30 seconds after power up to allow heater to warm T C then re check the Code Number Disconnect T C wires at detector Check field wiring for wire to wire and wire to ground shorts Correct wiring Disconnect heater wiring at Z board and check field wiring and heater continuity The heater is typically 45 55 ohms Correct wiring If T C is open replace Detector If Wiring amp Detector are OK replace Z option board 6 Blown Fuse or No AC Power Verify that 120 Vac is present on term 39 amp 40 of Z board Check F1 on Z board 7 High Combustibles This code is invalid unless th
11. splices Use only Preferred Instruments P N 190130 cable between the ZP and PCC III The twisted shielded Cell and T C wire with twisted AC wiring prevents electrical noise Multiple ZP cables may be run in one conduit Flue Gas Temperature wire can be in this conduit if shielded T C wire is used Do not include any other AC or DC wires in this conduit 1 2 conduit or larger is required for one 190130 cable 2 Connect Detector Ground wire directly to Power Supply Ground 16 ga min 3 Connect a separate signal shields Ground wire directly to Power Supply Ground 22 ga min The S terminals are connected internally 4 Connect shields to S Insulate shields to prevent shorts to the case or other shields 5 Do not connect shields at the sensor Insulate shields to prevent shorts to the case or other shields 6 x 1 or 2 Indicates which PCC III option slot is being used 7 Flue Gas Temperature FGT Sensor is optional Jumper Input if not used Shielded cable is not required if run in conduits that do not have ZP probe wires AC wires or noisy DC wiring Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 9 Calibration WARNING If the ZP sensor is part of an Oxygen Trim Combustion Control system or any other automatic control system the control system must be disabled bypassed or placed in Manual by a qualified control system technician before applying any test gas to the ZP Detector Failure to do so could result in equipmen
12. transmitter which simplifies installation The microprocessor based PCC III Controller provides digital zirconia cell temperature control electrical isolation diagnostics and multiple alarms Calibration is simple connect the test gas and press a button An optional unattended automated two point calibration gas manifold with gas availability feedback is available for EPA CEM applications The PCC III Blockware Control Logic can use the Oxygen Input s for any or all of the following purposes Oxygen Trim control of fuel air ratio Windbox FGR Control multiple ZP sensor averaging Alarming Front Panel numeric and or bargraph indication 4 20 mA re transmission or RS485 Modbus into a SCADA system The Blockware Control Logic loaded into the memory of each individual PCC III controller determines how the Oxygen Input s are used Preferred Instruments offers a wide variety of standard off the shelf Blockware Control Strategies for all common Combustion Control Applications jackshaft parallel positioning VFD fan control full metering steam flow air flow for solid fuels Windbox FGR Users Instrument and Combustion Technicians or Systems Integrators trained in PCC III Blockware Configuration can modify the Standard Blockware or create their own custom Blockware to suite on site requirements For a complete understanding of the Oxygen Analyzer System and operation of the PCC III the user must obtain the site specific PCC II
13. using the calibration data that existed before this calibration was attempted The Normal Operation DABO output changes from 0 to 1 The Calibration in Progress DABO output changes from 1 to 0 Press ESC to return to the CALIBRATE I O menu Press ESC to return to the BOARD x OXYGEN INPUT display EDIT A to the EXIT S M display Press ESC to exit S M mode Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 12 PCC IIl Blockware for the ZP Sensor and Z Option Board This section provides engineering information on Blockware Functions ZAIN AABO and DABO that are specific to the PCC III Z option board and the ZP Oxygen Analyzer These Blockware functions require PCC III CPU ROM software version 3 0 or higher and CPU hardware rev D or higher WARNING If the ZP analyzer is used as part of an automatic combustion control system for example oxygen trim for ratio control the BlockWare must utilize the DABO Normal Operation status as a safety interlock The control logic designer must determine and program appropriate system response after an analyzer failure All zirconium cells have a limited life of two to five years of use and typically fail by indicating a higher than actual Oxygen concentration Failure to do so can result in equipment damage injury or Death Refer to the PCC III Instruction Manual for information on all other PCC II Blockware control logic controller operation and safety precautions An e
14. verify that the Z board top LED is OFF DS3 see page 5 If the Diagnostic Code AABO Block is used in the Blockware either view the code on the Front Panel Display or use EXAMINE mode to view the Block Output 0 Normal 15 Not at operating temperature see table for other codes Verify that the Cell is At Temperature by one of the following methods Remove the PCC III front door the Z board middle LED should be ON and not blinking DS2 see pg 5 If the Cell Temp AABO Block is used in the Blockware either view the temperature on the Front Panel Display or use EXAMINE mode to view the Block Output 80 800C Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 10 Wait an additional 15 minutes after the Cell is At Temperature to allow the Detector internal temperatures to stabilize Connect the Low Range Calibration Gas cylinder and flow meter to the Detector Place the PCC III into service manual mode S M PCC III Key strokes EDIT EDIT W to EXIT S M then ENTER at ALL S M press ENTER EXIT S M is displayed again Activate the Oxygen Calibration Menu Item EDIT to CALIBRATE I O then ENTER EDIT to BOARD x OXYGEN INPUT then ENTER OPEN L LLL GAS VALVE PRESS ENTER AFTER OPENING will be displayed L LLL should be the exact concentration of Cal Gas as entered in ZAIN Parameter 3 The Normal Operation DABO output changes from 1 to 0 The Calibration in Progress DA
15. 00 Deg C A solid electrolyte tube coated with porous platinum on both surfaces acts as an oxygen sensor The differential oxygen concentration flue gas oxygen vs room air oxygen in contact with both platinum electrodes produces a voltage as follows E RT 4F In P1 P2 Gas Constant Faraday Constant Temperature of Electrodes Deg K Reference Air Oxygen Concentration Measured Oxygen Concentration vva nI NO 72mm Measuring Reference Thermal electrode electrode insulator Ceramic Zirconia heater element For example when the sensor element is heated to 800 Deg C Reference Oxygen P1 20 6 and the Measured Oxygen P2 2 0 an output signal of about 54 mV is generated Lower Measured Oxygen levels produce higher voltage levels A ceramic heater with type R thermocouple temperature feedback is used to maintain the zirconia oxygen sensor at precisely 800 C 1472 F The PCC III s Z option board monitors the thermocouple and regulates the power applied to the heater Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 3 Ambient air provides the oxygen for the Reference side of the cell Air circulates around the Reference electrode of the zirconia element The air is rapidly circulated by convection because the sensor is very hot and the gas volume is small The sample gas reaches the measuring electrode by rapid convection in a manner similar to the Reference electro
16. 20 23 0 2 428 5 5 29 10 24 0 3 366 6 0 27 18 25 0 4 266 Slow Response Time Check for excessive dirt on Detector Filter or inside the Probe As the Cell approaches the end of it s life the Cell Impedance increase toward 1100 ohms and the Cell response time becomes longer Reading is Lower than Expected See Wet vs Dry measurement discussion above Check for CO or Combustibles in the flue gas CO or combustibles will oxidize on the internal surface of the Cell this consumes the Oxygen locally within the Detector and causes a low reading Check the Diagnostic Code as described above Check with a certified calibration gas Check to see if the Filter is dirty or blocked Check for Detector Leaks see below Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 21 Reading is Higher than Expected It is important to remember that the cell makes a differential measuerment That is the cell compares the unknown oxygen percentage in the flue gas against the known oxygen percentage in the ambient air inside the cell Ambient air is typically 20 6 Oxygen however it can range from 19 5 to 20 9 as relative humidity and temperature change If the flue gas duct is pressurized and a duct leak allows flue gas to enter the detector head the ambient oxygen percentage can be substantially lower Combustible gasses in the ambient air will consume the oxygen on surface of the cell and will also lower th
17. BO output changes from 0 to 1 Open the Calibration Gas valve Verify a flow of 2 3 SCFH of gas to the Detector Press ENTER signal settling is displayed for a short time y yyy change is displayed and updated until the cell mV signal stabilizes It can take 2 to 5 minutes for the signal to stabilize Less than 0 015 change for 15 seconds is required Press ESC to abort if the signal never stabilizes due to electrical noise line voltage variations low gas flow or gas leaks CLOSE LOW VALVE OPEN HH HHH GAS VALVE PRESS ENTER AFTER OPENING is displayed after the signal stabilizes HH HHH should be the exact concentration of Cal Gas as entered in ZAIN Parameter 4 Close the Calibration Gas Valve Disconnect the Low Range Calibration Gas Connect the High Range Calibration Gas cylinder and flowmeter to the Detector Open the Calibration Gas valve Verify a flow of 2 3 SCFH of gas to the Detector Press ENTER signal settling is displayed for a short time y yyy change is displayed and updated until the cell mV signal stabilizes It can take 2 to 5 minutes for the signal to stabilize Less than 0 015 change for 15 seconds is required Press ESC to abort if the signal never stabilizes due to electrical noise line voltage variations low gas flow or gas leaks CLOSE CAL GAS VALVE PRESS ENTER WHEN CLOSED is displayed after the signal stabilizes Close the Cal Gas Valve Pre
18. Blockware Documentation and the PCC III Instruction Manual Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 2 Oxygen Sensor The ZP Oxygen Sensor is pre assembled and consists of a Detector and a Probe The ZP Sensor is field installed into the boiler flue gas outlet to sense flue gas oxygen concentration The Oxygen Sensor is a direct sampling IN SITU type and does not require an extractive sampling system Detector The detector consists of a zirconia oxide cell a ceramic heater with thermocouple terminals for connecting to the Controller Unit a flange for connection to the probe an opening to accept reference ambient air and a connection for calibration gas FURNANCE ENVIRONMENT AIR ENVIRONMENT TERMINAL TERMINAL BOX BOX COVER CERAMIC FILTER CERAMIC HEATER MEASURED GAS QUARTZ FILTER CALIBRATION GAS INLET CONDUIT CONNECTION The detector works on a principle that when heated to 800 C 1472 F the cell generates an electrical signal directly related to the oxygen concentrations of the flue gas Flue gases are passed through a filter to prevent dust and dirt from contaminating the cell Calibration gas can be injected into the space behind the ceramic and quariz filters to allow on line calibration wihtout removal from the stack Measuring Principle Zirconia ZrO2 ceramic sintered with a small amount of yttria Y203 is a solid electrolyte with oxygen ion conductivity at temperatures above 5
19. Model ZP In Situ Oxygen Sensor for use with PCC II Zxx0 Controllers Instruction Manual Revision 1 3 6 24 04 Instruction Manual Part Number 90179 Preferred Instruments A Division of Preferred Utilities Mfg Corp 31 35 South St Danbury CT 06810 Ph 203 743 6741 Fax 203 798 7313 www preferred mfg com Preferred Utilities Manufacturing Corp PUMC is an engineering based manufacturer of combustion control and data acquisition systems instrumentation fuel handling systems specialty burners nuclear power plant outage support tools and component parts for industrial institutional and commercial power plants Our Core Business is Combustion Control Systems Preferred s headquarters is located in Danbury CT with direct sales and service offices located in the Boston Chicago New York New Jersey and Washington D C areas Sales representative organizations cover all of the other major markets throughout the United States Call 203 743 6741 or visit www preferred mfg com for the WARNING The ZP Oxygen Sensor is an input to a PCC II controller The User must also consult the PCC III Instruction Manual The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes Only qualified Instrument Engineers or Technicians who have read the ZP and PCC III Instruction Manuals and are familiar with all aspects of the Process being controlled and are aware of the particular Blockware Con
20. al Passed DABO changes to 0 Throughout the Auto Cal cycle the Diagnostic Code AABO changes to indicate the current status If an error occurs at any point during the Auto Cal cycle the Auto Cal Failed DABO will change to 1 for 10 seconds and the Diagnostic Code AABO will indicate the Error Code for 10 seconds Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 17 Automatic Calibration Diagnostic Codes Code Description Comment 0 Normal Operation 30 Auto Cal in progress 31 Semi Automatic Calibration already in progress Auto Cal aborted 32 Cal Gas pressure switch was ON before opening Low Cal Gas Check solenoid vale and pressure switch operation valve 33 Low Cal Gas pressure was low Check Cal Gas cylinder pressure 34 Low Cal Gas timeout signal did not stabilize within 6 minutes Check for electrical noise interference 35 Low Cal was gt 4 oxygen based on previous calibration data Check Cal Gas value 36 Low Cal was gt 0 75 difference from last calibration Check Cal Gas value 37 Cal Gas pressure switch was ON before opening High Cal Gas Check solenoid vale and pressure switch operation valve 38 High Cal Gas pressure was low Check Cal Gas cylinder pressure 39 High Cal Gas timeout signal did not stabilize within 6 minutes Check for electrical noise interference 40 High Cal was lt 5 oxygen based on previous calibration data Check Cal Gas value
21. al amount of gaseous water The ceramic detector cell operates at 800 C 1472 F if liquid water comes in contact with the cell the ceramic cell will damaged The Probe should not be vertical and should not be pitched down more than 45 to avoid overheating the mounting flange and internal seals Mounting Nipple and Flange The 3 125 flat faced mounting flange must be mounted on an exposed non insulated nipple as shown in the diagram below This nipple cools the flue gas to prevent overheating the Detector Head The ZP Detector flange must be less than 260 F in order to prevent damage to the calibration gas and ambient air seals within the Detector head The mounting flange bolt holes should be installed so that the ZP flow arrows are aligned with the flue gas flow This allows the end of the probe tip to function as a scoop when in the flue gas flow The tip is designed to direct the flue gas to the detector by utilizing the dynamic differential pressure produced by the probe tip The ZP Sensor flange has 8 bolt holes but only 4 will be used The extra 4 holes allow the user to rotate the probe after installation see below gt 3 125lb flange flat face _4 3 Probe Length 20 30 45 65 or 90 2 1 4 WSR SSSA RQ a o7v R0ngxe RR a 7 w RQ a 07v RR eae w NR Box te lt lt Termination ji 44 2 FNPT Calibration gas
22. ation cycle is in process the Normal Operation DABO changes to 0 Zirconium Oxide sensors have a limited life typ 2 5 years If the Oxygen signal is used as part of an automatic combustion control system the Blockware Logic Designer must use the Normal Operation signal as an interlock that prevents a dangerous control response when the Oxygen Sensor fails FUNCTION 94 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 5 NAME DABO SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A or D MASTER BLOCK 1 2 Parameter Description Default Max Min Code Notes 1 AUX OUT CH 0 x 0 3 3 Notes 1 This is NOT a normal Block Input This Input is the Master Block that will be used as the Source for the auxiliary output signals There is no Input Type mis match error checking because the Master Block output value is not used by the DABO 2 If the Input Block ie Master Block does not have any Auxiliary Block Outputs then the DABO Block Output The Input current value ie Master Block Output An error message is generated when you attempt to leave S M mode The PCC III will not leave S M mode until a proper Master Block is assigned 3 The scaling function and quantity of auxiliary output channels is determined by the Master Block Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 15 ZP Oxygen Sensor Diagnostic Codes AABO ch 5 provides a diagnostic code that indicates the current status of the ZP sensor and the Z board For a
23. ations and are only used during the calibration cycle The precise certified concentrations must be entered do not enter the nominal concentrations Block Outputs Traditional PCC II Blockware has only one Block Output value per Block The ZAIN function has one Primary Block Output and 11 Auxiliary Block Outputs xABO The Primary Block Output is the current Oxygen Concentration AABO and DABO Auxiliary Block Outputs There are 5 Analog Auxiliary Block Output AABO channels and 6 Discrete Auxiliary Block Output DABO channels listed below with the scaling and description of each channel The Auxiliary Outputs are made available by soft wiring the ZAIN Primary Output into multiple AABO and DABO Blocks The channel Parameter in each AABO or DABO Block determines which ZAIN auxiliary output signal will become the output signal of each individual xABO Block See the sample Blockware diagram below ZAIN Blockware Inputs and Parameters FUNCTION 6 TEMP BYTES 13 RETENTIVE BYTES 0 DATA BYTES 23 NAME ZAIN SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 D ENABLE AUTO CAL 1 2 D START AUTO CAL CYCLE 2 3 D CAL GAS PRESSURE SWITCH 3 Parameter Description Default Max Min Code Notes 1 OPTION BOARD 1 2 1 2 1 3 2 SCALING xx O02 100 OUTPUT 10 25 5 3 3 LOW 02 CAL GAS 0 400 3 000 0 300 2 4 HIGH 02 CAL GAS 8 000 19 000 7 000 2 5 AUTO CAL TIMER HOURS 0 ON DEMAND 24 199 0 1 Analog Auxiliary Outputs Description N
24. de When troubleshooting a Zirconium Oxide Oxygen Analyzer it is important to remember that the cell makes a differential measuerment Said another way the cell compares the unknown oxygen percentage in the flue gas against the known oxygen percentage in the ambient air inside the cell Ambient air typically is 20 6 however it can range from 19 5 to 20 9 as relative humidity and temperature change If the flue gas duct is pressurized and a duct leaks allow flue gas to enter the detector head the ambient oxygen percentage can be substantially lower Combustible gasses in the ambient air will consume the oxygen on surface of the cell and will also lower the percent oxygen in the ambient air inside the cell If the ambient oxygen percentage is low a Zirconium cell will sense a lower differential and will cause the analyzer to indicate a higher oxygen level than is actually in the flue gas Probe The probe is a stainless steel assembly that mounts on a 3 inch 125 Ib flange flat face located on the flue gas duct or stack The probe protrudes into the flue gas stream and directs boiler flue gases from the middle third of the flue gas stream to the detector The probe design provides for the removal of the detector for service or replacement without the need for probe removal The probe is installed such the tip of the probe functions as a scoop when in the flue gas flow The probe utilizes the dynamic differential pressure prod
25. e cell is near operating temperature Or Check the Flue Gas for Combustibles Cell Wires Open Check continuity of field wiring Check continuity of Cell Cell must be warm before checking Replace detector if open 8 T C cold junction temperature sensor is bad Replace Z option board 9 high cell temperature Heater mis wired heater turns off High AC Line Voltage Above 135 Vac 10 Z board cell impedance test relay bad For New Detectors Ignore Intermittent Code 10 this is not unusual due to low cell Impedance a good thing The test and this code are updated every 10 minutes Check for Excessive electrical noise on the Cell field wiring For older cells if Code occurs continuously Replace z option board 11 Cell ohms gt 1100 ohms Replace detector cell is at end of life 15 NOT at Normal Cell Operating Temperature 760 830 C 50 Z board slope coefficient is bad Default Data in use Z Board was never factory calibrated 51 Z board ambient Oxygen coefficient is bad Default Data in Z Board was never factory calibrated use 52 Z board Calibration Cell Temperature is bad Default Data in Z Board was never factory calibrated use 60 Flue Gas Temp FGT T C Wire Open Flue Gas thermocouple wiring is open or not installed Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 16 Automatic Calibration Automatic Calibration is optional and is typically only required for EPA Continuous Emissions Monitoring syst
26. e percent oxygen in the ambient air inside the cell If the ambient oxygen percentage inside the cell is low a Zirconium cell will sense a lower differential and will cause the analyzer to indicate a higher oxygen level than is actually in the flue gas If the ceramic Cell is dropped and cracks the measured flue gas and ambient air will intermingle and the oxygen percentage on both sides of the cell will equalize a Zirconium cell will sense a lower differential and will cause the analyzer to indicate a higher oxygen level than is actually in the flue gas See Wet vs Dry measurement discussion above Check the Diagnostic Code as described above Check with a certified calibration gas Verify that the calibration gas port and tubing are plugged or valved closed during operatin to prevent infiltration of air Check to see if the Filter is dirty or blocked Check for Detector Leaks see below Cell will not come up to Operating Temperature Check the Diagnostic Code as described above Check the AC line voltage must be 60 Hz and greater than 102 volts Check the AC line voltage for excessive electrical noise Low Calibration Gas Flow Rate Disconnect the tubing at the Calibration Port on the Detector Verify that the gas is flowing up to the Detector If the Detector flange is overheated the elastomer calibration gas check valve may become stuck shut Use a toothpick or paper clip to gently push open the check valve Se
27. e the figure on the next page for the location of the check valve Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 22 ALVE INS VITON SEAL INSIDE Detector Leak Test If the Cell is cracked or broken flue gas can leak into the reference side of the Cell and cause an incorrect reading If the Viton seal between the Cell tube extention and the Detector head is overheated it can leak and cause an incorrect reading See Oxygen Sensor Measuring Principle above for a drawing and for the principle of operation Test for Leaks as follows Turn off power and remove the detector from the process Wait for the detector to cool down Remove the outer filter and the inner calibration gas deflector washer Insert small paper clip or toothpick into the check valve to hold it open during the test remove after testing Using a rubber sheet or the palm of your hand to seal the end of threaded tube pressurize the calibration port to 10 15 H20 The detector should hold pressure If the pressure rapidly drops to zero the cell is broken replace the detector All detectors are inspected and presure tested before shipment The reason for the broken Cell could be a dropped during shipping receiving or installation b hit with liquid water when hot Damage by liquid water can be caused by water in the calibration line or blow down line if a self cleaning probe is used If unit leaks slowly inspect the temperature label If black the
28. eating by insulating exposed ductwork Add another flange gasket Rotate the probe one bolt hole to reduce flue gas flow to the detector NOTE The temperature sensitive label can NOT be re used if the temperature exceeded 260F Use a new label or some other means thermocouple surface thermometer to measure the temperature after modifications are made Rotating the Probe to Lower Flange Temperature If the flue gas velocity in the duct is unusually high the higher flow rate through the probe and past the Detector can cause Detector over heating Rotating the probe flange one bolt hole to purposely mis align the probe tip will reduce the flue gas flow rate through the probe If the probe is horizontal rotate it counter clockwise The detector has an opening for atmospheric air on the lower left side of the Detector housing Rotating counter clockwise will keep the inlet pointing downward minimizing the possibility of water infiltration Rotating the Probe ONE Bolt Hole To Lower Detector Flange Temperature Normal High Temperature Orientation Orientation Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 7 Calibration Gas Tubing When the detector is installed the detector calibration gas inlet fitting and tubing should slope downwards to prevent the entry of condensed water into the Cell Install copper tubing from the calibration gas port down to an easily accessible location Terminate the end with a valve cap p
29. ems Auto Cal requires two permanently installed calibration gas cylinders with regulators and electric solenoid valves and a common rotometer flow regulator and a Cal gas pressure switch DABO Blocks are used to link the ZAIN to PCC III output channels that control the solenoid valves and the Pressure switch is linked via a DIN to ZAIN input channel 3 Typically the Auto Cal cycle is triggered by the ZAIN Block s internal timer every 24 hours However Auto Cal can be triggered by Discrete Input 2 If the Input 1 ENABLE AUTO CAL signal is Low Auto Cal is disabled If the Input 1 ENABLE AUTO CAL signal is High Parameter 5 determines the Automatic Calibration cycle interval Auto Calibration Cycle ZAIN timer or Input 2 triggers the start of the Auto Cal cycle Normal Operation DABO changes to 0 Calibration in Progress DABO changes to 1 Open Low Cal Gas DABO changes to 1 Low Range Cal Gas starts to flow which closes the cal gas pressure switch After the cell mV signal settles Open Low Cal Gas DABO changes to 0 ZAIN verifies that the valves closes when the cal gas pressure switch opens Open High Cal Gas DABO changes to 1 After the cell mV signal settles Open High Cal Gas DABO changes to 0 ZAIN verifies that the valves closes when the cal gas pressure switch opens ZAIN starts a 10 sec Cell Purge timer Normal Operation DABO changes to 1 Calibration in Progress DABO changes to 0 Auto Cal Passed DABO changes to 1 10 seconds later Auto C
30. ers of certified calibration gas a 0 30 psi pressure regulator a 0 5 SCFH rotometer flow meter tubing and compression fittings The Low Range Calibration Gas must be between 0 300 and 3 000 oxygen mixed with dry nitrogen 1 2 is typical for combustion applications The High Range Calibration Gas must be between 7 000 and 19 000 oxygen mixed with dry nitrogen 8 is typical for combustion applications 18 for FGR ratio Flue Gas Recirculation applications Calibration Test Gas that is tested and certified to be within 2 of labeled Oxygen concentration can be obtained from Preferred Instruments 203 743 6741 or Scott Specialty Gases 800 217 2688 Obtain the site specific PCC III Blockware drawing for your controller to determine the Block number of the ZAIN Block that is controlling this ZP Sensor there can be two ZP sensors connected to one PCC III Obtain the calibration gas factory certification test results to determine the actual oxygen concentration in each cylinder Using the PCC III Front Panel Edit Menus or PC3_Edit or PC3_Draw enter the certified values not the nominal values into Parameter 3 LOW O2 CAL GAS and Parameter 4 HIGH O2 CAL GAS of the ZAIN Block Apply 120 Vac power to the PCC III Z board Wait 5 10 minutes for the Cell temperature to come up to the 800 C operating temperature Verify that the System is operating properly by one of the following methods Remove the PCC III front door and
31. irst and keep the ZP powered until after the temperature inside the stack or duct has cooled down to it s lowest normal off line temperature If the Boiler is going to remain in operation or if you can t wait for the stack to cool down Leaving the ZP probe in the stack cautiously remove ZP Detector from the probe flange with gloved hands and expose it to room air and then power down the ZP If the duct pressure is positive a cover plate and should be used to prevent flue gas flow through the open hole in the probe flange after the Detector is removed Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 19 Maintenance See the Calibration section above for suggested calibration frequency WARNING If the ZP sensor is part of an Oxygen Trim Combustion Control system or any other automatic control system the control system must be disabled bypassed or placed in Manual by a qualified control system technician before removing the Detector from the Stack or Duct Failure to do so could result in equipment damage injury or Death CAUTION The ZP flange and tip external surface temperatures approach 200 F when outside the stack or duct When installed Flue gas Temperatures can substantially increase the ZP surface temperatures Always wear protective gloves to avoid burns Inspect and Clean the Detector Filter and the Probe Fuel Type Frequency Solid Fuels and 6 oil every 3 months 2 oil and off gasses every 6 months Natural Ga
32. ld calibration indicates that the Cal Gas MAY be incorrect Check uV TOO HIGH errors above if OK press ENTER to accept Check displayed Oxygen against a third Cal gas or a portable lanalyzer after the completion of the calibration ERROR xx xxx mV decade SLOPE IS OUT OF RANGE ESC to exit The Cal Gas Oxygen values are incorrect in the ZAIN Parameters 3 amp 4 or The Cal Gas is marked incorrectly or The Detector is old or damaged and needs to be replaced ERROR x xxx CELL OFFSET IS OUT OF RANGE ESC to exit The Cal Gas Oxygen values are incorrect in the ZAIN Parameters 3 amp 4 or The Cal Gas is marked incorrectly or The Detector is old or damaged and needs to be replaced ERROR xxx deg C CELL TEMP IS OUT OF RANGE ESC to exit The Cell Temperature drifted out of range during the Calibration cycle Check wiring Check for 120 Vac line noise After any of the above error messages are displayed or is the Calibration is aborted with the ESC button the Cell must be purged The Following messages will be displayed if the calibration is unsuccessful CLOSE CAL GAS VALVE PRESS ENTER Close the Cal Gas Valve Press ENTER WHEN CLOSED is displayed purging cal gas will be displayed for 10 seconds This allows the Cal Gas to be purged from the Detector by the Flue Gas purge complete ESC to exit is displayed at the completion of purge The Sensor resumes operation
33. lug ZP Cal assembly or other means to positively prevent ambient air infiltration into the calibration gas port NONE SK 1629 ZP RRED INSTRUMENTS suas soum smar DAAB COMESTRUT SCHEMATIC am OXYGEN ANALYZER MANIFOLD b Obdon of Prefered Dil Mowuleclurhes Cora ame INC 3 19 07 a ELECTRICAL OUTPUT 4 20 mA D G POWER SUPPLY 115V 60 HZ arc or ounce grea FE g CONNECTING 7 WRE CABLE DETECTOR CoA CABLE GLAND i PUMC 190130 FOR MOUNTING DETAILS REFER TO INSTRUCTION MANUAL I i SUPPLIED _ BY OTHERS L4 7 CONNECT CALIBRATION GAS TUBE TO GAS INLET CINNECTION WITH ORIFICE INSTALLED PROPERLY CALIBRATION GAS TUBE 1 4 0 D COPPER TUBE PROBE a SAMPLE GAS TEMPERATURE 1150F MAX Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 8 Mount PCC IIl Controller Mount the PCC III Controller in a location that is easily accessible to the operator and no more than 500 ft of wiring distance from the ZP Sensor The location must be free from vibration extreme temperatures 32 122 F and condensing humidity The PCC III Controller front panel is rain proof but should not be subjected to prolonged direct sun light Use the full size panel cut out template provided to help cut the hole in the panel
34. me that the LED turns ON to determine the Code The ZP is Normal or Code 0 when this LED is OFF See page 5 for the location of the Diagnostic Code LED on the z option board The Diagnostic Code AABO Block in the PCC III Blockware can be used to view all of the ZP Diagnostic Codes Consult the site specific PCC III Blockware documentation for your Controller to determine if and where this AABO Block is located The Ouput of this Block can be viewed with the PCC front panel EXAMINE function or via the PC3_Edit View Blocks option or if configured from the PCC III front panel display Normal Operating Values The Values below are approximate and provided for trouble shooting purposes The values for each individual ZP Sensor will vary somewhat See page 9 for the wiring terminal numbers Cell Thermocouple type R 7 8 8 0 mV Cell Heater 45 55 ohms Cell mV for various Oxygen Concentrations are shown below Oxygen Cell mV Oxygen Cell mV 0 01 168 15 6 5 25 42 0 05 132 68 7 0 23 79 0 1 117 41 7 5 22 27 0 5 81 94 8 0 20 84 1 0 66 67 9 0 18 25 1 2 62 65 10 0 15 93 1 4 59 25 11 0 13 83 1 5 57 73 12 0 11 91 1 6 56 31 13 0 10 14 1 8 53 71 14 0 8 511 2 0 51 39 15 0 6 991 2 2 49 29 16 0 5 569 2 4 47 37 17 0 4 233 2 6 45 61 18 0 2 973 2 8 43 98 19 0 1 782 3 0 42 46 20 0 0 651 3 5 39 06 20 6 0 0 4 0 36 12 21 0 0 4238 4 5 33 52 22 0 1 449 5 0 31
35. otes 1 A FLUE GAS TEMPERATURE 0 100 0 1000 F 2 A CELL TEMPERATURE 0 100 0 1000 C 3 A CELL IMPEDANCE 0 100 0 1000 ohms 4 A HOURS UNTIL NEXT AUTO CAL 0 199 0 199 HRS 4 5 A DIAGNOSTIC CODE 0 100 CODE 0 100 see chart below Discrete Auxiliary Outputs Description Notes 1 D NORMAL OPERATION 1 Normal 5 2 D CALIBRATION IN PROGRESS 1 In Progress 3 D AUTO CAL PASSED 1 Passed 4 D AUTO CAL FAILED 1 Failed 5 D OPEN LOW CAL GAS 1 Open Low Gas Valve 6 D OPEN HIGH CAL GAS 1 Open High Gas Valve Notes 1 1 Enable Auto Cal cycles This input does not actually start the cycle 2 AO to 1 rising edge transition starts the Auto Cal cycle 3 Locate on the common pipe to the Detector Proves Cal Gas is Present 4 0 off timer disabled Input 2 is still active 5 1 Normal 0 Not Normal If a Calibration is in Progress OR If Diagnostic Code 1 9 15 30 50 52 is active see page 16 Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 14 F4 AABO Analog Auxiliary Block Output Function AABO allows the ZAIN Analog Auxiliary Block Outputs to be connected to other Blockware Inputs The Input of the AABO must be soft wired to a ZAIN Block Parameter 1 is used to select the ZAIN Auxiliary Output signal that will become the Output signal of this AABO Block See the ZAIN Block description for a list of the available Auxiliary Outputs and for the scaling of each Aux Output FUNCTION 4 TEMP BYTES 0
36. rating normally DS3 blinks 1 10 times if a problem exists See the Diagnostic Codes on page 16 for the explanations of the DS3 Diagnostic LED blink codes 120VAC Heater Fuse Optical Isolators Heater Triac DS3 Diagnostic a vd R6C17 jy C4 N S 2A NORMAI A S gt 5X2 mm LOAD bel 8 gq ic Pe w n S 38 K1 R14R15 Do ea cs i O a 16 Y2 UB ae fe a 3 e lt 8 Riel ll I C Rr C8 e o gt eg nRa PA g i Dr DS2 S x P Fig ago a Blinking Light Warming Up a2 C258 2 He g eB EN j oe Solid Light At Temperature ad rr k arr 3 2 a c10 pa B 1 pL E as S m Y alle qe a ae SB Ie i D C2 s 2 Rne t C27 419 PREF INSTR DANBURY CT 06810 s Yi 50 60 Hz Isolated DC DS1 Noise Filters Power Supply uP T C Cold Junction Sensor Run amp Calibration Data EEPROM A D with 10db DSP Noise Filter Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 5 Installation Note The ZP Sensor and the Z option board are factory calibrated as a matched pair The Sensor and zZ board are marked with the same serial number Install and wire the ZP Sensor and PCC III Z board as a matched pair CAUTION FRAGILE DO NOT DROP the Detector If the ceramic zirconium oxide cell inside the detector is cracked
37. ration Error Messages PCC III BLOCKWARE FOR THE ZP SENSOR AND Z OPTION BOARD F6 ZAIN Zirconium Oxide Oxygen Analyzer Analog Input Block Outputs AABO and DABO Auxiliary Block Outputs ZAIN Blockware Inputs and Parameters F4 AABO Analog Auxiliary Block Output F94 DABO Discrete Auxiliary Block Output ZP Oxygen Sensor Diagnostic Codes Automatic Calibration Auto Calibration Cycle Automatic Calibration Diagnostic Codes HANDLING OPERATION AND MAINTENANCE Handling Precautions Operation Boiler Start up and Shut down Insertion into a Hot Stack or Duct Powering Down a ZP Maintenance Inspect and Clean the Detector Filter and the Probe Cleaning the Detector and Probe Changing Filter TROUBLE SHOOTING ZP Wet Measurement vs Dry Measurements Diagnostic Codes Normal Operating Values Slow Response Time Reading is Higher than Expected Reading is Lower than Expected Cell will not come up to Operating Temperature Low Calibration Gas Flow Rate Detector Leak Test PARTS Model ZP Oxygen Sensor Instruction Manual rev 1 3 OCOODNNDODD aMagwwnw N ao Noo eaoonwnonnananinin ONNOOGHARAA OW NNN Naaa CODOOOOOO O NNNNNNNNNN UNN gt N gt gt 00 N B Page 1 Model ZP Oxygen Sensor Detector PCC IIl Zxx0 Probe Controller 190130 Connecting Cable OO o o F Power Supply VJ Calibration Gas Connection at Grade Level
38. rnally the Cell and Heater operate at 800 C 1470 F The system should remain powered up whenever possible The Heater uses less than 70 Watts typically 40 50 W Do not subject the Detector to excessive heat up and cool down cycles If the burner cycles more than once per day the ZP should not be routinely powered up and down every time the burner cycles on and off Flue gas contains a substantial percentage of water vapor Avoid water condensation in the Detector If the Detector is hotter or the same temperature as the Flue gas the water vapor can not condense Boiler Start up and Shut down If the ZP is kept in the stack powered up and kept at operating temperature the burner can be started and stopped at any time without affecting the ZP Because the Cell is at 800C water will not condense inside the ZP Detector Insertion into a Hot Stack or Duct If a room temperature ZP is inserted into hot stack or duct the cold metal of the ZP can condense the flue gas water vapor and form liquid water droplets inside the Cell or Heater This can damage or corrode the ZP internals Before inserting a ZP into a hot stack or duct power up the ZP and allow it to reach operating temperature and then insert it into the stack CAUTION The ZP flange and tip external surface temperatures approach 200 F Always wear protective gloves to avoid burns Powering Down a ZP If both the Boiler and the ZP are being shut down Shut down the boiler f
39. s every 12 months Cleaning the Detector and Probe Leaving the ZP probe in the stack cautiously remove ZP Detector from the probe flange with gloved hands and expose it to room air and then power down the ZP If the duct pressure is positive a cover plate and should be used to prevent flue gas flow through the open hole in the probe flange after the Detector is removed Using clean dry compressed air or nitrogen blow air gently across the face of the filter see pg 2 at a 20 degree angle Caution Water in the air can damage filter Using compressed air connected to a long tube blow any dust inside the ZP Probe duct into the stack or duct Changing Filter If the filter is clogged with dust replace it with a spare filter The filter assembly can be removed by turning it counter clockwise with a wrench Trouble Shooting ZP Wet Measurement vs Dry Measurements The most common problem encountered is that the ZP Oxygen does not match the Oxygen measured by a portable or extractive Oxygen Analyzer This is normal and the two measurements should NOT be the same Wet Measurement ZP The ZP Detector Cell is located inside the Flue Gas and measures Oxygen as a percentage of all of the total flue gas component gasses O2 N2 CO2 CO H20 This is known as a Wet oxygen measurement because the water vapor occupies a substantial percentage of the total volume of the flue gas Dry Measurement Portable
40. ss ENTER purging cal gas will be displayed for 10 seconds This allows the Cal Gas to be purged from the Detector by the Flue Gas calibration successful ESC to exit is displayed at the completion of purge Calibration is completed The Normal Operation DABO output changes from 0 to 1 The Calibration in Progress DABO output changes from 1 to 0 Press ESC to return to the CALIBRATE I O menu Press ESC to return to the BOARD x OXYGEN INPUT display EDIT 4 to the EXIT S M display Press ESC to exit S M mode Cap off plug or close a valve to prevent room air from entering the calibration gas tubing and or port of the ZP Detector Infiltrating air will cause the ZP to read higher than actual Oxygen Levels Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 11 ZP Calibration Error Messages ERROR MUST BE IN S M TO CALIBRATE The PCC III must be in S M Service Manual mode before activating the Calibration cycle ERROR AUTO CAL IN PROGRESS PRESS ESC A Semi Automatic Calibration from the PCC III Front Panel can not occur while an Auto Calibration cycle is in progress ERROR BAD Z OPTION BOARD PRESS ESC The Z Option Board is not communicating with the CPU board Verify that board is properly plugged in Replace if required ERROR T C OPEN PRESS ESC Check Cell thermocouple field wiring and Detector for an open circuit ERROR T C REVERSED PRESS ESC Check Cell thermocouple field
41. t damage injury or Death The ZP analyzer and PCC III Z option board are factory calibrated as a matched pair If anew Sensor and PCC III Z board are installed as a matched pair field calibration is not required Calibration data is stored in a non volatile EEPROM memory located on the Z Option Board not in the CPU board EEPROM Due to the excellent stability of the detector there is very little drift even over long periods of time Six to twelve month calibration checks are normal for natural gas and 2 diesel fuel oil fired units Fuels with high sulfur heavy metals or other contaminants should be checked every three to nine months The main indicator for the need for re calibration is Cell Impedance If the Cell Impedance AABO Block is configured note and record the Cell Impedance during Start up and after each re calibration Re calibrate again after Cell Impedance increases another 100 200 ohms The ZP Oxygen Sensor can be checked or calibrated without being removed from the stack and without shutting down the burner To check for proper operation simply apply a known concentration test gas at 2 3 SCFH at 1 5 psig to the 4 compression fitting at the bottom of the ZP Detector A single Test Gas can be used to check the operation of the ZP Sensor and Z Board Two certified Test Gasses are required in order to Calibrate a ZP Sensor Z board pair ZP Oxygen Sensor Semi Automatic Calibration Procedure Obtain two cylind
42. trol Logic in the PCC III at the site should attempt to re configure the Blockware Control Logic contained in the memory of a PCC III Controller PCC III Blockware Control Logic is field configurable and can be created or modified by the systems integrator field start up technician or on site personnel The user must obtain and maintain accurate Blockware Control Logic documentation that reflects the actual on site control logic Do NOT assume that any Blockware Control Logic examples shown in this manual are used in the on site PCC III VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE MODIFYING ANY OF THE BLOCKWARE DATA IN ANY BLOCK IN THE PCC IT MEMORY AND BEFORE CALIBRATING OR SHUTTING DOWN THE OXYGEN SENSOR FAILURE TO COMPLY WITH ALL OF THE ABOVE CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH The information in this document is subject to change without notice Copyright 2002 PUMC All Rights Reserved Table of Contents SYSTEM OVERVIEW Oxygen Sensor Detector Measuring Principle Probe Z Option Board P N 190371 Z board diagnostic LED s INSTALLATION Location Mounting Nipple and Flange Check Flange Temperature Check Flange Temperature Rotating the Probe to Lower Flange Temperature Calibration Gas Tubing Mount PCC III Controller Wiring CALIBRATION ZP Oxygen Sensor Semi Automatic Calibration Procedure ZP Calib
43. uced by the flue gas velocity and the probe tip as the means to move the flue gas through the probe The probe internal pressure drop is very low and high velocity sample gas flow is provided to the detector even when mounted vertically or upside down gt gt gt m 5 i lt _ lt _ EN Poi GAS FLOW n foo Oxygen Sensor Gas Flow The ZP probe must always be horizontal or pitched down away from the detector to prevent accumulation of condensed flue gas water at the Detector Flue gas contains a significant amount of water vapor If liquid water comes in contact with the cell heated to 800 C the ceramic will crack and will have to be replaced This is true for all brands of zirconium oxide Oxygen Analyzers Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 4 Z Option Board P N 190371 The Z option board is plugged into either of the two option board slots in a PCC III controller Two Z boards and ZP probes may used in one PCC III The Block diagram below shows the functions that the Z board performs Cell Temperature Control Signal A D converter Cell Impedance Testing Detector and field wiring diagnostics logic and LED indicators Calibration Data Storage and Electrical isolation of all ZP parts from the PCC III
44. wiring ERROR T C SHORT PRESS ESC Check Cell thermocouple field wiring ERROR FUSE OPEN NO POWER PRESS ESC Check Z board 120 Vac power input and Z board fuse ERROR CELL OPEN OR COMBUSTIBLES PRESS ESC Cell mV input is above 130 mV If Cell is cold wait for Cell to Warm up Check Cell field wiring and Detector for an open circuit Are Combustibles present in the Flue Gas ERROR CELL IMPEDANCE xxx MUST BE lt 1100 PRESS ESC If Cell is gt 2 years old replace the Detector assy If Cell is new check wiring for loose connections ERROR CELL NOT AT TEMPERATURE PRESS ESC Wait for Cell Temperature to stabilize at 800C ERROR CELL uV TOO LOW PRESS ESC The Cal Gas Oxygen Content was too high or Cal Gas flow was too low or Outer filter is cracked and Cal gas is escaping or Ambient air was leaking into the Cell WARNING XX XX GAS vs ZZ ZZ PROBE EXISTING CALIBRATION PRESS ESC to exit or ENTER to accept The old calibration indicates that the Cal Gas MAY be incorrect Check uV TOO LOW errors above if OK press ENTER to accept Check displayed Oxygen against a third Cal gas or a portable lanalyzer after the completion of the calibration ERROR CELL uV TOO HIGH PRESS ESC The Cal Gas Oxygen Content was too low or The Cal Gas contains combustibles or Cell wiring partially open WARNING IS CAL GAS HH HHH ESC abort ENTER accept or to exit The o
45. xample of Blockware for a ZP sensor is shown below Oxygen Analyzer ZAIN ch 1 1 0 10 OXYGEN o e DISCH1 gt PvsG1 SPBG1 gt Oxygen AABO FLUE GAS Tep Flue F La DIS CH2 gt gt a oa AABO HIALM HIALM MB CELL 7 TEMP me Cell C 1 DE 1 DE rZ gt DIS CH3 p E gt ALM 1 AABO High Flue Temp Alarm MB CELL e OHMS ima Cell Imp INVERT NC 82 gt biscH4 148 6U High Flue Temp Shutdown AABO MB DIAG 7 o gt CODE E Diag a DIS CH5 DABO NOT Ei Cell OK 1 mece i E NORMAL e e Cell Fault i 1 34 35 p Ama p gt ALM 4 i TOALM i TED i Pv MID gt RIGHT Low Oxygen Alarm 1 DE 56 76 Model ZP Oxygen Sensor Instruction Manual rev 1 3 Page 13 F6 ZAIN Zirconium Oxide Oxygen Analyzer Analog Input Function ZAIN is the Blockware interface to the PCC Ill Z option board and the ZP Oxygen Detector There can be up to two Z option boards in a PCC III Parameter 1 specifies the slot Parameter 2 determines the scaling of the primary Block Output The default is 10 oxygen cause a 100 Block Output The Block Scaling can be changed at any time without having to re calibrate the ZP Sensor Parameters 3 amp 4 are the Calibration Gas Concentr
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