User’s Manual Model ZR22G, ZR402G Separate type Zirconia Oxygen Analyzer IM 11M12A01-02E R IM 11M12A01-02E 8th Edition
Blank Page
i Introduction The EXAxt ZR Separate type Zirconia Oxygen Analyzer has been developed for combustion control in various industrial processes. This analyzer basically consists of a detector and a converter. You can select between several versions, based upon 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.
ii This manual consists of twelve chapters. Please refer to the reference chapters for installation, operation and maintenance. Table of Contents Relates to Installation Operation Maintenance Outline Equipment models and system configuration examples Standard specification, model code (or part 2. Specifications number), dimension drawing for each equipment Installation method for each equipment 3. Installation 4.
iii n For the safe use of this equipment WARNING EXAxt ZR is very heavy. Handle it with care. Be sure not to accidentally drop it. Handle safely to avoid injury. Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment. In addition, confirm that the power is switched off when connecting power supply. Some sample gas is dangerous to people.
iv (2) Safety and Modification Precautions • Follow the safety precautions in this manual when using the product to ensure protection and safety of personnel, product and system containing the product. (3) The following safety symbols are used on the product as well as in this manual. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
v n NOTICE • 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.
vi n After - Sales Warranty l Do not modify the product. l 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. l 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.
TocA-1 Model ZR22G, ZR402G Separate type Zirconia Oxygen Analyzer IM 11M12A01-02E 8th Edition CONTENTS Introduction...............................................................................................................i 1. Overview..................................................................................................... 1-1 1.1 1.2 2. < EXAxt ZR > System Configuration................................................................ 1-1 1.1.1 System 1.................................
TocA-2 3. Case Assembly for Calibration Gas Cylinder (E7044KF)................. 2-27 2.7.10 ZR22A Heater Assembly.................................................................. 2-27 Installation.................................................................................................. 3-1 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4. 2.7.9 Installation of General-purpose Detector........................................................ 3-1 3.1.1 Installation Location................................
TocA-3 4.4 5. 5.2 5.3 5.4 5.5 5.6 5.7 5.8 Piping Parts for a System using Detector with Pressure Compensation................................................................... 4-12 4.4.2 Piping for the Calibration Gas........................................................... 4-12 4.4.3 Piping for the Reference Gas........................................................... 4-12 General.............................................................................................................
TocA-4 7.3 Supplying Power to the Converter................................................................... 7-1 7.4 Touchpanel Switch Operations........................................................................ 7-3 7.4.1 Basic Panel and Switch...................................................................... 7-3 7.4.2 Display Configuration (for Oxygen Analyzer)..................................... 7-4 7.4.3 Display Functions...............................................................
TocA-5 8.5 8.6 9. 8.5.1 Input Contact Functions.................................................................... 8-13 8.5.2 Setting Procedure............................................................................. 8-14 8.5.3 Default Values................................................................................... 8-14 Other Settings.................................................................................................. 8-15 8.6.1 Setting the Date-and-Time.................
TocA-6 11. Inspection and Maintenance.................................................................. 11-1 11.1 11.2 11.3 12. Inspection and Maintenance of the Detector................................................ 11-1 11.1.1 Cleaning the Calibration Gas Tube................................................... 11-1 11.1.2 Replacing the Sensor Assembly....................................................... 11-2 11.1.3 Replacement of the Heater Unit...............................................
1. 1-1 <1. Overview> Overview The EXAxt ZR Separate type Zircon 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, paper and pulp, food, or textiles, as well as incinerators and medium/ small boilers. It can help conserve energy in these industries.
1-2 <1. Overview> NOTE 1.1.2 • As this system uses ambient air for the reference gas, measuring accuracy will be affected by the installation location. • A needle (stop) valve should be connected to the calibration gas inlet of the detector. The valve should be fully closed unless calibration is in progress. System 2 This system is for monitoring and controlling oxygen concentration in the combustion gases of a large-size boiler or heating furnace.
1.1.3 1-3 <1. Overview> System 3 This example, System 3, represents typical applications in large boilers and heating furnaces, where there 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 ZR40H automatic calibration unit, with auto-switching of the calibration gas. A “combustible gas detected” contact input turns off power to the heater.
1-4 <1. Overview> 1.2 < EXAxt ZR > System Components 1.2.1 System Components Separate type System config. Ex.1 Ex.2 Ex.
2. 2-1 <2. Specifications> Specifications This chapter describes the specifications for the following: 2.1 2.1.1 ZR22G General use separate type detector (See Section 2.2.1) ZO21R Probe protector (See Section 2.2.2) ZR22G (0.15 m) High temperature separate type detector (See Section 2.3.1) ZO21P Adapter for High temperature probe (See Section 2.3.2) ZR402G Separate type converter (See Section 2.4) ZA8F Flow setting unit (See Section 2.5.
2-2 <2. Specifications> (Sample gas pressure: within ±0.49 kPa) ±5% Maximum value of set range ; 0 to 50 vol% O2 or more and up to 0 to 100 vol% O2 range (Sample gas pressure: within ±0.49 kPa) 2.2 Drift: (Excluding 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.
2-3 <2. Specifications> Construction: Heater and thermocouple replaceable construction. Non explosion-proof JIS C0920 / equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version.) Terminal Box Case: Material; Aluminum alloy Terminal Box Paint Color: Case; Mint green (Munsell 5.6BG3.3/2.9) Cover; Mint green (Munsell 5.6BG3.3/2.
2-4 <2. Specifications> Model and Codes Style : S2 Model Suffix code Option code Description ZR22G ---------------------------------- ---------- Separate type Zirconia Oxygen Analyzer, Detector Length -015 -040 -070 -100 -150 -200 -250 -300 -360 -420 -480 -540 ------------------------------------------------------------------------------------------------------------- 0.15 m (for high temperature use) 0.4 m 0.7 m 1.0 m 1.5 m 2.0 m 2.5 m (*2) 3.0 m (*2) 3.6 m (*2) 4.2 m (*2) 4.8 m (*2) 5.
2-5 <2. Specifications> EXTERNAL DIMENSIONS 1. Model ZR22G Separate type Zirconia Oxygen Analyzer, Detectors L 283 to 292 Unit : mm 85 Ø124 Ø50.8 t L=0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 3.6, 4.2, 4.8, 5.4 (m) Rc1/4 or 1/4NPT Reference gas inlet 155 to 163 69 2-G1/2,2-1/2NPT etc.
2-6 <2. Specifications> 2. Model ZR22G...-P (with pressure compensation) Separate type Zirconia Oxygen Analyzer, Detectors 303 t 85 ø124 Ø50.8 L L=0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 3.6, 4.2, 4.8, 5.4 (m) 156 Rc1/4 or 1/4NPT Reference gas inlet 87 2-G1/2, 2-1/2NPT etc.
<2. Specifications> 2.2.2 2-7 ZO21R Probe Protector Used when sample gas flow velocity is approx. 10 m/sec or more and dust particles wears the detector in cases such as pulverized coal boiler of fluidized bed furnace (or burner) to protect the detector from wearing by dust particles. When probe insertion length is 2.5 m or more and horizontal installation, specify the ZO21R-L-200- *B to reinforce the probe. □ Insertion Length: 1.05 m, 1.55 m, 2.05 m. Flange: JIS 5K 65A FF equivalent.
2.3 2.3.1 2-8 <2. Specifications> Separate type Detector for High Temperature and Related Equipment ZR22G (0.15m) Separate type Detector for High Temperature Standard Specifications Construction: Water-resistant, non-explosionproof Probe length: 0.15 m Terminal box: Aluminum alloy Probe material: Probe material in contact with gas: SUS 316 (JIS) (Probe), SUS 304 (JIS) (Flange), Zirconia (Sensor), Hastelloy B, (Inconel 600, 601) Weight: Approx.
2-9 <2. Specifications> 2.3.2 ZO21P High Temperature Probe Adapter Measuring O2 in the high temperature gases (exceeds 700 °C) requires a general use probe ZR22G of 0.15 m length and a high temperature probe adapter. Sample gas temperature: 0 to 1400 °C (when using SiC probe) 0 to 800 °C (when using SUS 310S probe) Sample gas pressure: -0.5 to + 5 kPa. When using in the range of 0 to 25 vol% O2 or more, the sample gas pressure should be in the range of -0.5 to +0.5 kPa.
2-10 <2. Specifications> Unit: mm Approx. 351 Sample gas outlet Flange (Thickness 5) JIS 5K 32 FF equivalent 180 Rc1/2(Note2) Ø124±3 110 ØA 85 Ø115 Ø60.5 170 Ø60.5 t Approx. 100 Flange <1> Detector(ZR22G) Flange provided by customer Approx. 48 Ø52 over Reference gas inlet Rc1/4 or 1/4NPT 69 High temperature Probe SiC pipe Ø30 48 25 L (Insertion length) (Note1) Approx. 215 Gasket (Thickness 1.
2-11 <2. Specifications> 2.4 ZR402G Separate type Converter 2.4.1 Standard Specification The ZR402G Separate type Converter can be controlled by LCD touchscreen on the converter. Display: LCD display of size 320 by 240 dot with touchscreen.
2.4.2 2-12 <2. Specifications> Functions Display Functions: Value Display; Displays values of the measured oxygen concentration, etc Graph Display; Displays trends of measured oxygen concentration Data Display; Displays various useful data for maintenance, such as cell temperature, reference junction temperature, maximum/minimum oxygen concentration, or the like Status Message; Indicates an alarm or error occurrence with flashing of the corresponding icon.
2-13 <2. Specifications> Equipment Related Items: Measuring gas selection Output Related Items: Analog output/output mode selection, output conditions when warming up/maintenance/calibrating (during blow back)/abnormal, 4 mA/20 mA point oxygen concentration (vol% O2), time constant.
2-14 <2. Specifications> Zero calibration gas concentration setting range: 0.3 to 100 vol% O2 (in increments of 0.01 vol% O2 in smallest units). Span calibration gas concentration setting range: 4.5 to 100 vol% O2 (in increments of 0.01 vol% O2 in smallest units). Use nitrogen-balanced mixed gas containing 0 to 10 vol% O2 scale of oxygen, and 80 to 100 vol% O2 scale of oxygen for standard zero gas and standard span gas respectively.
2-15 <2. Specifications> ● External Dimensions Unit: mm 1 to 6 (Panel Thickness) 2B mounting pipe 4 - Ø6 holes for Wall mounting 20.2 (*1/2NPT) 100 126.5 280 EXA ZR402G 8 40 228 40 10 57.3 36 54.7 136.3 40 111 36 23 8-G1/2, *8-1/2NPT etc (Wiring connection) 38 24 14 38 ( for wall mounting) *: 1/2NPT with plug 126.5 274 +2 0 4 - Ø6 holes 4-R8 to R10 or 4-C5 to C8 +2 0 190 183 Wall mounting Panel Cut-out With sun shield hood (option code /H) 243 ±2 123 ±4 155.
2-16 <2. Specifications> 2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit 2.5.1 ZA8F Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration (System 2). Used when instrument air is provided. This unit consists of a flowmeter and flow control valves to control the flow rates of calibration gas and reference gas. Standard Specifications FIowmeter Scale: Calibration gas; 0.1 to 1.0 l/min. Reference gas; 0.1 to 1.
2-17 <2. Specifications> ● External Dimensions 180 ø6 Hole Unit : mm 140 7 REFERENCE CHECK REFERENCE SPAN 235.8 ZERO 2B mounting pipe 222.8 Calibration gas outlet Span gas inlet Reference gas outlet Zero gas inlet 32 Piping connection port A ZERO IN AIR IN SPAN IN CHECK OUT REF OUT 70 Model 35 20 35 35 7 35 35 20 Instrument air inlet Piping connection port A ZA8F-J*C 5 - Rc1/4 ZA8F-A*C 5 - 1/4NPT Weight : Approx. 2.
2-18 <2. Specifications> 2.5.2 ZR40H 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). • Specifications Used when auto calibration is required for the separate type and instrument air is provided. The solenoid valves are provided as standard.
2-19 <2. Specifications> ● External Dimensions Unit: mm Wiring inlet ; 2-G1/2,Pg13.5,M20X1.5 or 1/2NPT(Female) 2B pipe mounting example (wiring inlet is at same position on rear) *1 with four ISO M6 screws can wall-mount 90 26 54 41.2 116.5 71.5 *1 4 - Ø6.5 41.2 49.
2-20 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. 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.
<2. Specifications> 2.7 2-21 Other Equipments 2.7.1 Dust Filter for the Detector (K9471UA) This filter is used to protect the detector sensor from a corrosive dust components or high velocity dust in recovery boilers and cement kilns. Sample gas flow rate is needed to be 1 m/sec or more to replace gas inside zirconia sensor. • Standard specification Applicable detector: Standard-type detector for general use (the sample gas flow should be approximately perpendicular to the probe.
2-22 <2. Specifications> 2.7.3 Ejector Assembly for High Temperature (E7046EC, E7046EN) This ejector assembly is used where pressure of sample gas for high temperature detector is negative. This ejector assembly consists of an ejector, a pressure gauge assembly and a needle valve. Standard Specifications Ejector Ejector Inlet Air Pressure: 29 to 68 kPa G Air Consumption: Approx.
2-23 <2. Specifications> Graph explanation 1) Graph 1 is to compensate for pressure loss in piping between the ejector and the pressure gauge, and find Po (pressure setting). 2) Graph 2 shows correlation between P (drive pressure) and Qa (air consumption). 3) Graph 3 shows correlation between P (drive pressure) and Pg (suction pressure; when the sample gas inlet of the ejector is closed). 4) Graph 4 shows correlation between P (drive pressure) and Qg (suction flow) for each gas pressure.
2.7.4 2-24 <2. Specifications> Stop Valve (L9852CB, G7016XH) This valve mounted on the calibration gas line in the system to allow for one-touch calibration. This is applies to the system configuration shown for system 1 in section 1. Standard Specifications Connection: Material: Weight: Rc 1/4 or 1/4 FNPT SUS 316 (JIS) Approx. 80 g Part No.
2-25 <2. Specifications> 2.7.6 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases. Standard Specifications • G7003XF, 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.
2.7.7 2-26 <2. Specifications> Zero Gas Cylinder (G7001ZC) The gas from this cylinder is used as the calibration zero gas and detector purge gas. Standard Specifications Capacity: 3.4 l Filled pressure: 9.8 to 12 MPa G Composition: 0.95 to 1.0 vol% O2 in N2 Weight: Approx. 6 kg (Note) Export of such high pressure filled gas cylinder to most countries is prohibited or restricted. 325 485 Unit : mm Φ140 2.7.8 F2-13E.
<2. Specifications> 2.7.9 2-27 Case Assembly for Calibration Gas Cylinder (E7044KF) This case assembly is used to store the zero gas cylinders. Standard Specifications Installation: 2B pipe mounting Material: SPCC (Cold rolled steel sheet) Case Paint: Baked epoxy resin, Jade green (Munsell 7.5 BG 4/1.5) Weight: Approx. 10 kg with gas cylinder (Note) Export of such high pressure filled gas cylinder to most countries prohibited or restricted.
<2. Specifications> 2-28 Unit : mm 30 Φ 45 (K9470BX) K9470BX Jig for change Φ 21.7 • External Dimensions L±12 Model & Codes L Weight (kg) ZR22A-015 302 Approx. 0.5 ZR22A-040 552 Approx. 0.8 ZR22A-070 852 Approx. 1.2 ZR22A-100 1152 Approx. 1.6 ZR22A-150 1652 Approx. 2.2 ZR22A-200 2152 Approx. 2.8 ZR22A-250 2652 Approx. 3.4 ZR22A-300 3152 Approx. 4.0 F2-16E.ai IM 11M12A01-02E 8th Edition : Jan.
3. 3-1 <3. Installation> Installation This chapter describes installation of the following equipment: 3.1 3.1.1 Section 3.1 General-purpose Detector (except ZR22G-015) Section 3.2 High Temperature Detector (ZR22G-015) Section 3.3 Converter Section 3.4 ZA8F Flow Setting Unit Section 3.5 ZR40H Automatic Calibration Unit Section 3.
3-2 <3. Installation> (1) Do not mount the probe with the tip higher than the probe base. (2) If the probe length is 2.5 meters or more, the detector should be mounted vertically (no more than a 5° tilt). (3) The detector probe should be mounted at right angles to the sample gas flow or the probe tip should point downstream. Bounds of the probe insertion hole location (vertical) Flange matches the detector size 100 mm *1 Note *1 Type Outside diameter of detector Standard 50.
3-3 <3. Installation> CAUTION • 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 cement kilns. If a filter is used in combustion systems other than these, it may have adverse effects such as response delay. These combustion conditions should be examined carefully before using a filter. • The dust filter requires gas flow of 1 m/sec or faster at the front surface of the filter.
3-4 <3. Installation> The detector is used with a probe protector to support the probe (ZR22G) when the probe length is 2.5 m or more and it is mounted horizontally. (1) Put a gasket (provided by the user) between the flanges, and mount the probe protector in the probe insertion hole. (2) Make sure that the sensor assembly mounting screws (four bolts) at the tip of the detector are not loose.
3.2 3.2.1 3-5 <3. Installation> Installation of High Temperature Detector (ZR22G-015) Installation Location This detector is used with the High Temperature Probe Adapter (Model ZO21P-H) when the temperature of sample gas exceeds 700 °C, or when it is required due to maintenance spaces. The following should be taken into consideration when installing the detector: (1) Easy and safe access to the detector for checking and maintenance work.
3-6 <3. Installation> (1) When the furnace pressure is negative, raise the pressure setting to increase induction flow of the sample gas. Refer to Section 2.7.3, Ejector Assembly for High Temperature, for the setting of induction flow. If there is much dust in the gas, the ejector may become clogged as induction flow increases.
3-7 <3. Installation> Table 3.
3.3 3.3.1 3-8 <3. Installation> Installation of the ZR402G Converter Installation Location The following should be taken into consideration when installing the converter: (1) Readability of the indicated values of oxygen concentration or messages on the converter display. Easy and safe access to the converter for operating keys on the panel. (2) Easy and safe access to the converter for checking and maintenance work.
3-9 <3. Installation> (1) Drill mounting holes through the wall as shown in Figure 3.8. Unit: mm Four holes 6 mm in diameter for M5 screws 126.5 190 F3-8E.ai Figure 3.8 Mounting holes (2) Mount the converter. Secure the converter on the wall using four screws. Note: For wall mounting, the bracket and bolts are not used. F3-9E.ai Figure 3.9 Wall Mounting (1) Cut out the panel according to Figure 3.10. Unit: mm +2 274 0 Washer Bolt +2 183 0 F3-10E.
3-10 <3. Installation> 3.4 Installation of ZA8F Flow Setting Unit 3.4.1 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 or 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. 3.4.
3.5 3-11 <3. Installation> Installation of ZR40H Automatic Calibration Unit 3.5.1 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 or 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. 3.5.
<3. Installation> 3-12 (2) Mount the automatic calibration unit. Remove the U-bolt from the automatic calibration unit and attach the unit on the wall with four screws. When setting it with M5 bolts, use washers. 4-Φ6.5 F3-16_1E.ai Figure 3.17 Wall Mounting IM 11M12A01-02E 8th Edition : Jan.
3.6 3.6.1 <3. Installation> 3-13 Installation of the Case Assembly(E7044KF) The case assembly is used to store the G7001ZC zero gas cylinders. 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 or 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 or radiated heat. (5) No vibration 3.6.
3.7 3-14 <3. Installation> Insulation Resistance Test Even if the testing voltage is not so great that it causes dielectric breakdown, testing may cause deterioration in insulation and a possible safety hazard. Therefore, conduct this test only when it is necessary. The applied voltage for this test shall be 500 V DC or less. The voltage shall be applied for as short a time as practicable to confirm that insulation resistance is 20 MΩ or more. Remove wiring from the converter and the detector. 1.
4. 4-1 <4. Pipomg> Piping This chapter describes piping procedures based on three typical system configurations for EXAxt ZR Separate type Zirconia Oxygen Analyzer. • Ensure that each check valve, stop valve and joint used for piping do not allow leakage. Especially, if there is any leakage of the calibration gas from pipes and joints, it may cause clogging of the pipes or incorrect calibration. • Be sure to conduct leakage test after piping.
4-2 <4. Pipomg> Piping in System 1 is as follows: • Connect a stop valve to the nipple at the calibration gas inlet of the detector. Then mount a joint for a 6 mm (O.D.) x 4 mm (I.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.
4.1.2 4-3 <4. Pipomg> Connection to the Calibration Gas Inlet When carrying out calibration, connect the piping (6(O.D) ~4(I.D.) mm tube) from the standard gas unit to the calibration gas inlet of the detector. First, mount a stop valve (of a quality specified by YOKOGAWA) on 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 detector prior to shipping the detector.
4-4 <4. Pipomg> If the temperature of the sample gas exceeds the specified value and its pressure exceeds 0.49 k Pa, the sample gas temperature may not be below 700 °C at the detector. In such a case, connect a needle valve (found on the local market) through a nipple (also found on the local market) to the probe adapter sample gas exhaust (Rc 1/2) so that the sample gas exhaust volume is restricted. Reducing nipple (R1/2-R1/4 or R1/2-1/4NTP) Needle valve F4-4E.ai Figure 4.
4.2 4-5 <4. Pipomg> Piping for System 2 Piping in System 2 is illustrated in Figure 4.7.
4.2.1 4-6 <4. Pipomg> Piping Parts for System 2 Check that the parts listed in Table 4.2 are ready. Table 4.
4-7 <4. Pipomg> Stop valve or Check valve Piping for the calibration gas, 6 mm (O.D.) by 4 mm (I.D.) Stainless steel pipe Piping for the reference gas, 6 mm (O.D.) by 4 mm (I.D.)Stainless steel pipe 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 detector.
4.3 4-8 <4. Pipomg> Piping for System 3 Piping in System 3 is illustrated in Figure 4.10. 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 reducing valve so that these two pressures are approximately the same. The flow rate of zero and span gases (normally instrument air) are set by a single needle valve.
4-9 <4. Pipomg> 4.3.1 Blow Back Piping This piping is required when the blow back function is carried out. The piping described below provides automatic blow back operation when the “ Blow back start “ command is entered to the converter. Pressure reducing valve Solenoid valve Pipe junction Blow pipe F4-10E.ai Figure 4.11 Blow back Piping The following parts are required for blow back piping. • Flange (to be prepared as illustrated in Figure 4.12.
4-10 <4. Pipomg> 4.4 Piping for the Detector with Pressure Compensation The ZR22G----P Detector with Pressure Compensation may be used in System 2 and System 3. However, it cannot use piping for high temperature probe adapter or blow back piping. Use this detector whenever the furnace pressure exceeds 5 kPa (see Note). Even if the furnace pressure is high, the detector can measure by adjusting pressure of the detector to the furnace pressure using instrument air.
4-11 <4. Pipomg> CAUTION • As far as possible do not stop the instrument air flow, to prevent the sample gas from entering the detector and damaging the zirconia cell. • Connect the stop valve, which is at the calibration gas inlet, directly to the detector. If there is piping between the detector and the valve, condensation may damage the sensor by rapid cooling when calibration gas is introduced. Figure 4.14 illustrates an example of System 2 using a detector with pressure compensation.
4.4.1 4-12 <4. Pipomg> Piping Parts for a System using Detector with Pressure Compensation Check that the parts listed in Table 4.3 are ready. Table 4.
5-1 <5. Wiring> 5. Wiring In this Chapter, the wiring necessary for connection to the EXAxt ZR Separate type Zirconia Oxygen Analyzer is described. 5.1 General CAUTION • NEVER supply current to the converter or any other device constituting a power circuit in combination with the converter, until all wiring is completed. • This product complies with CE marking. Where compliance with CE marking is necessary, the following wiring procedure is necessary. 1.
5-2 <5. Wiring> CAUTION • Select suitable cable O.D. to match the cable gland size. • Protective grounding should be connected in ways equivalent to JIS D style (Class 3)grounding (the grounding resistance is 100 Ω or less). • Special consideration of cable length should be taken for the HART communication, For the detail, refer to Section 1.1.2 of the IM 11M12A01-51E “ Communication Line Requirements “. 5.1.
5-3 <5. Wiring> 5.1.2 Wiring Connect the following wiring to the converter. It requires a maximum of seven wiring connections as shown below. (1) Detector output (connects the converter with the detector.) (2) Detector heater power (connects the converter with the detector.
5.1.3 5-4 <5. Wiring> Mounting of Cable Gland For each cable connection opening of the converter, mount a conduit that matches the thread size, or a cable gland. EXA ZR402G 8-G1/2, 8-1/2NPT or the like (Wiring connection) Ground terminal (M4) Adapter for 1/2NPT thread F5-4E.ai Figure 5.3 Cable gland mounting IM 11M12A01-02E 8th Edition : Jan.
5.2 5-5 <5. Wiring> Wiring for Detector Output This wiring enables the converter to receive cell output from the detector, output from a thermocouple and a reference junction compensation signal. Install wires that allow for 10 Ω of loop resistance or less. Keep detector wiring away from power wiring.
5-6 <5. Wiring> 5.2.2 Connection to the Detector To connect cables to the detector, proceed as follows: (1) Mount conduits of the specified thread size or cable glands to the wiring connections of the detector. The detector may need to be removed in future for maintenance, so be sure to allow sufficient cable length. (2) If the ambient temperature at the location of wire installation is 80 to 150 °C, be sure to use a flexible metallic wire conduit.
5.3 5-7 <5. Wiring> Wiring for Power to Detector Heater This wiring provides electric power from the converter to the heater for heating the sensor in the detector. (1) Ambient temperature of the detector: 80 °C or less ZR402G Converter ZR22G Detector HTR 7 HTR 8 HEATER (2) Ambient temperature of the detector: exceeding 80 °C ZR22G Detector Terminal box ZR402G Converter HTR 7 HTR 8 HEATER Heat-resistant wiring F5-7E.ai Figure 5.6 Wiring for power to detector heater 5.3.
<5. Wiring> 5-8 Notice when closing the cover of the detector NOTE • Before opening the detector cover, loosen the lock screw. If the screw is not loosened first, the screw will damage the cover, and the terminal box will require replacement. When opening and closing the cover, remove any sand particles or dust to avoid gouging the thread. • After screwing the cover in the detector body, secure it with the lock screw. Lock screw Detector cover F5-8E.ai Figure 5.7 5.3.
5.4 5-9 <5. Wiring> Wiring for Analog Output This wiring is for transmitting 4 to 20 mA DC output signals to a device, e.g. recorder. Maintain the load resistance including the wiring resistance at 550 Ω or less. ZR402G Converter Receiver 1 1 2 AO-1(+) AO-1(-) AO-2(+) AO-2(-) Receiver 2 Shielded cable FG 1 2 F5-9E.ai Figure 5.8 Wiring for analog output 5.4.1 Cable Specifications For this wiring, use a 2-core or a 4-core shielded cable. 5.4.
5.5.2 5-10 <5. Wiring> Grounding Wiring The ground wiring of the detector should be connected to the ground terminal of the detector case. The ground wiring of the converter should be connected to either the ground terminal of the converter case or the protective ground terminal in the equipment. The grounding terminals of the detector and the converter are of size M4. Proceed as follows: (1) Keep ground resistance to 100 Ω or less (equivalent JIS D style (Class 3)).
5.7 5-11 <5. Wiring> Wiring for ZR40H Automatic Calibration Unit This wiring is for operating the solenoid valve for the zero gas and the span gas in the ZR40H Automatic Calibration Unit, in a system where the calibration gas flow rate is automatically controlled (e.g. System configuration 3). When installing this wiring, proceed as follows: Wiring inlet 2-G1/2, Pg13.
5.8 <5. Wiring> 5-12 Contact Input Wiring The converter can execute specified function when receiving contact signals. To use these contact signals, wire as follows: ZR402G Converter Terminal box DI-1 Contact input 1 DI-2 DI-C Contact input 2 F5-14E.ai Figure 5.13 Contact Input Wiring 5.8.1 Cable Specifications Use 2-core or 3-core cable for this wiring. Depending on the number of input(s), determine which cable to use. 5.8.
6-1 <6. Components> 6. Components In this Chapter, the names and functions of components are described for the major equipment of the EXAxt ZR Separate type Zirconia Oxygen Analyzer. 6.1 ZR22G Detector 6.1.1 General-purpose Detector (except for ZR22G-015) Terminal box, Non explosion-proof JIS C0920 equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version.
6.1.2 6-2 <6. Components> High Temperature Detector (ZR22G-015) Sample gas outlet When a sample gas pressure is negative, connect the ejector assembly. When the sample gas is high temperature and high pressure, and does not fall below 700 °C, connect a pressure control valve (e.g. a needle valve). (Refer to Section 3.2.2.) Separate type High Temperature Detector (ZR22G-015) When the temperature of the sample gas is between 700 °C and 1400 °C, mount this detector with a ZO21P-H probe adapter.
6.2 6-3 <6. Components> ZR402G Converter Complete Operation Display ■ Interactive operations along with operation display. ■ A variety of display modes - enabling you to select the operation mode freely. ■ Back-lit LCD allows viewing even in the darkness. ■ Error codes and details of errors can be checked in the field without the need to refer to appropriate instruction manual.
6.3 6-4 <6. Components> ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve Flowmeter for reference gas Flowmeter for calibration gas F6-4E.ai Figure 6.4 ZA8F Flow Setting Unit Flowmeter for Calibration gas Flowmeter for Reference gas Reference gas flow setting valve Terminal Box Made in Japan REF.OUT CAL.OUT SPAN IN ZERO IN Calibration gas flow setting valve F6.5.ai Figure 6.
7. 7-1 <7. Startup> Startup The following describes the minimum operating requirements — from supplying power to the converter to analog output confirmation to manual calibration. System tuning by the HART communicator, refer to IM11M12A01-51E “ HART Communication Protocol ”. 7.1 7.2 Checking Piping and Wiring Connections Check that the piping and wiring connections have been properly completed in accordance with Chapter 4, “Piping,” and Chapter 5, “Wiring.
7-2 <7. Startup> Tag: 319 °C 4.00mA -Output1 4.00mA -Output2 Hold Warmup Figure 7.1 Display During Warm-up Tag: 21.0 % O2 17.43mA -Output1 17.43mA -Output2 Figure 7.2 Measurement Mode Display IM 11M12A01-02E 8th Edition : Jan.
7.4 7.4.1 7-3 <7. Startup> Touchpanel Switch Operations Basic Panel and Switch The converter uses a touchpanel switch which can be operated by just touching the panel display. Figure 7.3 shows the Basic panel display. The switches that appear in the switch display area vary depending on the panel display, allowing all switch operations. Table 7.1 shows the switch functions. Tag name display area Tag: Primary value 21.0 Switch display area % O2 Secondary value Alarm and error display area 17.
7.4.2 7-4 <7. Startup> Display Configuration (for Oxygen Analyzer) Figure 7.3.1 shows the configuration. A password the displays positioned below enables display “Execution/Setup” to be protected. If a password has not been set, press the [Enter] key to proceed to the next panel display. The [Home] key enables you to return to “Execution/Setup display” from any panel display.
7-5 <7. Startup> 7.4.3 Display Functions Individual panel displays in the display configuration provide the following functions: (1) Basic panel display: Displays the values measured in three selected items (see Section 7.9, Setting Display Item). (2) Execution/Setup display: Selects the calibration, maintenance and setup items. (3) Detailed-data display: This allows you to view such detailed data as the cell electromotive force and cell temperature (see Section 10.1.
<7. Startup> Operation Press the [ABC] key once. Press and hold the [ABC] key. 7-6 Display A_ AA B C Release the [ABC] key when the character B appears in the cursor position. Enter the character C in the same manner as above. Press the [other] key. AB_ Press and hold the [$%&] key and enter “%.” Then press the [0-9] key. ABC%_ Enter the numeric characters 1, 2 and 3 in turn. Press the [Enter] key to complete the entry. ABC%123_ ABC_ Siki7.
7.5 7-7 <7. Startup> Confirmation of Converter Type Setting This converter can be used for both the Oxygen Analyzer and the Humidity Analyzer. Before setting the operating data, be sure to check that the desired converter model has been set. Note that if the converter type setting is changed, the operating data that have been set are then initialized and the default settings remain. To set the desired operating data, follow these steps: (1) Press the [Setup] key.
7.6 7-8 <7. Startup> Confirmation of Detector Type Setting Check that the detector in Figure 7.7 is the one for this equipment. CAUTION 7.7 7.8 7.8.1 • If this converter is to be used in conjunction with the ZO21D, the power requirements are limited to 125 V AC or less, 50 Hz or 60 Hz (it cannot be used with a 125 V or greater, or in the EEC). • If detector settings are to be changed, first disconnect the wiring connections between the detector and the converter.
7.9 7-9 <7. Startup> Setting Display Item This section briefly describes the display item settings shown in Figure 7.11, “Basic Panel Display.” Tag: Primary value Secondary value Tertiary value 21.0 %O2 17.43mA -Output1 17.43mA -Output2 F7.11E.ai Figure 7.11 Basic Panel Display (1) Press the [Setup] key in the Basic panel display to display the Execution/Setup display. Then select “Maintenance” in the Execution/Setup display.
7-10 <7. Startup> Display item Display item Primary value: Oxygen Secondary value: mA-output1 Tertiary value: mA-output2 Tag name: Enter Primary value: Oxygen Oxygen Item of output1 damping Secondary value: Item of output2 damping mA-output1 Tertiary value: mA-output2 Tag name: Enter F7.14.ai Figure 7.14 Display Item Display F7.15.ai Figure 7.15 Display Item Selection Table 7.
7.10 <7. Startup> 7-11 Checking Current Loop The set current can be output as an analog output. (1) Press the [Setup] key on the Basic panel display to display the Execution/Setup display. Then select “Maintenance” in the Execution/Setup display. (2) Select “mA-output loop check” in the Maintenance panel display to display the mA - output loop check display, enabling you to check “mA-output1” and “mA-output2”. Select the desired output terminal for current-loop checking (see Figure 7.15.1).
<7. Startup> 7.11 Checking Contact I/O 7.11.1 Checking Contact Output 7-12 Conduct the contact input and output checking as well as operational checking of the solenoid valves for automatic calibration. To check the contact output, follow these steps: (1) Press the [Setup] key in the Basic panel display to display the Execution/Setup display. Select “Maintenance” in that display.
7.11.2 7-13 <7. Startup> Checking Calibration Contact Output The calibration contacts are used for solenoid valve drive signals for the ZR40H Automatic Calibration Unit. When using the ZR40H Automatic Calibration Unit, use the calibration contact output to check that the wiring connections have been properly completed and check equipment operation. (1) Referring to Section 7.11.1, display the contact check display. (2) Select the “Calibration contacts” to display the panel display as Figure 7.15.
7.12 7-14 <7. Startup> Calibration To calibrate this instrument, the procedure is to measure zero gas and span gas and set the instrument to read the known concentrations.
7-15 <7. Startup> (2) Span gas concentration With “Span gas conc” selected in the Calibration setup display, display the Numeric - data Entry display and enter an oxygen concentration value for the span gas calibration; If instrument air is used, enter 02100 for a 21 vol%O2 value. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a portable oxygen analyzer to measure the actual oxygen concentration, and then enter it.
7-16 <7. Startup> (3) Follow the display message in Figure 7.19 to turn on span gas flow. Open the span gas flow valve for the Flow Setting Unit by loosening the valve lock nut and slowly turning the valve shaft counterclockwise to flow the span gas at 600 ± 60 ml/min. Use the calibration gas flowmeter to check the flow. Manual calibration Manual calibration Open span gas valve. Set flow span gas to 600ml/min. 21.00% Valve opened Cancel calibration 0.5min./div 1.00% Enter 21.0 %O2 CAL.
7-17 <7. Startup> (7) Follow the instructions in the display as in Figure 7.23 to turn on the zero gas flow. To do this, open the zero gas flow valve for the Flow Setting Unit and adjust that valve to obtain a flow of 600 ± 60 ml/min. The valve should be adjusted by loosening its lock nut and slowly turning the valve shaft counterclockwise. Use the calibration gas flowmeter to check the flow. Manual calibration Manual calibration Open zero gas valve. 21.00% Set flow zero gas to 0.5min.
Blank Page
8. Detailed Data Setting 8.1 Current Output Setting 8.1.1 8-1 <8. Detailed Data Setting> This section describes setting of the analog output range. Setting Minimum Current (4 mA) and Maximum Current (20 mA) To set the minimum and maximum currents, proceed as follows: (1) Select [Commissioning] in the Execution/Setup display. (2) Select the “mA-output setup” in the Commissioning display. (3) Select “mA-output1” in the mA-outputs display. (4) Select “Min.
8-2 <8. Detailed Data Setting> Setting example 2 Maximum oxygen concentration, vol%O2 (for a maximum current of 20 mA) If the range minimum (corresponding to 4 mA output) is set to 75 vol%O2 then range maximum (corresponding to 20 mA output) must be at least 75x1.3=98 vol%O2 (rounding decimal part up).
8.2 8-3 <8. Detailed Data Setting> Output Hold Setting The “output hold” functions hold an analog output signal at a preset value during the equipment’s warm-up time or caribration or if an error arises. Outputs 1 and 2 can not be set individually. Table 8.1.2 shows the analog outputs that can be retained and the individual states. Table 8.1.2 Equipment status Output During warm-up hold values available 4 mA 20 mA Without hold feature Retains output from just before occurrence Set value (2.4 to 21.
8.2.2 8-4 <8. Detailed Data Setting> Preference Order of Output Hold Value The output hold value takes the following preference order: On error occurrence Under calibration or during blow back Preference order (high) Under maintenance During warm-up 8.2.2.siki For example, if the output current is set to 4 mA during maintenance, and no output-hold output for during calibration is preset, the output is held at 4 mA during the maintenance display.
8.2.4 8-5 <8. Detailed Data Setting> Default Values When the analyzer is delivered, or if data are initialized, output hold is the default as shown in Table 8.2. Table 8.2 Output Hold Default Values Status Output hold setting Preset value During warm-up 4 mA 4 mA Under maintenance Holds output at value just before maintenance started. 4 mA Under calibration or blow back Holds output at value just before starting calibration or blow back.
8.3 8-6 <8. Detailed Data Setting> Oxygen Concentration Alarms Setting 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 out the alarm operations and setting procedures. 8.3.1 Setting the Alarm Values (1) High-high and high alarm values If high-high and high alarm values are set to ON, then alarms occur if measured valves exceed the alarm set values.
8-7 <8. Detailed Data Setting> In the example in Figure 8.3, the high limit alarm point is set to 7.5 vol%O2, the delay time is set to five seconds, and hysteresis is set to 2 vol%O2. Alarm output actions in each section in this figure are as follows: A. Although the oxygen concentration value exceeds the high limit alarm setpoint, it falls below the high limit alarm setpoint before the preset delay time of five seconds elapses. So, no alarm is issued. B.
8-8 <8. Detailed Data Setting> Oxygen alarms Alarms setup Parameter: Hysteresis: Oxygen 0.1%O2 Contact delay: 3s Setpoints Enter High High alarm: OFF Set value: 1 0 0 . 0 % O2 High alarm: ON Set value: 1 0 0 . 0 % O2 Low alarm: OFF Set value: 0 . 0 % O2 Low Low alarm: OFF Set value: 0 . 0 % O2 Figure 8.4 Alarms Setup Display 8.3.4 Enter F8.5E.ai F8.4E.ai Figure 8.
8.4 8.4.1 8-9 <8. Detailed Data Setting> 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 operation modes of each contact output are as follows. For output contacts 1 to 3 you can select open or closed contact when the contact is “operated”. Default is closed. For output contact 4, contact is closed. When power fails, contact outputs 1 to 3 are open, and 4 is closed.
8-10 <8. Detailed Data Setting> Output contact 1 Contact setup Output contact 1 Output contact 2 Output contact 3 Alarms Others During power-off the contact is open and in condition it is Open lnput contacts Enter Enter F8.7E.ai Figure 8.6 Contact Setup Display Contact1 F8.8E.ai Figure 8.7 Output Contact 1 Display Others Warm up: Range change: Calibration: Maintenance: Blow back: Temp.input high: Cal.gas press.
8-11 <8. Detailed Data Setting> Table 8.5 Output Contact Settings Item to be selected Alarm and Error settings Other settings Brief description High-high limit alarm If “High-High alarm ON” is selected, contact output occurs when the high-high limit is issued. To do this, it is required, in Alarms setup, that the high-high alarm be set on beforehand (see Section 8.3). High limit alarm If “High alarm ON” is selected, contact output occurs when the high limit alarm is provided.
8.4.3 8-12 <8. Detailed Data Setting> Default Values When the analyzer is delivered, or if data are initialized, alarm and other setting defaults are as shown in Table 8.6. Table 8.
8-13 <8. Detailed Data Setting> 8.5 Input Contact Settings 8.5.1 Input Contact Functions The converter input contacts execute set functions by accepting a remote dry-contact (“voltagefree contact”) signal. Table 8.7 shows the functions executed by a remote contact signal. Table 8.7 Input Contact Functions tem Function Calibration gas pressure low Contact input disables Semi-automatic or Automatic Calibration.
8.5.2 8-14 <8. Detailed Data Setting> Setting Procedure This setting example shows how to set “When contact input 1 Opens, Start Semi_Auto Calibration”. 1) From the Basic panel display touch [Setup] key, and the [Execution/Setup] display appears. 2) Select “Commissioning” and the Commissioning display appears. 3) Select “Contact Setup” then “Input contacts”. 4) Select “Input 1” . Function Selection window (Fig 8.11) appears. 5) Select “Calibration start”.
8-15 <8. Detailed Data Setting> 8.6 Other Settings 8.6.1 Setting the Date-and-Time The following describe how to set the date-and-time. Automatic calibration or blow back works following this setting. Proceed as follows: 1) From the Basic panel display if you touch the [Setup] key, the Execution/Setup display appears. 2) Select “Commissioning” and the Commissioning display appears. 3) Select “Others” and the display of Fig 8.12 appears. 4) Select “Clock” and the display of Fig 8.13 appears.
8-16 <8. Detailed Data Setting> Averaging Set period over which average is calculated: 1h Set period over which maximum and minimum is stored: 24h Enter F8.14E.ai Figure 8.14 Setting Average-Value Calculation Periods and Maximum- and Minimum-Value Monitoring Periods 8.6.2.2 Default Values “Set period over which average is calculated” is set to 1hr, and “Set period over which maximum and minimum is stored” is set to 24 hrs prior factory shipment or after data initialization.. . 8.6.
8-17 <8. Detailed Data Setting> For liquid fuel Amount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} (m3 /kg) (m3 /kg) Theoretical amount of air (Ao) = 12.38 x (Hl/10000) – 1.36 Low calorific power = Hl X value = (3.37 / 10000) x Hx – 2.
8-18 <8. Detailed Data Setting> 40 39 0.046 38 0.044 0.042 37 0.040 36 0.038 35 0.036 34 0.034 33 0.032 32 0.030 31 0.028 30 Wet-bulb temperature, °C 29 0.026 Absolute 28 0.024 27 26 0.022 25 0.020 24 0.018 22 20 0.016 18 0.014 16 0.012 14 12 4 2 0 8 6 humidity, kg/kg 0.010 10 0.008 0.006 0.004 -2 0.002 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 Dry-bulb temperature, °C 38 40 0.000 F8.16E.ai Figure 8.
8-19 <8. Detailed Data Setting> Table 8.8 Fuel Data • For liquid fuel Fuel properties Specific weight kg/l Type Chemical component (weight percentage) C H O N S w Calorific power kJ/kg Ash Higher Lower content order order Theoretical amount of air for combustion Nm3/kg Amount of combustion gas Nm3/kg X value N2 Total CO2 H2O SO2 Kerosene 0.78~ 85.7 14.0 0.83 0.5 0.0 0.0 46465 43535 11.4 1.59 1.56 0.00 9.02 12.17 0.96 Light oil 0.81~ 85.6 13.2 0.84 1.2 0.0 0.
8-20 <8. Detailed Data Setting> 8.6.3.2 Procedure To make a fuel setting, follow these steps: (1) Press the [Setup] key in the Basic panel display to display the Execution/Setup display. (2) Select “Commissioning” in the Execution/Setup display. The Commissioning (Setup) display then appears. (3) Select “Others” in that display and then the Fuel setup shown in Figure 8.17. (4) Choose the “Theoretical air quantity required” and the “Contents of moisture in exhaust gas” in turn.
8-21 <8. Detailed Data Setting> 8.6.4 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 calibration due to condensed water in the pipe. Open the solenoid valve for the automatic calibration span gas during purging and after the purge time has elapsed, close the valve to start warm-up.
8.6.5 8-22 <8. Detailed Data Setting> Setting Passwords Unauthorized access to lower level menu displays from the Execution/Setup display can be protected by passwords. You can set separate passwords for Calibration, Blow back, and Maintenance and for Commissioning Proceed as follows: 1) From the Basic panel display touch the [Setup] key, and the Execution/Setup display appears. 2) Select “Commissioning” , and the Commissioning display appears. 3) Select “Others” then “Passwords”.
9. Calibration 9.1 Calibration Briefs 9.1.1 9-1 <9. Calibration> Principle of Measurement This section sets forth the principles of measurement with a zirconia oxygen analyzer before detailing calibration. A solid electrolyte such as zirconia allows the conductivity of oxygen ions at high temperatures.
9-2 <9. Calibration> 120 100 0.51 vol% O2,81.92mV(Zero origin of calibration) 80 Cell voltage (mV) 60 40 20 21.0 vol% O2, 0mV (Span origin of calibration) 0 -20 -40 0.1 0.5 1 5 10 21.0 50 100 Oxygen concentration (vol % O2) F9.1E.EPS Figure 9.1 Oxygen concentration in a Sample Gas vs Cell Voltage (21 vol%O2 Equivalent) The measurement principles of a zirconia oxygen analyzer have been described above.
9-3 <9. Calibration> 9.1.3 Compensation The deviation of a measured value from the theoretical cell electromotive force is checked by the method in Figure 9.2 or 9.3. Figure 9.2 shows a two-point calibration using two gases: zero and span. Cell 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.
9.1.4 9-4 <9. Calibration> 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 semiautomatic calibration), these data are not collected in the current calibration. These data can be observed by selecting the [Detailed-data] key from the Basic panel display.
9.2 9-5 <9. Calibration> Calibration Procedures NOTE 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.
9-6 <9. Calibration> 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. Select “Points” from the Calibration setup display and then you can select “Both,” “Span” or “Zero” (see Figure 9.5). Calibration setup Calibration setup Mode: Manual Points: Both Span Zero gas conc: 1.00% Zero Span gas conc: 21 . 0 0 % Timing Mode: Manual Points: Semi_Auto Auto Zero gas conc: 1.
9-7 <9. Calibration> 9.2.1.5 Setting Calibration Time • When the calibration mode is in manual: First set the “Hold time” (output stabilization time). This indicates the time required from the end of calibration to entering a measurement again. This time, after calibration, the sample 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.
9-8 <9. Calibration> NOTE When setting calibration timing requirements, bear the following precautions in mind: (1) If the calibration interval is shorter than the sum of hold (output stabilization) time plus calibration time, the second calibration start time will conflict with the first calibration. In such a case, the second calibration will not be conducted.
9.2.3 9-9 <9. Calibration> Calibration NOTE 1) Perform calibration under normal working conditions (e.g. continuous operation with sensor mounted on furnace). 2) Perform both Span and Zero calibration for best resultant accuracy. 3) When instrument air is used for the span calibration, remove the moisture from the instrument air at a dew-point temperature of -20 °C and also remove any oily mist and dust from that air.
<9. Calibration> 9-10 To start calibration using an input contact, follow these steps: (1) Make sure that Calibration start has been selected in the Input contacts display (see Section 8.5, earlier in this manual). (2) Apply an input contact to start calibration. To stop calibration midway, follow these steps: (1) Press the [Reject] key. If this key is pressed midway during calibration, the calibration will stop and the hold (output stabilization) time will be set up.
10-1 <10. Other Functions> 10. Other Functions 10.1 Display 10.1.1 Detailed-data Display Press the [Detailed-data] key on the Basic panel display to view the detailed operation data as shown in Figure 10.1. Pressing the [▼] or [▲] key, you can advance the page or go back to your desired page. • Detailed-data display There are ten panel displays for viewing detailed data. The following briefly describe the operational data displayed on the Detailed-data display. Tag: Span gas ratio: 0.
10-2 <10. Other Functions> 10.1.1.2 Cell Response Time The cell’s response time is obtained in the procedure shown in Figure 10.3. If only either a zeropoint or span calibration has been carried out, the response time will not be measured just as it will not be measured in manual calibration. Five minutes maximum Response time mA 100% 90% 10% of analog output span Time Start calibration Calibration complete The response time is obtained after the corrected calibration curve has been found.
<10. Other Functions> 10-3 10.1.1.6 Cell Voltage The cell (sensor) voltage will be an index to determine the amount of degradation of the sensor. The cell voltage corresponds to the oxygen concentration currently being measured. If the indicated voltage approximates the ideal value (corresponding to the measured oxygen concentration), the sensor will be assumed to be normal.
10-4 <10. Other Functions> 10.1.1.11 Maximum Oxygen Concentration The maximum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed. After the present monitoring interval has elapsed, the maximum oxygen concentration that has been displayed so far will be cleared and a new maximum oxygen concentration will be displayed.
10.1.2 10-5 <10. Other Functions> Trend Graph Press the [Graph display] key in the Basic panel display to switch to the graph display. This will help grasp the measured-value trend. Touching anywhere on the graph display will return to the Basic panel display. To set the Trend graph display, follow the steps in Section 10.1.2.1. 10.1.2.1 Setting Display Items (1) Press the [Setup] key in the Basic panel display to display the Execution/Setup display.
10-6 <10. Other Functions> Preset upper limit 25.0 vol%O2 10 min./div Preset lower limit 0.0 vol%O2 12.3 vol%O2 Time per division, calculated by the set sampling interval Currently measured value 60 data Sampling period F10.5E.ai Figure 10.5 Plotting Graph for Sampling Interval 10.1.2.3 Setting Upper and Lower Limit Values on Graph Set upper- and lower-limit values on the graph in the following procedure: Press “Upper limit” in the Trend graph display. The numeric-data entry key appears.
10.1.3 10-7 <10. Other Functions> Auto-Return Time On the Execution/Setup display or lower level menu displays, if no keys are touched for a preset time, the Auto return time, then the display will automatically revert to the Basic panel display. The “Auto return time” can be set in the range 0 to 255 minutes. If it is set to 0, then the display does not automatically revert. By default, the “Auto return time” is set to 0 (zero).
10.2 <10. Other Functions> 10-8 Blow Back 10.2.1 Blow back Setup This section explains the parameter settings for performing blow back. 10.2.1.1 Mode There are three modes of blow back operation: no function, semi-automatic, and automatic. Blow back is not performed when the mode is set to “No function”. In “Semi_Auto” mode, blow back can be started by key operation on the display or by a contact input signal, and then sequentially performed at a preset blow back time and hold time.
10-9 <10. Other Functions> 10.2.1.2 Operation of Blow back Figure 10.9 shows a timing chart for the operation of blow back. To execute blow back with a contact input, use a contact input with an ON-time period of one to 11 seconds. Once blow back starts, a contact output repeatedly opens and closes at an interval of approximately 10 seconds during the preset blow back time.
<10. Other Functions> 10-10 NOTE • If the blow back is executed with an input contact, it must be preset in the Input contact settings (for more details, see Section 8.5, earlier in this manual). • In Section 8.4, Output Contact Setup, earlier in this manual, set the contact used as the blow back switch beforehand. • Do not set any other function for the contact used as the blow back switch. Otherwise, blow back may be activated when the contact is closed by any other function.
10-11 <10. Other Functions> 10.3 Parameter Initialization Parameter settings can be initialized to the factory default settings. Initialization can be done for all parameters or for individual parameters. The parameters that can be initialized and their defaults are listed in Table 10.5. (1) On the Basic panel display, touch the [Setup] key to display the Execution/Setup display. (2) Select “Commissioning”, next “Others” then “Defaults”. A display like Figure 10.11.
10-12 <10. Other Functions> Table 10.
10-13 <10. Other Functions> Table 10.5 Initialization Items and Default Values - Part 2 Item Initialization Parameter Alarm setting Alarm data Alarm set value Default setting Parameter Oxygen concentration Hysteresis 0.
10-14 <10. Other Functions> Average value/ Maximum and minimum values Other data Fuel set value Average-value calculation One hour Intervals over which max. and min. values are monitored 24 hours Amount of water vapor in exhaust 0.00 m3/kg (m3) gas Theoretical amount of air 1.00 m3/kg (m3) X value 1.00 Absolute humidity of atmosphere 0.0 kg/kg Password Deleted IM 11M12A01-02E 8th Edition : Jan.
10-15 <10. Other Functions> 10.4 Reset Resetting enables the equipment to restart. If the equipment is reset, the power is turned off and then back on. In practical use, the power remains on, and the equipment is restarted under program control.
10.5 10-16 <10. Other Functions> Handling of the ZO21S Standard Gas Unit The following describe how to flow zero and span gases using the ZO21S Standard Gas Unit. Operate the ZO21S Standard Gas Unit, for calibrating a system classified as System 1, according to the procedures that follow. 10.5.1 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.
10.5.2 10-17 <10. Other Functions> Installing Gas Cylinders Each ZO21S Standard Gas Unit comes with six zero gas cylinders including a spare. Each gas cylinder contains 7-liters of gas with a 0.95 to 1.0 vol%O2 (concentration varies with each cylinder) and nitrogen, at a pressure of 700 kPaG (at 35 °C). The operating details and handling precautions are also printed on the product. Please read them beforehand.
<10. Other Functions> 10-18 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 described in Section 10.5.2. For operation of the converter, see Section 7.12, earlier in this manual.
10-19 <10. Other Functions> (1) Use the needle of the zero gas valve “ CHECK GAS “ to puncture a hole in the gas cylinder installed as described in Section 10.5.2. Fully clockwise turn the valve regulator by hand. (2) Next, adjust the flow 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 valves back slowly counterclockwise.
<10. Other Functions> 10.6 10-20 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F Flow Setting Unit is used as a calibration device 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 each time calibration is made (starting and stopping the calibration gas flow and adjusting the flow rate). This applies even if you are using the ZR40H Automatic Calibration Unit.
<10. Other Functions> 10.6.3 10-21 Operating the Zero Gas Flow Setting Valve Operate the zero gas flow setting valve during zero-point calibration in the following procedures: (1) When the display shown in Figure 10.19 appears during calibration, open the zero gas flow setting valve of the flow setting unit and adjust the flow rate to 600 ± 60 ml/ min. To rotate the valve shaft, if the valve has a lock nut loosen the lock nut and slowly turn it counterclockwise.
Blank Page
11. 11-1 <11. Inspection and Maintenance> 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. 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.
11-2 <11. Inspection and Maintenance> Exploded view of components Rod (with outside diameter of 2 to 2.5 mm) Calibration gas tube F11.1E.ai Figure 11.1 Cleaning the Calibration Gas Tube 11.1.2 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 gas ratio of 100 ± 30% or a span gas ratio of 0 ± 18%.
11-3 <11. Inspection and Maintenance> (5) Clean the sensor assembly, especially the metal O-ring contact surface to remove any contaminants adhering to that part. If you can use any of the parts from among those removed, also clean them up to remove any contaminants adhering to them. (Once the metal O-ring has been used, it can not be reused. So, be sure to replace it.) 3. Part assembly procedure (1) First, install the contact.
11-4 <11. Inspection and Maintenance> Metal O-ring Sensor Dust filter (optional) Bolts (four) U-shaped pipe support Contact Probe Screw Filter U-shaped pipe Washers (four) 1/8 turn – tighten bolts 1/8 turn (approximately 45°) each F11.3E.ai Figure 11.3 Exploded View of Sensor Assembly NOTE 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.
11-5 <11. Inspection and Maintenance> 16 A 14 14 11 10 14 12 35 A 13 15 24 8 9 24 7 5 4 6 3 24 2 1 23 TC + View A-A 17 25 36 28 29 19 1 CELL 2 3 TC 4 5 6 CJ 35 20 30 33 13 14 34 26 18 22 37 TC - CELL + 32 7 21 H T R 8 F11.4.ai Figure 11.4 Exploded View of Detector (When pressure compensation specified) Note: The parts marked by is not equipped with the types except the pressure compensation type.
11-6 <11. Inspection and Maintenance> Replacement of heater strut assembly (ZR22G : Style S2 and after) Refer to Figure 11.4 as an aid in the following discussion. Remove the cell assembly (6), following Section 11.1.2, earlier in this manual. Open the terminal box (16) and remove the three terminal connections – CELL +, TC + and TC -.Before disconnect the HTR terminals, remove the terminal block screw (28). Keeping the other terminal remaining to be connected. Disconnect the two HTR connections.
Part No. 11.1.6 11-7 <11. Inspection and Maintenance> Description (7) K9470BJ Metal O-ring (14) K9470ZS O-ring with grease (21) (22) K9470ZP Two pairs of O-rings with grease Cleaning the High Temperature Probe Adapter CAUTION • Do not subject the probe of the High Temperature Probe Adapter (ZO21P-H-A) to shock. This probe uses silicon carbide (SiC) which may become damaged if it is subjected to a strong shock or thermal shock.
11.2 11-8 <11. Inspection and Maintenance> 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. A dirty touchpanel should be wiped off with a soft dry cloth. 11.2.1 Replacing Fuses The converter incorporates a fuse, as indicated in Figure 11.5. If the fuse blows out, replace it in the following procedure.
11-9 <11. Inspection and Maintenance> To replace the fuse, follow these steps: (1) Turn off the power to the converter for safe replacement. (2) Remove the fuse from its holder. With the appropriate flat-blade screwdriver that just fits the holder cap slot (Figure 11.6), turn the fuse holder cap 90° counterclockwise. By doing so, you can remove the fuse together with the cap. Cap Flat-blade screwdriver Socket Fuse F11.6E.ai Figure 11.
11-10 <11. Inspection and Maintenance> 11.3 (1) (2) (3) (4) Replacing Flowmeter in ZR40H Automatic Calibration Unit Remove piping and wiring, and remove the ZR40H from the 2B pipe or wall mounting. Remove four M6 bolts between brackets. Remove piping extension 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. (5) Replace piping, and fix M6 bolts between brackets.
12. 12-1 <12. Troubleshooting> Troubleshooting This chapter describes errors and alarms detected by the self-diagnostic function of the converter. It also explains inspections and remedies when other problems occur. 12.1 Displays and Remedies When Errors Occur 12.1.1 Error Types An error occurs when an abnormality is detected in the detector or the converter, e.g., in the cell (sensor), detector heater, or internal circuits of the the converter..
12-2 <12. Troubleshooting> 12.1.2 Remedies When an Error Occurs 12.1.2.1 Error1: Cell Voltage Failure Error1 occurs when the cell (sensor) voltage input to the converter falls below -50 mV (corresponding to about 200 vol% O2).
12-3 <12. Troubleshooting> 12.1.2.2 Error2: Heater Temperature Failure This error occurs if the detector heater temperature does not rise during warm-up, falls below 730 °C after warm-up, or exceeds 780 °C. When Error2 occurs, Alarm 10 (cold junction temperature alarm) or Alarm 11 (thermocouple voltage alarm) may be generated at the same time. Be sure to press the error indication to get the error description and confirm whether or not these alarms are being generated simultaneously.
12-4 <12. Troubleshooting> NOTE • Measure the thermocouple resistance value after the temperature difference between the detector tip and the ambient atmosphere has decreased to 50 °C or less. If the thermocouple voltage is large, accurate measurement cannot be achieved. 12.1.2.3 Error3: A/D Converter Failure/Error4: Writing-to-memory Failure • A/D Converter Failure It is suspected that a failure has occurred in the A/D converter mounted in the electrical circuits inside the converter.
12-5 <12. Troubleshooting> 12.2 Displays and Remedies When Alarms are Generated 12.2.1 Alarm Types 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. Tag: Tag: 21.0 Alarm 6 :Zero conc.ratio %O2 17.42mA -Output1 17.42mA -Output2 F12.4E.ai F12.3E.ai Figure 12.3 Figure 12.4 Table 12.
12.2.2 12-6 <12. Troubleshooting> Remedies 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 8.3, Setting Oxygen Concentration Alarms, in the chapter on operation. 12.2.2.
12-7 <12. Troubleshooting> (4) Check whether the deterioration of or damage to the sensor assembly that caused the alarm has occurred suddenly during the current calibration in the following procedure: a. Call up the Detailed-data Display. b. Use the [Page Scroll] key to check Calibration Data (Figure 12.6). The span and zero correction ratios of the last ten calibration can be checked here. By checking these data, whether the sensor deterioration has occurred suddenly or gradually can be determined.
12-8 <12. Troubleshooting> (1) Confirm the following and carry out calibration again: If the items are not within their proper states, correct them. a. If the display “Span gas conc” is selected in Calibration setup, the set point should agree with the concentration of span gas actually used. b. The calibration gas tubing should be constructed so that the span gas does not leak.
12-9 <12. Troubleshooting> (3) A failure of the cold junction temperature sensor located at the detector terminal block occurred. (4) A failure of the electrical circuits inside the converter occurred. If “C.J.temperature” exceeds 150 °C or falls below -20 °C, the following can be considered. • The temperature of the detector terminal block is out of the operating temperature range (-20 °C to 150 °C).
<12. Troubleshooting> 12-10 12.2.2.6 Alarm 11: Thermocouple Voltage Alarm This alarm is generated when the emf (voltage) of the thermocouple falls below -5 mV (about -170 °C) or exceeds 42.1 mV (about 1020 °C). Whenever Alarm 11 is generated, Error2 (heater temperature failure) occurs. (1) Breakage of the heater thermocouple signal wire between the converter and the detector occurred, or the cable is not securely connected to the connecting terminals.
12.3 <12. Troubleshooting> 12-11 Countermeasures When Measured Value Shows Error The causes that the measured value shows an abnormal value is not always due to instrument failures. There are rather many cases where the causes are those that 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.
12.3.2 <12. Troubleshooting> 12-12 Measured Value Lower Than True Value (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.
Customer Maintenance Parts List Model ZR22G Zirconia Oxygen Analyzer, Detector (Separate type) A 13 A 1 13 View A-A 2 7 6 5 4 3 10 11 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 9 8 12 Part No. Qty F02E.
Customer Maintenance Parts List Model ZR402G Zirconia Oxygen Analyzer/High Temperature Humidity Analyzer,Converter 1 Hood for ZR402G ZR402G 2 Item Part No. Qty Description 1 A1113EF 1 Fuse (3.15A) 2 K9471UF 1 Hood All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. CMPL 11M12C01-01E 1st Edition : Jan. 2000 (YK) 3rd Edition : Feb.
Customer Maintenance Parts List Model ZR40H Separate type Zirconia Oxygen / High Temperature Humidity Analyzer, Automatic Calibration Unit 6 LOCK ZERO LOCK COMMON SPAN ZERO 10 9 AUTO CALIBRATION UNIT MODEL SUFFIX ZR40H STYLE S1 SUPPLY 690kPa MAX. AMB.TEMP-20 TO 558C USED WITHZR402G NO. Made in Japan REF.OUT CAL.OUT SPAN IN ZERO IN Item Part No. Qty Description 6 K9473XC 1 Flowmeter All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation.
Customer Maintenance Parts List Model ZO21P-H Zirconia Oxygen Analyzer High Temperature Probe Adapter 5,6 4 7 3 8,9,10 11 ZR22G 2 1 Item Part No. Qty Description 1 E7046AL E7046BB E7046AP E7046AQ 1 1 1 1 Probe (SiC, L=1.0m) Probe (SiC, L=1.5m) Probe (SUS, L=1.0m) Probe (SUS, L=1.
Customer Maintenance Parts List E7046EC/E7046EN Zirconia Oxygen Analyzer Auxiliary Ejector Assembly (for Model ZO21P-H) 1 3 2 4 5 6 7 Item Part No.
Customer Maintenance Parts List Model ZO21S Zirconia Oxygen Analyzer/ High Temperature Humidity Analyzer, Standard Gas Unit 1 2 3 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 110 115 E7050AU AC 200 V 220 240 E7050AV All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. CMPL 11M3D1-01E 1st Edition : Jan.
i Revision Information Title : Model ZR22G, ZR402G Separate type Zirconia Oxygen Analyzer Manual No. : IM 11M12A01-02E Oct. 2000/1st Edition Newly published Mar. 2001/2nd Edition Revised section 1.1.3 “System 3” explanation changed 2.2 In “General use Separate type Detector”, some MS codes changed 2.4 Corrected errors in ZR402G External Dimensions figure, changed MS Code table 2.5.1 Changed reference gas pressure where check valves is used, style changed of ZA8F 2.5.
ii 4.3.1 4.4.1 “ Blow Back Piping” Changed part numbers of air set “ Piping Parts for a System using Detector with Pressure Conpensation” Changed part numbers of air set in Table 4.3 5.3.3 Added WARNING 11.2.1 Added instruction in Note 12.1.1 Added description in Error-2 of Table 12.1, Type of Errors and Reasons for Occurrence 12.1.2.1 Changed reference information 12.1.2.2 Added descriptions 12.2.1 Added Alarm 13 in Table 12.2, Types of Alarms and Reasons for Occurrence 12.2.2.7 Added Section 12.2.2.
