User’s Manual Model ZR202G Integrated type Zirconia Oxygen Analyzer IM 11M12A01-04E R IM 11M12A01-04E 7th Edition
Introduction The EXAxt ZR Integrated type Zirconia Oxygen Analyzer has been developed for combustion control in various industrial processes. There are several version of this analyzer so you can select one that matches your application. Optional accessories are also available to improve measurement accuracy and automate calibration. An optimal control system can be realized by adding appropriate options.
ii 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 3. Installation Installation method for each equipment 4. Piping Examples of piping in three standard system configurations 5.
iii For the safe use of this equipment WARNING EXAxt ZR is very heavy. Be sure not to accidentally drop it. Handle safely to avoid injury. Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment. In addition, confirm that the power is switched off when connecting power supply. Some process gas is dangerous to people.
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. The following safety symbols and wordings are used on the product as well as in this manual. (3) The following safety symbols are used in this manual. Throughout this user’s manual, you will find several different types of symbols are used to identify different sections of text.
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. message display → (Ex. data display → • Drawing for flashing Indicated by gray characters (Flashing) • Displays on the LCD display panel Alphanumerics LED Display Alphanumerics (Ex.
vi 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.
vii After-Sales Warranty Do not modify the product. During the warranty period, for repair under warranty carry or send the product to the local sales representative or service office. Yokogawa will replace or repair any damaged parts and return the product to you. Before returning a product for repair under warranty, provide us with the model name and serial number and a description of the problem. Any diagrams or data explaining the problem would also be appreciated.
viii IM 11M12A01-04E
Toc-1 Model ZR202G Integrated type Zirconia Oxygen Analyzer IM 11M12A01-04E 7th Edition CONTENTS Introduction...............................................................................................................i For the safe use of this equipment............................................................................... iii NOTICE............................................................................................................................
Toc-2 3. Installation.................................................................................................. 3-1 3.1 3.2 3.3 3.4 3.5 4. 4.2 Installation Location............................................................................ 3-1 3.1.2 Probe Insertion Hole........................................................................... 3-2 3.1.3 Installation of the Probe...................................................................... 3-2 3.1.
5.3 5.4 5.5 6. Wiring Power and Ground Terminals.............................................................. 5-4 5.3.1 Wiring for Power Line.......................................................................... 5-4 5.3.2 Wiring for Ground Terminals............................................................... 5-4 Wiring for Contact Output................................................................................. 5-5 5.4.1 Cable Specifications................................
Toc-4 8. Detailed Data Setting................................................................................ 8-1 8.1 Setting Display Item........................................................................................... 8-1 8.2 Current Output Setting...................................................................................... 8-1 8.3 8.4 8.5 8.6 8.7 9. Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum Oxygen Concentration ( at 20 mA)......................
10. Other Functions....................................................................................... 10-1 10.1 Detailed Display............................................................................................... 10-1 10.1.1 Air Ratio............................................................................................ 10-3 10.1.2 Cell Temperature............................................................................... 10-3 10.1.3 C. J. Temperature.............
Toc-6 11.2 Inspection and Maintenance of the Converter............................................. 11-8 11.2.1 11.3 12. Replacing Fuses............................................................................... 11-8 Replacement of Flowmeter for ZR20H Automatic Calibration Unit ........ 11-10 Troubleshooting...................................................................................... 12-1 12.1 12.2 Displays and Measures to Take When Errors Occur.............................
<1.Overview> 1. 1-1 Overview The EXAxt ZR Integrated type Zirconia Oxygen Analyzer is used to monitor and control the oxygen concentration in combustion gases, in boilers and industrial furnaces, for wide application in industries which consume considerable energy-such as steel, electric power, oil and petrochemical, ceramics, pulp and paper, food, or textiles, as well as incinerators and medium/small boilers. It can help conserve energy in these industries.
1-2 <1. Overview> CAUTION 1.1.2 • As this system uses ambient air for the reference gas, measuring accuracy will be affected by the installation location. • A stop valve should be connected to the calibration gas inlet of the equipment. 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 is a need to monitor and control oxygen concentration. The reference gas and calibration-time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder. System 3 uses the ZR20H automatic calibration unit, with auto-switching of the calibration gas. A “combustible gas detected” contact input turns off power to the heater.
1-4 <1. Overview> 1.2 1.2.
2. 2-1 <2. Specifications> Specifications This chapter describes the specifications for the following: 2.1 2.1.1 ZR202G General-use Integrated type Zirconia Oxygen Analyzer (See Section 2.1.2) ZO21R-L Probe Protector (See Section 2.1.3) ZA8F Flow Setting Unit (See Section 2.2.1) ZR20H Automatic Calibration Unit (See Section 2.2.2) ZO21S Standard Gas Unit (See Section 2.3) K9471UA Dust Filter for Oxygen Analyzer (See Section 2.
2-2 2.1.2 <2. Specifications> 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. (Measured after gas is introduced from calibration gas inlet and analog output starts changing.) ZR202G Integrated type Zirconia Oxygen Analyzer Can be operated in the field without opening the cover using optical switches.
2-3 <2. Specifications> Safety and EMC conforming standards Safety: EN61010-1, CSA C22.2 No.61010-1, UL61010-1 EMC: EN 61326 Class A, EN 55011 Class A Group 1, EN 61000-3-2, AS/NZS CISPR 11 KC Marking: Korea Electromagnetic Conformity Standard CAUTION This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this instrument in the industrial environment only.
2-4 <2. Specifications> Functions Display Function: Displays values of the measured oxygen concentration, etc. Alarm, Error Display: Displays alarms such as “AL-06” or errors such as “Err-01” when any such status occurs. Calibration Functions: Auto-calibration; Requires the Automatic Calibration Unit. It calibrates automatically at specified intervals. Semi-auto Calibration; Requires the Automatic Calibration Unit.
Converter Output: <2. Specifications> 2-5 One mA analog output point (4 to 20 mA DC (maximum load resistance of 550Ω)) with mA digital output point (HART) (minimum load resistance of 250Ω). Range; Any setting between 0 to 5 through 0 to 100 vol% O2 in 1 vol% O2, and partial range is available (Maximum range value/minimum range value 1.3 or more) For the log output, the minimum range value is fixed at 0.1 vol% O2. 4 to 20 mA DC linear or log can be selected. Input/output isolation.
2-6 <2. Specifications> Model and Codes Model Suffix code ZR202G -------------------------------------- ---------- Integrated type Zirconia Oxygen Analyzer Length -040 -070 -100 -150 -200 -250 -300 ---------------------------------------------------------------- 0.4 m 0.7 m 1.0 m 1.5 m 2.0 m 2.5 m 3.
2-7 <2. Specifications> • External Dimensions Model ZR202G Integrated type Zirconia Oxygen Analyzers L 338 to 351 t L= 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 (m) Unit: mm Ø123 Display side 125 48.5 25 Ø50.8 122 Rc1/4 or 1/4NPT Reference gas inlet 153 to 164 4-G1/2,2-1/2NPT etc.
2-8 <2. Specifications> Model ZR202G...-P Integrated type Zirconia Oxygen Analyzer with pressure compensation Unit: mm L 342 ± 4 t L= 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 (m) Ø123 Display side Reference gas outlet 125 48.5 25 Ø50.8 122 Rc1/4 or 1/4NPT Reference gas inlet PIPING :B 4-G1/2,2-1/2NPT etc.
2.1.3 2-9 <2. Specifications> ZO21R Probe Protector This probe protector is required for the general-use detector when it is used for oxygen concentration measurements in powdered coal boilers or in fluidized furnaces to prevent abrasion due to dust particles when gas flow exceeds 10 m/sec. When probe length of the ZR202G is 2.5 m or more and mounted horizontally, be sure to select a probe protector ZO21R-L-200-*B to support the probe. Insertion Length: 1.05 m, 1.55 m, 2.05 m.
2-10 <2. Specifications> 2.2 2.2.1 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit ZA8F Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration (System 2). This unit consists of a flowmeter and flow control valves to control the flow of calibration gas and reference gas. • Standard Specifications Flowmeter: Calibration gas; 0.1 to 1.0 l/min. Reference gas; 0.1 to 1.0 l/min.
2-11 <2. Specifications> • External Dimensions 180 ø6 Hole Unit : mm (inch) 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 REF OUT 70 AIR IN CHECK OUT SPAN IN ZERO IN 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.
2-12 2.2.2 <2. Specifications> 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)”.
<2. Specifications> 2-13 External Dimensions (1) Horizontal Mounting (-A) Unit: mm 243 258 Ø84 Ø80 AUTO CAL. UNIT SPAN IN REF IN ZERO IN MODEL SUFFIX ZR20H STYLE S1 SUPPLY AMB.TEMP 690kPa MAX. -20 TO 558C USED WITH ZR202G 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 Ø8 111 0 AUTO CAL.
2-14 <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.
2.4 2.4.1 2-15 <2. Specifications> Other Equipment Dust Filter for Oxygen Analyzer (part no. K9471UA) This filter is used to protect the detector sensor from corrosive dust components or from a high concentration of dust when the oxygen concentration in utility boilers or concrete kilns are to be measured. This filter requires the measuring gas flow of 1 m/sec or faster to replace gas inside zirconia sensor.
2-16 2.4.3 <2. Specifications> Stop Valve (part no. L9852CB or G7016XH) This valve is mounted on the calibration gas line in the system to allow for one-touch calibration. This is applied to a system configuration (System 1). • Standard Specification Connection: Rc 1/4 or 1/4 FNPT Material: SUS 316 (JIS) Weight: Approx. 80 g Part No. Description L9852CB Joint: Rc 1/4, Material: SUS316 (JIS) G7016XH Joint: 1/4 NPT, Material: SUS316 (JIS) Rc1/4 or 1/4NPT 40 2.4.
2.4.5 <2. Specifications> 2-17 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases. Standard Specifications • Part no. G7003XF or K9473XK Primary Pressure: Max. 1 MPa G Secondary Pressure: 0.02 to 0.2 MPa G Connection: Rc1/4 or 1/4FNPT with joint adapter Weight: Approx.1 kg Part No. Description G7003XF Joint: RC 1/4, Material: Zinc alloy K9473XK Joint: 1/4 FNPT, Material: Zinc alloy with adapter (SUS316) • Part. no.
2-18 2.4.6 <2. Specifications> Zero Gas Cylinder (part no. 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 remaining N2 (Note) Export of such high pressure filled gas cylinder to most countries is prohibited or restricted. 485 325 Unit : mm Weight : Approx. 6 kg ø140 2.4.7 F32.
2.4.8 <2. Specifications> 2-19 Case Assembly (E7044KF) for Calibration gas Cylinder 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 Weight: Approx. 10 kg (including gas cylinder) (Note) Export of such high pressure filled gas cylinder to most countries is prohibited or restricted.
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3-1 <3. Installation> 3. Installation This chapter describes installation of the following equipment: 3.1 Model ZR202G Integrated type Zirconia Oxygen Analyzer 3.2 Model ZA8F Flow Setting Unit 3.3 Model ZR20H Automatic Calibration Unit 3.4 Case Assembly (E7044KF) for Calibration gas Cylinder 3.1 3.1.
3-2 3.1.2 <3. Installation> Probe Insertion Hole CAUTION • The outside dimension of detector may vary depending on its options. Use a pipe that is large enough for the detector. Refer to Figure 3.1 for the dimensions. If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards. • When using the detector with pressure compensation, ensure that the flange gasket does not block the reference gas outlet on the detector flange.
3-3 <3. Installation> The following should be taken into consideration when mounting the general-use detector: (1) Make sure that the cell mounting screws (four bolts) at the probe tip are not loose. If a dust filter (see Section 2.4.1) is used, make sure it is properly attached to the detector. Refer to Section 3.1.4 for installation of the dust filter. (2) Where the detector is mounted horizontally, the calibration gas inlet and the reference gas inlet should face downward.
3-4 <3. Installation> < Procedures for installing the dust guard protector (K9471UC)> The ZR202G is shipped with the dust guard protector when the option code /F2 is specified in case of ordering the detector. The protector should be used when preventing dusts and water drops from lowering the detector performance is desired. Screw the protector on the top of the detector so as to cover the top.
3-5 <3. Installation> The detector is used with a probe protector to prevent the sensor from being worn by dust particles when there is a high concentration of dust and gas flow exceeds 10 m/sec (fine-carbon boiler or fluidbed furnace). (1) Put the gasket that is provided by user between the flanges, and mount the probe protector in the probe insertion hole.
3-6 <3. Installation> 3.2.2 Mounting of ZA8F Flow Setting Unit The flow setting unit can be mounted either on a pipe (nominal JIS 50 A) or on a wall. It should be positioned vertically so that the flowmeter works correctly. (1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting the flow setting unit. (The unit weighs approximately 2 to 3.5 kg.
3-7 <3. Installation> (2) Mount the flow setting unit. Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit securely on the wall with four screws. F3.14E.ai Figure 3.14 3.3 3.3.1 Wall mounting Installation of ZR20H Automatic Calibration Unit Installation Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector and the converter (3) No corrosive gas.
3-8 <3. Installation> Unit: mm Horizontal mounting on the ZR202G (-A) 214 44 MAX Terminal box side 243 258 Display side 40 40 Zero gas inlet Rc1/4 or 1/4NPT(Female) 66.5 166.5 Reference gas 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 gas inlet Rc1/4 or 1/4NPT(Female) 40 40 66.5 Zero gas inlet Rc1/4 or 1/4NPT(Female) F3.15E.ai Figure 3.
3.4 3-9 <3. Installation> Installation of the Case Assembly (E7044KF) for Calibration Gas Cylinder The case assembly is used to store the G7001ZC zero gas cylinders. 3.4.1 Installation Location The following should be taken into consideration: (1) Easy access for cylinder replacement (2) Easy access for checking (3) Near to the detector and converter as well as the flow setting unit. (4) The temperature of the case should not exceed 40°C due to rays of the sun or radiated heat. (5) No vibration 3.
3-10 <3. Installation> 3.5 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.
4-1 <4. Piping> 4. Piping This chapter describes piping procedures in the three typical system configurations for EXAxt ZR Integrated type Zirconia Oxygen Analyzer. • Ensure that each check valve, stop valve and joints used for piping are not leaking. Especially, when there is any leakage at piping and joints for the calibration gas, it may cause clogging of the piping or incorrect calibration. • Be sure to conduct leakage test after setting the piping.
4-2 <4. Piping> 4.1.1 Piping Parts for System 1 Check that the parts listed in Table 4.1 are provided. Table 4.1 Piping Parts Equipment Piping location Oxygen Analyzer Calibration gas inlet Reference gas inlet Parts Name Description Stop valve (L9852CB or G7016XH) recommended by YOKOGAWA Nipple * Rc1/4 or 1/4 NPT General parts Joint for tube connection Rc1/4 (1/4NPT) for a 6x4mm soft tube General parts (Sealed up) (when piping is required, refer to Section 4.1.
4.2 4-3 <4. Piping> Piping for System 2 Piping in System 2 is illustrated in Figure 4.7. ZR202G Integrated type Zirconia Oxygen Analyzer Stop valve or Check valve ~ Reference gas 100 to 240 V AC Contact input Analog output, contact output Digital output (HART) Flowmeter Needle valve Air Set Calibration gas Instrument air Span gas(Same as Zero gas calibration) ZA8F flow setting unit Pressure regulator Zero gas cylinder Calibration gas unit case F1.2E.ai Figure 4.
4-4 <4. Piping> Piping for the reference gas 6mm (O.D.) by 4mm (I.D.) stainless steel pipe Piping for the calibration gas 6mm (O.D.) by 4mm (I.D.) stainless steel pipe Stop valve or check valve F4.8E.ai Figure 4.8 4.2.3 Piping for the Calibration Gas Inlet Piping for the Reference Gas Reference gas piping is required between the air source (instrument air) and the flow setting unit, and between the flow setting unit and the analyzer.
4-5 <4. Piping> • Installation of ZR20H Automatic Calibration Unit Unit: mm Horizontal mounting on the ZR202G (-A) 214 Terminal box side 243 258 Display side 44 MAX 40 40 Zero gas inlet Rc1/4 or 1/4NPT(Female) 66.5 166.5 Reference gas 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 gas inlet Rc1/4 or 1/4NPT(Female) 40 40 66.
4-6 <4. Piping> 4.4 Piping for the Oxygen Analyzer with Pressure Compensation ZR202G-----P Oxygen Analyzer with pressure compensation may be used in System 2 and System 3. Use this style analyzer whenever the furnace pressure exceeds 5 kPa (see Note). Even if the furnace pressure is high, the detector can measure by adjusting pressure of the probe with the furnace pressure using instrument air.
4-7 <4. Piping> 4. Set the instrument air pressure higher than furnace internal pressure. 5. Completely open the stop valve in front of the reference gas outlet and, after turning on instrument air flow, start furnace operation. As furnace internal pressure rises, confirm that instrument air continues to flow and adjust the valve or increase supply pressure if necessary. 6. After furnace internal pressure stabilizes, adjust flow. 7.
4-8 4.4.1 <4. Piping> Piping Parts for Oxygen Analyzer with Pressure Compensation Check that the parts listed in Table 4.3 are provided. Table 4.
5-1 <5. Wiring> 5. Wiring This chapter describes wiring procedures necessary for the EXAxt ZR Integrated type Zirconia Oxygen Analyzer. 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 a performance suit for CE marking is necessary, the following wiring procedure is necessary. 1.
5-2 5.1.1 <5. Wiring> Terminals for the External Wiring Remove the terminal cover on the opposite side of the display to gain access to the external wiring terminals. DI DI 1 2 C DO 1 FG + AO – L DO 2 N G FG F5101.ai Figure 5.1 5.1.2 Terminals for External Wiring Wiring Make the following wiring for the equipment. It requires a maximum of four wiring connections as shown below.
5.1.3 5-3 <5. Wiring> 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 gas inlet Cable gland Rc1/4 or 1/4NPT Calibration gas inlet 4-G1/2,2-1/2NPT etc. Cable connection port Figure 5.3 5.2 F5.3E.ai Cable Gland Mounting Wiring for Analog Output This wiring is for transmitting 4 to 20mA DC output signals to a device, e.g. recorder.
5-4 <5. Wiring> 5.3 Wiring Power and Ground Terminals Wiring for supplying power to the analyzer and grounding the equipment. Ground DI DI 1 2 Grounding to the earth terminal on the equipment case Equipment case Grounding terminal FG + AO- Lock washer Crimp contact of the grounding line 5.3.1 DO 1 L N DO 2 G FG Jumper plate ~ 100~240VAC 50/60Hz Figure 5.5 C F5.5E.ai Power and Grounding Wiring Wiring for Power Line Connect the power wiring to the L and N terminals of the equipment.
5.4 5-5 <5. Wiring> Wiring for Contact Output The equipment can output a maximum of two contact signals. These contact outputs can be used for different applications such as a low alarm or high alarm. Do the contact output wiring according to the following requirements. Analyzer Terminal box Annunciator or the like DO-1 DO-1 #1 Output DO-2 DO-2 #2 Output F5.6E.ai Figure 5.6 5.4.1 Contact Output Wiring Cable Specifications The number of cores varies depending on the number of contacts used.
5-6 5.5.2 <5. Wiring> Wiring Procedure (1) M4 screws are used for the terminal of the converter. Each cable should be equipped with the corresponding crimp contact. (2) The ON/OFF level of this contact input is identified by the resistance. Connect a contact input that satisfies the descriptions in Table 5.2. Table 5.
6-1 <6. Components> 6. Components This chapter describes the names and functions of components for the major equipment of the EXAxt ZR Integrated type Zirconia Oxygen Analyzer. 6.1 6.1.1 ZR202G Zirconia Oxygen Analyzer Integrated type Zirconia Oxygen 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 <6. Components> 6.2 ZA8F Flow Setting Unit, 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 Figure 6.2 F6-4E.
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. 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.ai Figure 7.
7-2 <7. Startup> 7.1 Checking Piping and Wiring Connections Refer to Chapters 4 and 5, earlier in this manual, for piping and wiring confirmations. 7.2 Valve Setup Set up valves and associated components used in the analyzer system in the following procedures: (1) If a stop valve is used in the detector’s calibration gas inlet, fully close this valve. (2) If instrument air is used as the reference gas, adjust the Air set secondary pressure so that the air pressure of sample gas pressure plus approx.
7.4.1 Operation of Infrared Switch 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. 4: Decimal point 1: Data display area µMmNkgalbbl % scftm3 /d /s /h /m > > 7.4 7-3 <7. Startup> ENT 3: Engineering-unit display area 2: Infrared switch Figure 7.3 F7.3E.ai Infrared switch and the display 1.
7-4 <7. Startup> 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.
Table 7.2 Display Functions Display Basic panel Function and item to be set Displays the oxygen concentration in normal operation, or displays the detector heater temperature while warming up. If an error or alarm arises, the corresponding error or alarm number appears. Enters the password for the parameter code selection display. Displays detailed data, such as the cell voltage or temperature. Sets and performs calibration. Sets analog output. Sets an alarm. Sets the input and output contacts.
7-6 7.4.4 <7. Startup> Selecting Parameter Codes > Switch operation ∧ > ∧ > ∧ > ∧ ENT ENT ENT ENT Display A01 A01 A01 A01 Description Password has been entered and the parameter code selection display has appeared. Character A is flashing, indicating that character A can be changed. If you touch the [>] key once, the position of the digit that is flashing will move to the right. This allows you to change 0.
7-7 <7. Startup> (2) Entering numeric values such as oxygen concentration values and factors > > Switch operation ∧ ∧ ENT ENT Display Description 00.0 The set value is displayed after the parameter code selection. 00.0 Touch the [>] key to move the position of the digit that is flashing to the digit to be An example of entering "9.8" is given below. (The currently set value is 0.0) changed. Continuously touch the [>] key, and the position of the digit that is flashing will > ∧ ENT 09.
7-8 <7. Startup> 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.
7.6 7-9 <7. Startup> Selection of Measurement Gas Combustion gases contain moisture created by burning hydrogen in the fuel. If this moisture is removed, the oxygen concentration might be higher than before. You can select whether the oxygen concentration in a wet gas is to be measured directly, or compensated for its dry-gas value before use. Use the parameter code「F02」to set the measurement gas. For details on the parameter code, see Table 10.7, later in this manual. Table 7.
7-10 <7. Startup> Table 7.5 > Minimum and Maximum Value Setting Procedure Switch operation > Display Description ∧ ENT A01 Display after the password has been entered. ∧ ENT C01 Set the oxygen concentration at 4 mA. Change the parameter code to C11. Touch the [∧] key to switch to Group C. > ∧ ENT C01 Touch the [>] key to move the position of the digit that is flashing to the right. > ∧ ENT C11 Touch the [∧] key to enter the numeric value 1.
7.8 7-11 <7. Startup> Checking Current Loop The set current can be output as an analog output. This enables the checking of wiring between the converter and the receiving instrument. Current loop checking is performed using parameter code 「G01」. Table 7.6 > Checking Current Loop Switch operation Description ENT A01 Display after the password has been entered. > ∧ ENT G01 Touch the [∧] key to switch to Group G. > ∧ ENT 00.0 Touch the [ENT] key.
7-12 <7. Startup> 7.9.1 Contact Output Check Follow Table 7.8 to check the contact output. The table uses an example with contact output 1. Table 7.8 > Checking Contact Output Switch operation Display Description ∧ ENT A01 Display after the password has been entered. > ∧ ENT G01 Touch the [∧] key to switch to Group G. > ∧ ENT G01 Touch the [>] key to move the position of the digit that is flashing to the right one G11 Touch the [∧] key to enter 1. digit.
7.9.2 <7. Startup> 7-13 Checking Calibration Contact Output The calibration contacts are used for the solenoid valve drive signals for the Automatic Calibration Unit. This output signal enables you to check the equipment operation. Check the flowmeter gas flow for that operation. Follow the steps in Table 7.9. The table uses an example with a zero gas solenoid valve. Table 7.
7-14 7.9.3 <7. Startup> Checking Input Contacts Follow Table 7.10 to check the input contacts. The table uses an example with input contact 1. Table 7.10 > Checking Input Contacts Switch operation Display Description ∧ ENT A01 Display after the password has been entered. > ∧ ENT G01 Touch the [∧] key to switch to Group G. > ∧ ENT G01 Touch the [>] key to move the position of the digit that is flashing to the right one Touch the [∧] key to enter 2. > ∧ ENT G21 > ∧ ENT 0 digit.
7-15 <7. Startup> 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.
7-16 <7. Startup> Table 7.12 > Calibration Setup Procedure Switch operation > Display Description ∧ ENT A01 Display after the password has been entered. ∧ ENT b01 Set the zero gas concentration. Switch the parameter code to B01. Here, set 0.98%. > ∧ ENT 001.00 % Touch the [ENT] key to display the currently set value. > ∧ ENT 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.
7-17 <7. Startup> 7.10.2 Manual Calibration The following describes how to conduct a calibration. 7.10.2.1 Preliminary Before conducting a manual calibration, be sure that the ZA8F Flow Setting Unit zero gas flow valve is fully closed. Open the zero gas cylinder pressure regulator so that the secondary pressure will be a sample gas plus approx. 50 kPa (or sample gas pressure plus approx. 150 kPa when a check valve is used, maximum pressure rating is 300 kPa). 7.10.2.
7-18 <7. Startup> Table 7.13 > Conducting Calibration (Continued) Switch operation ∧ ENT Display ZEro Y Description If you touch the [ENT] key again, the flashing stops and "ZEro Y" appears. Close the span gas flow valve. Secure the span gas lock nut for leakage. If the automatic calibration unit is connected, close the span gas solenoid valve. If zero gas calibration is omitted, touch the [>] key to change "Y" to "N". > ∧ ENT 0.
<8. Detailed Data Setting> 8. Detailed Data Setting 8.1 Setting Display Item 8-1 Display items are defined as items displayed on the basic panel display. Parameter code「A00」or「F08」is used to set the display items as shown in Table 8.1. The oxygen concentration is set at the factory before shipment. In addition, if the data initialization is performed, the oxygen concentration will be set. Table 8.
8-2 <8. Detailed Data Setting> 8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum Oxygen Concentration ( at 20 mA) Set the oxygen concentration values at 4 mA and 20 mA. The minimum concentration of oxygen for the minimum current (4 mA) is 0% O2 or 6% to 76% O2. The maximum concentration of oxygen for the maximum current (20 mA) ranges from 5% to 100% O2, and must be greater than 1.3 times the concentration of oxygen set for the minimum.
8-3 <8. Detailed Data Setting> 8.3 Output Hold Setting The “output hold” functions retain an analog output signal at a preset value during the equipment’s warm-up time or calibration or if an error arises. Table 8.4 shows the analog outputs that can be retained and the individual states. Table 8.
8-4 <8. Detailed Data Setting> > Switch operation Display ∧ ENT b10 > ∧ ENT CAL > ∧ ENT CAL > ∧ ENT SPAn Y > ∧ ENT 21.00 % > ∧ ENT > ∧ ENT 20.84 % > ∧ ENT ZEro Y > ∧ ENT 0.98 % > ∧ ENT > ∧ ENT 0.89 % > ∧ ENT CALEnd > ∧ ENT b10 > ∧ ENT Measured-value display Figure 8.1 OPEn/20.84 Output hold time during calibration OPEn/0.
8.3.2 8-5 <8. Detailed Data Setting> Preference Order of Output Hold Value The output hold value takes the following preference order: During error occurrence During calibration During maintenance During warm-up Preference order (high) 8.3.2E.siki For example, if the output current is set to “4 mA” during maintenance, and “without hold” output during calibration is preset, the output is held at 4 mA in the maintenance display.
8-6 <8. Detailed Data Setting> 8.4 Setting Oxygen Concentration Alarms The analyzer enables the setting of four alarms high-high, high, low, and low-low alarms depending upon the oxygen concentration. The following section sets forth the alarm operations and setting procedures. 8.4.
8-7 <8. Detailed Data Setting> In the example in Figure 8.2, the high alarm point is set to 7.5% O2, the delayed time is set to five seconds, and hysteresis is set to 2% O2. Alarm output actions in this figure are expressed as follows: (1) Although oxygen concentration measurement “A” has exceeded the high alarm setpoint, “A” falls lower than the high alarm setpoint before the preset delayed time of five seconds elapses. So, no alarm is issued.
8-8 8.4.4 <8. Detailed Data Setting> Default Values When the analyzer is delivered, or if data are initialized, the default alarm set values are as shown in Table 8.8. Table 8.8 Alarm Setting Default Values Set item High-high alarm setpoint 100% O2 High alarm setpoint 100% O2 Low alarm setpoint 0% O2 Low-low alarm setpoint 0% O2 Alarm hysteresis 0.
8.5.2 8-9 <8. Detailed Data Setting> Setting Output Contact Set the output contacts following Table 8.10. Table 8.
8-10 8.5.3 <8. Detailed Data Setting> Default Values When the analyzer is delivered, or if data are initialized, output contacts are by default as shown in Table 8.11. Table 8.
8-11 <8. Detailed Data Setting> 8.6 Input Contact Settings The converter input contacts execute set functions by accepting a remote (contact) signal. Table 8.12 shows the functions executed by a remote contact signal. Table 8.12 Input Contact Functions Set item Function Calibration gas pressure decrease While a contact signal is on, neither semi-automatic nor automatic calibrations can be made. Measuring range change While contact input is on, the analog output range is switched to 0-25% O2.
8-12 <8. Detailed Data Setting> 8.7 Other Settings 8.7.1 Setting the Date-and-Time The following describe how to set the date-and-time. Automatic calibration works following this setting. Use parameter code「F10」to set the date-and-time. Table 8.14 > > > Data-and-time Settings Switch operation Display ∧ ENT ∧ ENT ∧ ENT F10 00.01.01 00.01.01 Description Select the parameter code F10. If you touch the [ENT] key, the current date will be displayed.
8.7.2 <8. Detailed Data Setting> 8-13 Setting Periods over which Average Values are Calculated and Periods over which Maximum and Minimum Values Are Monitored The equipment enables the display of oxygen concentration average values and maximum and minimum values under measurement (see Section 10.1, later in this manual). The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored. 8.7.2.
8-14 8.7.3 <8. Detailed Data Setting> Setting Fuels 8.7.3.1 Input Parameters The analyzer calculates the moisture content contained in exhaust gases. The following sets forth the fuel parameters necessary for calculation and their entries.
<8. Detailed Data Setting> 8-15 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.
8-16 <8. Detailed Data Setting> 40 39 0.046 38 37 36 35 34 0.044 0.042 0.040 0.038 0.036 0.034 33 32 31 30 Wet-bulb temperature, °C 29 28 27 26 25 24 0.032 0.030 0.028 0.026 Absolute 0.024 0.022 0.020 0.018 22 20 0.016 18 0.014 16 0.012 14 12 4 2 0 8 6 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 Figure 8.4 IM 11M12A01-04E Absolute Humidity of Air 38 40 0.000 F8.4E.
8-17 <8. Detailed Data Setting> Table 8.16 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.
8-18 <8. Detailed Data Setting> 8.7.3.2 Procedure Use the parameter code table below to set fuel values. Table 8.17 Setting Fuel Values Set item Parameter code Set value Engineering units Amount of water vapor in exhaust gas F20 0 to 5 m3/kg (m3) Theoretical amount of air F21 1 to 20 m3/kg (m3) X value F22 0 to 19.99 Absolute humidity of the atmosphere F23 O to 1 8.7.3.
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 Oxygen concentration (vol % O2) 21.0 50 100 F9.1E.ai Figure 9.1 Oxygen Concentration in a Measurement Gas vs. Cell Voltage (21 vol%O2 Equivalent) The measurement principles of a zirconia oxygen analyzer have been described above.
9-3 <9. Calibration> 81.92 Zero origin ez e2 Cell electromotive force, mV Calibration curve before correction e1 es B A Corrected calibration curve (theoretical calibration curve) C 0 21.0 p1 Span gas concentration Span origin p2 0.51 Zero gas concentration Oxygen concentration (vol%O2) Zero correction ratio = (B/A) x 100 (%) Span correction ratio = (C/A) x 100 (%) Correctable range: 100 ± 30% Correctable range: 0 ± 18% F9.2E.ai Figure 9.
9-4 9.1.4 <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 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」.
9-5 <9. Calibration> 9.2 Calibration Procedures CAUTION Calibration should be made under normal operating conditions (if the probe is connected to a furnace, the analyzer will undergo calibration under the operating conditions of the furnace). To make a precise calibration, conduct both zero and span calibrations. 9.2.1 Calibration Setting The following sets forth the required calibration settings: 9.2.1.
9-6 <9. Calibration> 9.2.1.4 Span gas Concentration Set the oxygen concentration for span calibration. If instrument air is used as the span gas, enter 21 %O2. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a handheld oxygen analyzer to measure the actual oxygen concentration, and then enter it.
9-7 <9. Calibration> 9.2.1.6 Setting When setting calibration timing requirements, bear the following precautions in mind: CAUTION (1) If the calibration interval is shorter than the sum of hold (output stabilization) time plus calibration time, the second calibration start time will conflict with the first calibration. In such a case, the second calibration will not be conducted.
9-8 <9. Calibration> 9.2.2 Calibration 9.2.2.1 Manual Calibration For manual calibration, consult Section 7.10, “Calibration,” earlier in this manual. 9.2.2.2 Semi-automatic Calibration (1) Calibration startup using infrared switches Table 9.3 > Semi-automatic Calibration Procedure Switch operation Display ∧ ENT b11 > ∧ ENT SA-CAL > ∧ ENT SPAn /20.84 > > > ∧ ∧ ∧ ENT ENT ZEro /0.89 CALEnd Description Change the parameter code to b11.
<10. Other Functions> 10-1 10. Other Functions 10.1 Detailed Display Select the desired parameter code to display the detailed operation data (see Table 10.1, “Parameter Codes for Detailed Operation Data”. NOTE Refer to Section 8.1, “Setting Display Item”, for parameter code「A00」.
10-2 <10. Other Functions> Table 10.1 Parameter Codes for Detailed Operation Data Engineering Code unit Item A00 Selection 0 Oxygen concentration of display 1 Oxygen analyzer (0.0) items 2 Oxygen analyzer (0.
10-3 <10. Other Functions> 10.1.1 Air Ratio “Air ratio” is defined as the ratio of (the amount of air theoretically required to completely burn all the fuel) to (the amount of air actually supplied). For this equipment, the air ratio will be obtained in a simplified way by measuring the oxygen concentration in the exhaust gas. The air ratio may be expressed mathematically by: m= 1 (21- oxygen concentration) x 21 If you use the air ratio data for estimating the combustion efficiency, etc.
10-4 <10. Other Functions> 10.1.5 Cell Voltage The cell (sensor) voltage will be an index to determine the amount of degradation of the sensor. The cell voltage corresponds to the oxygen concentration currently being measured. If the indicated voltage approximates the ideal value (corresponding to the measured oxygen concentration), the sensor will be assumed to be normal. The ideal value of the cell voltage (E), when the oxygen concentration measurement temperature is controlled at 750°C.
<10. Other Functions> 10-5 10.1.9 Response Time The cell’s response time is obtained in the procedure shown in Figure 10.1. If only either zero or span calibration has been carried out, the response time will not be measured just as it will not be measured in manual calibration. Five minutes maximum Response time mA 90% 100% 10% of analog output span Time Start calibration Calibration complete The response time is obtained after the corrected calibration curve has been found.
10-6 <10. Other Functions> 10.1.12 Heater On-Time Ratio The probe sensor is heated to and maintained at 750°C. When the sample gas temperature is high, the amount of heater ON-time decreases. 10.1.13 Oxygen Concentration (with time constant) When the output damping is specified in the mA-output range setting, the corresponding time constant is also displayed. 10.1.
10-7 <10. Other Functions> 10.1.18 History of Calibration Time The calibration-conducted dates and times for the past ten calibrations are stored in memory. 10.1.19 Time The current date and time are displayed. These are backed up by built-in batteries, so no adjustment is required after the power is switched off. The following shows an example of displaying June 21, 2000, 3:06 p.m. Displayed alternately 00.06.21 15.06 F10.3E.ai Figure 10.3 Date-and-time Display 10.1.
10-8 <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 ∧ ENT Display F30 > ∧ ENT 0000 > ∧ ENT 1000 > ∧ ENT 1000 > ∧ ENT 1200 > ∧ ENT 1200 > ∧ ENT 1250 > ∧ ENT 1250 > ∧ ENT 1255 > ∧ ENT 1255 Description Enter the parameter code for the item to be initialized. The following show an example of entering "F30.
10-9 <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.
10-10 <10. Other Functions> Table 10.6 > Resetting Switch operation ∧ ENT Display Err-01 /-----PASSno Brief Description If an error occurs, the error number and "------" are displayed alternately, as given on the left. > ∧ ENT > ∧ ENT 0000 Touch the [ENT] key again to switch to the password entry display. > ∧ ENT 1000 Enter the password 1102. Intermediate switch operations omitted.
<10. Other Functions> 10-11 CAUTION • Parameters of blank item are not used for Oxygen Analyzer. Table 10.7 Parameter Codes Display-related Items in Group A Code A00 Item Selection of display items Engineering Code unit Item Engineering unit 0 Oxygen concentration A50 Span correction ratio 0 % 1 Oxygen analyzer (0.0) A51 Span correction ratio 1 % 2 Oxygen analyzer (0.
10-12 <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 Hold (Output stabilization) time 0 minutes, 0 seconds to 60 minutes, 59 seconds MM.
10-13 <10. Other Functions> Output-related Items in Group C Code C01 Item Analog output Tuning Engineering unit 0 Oxygen concentration Default setting Oxygen concentration 1 Amount of moisture content 2 Mixed ratio C03 Output mode 0 Linear Linear 1 Logarithm C04 Output during warm-up 0 Held at 4 mA 1 Held at 20 mA 2 Set value remains held. C05 Held at 4 mA. Output during maintenance 0 Not held Held output just before maintenance service. 1 Held output just before maintenance service.
10-14 <10.
10-15 <10.
10-16 <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. Other Functions> 10-17 The operating details and handling precautions are also printed on the product. Please read them beforehand. To install the gas cylinder, follow these steps: (1) Attach the zero gas valves onto the gas cylinder. First, turn the valve regulator of the zero gas valves counterclockwise to completely retract the needle at the top from the gasket surface. Maintaining the valve in this position, screw the valve mounting into the mouthpiece of the gas cylinder.
10-18 <10. Other Functions> (2) Next, adjust the flow rate to 600 ± 60 ml/min using the span gas valve “AIR” (the flow check ball stops floating on the green line when the valve is slowly opened). To rotate the valve shaft, loosen the lock nut and turn it using a flat-blade screwdriver. Turning the valve shaft counterclockwise increases the flow rate. (3) After adjusting the flow rate, tighten the valve lock nut.
10-19 <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 Unit each time calibration is made (starting and stopping the calibration gas flow and adjusting the flow rate). For the operation of the converter, refer to Section 7.10. 10.6.
10-20 <10. Other Functions> Table 10.9 Sample gas pressure, (kPa) 50 100 150 200 250 Flow rate, (ml/min) 500 430 380 350 320 (3) Adjust the flow rate. After the measured oxygen concentration is stabilized, touch the [ENT] key, then all the digits will flash. Touch the [ENT] key again to flash “CAL End.” (4) Close the zero gas flow setting valve to stop the zero gas flow.
11-1 <11. Inspection and Maintenance> 11. Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxt ZR Zirconia Oxygen Analyzer to maintain its measuring performance and normal operating conditions. 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.
<11. Inspection and Maintenance> 11-3 (4) Use tweezers to pull the contact out of the groove. (5) Clean the sensor assembly, especially the metal O-ring contact surface to remove any contaminants adhering to that part. If you can use any of the parts from among those removed, also clean them up to remove any contaminants adhering to them. (Once the metal O-ring has been tightened, it can no longer be used. So, be sure to replace it.) 3. Part assembly procedure (1) First, install the contact.
11-4 <11.Inspection and Maintenance> Metal O-ring Sensor (cell) 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 Figure 11.3 F11.3E.ai 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.
11-5 <11. Inspection and Maintenance> 16 A 11 10 14 12 A 13 15 24 8 9 24 7 5 4 6 3 24 2 1 23 View A-A 18 17 25 19 13 22 14 Figure 11.4 20 21 F11.4E.
11-6 <11.Inspection and Maintenance> Replacement of heater assembly Refer to Figure 11.4 as an aid in the following discussion. Remove U-shaped pipe support ④, U-shaped pipe ⑤, Filter and the sensor (cell) 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. Inspection and Maintenance> 11-7 CAUTION When operating an instrument such as boiler or industrial furnace is stopped with the zirconia oxygen analyzer operation, moisture can condensate on the sensor portion and dusts may stick to it. If operation is restarted in this condition, the sensor which is heated up to 750°C firmly fixes the dusts on itself. Consequently, the dusts can make the sensor performance very lower.
11-8 <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.
<11. Inspection and Maintenance> 11-9 (7) To restore the electronics, reverse the above removal procedures. When restoring the electronics, do not get leadwire jammed in any part of the unit. (8) Place the electronics and the printed-circuit board on which the fuse is installed properly; these are directly connected with connectors. (9) Tighten the four screws in their positions. (10) Replace and tighten the display cover properly.
11-10 <11.Inspection and Maintenance> 11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit (1) Remove pipe holding piping fitting (2) Remove bolts holding flowmeter, and replace it. A white back plate (to make the float easy to see) is attached. The end of the pin holding down the back plate must be on the bracket side. (3) Replace piping, and fix M6 bolts between brackets. *1 *1 : When disassembling and reassembling, mark original positions, and tighten an extra 5-10° when reassembling.
<12. Troubleshooting> 12-1 12. Troubleshooting This chapter describes errors and alarms detected by the self-diagnostic function of the converter. This chapter also describes the check and restoration methods to use when problems other than the above occur. 12.1 Displays and Measures to Take When Errors Occur 12.1.1 What is an Error? An error is detected if any abnormality is generated in the detector or the converter, e.g.
12-2 <12. Troubleshooting> 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).
12-3 <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 5Ω or less. If the value is higher than 5Ω, the thermocouple wire may be broken or about to break. In this case, replace the heater assembly (refer to Section 11.1.
12-4 <12. Troubleshooting> 12.2 Displays and Measures to Take When Alarms are Generated 12.2.1 What is an Alarm? When an alarm is generated, the alarm indication blinks in the display to notify of the alarm (Figure 12.3). Pressing the alarm indication displays a description of the alarm. Alarms include those shown in Table 12.2. Displayed alternately AL-06 21.0% F12.4E.ai Figure 12.4 Table 12.
<12. Troubleshooting> 12-5 (1) Confirm the following and carry out calibration again: If the items are not within their proper states, correct them. a. If the indication for “Zero gas conc.” is selected in “Calibration setup,” the set value should agree with the concentration of zero gas actually used. b. The calibration gas tubing should be constructed so that the zero gas does not leak.
12-6 <12. Troubleshooting> 12.2.2.3 Alarm 7: Span Calibration Coefficient Alarm In calibration, this alarm is generated when the span gas correction ratio is out of the range of 0 ± 18% (refer to Section 9.1.3, “Compensation”). The following are suspected as the cause: (1) The oxygen concentration of the span gas does not agree with the value of the span gas set “Calibration setup.” (2) The flow of the span gas is out of the specified flow value (600 ± 60 ml/min).
12-7 <12. Troubleshooting> In addition, if an error occurs in calibration even after the cell assembly is replaced, the influence of sample gas flow may be suspected. Do not let the sample gas flow toward the tip of the detector probe, for example, by changing the mounting position of the detector. 12.2.2.5 Alarm 10: Cold Junction Temperature Alarm The equipment incorporates a temperature sensor. An alarm is issued when the sensor temperature exceeds 85°C.
12-8 <12. Troubleshooting> CAUTION • Measure the thermocouple resistance value after the difference between the probe tip temperature and the ambient temperature decreases to 50°C or less. If the thermocouple voltage is large, accurate measurement cannot be achieved. Thermocouple YEL GRN RED WHT 1 2 3 4 Multimeter (Ω) F12.3E.ai Figure 12.6 (4) If the inspection indicates that the thermocouple is normal, the electronics may be defective. Consult your local Yokogawa service or sales representative.
<12. Troubleshooting> 12-9 12.3 Measures When Measured Value Shows an 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.
12-10 <12. Troubleshooting> 12.3.2 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 ZR202G Zirconia Oxygen Analyzer (Integrated type) A A 13 1 13 View A-A 2 6 5 4 7 3 11 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 8 9 10 12 Part No. Qty F04E.
Hood for ZR202G 1 ZR202G_F.ai Item 1 CMPL 11M12A01-04E Part No. K9471UA Qty 1 Description Hood 7th Edition : Apr.
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 Qty Description 8 K9473XC 1 Flowmeter All Rights Reserved, Copyright © 2001, Yokogawa Electric Corporation. Subject to change without notice. NUPRO Part No. SS-2C2-10 Item CMPL 11M12A01-12E 1st Edition : Feb. 2001 (YK) 3rd Edition : Apr.
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.
Revision Information Model ZR202G Integrated type Zirconia Oxygen Analyzer Title: Manual No.: IM 11M12A01-04E Edition Date 1st Oct. 2000 Remark (s) Newly published 2nd Mar. 2001 Revised Section 1.1.3 Explanation changed in “System 3” example 1.2.1 ZR20H added to list of Equipment Models 2.1.2 Some changes to ZR202G Integrated type in MS code table, and notes added 2.2 Reference gas pressure of ZA8F with check valve changed, detailed explanation added to ZR20H Automatic Calibration Unit 3.
ii 6th Sep.2006 Revised Section 2.4.5 "Air Set," Part No. K9473XH or K9473XJ, Standard Specification: Changed descriptions partly; "Air Set,"Part No. G7004XF or K9473XG, Standard Specification: Changed descriptions partly; 2.4.7 "Cylinder Regulator Valve (Part No. G7013XF or G7014XF)", Standard Specifications; Changed descriptions partly and drawing; 5.3 "Wiring Power and Ground Terminals": Added description in Figure 5.5; 5.3.2 "Wiring for Ground Terminals": Added item (4); 7.4.
