User's Manual Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer IM 11M12A01-05E IM 11M12A01-05E 6th Edition
Introduction The EXAxt ZR series of Integrated-type Zirconia High-temperature Humidity Analyzers was developed for humidity control in various industrial processes. There are versions for virtually every application. Optional accessories are also available to improve measurements and automate calibration. An optimal control system can be realized by adding appropriate options.
This manual consists of twelve chapters. Please refer to the reference chapters for installation, operation and maintenance. Chapter Outline 1. Overview Equipment models and system configuration examples 2. Specifications Standard specification, model code (or part number), dimension drawing for each equipment Installation method for each equipment 3. Installation 4. Piping 5.
r For the safe use of this equipment CAUTION The cell (sensor) at the tip of the probe is made of ceramic (zirconia element). Do not drop the equipment or subject it to pressure stress. • Do NOT allow the sensor (probe tip) to make contact with anything when installing the analyzer. • Avoid any water dropping directly on the probe (sensor) of the analyzer when installing it. • Check the calibration gas piping before introducing the calibration gas to ensure that there is no leakage of the gas.
(1) About This Manual j This manual should be passed on to the end user. j The contents of this manual are subject to change without prior notice. j The contents of this manual shall not be reproduced or copied, in part or in whole, without permission. j This manual explains the functions contained in this product, but does not warrant that those will suit the particular purpose of the user. j Every effort has been made to ensure accuracy in the preparation of this manual.
(3) The following safety symbols are used in this manual. DANGER This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injury, electric shock or fatalities . The manual describes what special care the operator must exercise to avoid such risks.
j Special descriptions in this manual This manual indicates operation keys, displays and drawings on the product as follows: • Operation keys, displays on the panel Enclosed in [ ]. (Ex. "MODE" key) (Ex. message display (Ex. data display "BASE-L") "102" lit, "102" flashing) • Drawing representing flashing Indicated by gray characters. (Flashing) (lit) • Displays on the LCD display panel Alphabetic code LCD display Alphabetic code LCD display Numeric code LCD display LCD display.
r 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.
d Yokogawa does not warrant conformance with the specific application at the user site. Yokogawa will not bear direct/indirect responsibility for damage due to a specific application. d Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product. d Maintenance service and supplying repair parts will be covered for five years after the production ends.
Contents Introduction ........................................................................................................................... i r For the safe use of this equipment ............................................................................... iii r NOTICE ......................................................................................................................... vii r After-Sales Warranty .....................................................................................
3.2.2 Mounting of ZA8F Flow Setting Unit ................................................... 3-4 3.3 Installation of ZR20H Automatic Calibration Unit ........................................ 3-6 3.3.1 Location ................................................................................................... 3-6 3.3.2 Mounting of ZR20H Automatic Calibration Unit .................................. 3-6 3.4 Installation of the Calibration-gas Unit Case (E7044KF) .............................. 3-8 3.4.
7.4 Operation of Infrared Switch .......................................................................... 7-3 7.4.1 Display and Switches .............................................................................. 7-3 7.4.2 Display Configuration ............................................................................. 7-5 7.4.3 Entering Parameter Code Selection Display .......................................... 7-6 7.4.4 Selecting Parameter Codes ....................................................
9. Calibration .................................................................................................................. 9-1 9.1 Calibration Briefs ............................................................................................ 9.1.1 Measurement Principle of Zirconia Humidity Analyzer ........................ 9.1.2 Calibration Gas ....................................................................................... 9.1.3 Compensation .................................................
11. Inspection and Maintenance ................................................................................... 11-1 11.1 Inspection and Maintenance of the Detector ................................................ 11-2 11.1.1 Cleaning the Calibration Gas Tube ...................................................... 11-2 11.1.2 Replacing the Sensor Assembly ........................................................... 11-3 11.1.3 Replacement of the Heater Unit .................................................
1. Overview 1. Overview The EXAxt ZR Integrated-type Zirconia High-temperature Humidity Analyzer integrates the detector and the converter in one unit. This analyzer can measure humidity of hot air continuously, so can be used to measure humidity of air in driers which are heated by steam or electricity. It can also be used in a variety of manufacturing applications with humidifiers, as well as with driers, for humidity measurement and control. It can help improve productivity in these application fields.
1.1 < EXAxt ZR > System Configuration The system configuration determines whether calibration is initiated automatically or manually. The three basic system configurations are given below: 1.1.1 System 1 This is the simplest system which consists of an integrated-type (all-in-one) detector and analyzer. This system can be used for monitoring humidity in driers used in food processing, or the like. No piping is required for the reference gas (air) which is fed in at the installation site.
1. Overview 1.1.3 System 3 This system is also used where accurate monitoring and controlling of the humidity is required. Instrument air (clean and dry air of oxygen concentration 21%) is used as the reference gas and span gas for calibration. A calibration zero gas is supplied from a cylinder. This system uses an automatic calibration unit to control the calibration gas flow automatically.
1.2 < EXAxtZR > System Components 1.2.1 System Components Integrated type System config. Ex.1 Ex.2 Ex.
2. Specifications 2. Specifications This chapter focuses on the specifications for the High-temperature Humidity Analyzer (integrated model) and associated equipment, including: ZR202G Integrated type Zirconia High-temperature Humidity Analyzer (See Section 2.1.2) ZH21B Dust protector (See Section 2.1.3) ZA8F ZR20H Flow setting unit Automatic calibration unit (See Section 2.2.1) (See Section 2.2.2) ZO21S Standard gas unit (See Section 2.3) 2.1 General Specifications 2.1.
Linearity : (Excluding standard gas tolerance) (See Note 1) (Use oxygen of known concentration (in the measuring range) as the zero and span calibration gas.) 62 vol% H2O; (Sample gas pressure: within 60.49 kPa) 63 vol% H2O; (Sample gas pressure: 2 kPa or less) Drift: (Excluding the first two weeks in use) (See Note 1) Both zero and span 63 vol% H2O/month Response Time : Response of 90% within 5 second. (Measured after gas is introduced from calibration-gas inlet and analog output start changing.
2. Specifications EMC : EN 61326 Class A EN 55011 Class A Group 1 EN 61000-3-2 AS/NZS CISPR 11 Reference Air System : Natural Convection, Instrument Air Instrument Air System (excluding Natural Convection): Pressure; 200 kPa + the pressure inside the dryer (It is recommended to use air which is dehumidified to dew point -208 C or less, and with dust or oil mist removed.) Consumption; Approx.
Initial settings should be set to match the plant conditions when installing the converter. Current output data settings, alarm data settings, contact data settings, other settings.
2. Specifications (1) Abnormal, (2) High-high alarm, (3) High-alarm, (4) Low-low alarm, (5) Lowalarm, (6) Maintenance, (7) Calibration, (8) Range switching answer-back, (9) Warm-up, (10) Calibration-gas pressure decrease (answerback of contact input), (11) Flameout gas detection (answerback of contact input).
• Model and Codes Option code Suffix code Model Integrated type Zirconia High Temperature Homidity Analyzer ZR202G Length -040 -070 -100 -150 -200 -250 -300 Wetted material 0.4 m 0.7 m 1.0 m 1.5 m 2.0 m 2.5 m 3.
2. Specifications • External Dimensions Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzers Unit: mm 338 to 351 L [123 Display side t L= 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 (m) 125 48.5 25 [ 50.8 122 Rc1/4 or 1/4NPT Reference air inlet Rc1/4 or 1/4NPT Calibration gas inlet 153 to 164 4-G1/2,2-1/2NPT etc.
Model ZR202G...-P(with pressure compensation) Integrated type Zirconia High Temperature Humidity Analyzer Unit : mm 34264 L [123 Display side t L= 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 (m) Reference air outlet 125 48.5 25 [50.8 122 Rc1/4 or 1/4NPT Reference air inlet PIPING :B 4-G1/2,2-1/2NPT etc. Cable connection port PIPING:A 15663 25664 Stop valve Terminal side 170 49 Rc1/4 or 1/4NPT Calibration gas inlet C [A [B Flange Flange C Flange A 152.4 190.5 228.
2. Specifications • Hood (Option code /H) 150 64 63 150 63 274 Hood Material : Aluminum Hood Weight : Approx. 800g ZR202G-F.
2.1.3 ZH21B Dust Protector This protector is designed to protect the probe output from dust agitation (i.e., to prevent combustible materials from entering the probe cell where humidity measurements are made) in a dusty environment. Insertion length : 0.428m Flange : JIS 5K 80 FF equivalent or ANSI Class 150 4 FF SUS304. (However, flange thickness is different.) Material : SUS 316 (JIS), SUS 304 (JIS) (flange) Weight: Approx. 6kg (JIS), approx. 8.
2. Specifications 2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit 2.2.1 ZA8F Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration (System 2). This unit consists of a flow meter and flow control valves to control the flow of calibration gas and reference air. Standard Specifications Flowmeter: Calibration gas; 0.1 to 1.0 l/min. Reference air; 0.1 to 1.0 l/min.
External Dimensions [6 hole Unit: mm 180 140 REFERENCE ZERO SRAN Span gas inlet Zero gas outlet Zero gas inlet 26 Reference air outlet CHECK 222.8 235.8 REFERENCE 20 35 35 35 35 20 8 35 70 4-Rc1/4 or 4-NPT(F) Instrument air inlet CHECK OUT Flow meter ZERO GAS IN SPAN GAS IN REF OUT Flow meter AIR IN Instrument air Approx 1.5 l/min. Airset Air pressure: without check valve ; measured gas pressure 1 approx.50 kPaG with check valve ; measured gas pressure 1 approx.150 kPaG F2.
2. Specifications 2.2.2 ZR20H Automatic Calibration Unit This automatic calibration unit is applied to supply specified flow of reference gas and calibration gas during automatic calibration to the detector in a system configuration (System 3). • Specifications Equipped with the analyzer when automatic calibration is specified in the suffix code of the ZR202G Integrated type by selecting either “-A (Horizontal mounting)” or “-B (Vertical mounting)”.
• External Dimensions (1) For Horizontal Mounting (-A) Unit: mm 242 257 [ 84 [ 80 AUTO CAL. UNIT SPAN IN REF IN ZERO IN MODEL SUFFIX ZR20H STYLE S1 SUPPLY 690kPa MAX. -20 TO 558C ZR202G AMB.TEMP USED WITH NO. 40 40 66.5 166.5 44 MAX 56 Zero gas inlet Rc1/4 or 1/4NPT(Female) Reference gas inlet Rc1/4 or 1/4NPT(Female) Span gas inlet Rc1/4 or 1/4NPT(Female) (2) Vertical Mounting (-B) 49 [ 84 [8 111 0 AUTO CAL.
2. Specifications 2.3 ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system 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. Sealed Zero Gas Cylinders (6 provide): E7050BA Capacity : 1 l Filled pressure : Approx.
2.4 Other Equipment 2.4.1 Stop Valve (part number: L9852CB or G7016XH) This valve is mounted on the calibration gas line in the system to allow for one-touch calibration. This applies to the system configuration shown for System 1 in section1. Standard Specifications Connection : Rc 1/4 or 1/4 FNPT Material : SUS 316 (JIS) Weight : Approx. 80 g Description Part No. L9852CB Joint: RC 1/4, Material: SUS 316 (JIS) G7016XH Joint: 1/4 NPT, Material: SUS 316 (JIS) T2.9E.
2. Specifications K9292DN : Rc 1/4(A part),R 1/4(B) K9292DS : 1/4FNPT(A part),1/4NPT(Male)(B part) unit : mm A B Approx.19 Approx.54 F2.11E.EPS 2.4.3 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases. • Part number: K9473XH or K9473XJ Standard Specifications Primary Pressure : Max. 2 MPa G Secondary Pressure : 0 to 0.25 MPa G Connection : Rc1/4 or 1/4FNPT (included joint adapter) Weight: Approx.1 kg Description Part No.
• Part. no. G7004XF or K9473XG Standard Specification Primary Pressure: Max. 1 MPa G Secondary Pressure: 0.02 to 0.5 MPa G Connection: Rc1/4 or 1/4 FNPT with joint adapter Weight : Approx. 1 kg Part No. Description G7004XF Joint: Rc 1/4, Material: Zinc Alloy K9473XG Joint: 1/4 NPT (F) , Material: Body; Zinc Alloy, Adapter; SUS316 T2.13E.EPS Unit :mm View A Panel cut dimensions Horizontal mounting 22 Vertical mounting [15 40 +0.5 2-2.2 -0 40 2-[6.5 max.
2. Specifications 2.4.4 Zero-gas Cylinder (part number: G7001ZC) The gas from this cylinder is used as the calibration zero gas and detector purge gas. Standard Specifications Capacity : 3.4 l Filled pressure : 9.8 to 12 MPa G Composition : 0.95 to 1.0 vol% O2 in N2 (Note) Export of such high pressure filled gas cylinders to most countries is prohibited or restricted. 485 325 Unit : mm [140 Weight : Approx. 6 kg F2213.EPS 2.4.
2.4.6 Case Assembly for Calibration-gas Cylinder (part number: E7044KF) This case is used to store the zero gas cylinders. Standard Specifications Case Paint : Baked epoxy resin, Jade green (Munsell 7.5 BG 4/1.5) Installation : 2B pipe mounting Material : SPCC (Cold rolled steel sheet) Weight : Approx. 3.3 kg,10 kg with gas cylinder (Note) Export of such high pressure filled gas cylinders to most countries is prohibited or restricted.
2. Specifications 2.4.7 Model ZR202A Heater Assembly Model Suffix code Option code Description Heater Assembly for ZR202G ZR202A 0.4 m 0.7 m 1m 1.5 m 2m 2.5 m 3m -040 -070 -100 -150 -200 -250 -300 Length (p1) Jig for change with Jig None -A -N Always -A -A T2.2E.EPS (p1) Suffix code of length should be selected as same as ZR202G installed. * The heater is made of ceramic, do not drop or subject it to pressure stress. Unit : mm 30 [ 45 (K9470BX) K9470BX Jig for change [ 21.
3. Installation 3. Installation This chapter describes how to install the following equipment and how to test the insulation resistance. 3.1 High-temperature Humidity Analyzer 3.2 ZA8F Flow Setting Unit 3.3 ZR20H Automatic Calibration Unit 3.4 Case Assembly for Calibration-gas Cylinder (E7044KF) 3.5 Insulation Resistance Test 3.1 Installation of High-temperature Humidity Analyzer 3.1.
3.1.2 Probe Insertion CAUTION • The outside dimension of detector may vary depending on its options. Use a pipe that is large enough for the detector. Refer to Figure 3.1 for the dimensions. • If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards. • When using the detector with pressure compensation, ensure that the flange gasket does not block the reference air outlet on the detector flange.
3. Installation 3.1.3 Installation of the Detector CAUTION • The cell (sensor) at the tip of the detector is made of ceramic (zirconia). Do not drop the detector, as impact will damage it. • If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards. • A gasket should be used between the flanges to prevent gas leakage. The gasket material should be heatproof and corrosion-proof, suited to the characteristics of the measured gas.
3.2 Installation of ZA8F Flow Setting Unit 3.2.1 Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the analyzer for operating keys on the panel. (3) No corrosive gas. (4) An ambient temperature of not more than 558 C and little changes of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain. 3.2.
3. Installation (1) Make a hole in the wall as illustrated in Figure 3.4. unit : mm 223 140 4 - [6 hole, or M5 screw F3.13E.EPS Figure 3.4 Mounting holes (2) Mount the flow setting unit. Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit securely on the wall with four screws. F3.14E.EPS Figure 3.
3.3 Installation of ZR20H Automatic Calibration Unit 3.3.1 Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector and the converter (3) No corrosive gas. (4) An ambient temperature of not more than 558 C and little change of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain. 3.3.
3. Installation Basic spec. code -A : Horizontal mounting Display Terminal box 214 44 MAX 244 258 unit ; mm 40 40 Zero gas inlet Rc 1/4 or 1/4NPT(Female) 66.5 166.5 Reference gas inlet Rc 1/4 or 1/4NPT(Female) Span gas inlet Rc 1/4 or 1/4NPT(Female) Basic spec. code -B : Vertical mounting 166.5 45 60 160 Span gas inlet Rc 1/4 or 1/4NPT(Female) 180 44 MAX Reference gas inlet Rc 1/4 or 1/4NPT(Female) 40 40 66.5 Zero gas inlet Rc 1/4 or 1/4NPT(Female) F3.6E.EPS Figure 3.
3.4 Installation of the Calibration-gas Unit Case (E7044KF) The calibration gas unit case is used to store the G7001ZC zero gas cylinders. 3.4.1 Location The following should be taken into consideration: (1) Easy access for cylinder replacement (2) Easy access for checking (3) Near to the detector and converter as well as the flow setting unit. (4) The temperature of the case does not exceed 408 C due to rays of the sun or radiated heat. (5) No vibration 3.4.
3. Installation 3.5 Insulation Resistance Test Even if the testing voltage is not so great it causes dielectric breakdown, testing may cause deterioration in insulation and a possible safety hazard. Therefore, conduct this test only when it is necessary. The applied voltage for this test shall be 500 V DC or less. The voltage shall be applied for as short a time as practicable to conform that insulation resistance is 20 MV or more. Remove wiring from the converter and the detector. 1.
3.6 Installation of the High Temperature Humidity Analyzer (with pressure compensation) Installation for each flange type Unit: mm 1. ANSI Class 150 2 RF d ZR202G-hhh-h-A-P Flange : ANSI Class 150 2 RF SUS304 34264 L t C Rc1/4or1/4NPT Reference air inlet 33 25 [A [B Reference gas outlet PIPING :B Flange 2-G1/2,2-1/1NPT etc.
3. Installation 2. ANSI Class 150 3 RF d ZR202G-hhh-h-B-P Flange : Equivalent to ANSI Class 150 3 RF SUS304 Rc1/4 or 1/4NPT Reference air inlet 34264 L 2-G1/2, 2-1/2NPT etc. Cable connection port t C 42 25 [A [B Reference gas outlet PIPING :B Flange Flange PIPING:A 15663 25664 49 Flange L Model, Code Stop Valve Specification B A C PIPING t Weight (kg) ZR202G-040-h-B 400 Approx. 11 ZR202G-070-h-B 700 Approx.
4. DIN PN10 DN50 d ZR202G-hhh-h-E-P Flange : DIN PN10 DN50 SUS304 Rc1/4 or 1/4NPT Reference air inlet 34264 L 2-G1/2, 2-1/2NPT etc. Cable connection port t C 33 25 [A [B Reference gas outlet PIPING :B Flange Flange PIPING:A 15663 25664 49 Flange L Model, Code Stop Valve Specification B A C PIPING t Weight (kg) ZR202G-040-h-E 400 Approx. 9 ZR202G-070-h-E 700 Approx. 10 ZR202G-100-h-E 1000 ZR202G-150-h-E 1500 ZR202G-200-h-E 2000 Approx. 14 ZR202G-250-h-E 2500 Approx.
3. Installation 6. DIN PN10 DN100 d ZR202G-hhh-h-G-P Flange : DIN PN10 DN100 SUS304 Rc1/4 or 1/4NPT Reference air inlet 34264 L 2-G1/2, 2-1/2NPT etc. Cable connection port t C 45 25 [A [B Reference gas outlet PIPING :B Flange Flange PIPING:A 15663 25664 49 Flange L Model, Code Stop Valve Specification B A C Weight (kg) PIPING t ZR202G-040-h-G 400 Approx. 11 ZR202G-070-h-G 700 Approx. 13 ZR202G-100-h-G 1000 ZR202G-150-h-G 1500 ZR202G-200-h-G 2000 Approx.
8. JIS 10K 65 FF d ZR202G-hhh-h-L-P Flange : JIS 10K 65 FF SUS304 342–4 L t C Rc1/4 or 1/4NPT Reference air inlet 33 25 flA flB *1 Reference gas outlet PIPING :B Flange 2-G1/2, 2-1/2NPT etc.
3. Installation 10. JIS 10K 100 FF d ZR202G-hhh-h-P-P Flange : JIS 10K 100 FF SUS304 Rc1/4 or 1/4NPT Reference air inlet 34264 L 2-G1/2, 2-1/2NPT etc. Cable connection port t C 45 25 [A [B Reference gas outlet PIPING :B Flange Flange PIPING:A 15663 25664 Model, Code L ZR202G-040-u-P ZR202G-070-u-P ZR202G-100-u-P ZR202G-150-u-P ZR202G-200-u-P ZR202G-250-u-P ZR202G-300-u-P 400 700 1000 1500 2000 2500 3000 Stop Valve 49 Flange Specification A B C PIPING t Weight (kg) Approx. 10 Approx.
12. JPI Class 150 3 RF d ZR202G-hhh-h-S-P Flange : JPI Class 150 3 RF Rc1/4 or 1/4NPT Reference air inlet 34264 L t C 42 25 [A [B Reference gas outlet PIPING :B Flange Flange 2-G1/2, 2-1/2NPT etc. Cable connection port PIPING:A 15663 25664 Stop Valve 49 Rc1/4 or 1/4NPT Calibration gas inlet Flange Weight (kg) Model, Code L ZR202G-040-u-S 400 Approx. 11 ZR202G-070-u-S 700 Approx. 12 ZR202G-100-u-S 1000 ZR202G-150-u-S 1500 ZR202G-200-u-S 2000 Approx.
4. Piping 4. Piping This chapter describes piping procedures in the three typical system configurations for EXAxt ZR Integrated-type Zirconia High Temperature Humidity Analyzer. • Ensure that each check valve, stop valve and joints used for piping are not leaking. Especially, if there is any leakage of the calibretion gas from piping and joints, it may cause clogging of the piping or incorrect calibration. • Be sure to conduct leakage test after installing the piping.
4.1.1 Piping Parts for System Configuration 1 Check that the parts listed in Table 4.1 are provided. Table 4.1 Piping Parts Equipment Humidity Analyzer Piping location Calibration gas inlet Parts Stop valve Nipple * Joint for tube connection Reference gas inlet (Sealed up) Description (L9852CB or G7016XH) recommended by YOKOGAWA Rc1/4 or 1/4 NPT Commercially available Rc1/4 (1/4NPT) for a Commercially available [63[4mm soft tube (when piping is required, refer to Section 4.1.3) T4.1E.
4. Piping 4.2 Piping for System Configuration 2 Piping in System 2 is illustrated in Figure 4.7. Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Stop valve or Check valve ~ 100 to 240 V AC Contact input Analog output, Contact output Digital output (HART) Model ZA8F flow setting unit Flowmeter Reference gas Needle valve Air Set Instrument air Span gas (Same as Zero gas Calibration unit ) Calibration gas Calibration gas pressure regulator F4.7E.
4.2.2 Piping for the Calibration Gas This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit, and between the ZA8F flow setting unit and the ZR202G analyzer. The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 408 C. Mount a pressure regulator (recommended by YOKOGAWA) on the cylinder.
4. Piping 4.3 Piping for System Configuration 3 Piping in System 3 is illustrated in Figure 4.9. In System 3, calibration is automated; however, the piping is basically the same as that of System 2. Refer to Section 4.2. Adjust secondary pressure of both the air set and the zero gas regulator so that these two pressures are approximately the same. The flow rate of zero and span gases (normally instrument air) are set by individual needle valve.
d Installation of ZR20H AutoCalibretion Unit Unit: mm Horizontal mounting on the ZR202G (-A) 214 44 MAX terminal box side 244 258 display side 40 40 66.5 Zero gas inlet Rc1/4 or 1/4NPT(Female) 166.5 Reference air inlet Rc1/4 or 1/4NPT(Female) Span gas inlet Rc1/4 or 1/4NPT(Female) Vertical mounting on the ZR202G (-B) 166.5 45 60 160 Span gas inlet Rc1/4 or 1/4NPT(Female) 180 44 MAX Reference air inlet Rc1/4 or 1/4NPT(Female) 40 40 66.5 Zero gas inlet Rc1/4 or 1/4NPT(Female) F4-10E.
4. Piping Piping Diagram of ZR20H ZR202G body Calibration gas Reference gas Check valve Span-gas solenoid valve Span-gas flowmeter Reference-gas flowmeter SPAN IN Zero-gas solenoid valve To Air set REF. IN To Zero-gas cylinder Needle valve ZERO IN Autocalibration unit Span-gas flowmeter IM 11M12A01-05E F4.11E.
5. Wiring 5. Wiring In this Chapter, the wiring necessary for connection to the EXAxtZR Integrated type Zirconia High-temperature Humidity Analyzer is described. 5.1 General CAUTION • Never supply current to the equipment or any other device constituting a power circuit in combination with the equipment, 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.
5.1.1 Terminals for the External Wiring Remove the terminal cover on the opposite side of the display to gain access to the external wiring terminals. 1 DI 2 C FG + AO- DO 1 DO 2 L G FG N F5.1E.EPS Figure 5.1 Terminals for External Wiring 5.1.2 Wiring Make the following wiring for the equipment. It requires a maximum of four wiring connections as shown below.
5. Wiring 5.1.3 Mounting of Cable Gland For each wiring inlet connection of the equipment, mount the conduit appropriate for the screw size or a cable gland. 25 Rc1/4 or 1/4NPT (Reference air inlet) Cable gland Rc1/4 or 1/4NPT (Calibration gas inlet) 4-G1/2, 1/2 NPT or the like (Wiring connection) F5.3E.EPS Figure 5.
5.2 Wiring for Analog Output This wiring is for transmitting 4 to 20 mA DC output signals to a device, e.g. recorder. Maintain the load resistance including the wiring resistance of 550V or less. Analyzer Receiver + - AO(+) AO(-) Shielded cables FG F5.4E.EPS Figure 5.4 Wiring for Analog Output 5.2.1 Cable Specifications Use a 2-core shielded cable for wiring. 5.2.2 Wiring Procedure (1) M4 screws are used for the terminals.
5. Wiring 5.3 Wiring Power and Ground Terminals Wiring for supplying power to the analyzer and grounding the equipment. Ground 1 Grounding to the ground terminal on the equipment case Equipment case Grounding terminal Lock washer DI 2 C FG + AO- Crimp contact of the grounding line DO 1 DO 2 L G FG N Jumper plate ~ 100~240 V AC 50/60 Hz F5.5E.EPS Figure 5.5 Power and Grounding Wiring 5.3.1 Wiring for Power Line Connect the power wiring to the L and N terminals of the equipment.
5.4 Wiring for Contact Output The equipment can output a maximum of two contact signals. These contact outputs can be used for different applications such as a low-limit alarm or high-limit alarm. Do the contact output wiring according to the following requirements. Analyzer DO-1 DO-1 DO-2 DO-2 Terminal box Annunciator or the like #1 Output #2 Output F5.6E.EPS Figure 5.6 Contact Output Wiring 5.4.1 Cable Specifications The number of wires in cable varies depending on the number of contacts used. 5.
5. Wiring 5.5 Wiring for Contact Input The converter can execute specified function when receiving contact signals. To use these contact signals, proceed wiring as follows: Converter Terminal box DI-1 Contact input 1 DI-2 DI-C Contact input 2 F5.7E.EPS Figure 5.14 Contact Input Wiring 5.5.1 Cable Specifications Use a 2-wire or 3-wire cable for this wiring. Depending on the number of input(s), determine which cable to use. 5.5.
6. Components 6. Components This chapter describes the names and functions of components for the major equipment of the EXAxt ZR Integrated type Zirconia High-temperature Humidity Analyzer. 6.1 ZR202G High-temperature Humidity Analyzer 6.1.1 Integrated-type High-temperature Humidity Analyzer Terminal box, Non explosion-proof JIS C0920 / equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version.
6.2 ZA8F Flow Setting Unit and ZR20H 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 F6.2E.EPS Figure 6.
7. Startup 7. Startup The following describes the minimum operating requirements — from supplying power to the converter to analog output confirmation to manual calibration. Check piping and wiring connections Set output ranges Set up valves Check current loop Supply power Check contact action Confirm converter type setting Calibrate analyzer Select gas to be measured Set detailed data Place in normal operation F7.0E.EPS Figure 7.
7.1 Checking Piping and Wiring Connections Refer to Chapters 4 and 5, earlier in this manual, for piping and wiring confirmations. 7.2 Valve Setup Set up valves and associated components used in the analyzer system as follows procedures: (1) If a stop valve is used in the detector’s calibration-gas inlet, fully close this valve. (2) If instrument air is used as the reference gas, adjust the air-set secondary pressure so that an air pressure of measured gas pressure plus approx.
7. Startup 7.4 Operation of Infrared Switch 7.4.1 Display and Switches This equipment uses an infrared switch that enables operation with the cover closed. Figure 7.3 shows the infrared switch and the display. Table 7.1 shows the three switch (keys) and functions. Figure 7.3 shows the infrared switch and the display. 4: Decimal point 1: Data display area > > MmNkgalbbl % scftm3 /d /s /h /m ENT 3: Engineering-unit display area F7.3E.EPS 2: Infrared switch Figure 7.
CAUTION 1. Be sure to put the equipment case cover back on. If this is not done, the infrared switch will not reflect the infrared light-waves, and a “dSPErr” error will be issued. 2. Before placing the equipment in operation, be sure to wipe off any moisture or dust on the glass surface if it is wet or dirty. Also make sure your fingers are clean and dry before touching the glass surface of the switch. 3. If the infrared switches are exposed to direct sunlight, they may not operate correctly.
7. Startup 7.4.2 Display Configuration The parameter codes provided for the equipment are used to control the equipment display panels (see below). By selecting appropriate parameter codes, you can conduct calibration and set operation parameters. Figure 7.4 shows the configuration of display items. The parameter codes are listed in groups of seven; which are briefly described in Table 7.2. To enter parameters, you first need to enter the password.
7.4.3 Entering Parameter Code Selection Display This section briefly describes the password entry procedure for entering the parameter code selection display. The password is 1102 - it cannot be changed to a different password. Switch operation Continuously touch the [ENT] key for at least three seconds 0000 Touch the [ENT] key again. This allows you to change the leftmost 1000 Set the password 1102.
7. Startup 7.4.4 Selecting Parameter Codes Table Parameter Code Selection Switch operation A01 Touch the [>] key again to return the position of the digit that is flashing to A. Continuously touch the [>] key, and the position of the digit that is flashing will move continuously to the right. b01 If you touch the [ ] key once, character A will change to B. C01 Touch the [ ] key once to change to C.
7.4.5 Changing Set Values (1) Selecting numeric values from among preset values Switch operation . . ENT Display Description 0 The set value is displayed after the parameter code selection. An example of how to select either 0, 1, or 2 as the set value is given below. (The currently set value is 0.) ENT 2 Touch the [ ] key again to change to the numeric value 2. ENT 0 If you touch the [ ] key again, the numeric value will return to 0. . C01 . ENT .
7. Startup (3) If invalid numeric values are entered: 98.0 ENT Err . . ENT . . . . ENT 00.0 If an invalid numeric value (beyond the input range specified) is entered, "ERR" will appear for two seconds after touching the [ENT] key. "ERR" appears for two seconds, and the display returns to the first set value. Re-enter the numeric value. T7.4.5.3E.
7.5 Confirmation of Equipment Type Setting This equipment can be used for both the Oxygen Analyzer and the Humidity Analyzer. If you choose optional specification /HS at the time of purchase, the equipment is set for the Humidity Analyzer. Before setting the operating data, be sure to check that the desired model has been set. Note that if the equipment type setting is changed after operating data are set, the operating data that have been set are then initialized and the default settings remain.
7. Startup 7.6 Setting Display Item Display items are those items that are displayed on the basic panel display. Parameter code A00 or F08 is used to set the display items as shown in the table below. If the humidity analyzer /HS option was specified at the time of purchase, the equipment is a humidity analyzer. For other than the above, the equipment is set to oxygen concentration at the factory before shipment. If mix ratio is to be measured, change the existing setting as follows.
7.7 Current Output Setting 7.7.1 Analog Output Setting Select any one of the analog output settings — oxygen, humidity, and mixing ratio. If the /HS option was specified at the time of purchase, the equipment is a humidity analyzer. For other than this setting, the analyzer is an oxygen analyzer. If mixed measurement is required, change the existing output setting as follows. Use parameter code C01 for the setting (see Table 7.6).
7. Startup 7.7.2 Output Range Setting This section describes how to set the analog output range. (1) To provide an oxygen concentration, use parameter code C11 to set the minimum oxygen concentration at 4 mA, and use parameter code C12 to set the maximum oxygen concentration at 20 mA. (2) To provide a humidity output, use parameter code C13 to set the minimum humidity at 4 mA, and use parameter code C14 to set the maximum humidity at 20 mA.
7.7.3 Minimum Current (4 mA) and Maximum Current (20 mA) Settings This section describes how to set the humidity readings corresponding to 4 mA and 20 mA to 30% H2O and 80% H2O respectively. ENT ENT Display Description A01 C01 Display after the password has been entered. Set the humidity reading at 4 mA. Change the parameter . . . . . . . . . Touch the [ . . C13 ENT 000 Touch the [ENT] key to display the current set value. The . . ENT ENT 000 Touch the [ .
7. Startup 7.8 Checking Current Loop The set current can be output as an analog output. This enables the checking of wiring between the converter and the receiving instrument. Current loop checking is performed using parameter code G01. Table 7.7 Checking Current Loop . ENT . ENT . ENT . ENT > . ENT > ENT > > > > Description A01 G01 Display after the password has been entered. 00.0 Touch the [ENT] key. The output current remains preset with the output-hold feature (Section 2.3). 10.
7.9 Checking Contact I/O Conduct a contact input and output check as well as an operation check of the solenoid valves for the optional automatic calibration unit. Table 7.
7. Startup 7.9.1 Contact Output Check Follow Table 7.9 to check the contact output. The table uses an example with contact output 1. Table 7.9 Checking Contact Output > The symbol [ . > . > . > . ENT ENT ENT ENT ENT G11 Touch the [ENT] key once again to switch to the parameter code selection display. The contact then returns to the original state. ENT Basic panel display Touch the [>] key together with the [ENT] key to return to the basic panel display.
7.9.2 Checking Calibration Contact Output The calibration contacts are used for the solenoid valve drive signals for the Automatic Calibration Unit. This output signal enables you to check the equipment operation. Check the flowmeter gas flow for that operation. Follow the steps in Table 7.10. The table uses an example with a zero-gas solenoid valve. Table 7.10 Checking Calibration Contact Output > The symbol [ 7-18 Touch the [ ] key to enter 5. . > G15 .
7. Startup 7.9.3 Checking Input Contacts Follow Table 7.11 to check the input contacts. The table uses an example with input contact 1. Table 7.11 Checking Input Contacts . ENT > . ENT > . ENT > . ENT > ENT Description A01 G01 Display after the password has been entered. G01 Touch the [>] key to move the position of the digit that is flashing to the right one digit. G21 Touch the [ ] key to enter 2. 0 G21 Touch the [ ] key to switch to Group G. . > > Display . . ENT .
7.10 Calibration The converter is calibrated in such a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases. There are three types of calibration procedures available: (1) Manual calibration conducting zero and span calibrations, or either of these calibrations in turn.
7. Startup Table 7.13 Calibration Setup Procedure . > . > . > . 001.00 % Touch the [>] key to move the position of the digit that is flashing to 1. ENT 000.00 % Touch the [ ] key to change to 0. ENT 000.00 % Touch the [>] key to move the position of the digit that is flashing to the right one digit. ENT 000.90 % Touch the [ ] key to change the numeric value to 9. ENT 000.90 % Touch the [>] key to move the position of the digit that is flashing to the right one digit. ENT 000.
7.10.2 Manual Calibration The following describes how to perform a calibration. 7.10.2.1 7-22 Preliminary Before performing a manual calibration, be sure that the ZA8F Flow Setting Unit zerogas flow valve is fully closed. Open the zero-gas cylinder pressure regulator so that the secondary pressure equals measured gas plus approx. 50 kPa (or measured gas pressure plus approx. 150 kPa when a check valve is used, maximum pressure rating is 300 kPa.).
7. Startup 7.10.2.2 Performing Calibration This manual assumes that the instrument air is the same as the reference gas used for the span gas. Follow the steps below to conduct manual calibration. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it. Table 7.14 Performing Calibration Switch operation . . . ENT . ENT . ENT . ENT > .
Table 7.14 Performing Calibration (Continued) > . > . > ENT ENT . > Description ENT CALEnd Touch the [ENT] key again to get the measured value to agree with the zero-gas concentration. Close the zero-gas flow valve. Secure the valve lock nut for leakage during measurement. If the automatic calibration unit is connected, close the span—gas solenoid valve. "CALEND" flashes during the output hold time.
8. Detailed Data Setting 8. Detailed Data Setting 8.1 Current Output Setting This section describes setting of the analog output range. Table 8.1 shows the parameter codes for each setting item and set values. Table 8.1 Display Items Set item Current output Parameter code C01 Output mode C03 Min. oxygen concentration Max. oxygen concentration Min. humidity Max. humidity Min. mixing ratio Max.
8.1.1 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA Set the output items for oxygen concentration reading, humidity reading and mixing ratio corresponding to 4 mA and 20 mA.
8. Detailed Data Setting Humidity setting range The minimum humidity is set to 0% H2O or ranges from 26 to 100% H2O. The maximum humidity ranges from 25% to 100% H2O, and must be greater than 0.8 times plus 23 the humidity set for the minimum. Setting example 1 If the setting (for a 4 mA current) is 0% H2O, you must set the maximum (20 mA) point at more than 25% H2O. Setting example 2 If the setting (for a 4 mA current) is 26% H2O, you must set the maximum (20 mA) point at more than 44% H2O, (26 3 0.
“Mix ratio” setting range The minimum mix ratio is set to 0 kg/kg or ranges from 0.201 to 0.625 kg/kg. The maximum mix ratio setting ranges from 0.2 to 1.0 kg/kg, and must be greater than 1.3 times plus 0.187 the mix ratio set for the minimum. Setting example 1 If the setting (for a 4 mA current) is 0 kg/kg, you must set the maximum (20 mA) point at more than 0.2 kg/kg. Setting example 2 If the setting (for a 4 mA current) is 0.201 kg/kg, you must set the maximum (20 mA) point at more than 0.449 kg/kg, (0.
8. Detailed Data Setting 8.1.2 Entering Output Damping Constants If a measured value which is adversely affected by rapid changes in the process is used as the basis for control, frequent on-off actions of the output may result. To avoid this, the analyzer allows the setting of output damping constants ranging from 0 to 255 seconds. 8.1.3 Selection of Output Mode There are two output modes available: linear mode and logarithmic mode. Select the either mode for your desired analog output vs.
8.2 Output Hold Setting The “output hold” functions hold an analog output signal at a preset value during the equipment´s warm-up time or calibration or if an error arises. Table 8.3 shows the analog outputs that can be retained and the individual states. Table 8.3 Current Output Parameter Codes Equipment status During warm-up Output hold values available 4 mA 20 mA Without hold feature Retains output from just before occurrence Set value (2.4 to 21.
8. Detailed Data Setting > > > > > > > > > > > > > > > ENT ENT > > ENT ENT > > ENT ENT > > ENT ENT > > ENT ENT > > ENT ENT > > ENT > Switch operations ENT Display b10 CAL CAL SPAn Y 21.00 % OPEn/20.84 20.84 % ZEro Y 0.98 % Output hold time during calibration OPEn/0.89 0.89 % CALEnd b10 Measured-value display F8.1E.EPS Figure 8.
8.2.2 Preference Order of Output Hold Values The output hold value takes the following preference order: During error occurrence During calibration Preference order (high) During maintenance During warm-up 8.2.2E.siki For example, if the output current is set to 4 mA for “under maintenance”, and no output-hold output for during calibration is preset, the output is held at 4 mA during the “ under maintenance” display.
8. Detailed Data Setting 8.3 Alarm Setting The analyzer provides four alarms — high-high, high, low, and low-low alarms settable with measured values. The following sections describe the alarm operations and setting procedures for the oxygen concentration, humidity, and mixing ratio. 8.3.1 Alarm Values (1) High-high and high alarm values High-high alarms and high alarms are issued when they are set to be detected, and if the measured values exceed the preset values.
In the example in Figure 8.2, the high-limit alarm point is set to 7.5% H2O, the delayed time is set to five seconds, and hysteresis is set to 2% H2O. Alarm output actions in this figure are expressed as follows: (1) Although the measured value “A” has exceeded the high-limit alarm setpoint, “A” falls lower than the high-limit alarm setpoint before the preset delayed time of five seconds elapses. So, no alarm is issued.
8. Detailed Data Setting 8.3.3 Alarm Setting Procedure Set the alarm setpoints following Table 8.6 listing parameter codes. Table 8.
8.3.4 Default Values When the analyzer is delivered, or if data are initialized, the alarm set values are by default as shown in Table 8.7. Table 8.
8. Detailed Data Setting 8.4 Output Contact Setup 8.4.1 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. Output contact 1 enables the selection of an open or closed contact when the contact is "operated". For output contact 2, contact remains closed. The relay for output contact 1 is energized when its contacts are closed and vice versa.
8.4.2 Setting Output Contact Set the output contacts following Table 8.9. Table 8.
8. Detailed Data Setting 8.4.3 Default Values When the analyzer is delivered, or if data are initialized, output contacts are by default as shown in Table 8.10. Table 8.
8.5 Input Contact Settings The equipment input contacts execute set functions by accepting a remote contact signal. Table 8.11 shows the functions executed by a remote contact signal. Table 8.11 Input Contact Functions Set item Calibration-gas pressure decreased Measuring range change Calibration start Unburnt gas detection Function While the contact signal is on, neither semi-automatic nor automatic calibration is possible.
8. Detailed Data Setting 8.5.2 Default Values When the analyzer is delivered, or if data are initialized, both input setting are invalid, and operated when closed.
8.6 Input Contact Settings 8.6.1 Setting Input Contact The following describe how to set the date-and-time. Automatic calibration works following this setting. Use parameter code “F10” to set the date-and-time. Table 8.13 Data-and-time Settings Switch operations ` ` ENT > ` ENT > ` > Display Brief description F10 00.01.01 Select the parameter code "F10." ENT 00.01.01 Touch the [>] to move the position of the digit that is flashing to the right. ` ENT 00.06.
8. Detailed Data Setting 8.6.2 Setting Periods over which Maximum and Minimum Values Are Monitored and Average Values are Calculated. The equipment enables the display of oxygen concentration average values and maximum and minimum values under measurement (see Section 10.1, later in this manual). The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored. 8.6.2.
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.
9. Calibration 9. Calibration The following describes the calibration procedures for the ZR202G Zirconia Hightemperature Humidity Analyzer (integrated model). 9.1 Calibration Briefs 9.1.1 Measurement Principle of Zirconia Humidity Analyzer A solid electrolyte such as zirconia allows the conduction of oxygen ions at high temperatures.
Comparison water vapor Sample gas x% H2O 79% 100% 1 H O 2 concentration indicator 2 Electrode Air 100% Water vapor 100% Zirconia element N2 O2 y% 21% Sample-gas composition F9.1.EPS Figure 9.1 Schematic Diagram of Measurement Principle (B) For the “mixing ratio” measurement Assuming that the mixing ratio is r kg/kg, then “r” can be calculated from the value of H2O vol% as follows: r = 0.
9. Calibration Oxygen concentration vs, Humidity, Mixing ratio 100 1.0 90 0.9 Humidity, vol % H2O 0.7 60 0.6 50 0.5 40 0.4 30 0.3 20 0.2 10 0.1 0 0 9.1.2 0.8 1 2 3 4 5 6 kg/kg Mixing ratio, kg/kg Mixing ratio Humidity, vol % H2O 80 70 0.0 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Oxygen concentration, vol % O2 FBE.EPS Calibration Gas A gas with a known oxygen concentration is used for 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. Calibration 9.1.4 Characteristic Data from a Sensor Measured During Calibration During calibration, calibration data and sensor status data (listed below) are acquired. However, if the calibration is not properly conducted (an error occurs in automatic or semi-automatic calibration), these data are not collected in the current calibration. These data can be observed using parameter codes A20 to A22, and A50 to A79. For an explanation and the operating procedures of individual data, consult Section 10.
9.2 Calibration Procedures CAUTION Calibration should be made under normal operating conditions (if the probe is connected to a dryer, the analyzer will undergo calibration under the operating conditions of the dryer). To make a precise calibration, conduct both zero-point and span calibrations. 9.2.1 Calibration Setting The following sets forth the required calibration settings: 9.2.1.
9. Calibration CAUTION (1) When instrument air is used for the span calibration, remove the moisture from the instrument air at a dew-point temperature of -208C and also remove any oily mist and dust from that air. (2) If dehumidifying is not enough, or if foul air is used, the measurement accuracy will be adversely affected. 9.2.1.5Calibration Time • When the calibration mode is in manual: First set the output stabilization time.
9.2.1.6Setting When setting calibration timing requirements, bear the following precautions in mind: CAUTION (1) If the calibration interval is shorter than the sum of stabilization time plus calibration time, the second calibration start time will conflict with the first calibration. In such a case, the second calibration will not be conducted. (When both zero and span calibrations are to be performed, the calibration time is double that required for a single (zero or span) calibration.
9. Calibration 9.2.2 Calibration 9.2.2.1Manual Calibration For manual calibration, consult Section 7.10, “Calibration”, earlier in this manual. 9.2.2.2Semi-automatic Calibration (1) Calibration startup using infrared switches Table 9.3 Semi-automatic Calibration Procedure > . > . > . > SA-CAL ENT ENT . > b11 ENT ENT . > Display ENT CALEnd . Switch operation ENT Basic panel display Brief description Change the parameter code to B11.
10. Other Functions 10. Other Functions 10.1 Detailed Display Select the desired parameter code to display the detailed operation data (see Table 10.1, “Parameter Codes for Detailed Operation Data.
Table 10.
10. Other Functions 10.1.1 Oxygen Concentration The oxygen concentration in the process gas is displayed (consult Section 9.1.1, earlier in this manual). 10.1.2 Humidity The moisture content contained in air is displayed where the process gas contains water vapors and air (refer to Section 9.1.1, earlier in this manual). 10.1.3 Mixing Ratio Where the process gas contains water vapors and air, their mixing ratio is displayed (refer to Section 9.1.1, earlier in this manual). 10.1.
10.1.6 Cell Temperature The cell temperature can be obtained from the thermoelectromotive force and cold junction temperature; normally 7508C is displayed. 10.1.7 Process Gas Temperature A process gas temperature set with parameter code F13 is displayed. 10.1.8 Cold Junction Temperature This is the internal (where the electronics is installed) temperature of equipment, which compensates for the cold junction temperature for a thermocouple measuring the cell temperature.
10. Other Functions 10.1.12 Current Output The analog output current is displayed. 10.1.13 Response Time The cell’s response time is obtained in the procedure shown in Figure 10.1. If only either a zero-point or span calibration has been carried out, the response time will not be measured just as it will not be measured in manual calibration.
10.1.15 Robustness of a Cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed as one of four time periods during which the cell may still be used: (1) more than a year (2) more than six months (3) more than three months (4) less than one month The above four time periods are tentative and only used for preventive maintenance, not for warranty of the performance.
10. Other Functions 10.1.20 Average Oxygen Concentration, and Mixing Ratio The average oxygen concentration during the periods over which average values are calculated is displayed. If the setup period elapses, the average oxygen concentration that has been displayed so far will be cleared and a new average oxygen concentration will be displayed. If the setup period of time is changed, the current average oxygen concentration will be displayed (for more details, see Section 8.6.2 earlier in this manual).
10.2 Operational Data Initialization Individual set data initialization enables you to return to the default values set at the time of delivery. There are two types of initializations: an all set-data initialization and a parameter-code-based initialization. Table 10.7 lists the initialization items by a parameter code, and default values. Table 10.
10. Other Functions 10.3 Initialization Procedure Follow the table below to initialize parameters. The password for initialization is 1255. Table 10.5 Initialization Procedure Switch operation Display Description > ` ENT F30 Enter the parameter code for the item to be initialized. The following show an example of entering "F30." (Previous needed operations are omitted.) > ` ENT 0000 Touch the [ENT] key to switch to the password entry display.
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. Other Functions Table 10.6 Resetting Switch operation . ` ENT Display Err-01 /------ Brief description If an error occurs, the error number and "------" are displayed alternately, as given on the left. . ` ENT PASSno . ` ENT 0000 Touch the [ENT] key again to switch to the password entry display. . ` ENT 1000 Enter the password 1102. Hold down the [ENT] key for at least three seconds. Intermediate switch operations omitted. . ` ENT 1102 . ` ENT A01 . ` ENT G01 .
Note • Parameters of blank item are not used for High Temperature Humidity Analyzer. Table 10.7 Parameter Codes Display-related Items in Group A Parameter Item Engineering unit Code Item Engineering unit Selection of display items 0: Oxygen concentration A50 Span-gas ratio 0 % 1: Oxygen analyzer (0.0) A51 Span-gas ratio 1 % 2: Oxygen analyzer (0.
10. Other Functions Calibration-related Items in Group B Code Item Tuning Engineering unit Default setting B01 Zero-gas concentration 0.3 to 100 % O2 1% O2 B02 Span-gas concentration 4.5 to 100 % O2 21% O2 B03 Calibration mode 0: Manual calibration Manual calibration 1: Semi-automatic and manual calibration 2: Automatic, semi-automatic, and manual calibration B04 Output stabilization time B05 Calibration time 0 minutes, 0 seconds to 60 minutes, 59 seconds MM.
Output-related Items in Group C Code Item Tuning Engineering Default setting unit C01 Analog output 0: Oxygen concentration Humidity 1: Humidity 2: Mixed ratio C03 Output mode 0: Linear Linear 1: Logarithm C04 Output during warm-up up 0: Held at 4 mA 1: Held at 20 mA Output during 2: Set value remains held. 0: Not held Held at 4 mA. C05 maintenance 1: Held output just before maintenance service. Held output just before maintenance service.
10.
Contact-related Items in Group E Code Item Tuning Engineering Default setting unit E01 Selection of input contact 1 0: Invalid Invalid 1: Calibration gas pressure drop 2: Measurement range change 3: Calibration start 4: Detection of non-combusted gas E02 Selection of input contact 2 0: Invalid Invalid 1: Calibration gas pressure drop 2: Measurement range change 3: Calibration start 4: Detection of non-combusted gas E03 Selecting action of input contact 1 0: Action with closed contact Action
10. Other Functions Equipment Setup and Others in Group F Code Item Tuning F01 Equipment setup 0: Oxygen analyzer 1: Humidity analyzer Not initialized F02 F04 Selection of temperature units degree C F05 Selection of pressure units F08 Selection of display items 0: degree C 1: degree F 0: kPa 1: psi 0: Oxygen concentration 1: Humidity 2: Mixed ratio 3: Item selected with analog output F10 Date F11 Period over which average values are calculated Period over which max. and min.
Inspection-related Items in Group G Code Item Tuning G01 G11 mA-output loop Output contact 1 G12 Output contact 2 G15 Automatic calibration solenoid valve (zero) Automatic calibration solenoid valve (span) Input1 contact 4 to 20 0: Open 1: Closed 0: Open 1: Closed 0: Off 1: On 0: Off 1: On 0: Open 1: Closed 0: Open 1: Closed G16 G21 G22 Input2 contact G30 Reset Engineering Default unit setting mA 4 mA Open Open Off Off T10.6G.
10. Other Functions 10.5 Handling of the ZO21S Standard Gas Unit The following describe how to flow zero and span gases using the ZO21S Standard Gas Unit. Operate the ZO21S Standard Gas Unit, for calibrating a system classified as System 1, according to the procedures that follow. 10.5.1 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 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 358 C). The operating details and handling precautions are also printed on the product. Please read them beforehand. To install the gas cylinder, follow these steps: (1) Attach the zero gas valves onto the gas cylinder.
10. Other Functions 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 7.10.2, earlier in this manual. For operation of the converter, see Section 7.10.2.
(1) Fully close the needle valve mounted on the calibration gas inlet of the detector. (2) Remove the tube connecting the detector to the standard gas unit. WARNING 10-22 Store the standard gas unit with the gas cylinder mounted where the ambient temperature does not exceed 408 C. Otherwise, the gas cylinder may explode. Store the spare gas cylinders under the same condition.
10. Other Functions 10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F Flow Setting Unit is used as the calibration equipment for a system conforming to System 2. Calibration in such a system is to be manually operated. So, you have to operate the valve of the Flow Setting each time calibration is made (starting and stopping the calibration gas flow and adjusting the flow rate). This applies even if you are using the ZR20H Auto Calibration Unit. 10.6.
(3) Close the span gas flow setting valve to stop the span gas (air) flow. If the valve shaft has a lock nut, be sure to tighten the lock nut to prevent any leakage of span gas into the sensor during measurement. 10.6.
11. Inspection and Maintenance 11. Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxtZR Zirconia High-temperature Humidity Analyzer (integrated model) to maintain its measuring performance and normal operating 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.
11.1 Inspection and Maintenance of the Detector 11.1.1 Cleaning the Calibration Gas Tube The calibration gas, supplied through the calibration gas inlet of the terminal box into the detector, flows through the tube and comes out at the tip of the probe. The tube might become clogged with dust from the measurement gas. If you become aware of clogging, such as when a higher pressure is required to achieve a specified flow rate, clean the calibration gas tube.
11. Inspection and Maintenance 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 100630 % or a span-gas ratio of 0618 %. In addition, the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement.
3. Part assembly procedure (1) First, install the contact. Being careful not to cause irregularities in the pitch of the coil spirals (i.e., not to bend the coil out of shape), place it in the ringed groove properly so that it forms a solid contact. Groove in which the contact (E7042BS) is placed F11.2E.EPS Figure 11.2 Installing the Contact (2) Next, make sure that the O-ring groove on the flange surface of the sensor is clean.
11. Inspection and Maintenance Metal O-ring Sensor U-shaped pipe support Bolts (four) Contact Probe Screw Filter U-shaped pipe Washers (four) 1/8 turn — tighten bolts 1/8 turn (approximately 458) each F11.3E.EPS Figure 11.3 Exploded View of Sensor Assembly CAUTION Optional Inconel bolts have a high coefficient of expansion. If excess torque is applied while the bolts are being tightened, abnormal strain or bolt breakage may result. So, tighten the bolts following the instructions given above. 11.1.
16 A 11 10 14 12 A 13 15 24 8 9 24 7 5 4 3 6 2 24 23 View A-A 18 17 19 25 13 22 14 20 21 F11.4E.EPS Figure 11.
11. Inspection and Maintenance Replacement of heater strut assembly 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. Remove the two screws (15) that tighten the cover (12) and slide it to the flange side. Remove the four bolts (10) to remove the converter (16). Then remove the three connectors to which leadwire from the heater and thermocouple is connected.
11.1.5 Stopping and Re-starting Operation When operation is stopped, take care of the followings so that the sensor of the detector cannot become unused. CAUTION When operating an instrument such as boiler or industrial furnace is stopped with the zirconia oxygen analyzer operation, moisture can condensate on the sensor portion and dusts may stick to it. If operation is restarted in this condition, the sensor which is heated up to 7508 C firmly fix the dusts on itself.
11. Inspection and Maintenance 11.2 Inspection and Maintenance of the Converter The converter does not require routine inspection and maintenance. If the converter does not work properly, in most cases it probably comes from problems or other causes. 11.2.1 Replacing Fuses This equipment incorporates a fuse. If the fuse blows out, turn off the equipment power and replace it in the following procedure. CAUTION If a replaced fuse blows out immediately, there may be a problem in the circuit.
(7) To restore the electronics, reverse the above removal procedures. When restoring the electronics, do not get leadwire jammed in any part of the unit. (8) Place the electronics and the printed-circuit board on which the fuse is installed properly; these are directly connected with connectors. (9) Tighten the four screws in their positions. (10) Replace and tighten the display cover properly. If the cover is not tightened sufficiently, the infrared switches will not operate correctly.
11. Inspection and Maintenance 11.3 Replacement of Flowmeter for ZR20H Autocalibration Unit (1) Remove pipe holding piping connection. (2) Remove bolts holding flowmeter, and replace it. A white back plate (to make the float easy to see) is attached. The end of the pin holding down the back plate must be on the bracket side. (3) Replace piping, and fix M6 bolts between brackets. *1 *1 : When disassembling and reassembling, mark original positions, and tighten an extra 5-108 when reassembling.
12. Troubleshooting 12. Troubleshooting This chapter describes errors and alarms detected by the self-diagnostic function of the converter. This chapter also describes the check and restoration methods to use when problems other than the above occur. 12.1 Displays and Measures to Take When Errors Occur 12.1.1 What is an Error? An error is detected if any abnormality is generated in the detector or the converter, e.g.
12.1.2 Measures to Take When an Error Occurs 12.1.2.1 Error-1: Cell Voltage Failure Error-1 occurs when the cell (sensor) voltage input to the converter falls below -50 mV (corresponding to about 200% O2). The following are considered to be the causes for the cell voltage falling below -50 mV: (1) Continuity failure between the sensor assembly electrode and the contact (2) Damage or deterioration of the sensor assembly (3) Improper connection between the sensor and the electronics.
12. Troubleshooting (3) Next, check the resistance of the thermocouple from the probe. Use a multimeter to measure the thermocouple resistance between terminal 3 (red cable connected) and terminal 4 (white cable connected) as indicated in Figure 12.3. The thermocouple is normal if the resistance is 5V or less. If the value is higher than 5V, the thermocouple wire may be broken or about to break. In this case, replace the heater unit (refer to Section 11.1.3, “Replacement of the Heater Unit”).
12.2 Displays and Measures to Take When Alarms are Generated 12.2.1 What is an Alarm? When an alarm occurs, the alarm indication blinks in the display to notify of the alarm (Figure 12.4). Pressing the alarm indication displays a description of the alarm. Alarms include those shown in Table 12.2. Displayed alternately AL-06 ↔ 0.0% F12.4E.EPS Figure 12.4 Table 12.
12. Troubleshooting (1) Confirm the following and carry out calibration again: If the items are not within their proper ranges, correct them. a. If the indication for “Zero gas conc.” is selected in “Calibration setup,” the set value should agree with the concentration of zero gas actually used. b. The calibration gas tubing should be constructed so that the zero gas does not leak.
12.2.2.3 Alarm 7: Span Calibration Coefficient Alarm In calibration, this alarm is generated when the span gas ratio is out of the range of 0 6 18% (refer to Section 9.1.3, “Compensation”). The following are suspected as the cause: (1) The oxygen concentration of the span gas does not agree with the value of the span gas set “Calibration setup.” (2) The flow of the span gas is out of the specified flow value (600 6 60 mL/min). (3) The sensor assembly is damaged and the cell voltage is abnormal.
12. Troubleshooting 12.2.2.5 Alarm 10: Cold Junction Temperature Alarm The equipment incorporates a temperature sensor. An alarm is issued when the sensor temperature exceeds 858 C. If internal temperature of this equipment exceeds 858 C, the electronics may fail. This equipment can be used at ambient temperatures up to 558 C.
Thermocouple YEL GRN RED WHT 1 2 3 4 Multimeter (V) F12.3E.EPS Figure 12.6 (4) If the inspection indicates that the thermocouple is normal, the electronics may be defective. Consult your local Yokogawa service or sales representative. 12.2.2.7 Alarm 13: Battery Low Alarm An internal battery is used as backup for the clock. After this alarm occurs, removing power from the instrument may cause the clock to stop but should not affect stored parameters.
12. Troubleshooting 12.3 Countermeasures When the Measured Value Shows Error The causes that the measured value shows an abnormal value is not always due to instrument failures. There are rather many cases where the causes are those that 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.
(4) The reference gas is mixing into the measuring gas and vice versa. When such mixing occurs, since the deference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller, the measured value shows a lower value. See Section 11.1.2 to check that the sensor has been properly installed. An error which does not indicate Error-1 may occur in the sensor.
12. Troubleshooting 12.3.3 Measurements Sometimes Show Abnormal Values (1) Noise may be mixing in with the converter from the detector output wiring. Check whether the converter and detector are securely grounded. Check whether or not the signal wiring is laid along other power cords. (2) The converter may be affected by noise from the power supply.
12-12 IM 11M12A01-05E
Customer Maintenance Parts List Model ZR202G Zirconia High Temperature Humidity Analyzer (Integrated type) A A 13 13 View A-A 2 7 6 5 3 4 9 10 11 8 12 Parts No. MS-code Qty.
Hood for ZR202G 1 ZR202G_F.eps CMPL 11M12A01-05E Item Parts No. Qty. Description 1 K9472UF 1 Hood All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. 5 th Edition : Jul.
Customer Maintenance Parts List Model ZR20H Integrated type Zirconia Oxygen Analyzer/ High Temperature Humidity Analyzer, Automatic Calibration Unit 4 5 SPAN IN REF IN ZERO IN 8 7 10PSI K9473XC Qty Description 1 Flowmeter All Rights Reserved, Copyright © 2001, Yokogawa Electric Corporation. Yokogawa Electric Corporation NUPRO Part No. 8 SS-2C2-10 Item CMPL 11M12A01-12E 1st Edition : Feb. 2001 (YK) 2nd Edition : Aug.
Customer Maintenance Parts List Model ZO21S Zirconia Oxygen Analyzer/ High Temperature Humidity Analyzer, Standard Gas Unit Item Part No. Qty 1 2 3 ! E7050BA E7050BJ 1 1 1 Description Pump (see Table 1) Zero Gas Cylinder (x6 pcs) Needle Valve Table 1 Power Pump AC 100V 110 115 E7050AU AC 200V 220 240 E7050AV © Copyright 2000(YK). 3rd Edition: Dec.
Revision Record Manual Title : Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Manual Number : IM 11M12A01-05E Edition Date Remark (s) 1st Nov. 2000 Newly published 2nd Mar. 2001 Revised Section 2.1.2 Some parts of MS Code changed, Sun shield hood external dimensions added; 2.2 ZA8F Flow setting unit style changed, adjusting pressure value changed when a check valve is used, ZR20H Autocalibration unit added; 3.3 Installation of ZR20H added; 4.
Edition 6th Date Remark (s) Sep. 2006 Revised Section 2.4.3 "Air Set," Part No. K9473XH or K9473XJ, Standard Specification: Changed descriptions partly; "Air Set,"Part No. G7004XF or K9473XG, Standard Specification: Changed descriptions partly; 2.4.5 "Cylinder Regulator Valve (Part No. G7013XF or G7014XF)", Standard Specifications; Changed descriptions partly and drawing; 4.4 "Piping for the Detector with Pressure Compensation": Deleted Section. 5.
