User's Manual Model ZR202S Integrated type Explosionproof Zirconia Oxygen Analyzer IM 11M13A01-04E IM 11M13A01-04E 2nd Edition
Introduction The EXAxtZR Integrated-type Explosionproof Zirconia Oxygen Analyzer has been developed for combustion control in various industrial processes. There are several version of this analyzer so you can select one that matches your application. Optional accessories are also available to improve measurement accuracy and automate calibration. An optimal control system can be realized by adding appropriate options. This instruction manual describes almost all of the equipment related to the EXAxtZR.
This manual consists of twelve chapters. Please refer to the reference chapters for installation, operation and maintenance. Chapter 1. Overview Outline 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 ATEX Documentation This procedure is only applicable to the countries in European Union. GB All instruction manuals for ATEX Ex related products are available in English, German and French. Should you require Ex related instructions in your local language, you are to contact your nearest Yokogawa office or representative. DK Alle brugervejledninger for produkter relateret til ATEX Ex er tilgængelige på engelsk, tysk og fransk.
r For the safe use of this equipment WARNING Requirements for explosionproof use: The ambient temperature is in the range -20 to +558C. The surface temperature of the ZR202S is not over the temperature class T2 (3008C)fnote 1g * The surface temperature of the amplifier box does not exceed 708C. 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.
CAUTION This instrument is tested and certified as explosionproof type. Please note that the construction of the instrument, installation, external wiring, maintenance or repair is strictly restricted, and non-observation or negligence of restriction would result in dangerous condition. (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.
(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 injury to personnel, 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") "102" lit, "102" flashing) • Drawing for 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 Precautions in Handling Explosionproof Zirconia Oxygen Analyzer The explosionproof zirconia oxygen analyzer (Model ZR202S) are designed as explosionproof instruments. When using either of these instruments in an explosion-susceptible hazardous area, note the following and observe the given precautions: Use only the supplied, the explosionproof zirconia oxygen analyzer (Model ZR202S) and accessories, or any explosionproof certification may be invalidated.
r After-Sales Warranty d Do not modify the product. d 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. d 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.
Contents Introduction ........................................................................................................................... i r r r r r ATEX Documentation ............................................................................................. iii For the safe use of this equipment .......................................................................... iv Precautions in Handling Explosionproof Zirconia Oxygen Analyzer ................. viii NOTICE .............................
4.1.3 Piping for the Reference Gas Inlet .......................................................... 4-3 4.1.4 Piping for the Reference Gas Outlet ...................................................... 4-3 4.2 Piping for System 2 ........................................................................................ 4-4 5. Wiring ........................................................................................................................... 5-1 5.1 General ......................................
8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum Oxygen Concentration ( at 20 mA) ........................................................ 8-2 8.2.2 Entering Output Damping Constants ...................................................... 8-2 8.2.3 Selection of Output Mode ....................................................................... 8-3 8.2.4 Default Values ......................................................................................... 8-3 8.3 Output Hold Setting ......
10.1.13 Oxygen Concentration (with time constant) ......................................... 10-6 10.1.14 Maximum Oxygen Concentration ......................................................... 10-6 10.1.15 Minimum Oxygen Concentration .......................................................... 10-6 10.1.16 Average Oxygen Concentration ............................................................ 10-6 10.1.17 Span-gas and Zero-gas Correction Ratios ............................................. 10-6 10.1.
1. Overview 1. Overview The EXAxtZR Integrated type Explosionproof 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, paper and pulp, food, or textiles, as well as incinerators and medium/small boilers. It can help conserve energy in these industries.
1.1 < EXAxtZR > System Configuration The system configuration should be determined by the conditions; e.g. whether the calibration is to be automated, and whether flammable gas is present and requires safety precautions. The system configuration can be classified into two basic patterns as follows: 1.1.1 System 1 This system is for monitoring and controlling oxygen concentration in the combustion gases of a large-size boiler or heating furnace.
1. Overview 1.1.2 System 2 This example, System 2, 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 2 uses the autocalibration unit, with auto-switching of the calibration gas. A “combustible gas detected” contact input turns off power to the heater.
1.2 < EXAxtZR > System Components 1.2.1 System Components Integrated type System config. Ex.1 Ex.
2. Specifications 2. Specifications This chapter describes the specifications for the following: ZR202S Integrated-type Explosionproof 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) Automatic Calibration Unit (See Section 2.2.2) Standard Gas Unit (See Section 2.3) Other equipments (See Section 2.4) ZO21S WARNING Requirements for explosionproof use: The ambient temperature is in the range -20 to +558 C.
2.1 General Specifications 2.1.1 Standard Specifications Measured Object: Oxygen concentration in combustion exhaust gas and mixed gas (excluding inflammable gases. May not be applicable corrosive gas such as ammonia and chlorine.) The sampling gases containing a corrosive gas such as ammonia or chlorine may be applicable to our oxygen gas analyzer. In this case, contact with YOKOGAWA and its agency. Measured System: Zirconia system Oxygen Concentration: 0.
2. Specifications 2.1.2 ZR202S Integrated-type Explosionproof Oxygen Analyzer Flameproof Type CENELEC ATEX(KEMA): ZR202S-A No.KEMA 04ATEX2156 Type of Protection and Marking Cord: EEx d IIB 1 H2 Group: II Category: 2GD Temrerature Class: T2, T3008 C Enclosure: IP66 NAME PLATE INTEGRAL TYPE ZIRCONIA ANALYZER MODEL SUFFIX ZR202S STYLE SUPPLY 100-240VAC 50/60Hz MAX.300W AMB.TEMP. -20 TO 55 NO. 0344 2GD Tokyo 180-8750 JAPAN No.
FM Explosionproof: ZR202S-B Explosionproof for Class I, Division 1, Groups B, C and D Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure Rating: NEMA 4X Temperature Class: T2 CSA Explosionproof: ZR202S-C Explosionproof for Class I, Division 1, Groups B, C and D Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure: Type 4X Temperature Class: T2 IECEx Flameproof: ZR202S-D IECEx flameproof type Ex d IIB + H2 T2 Enclosure: IP66 IECEx type of protection “Dust” Ex
2. Specifications Sample Gas Pressure: -5 to +5 kPa No pressure fluctuation in the furnace be allowed. Probe Length: 0.4, 0.7, 1.0, 1.5, 2.
Installation: Flange mounting Probe Mounting Angle: Horizontal to vertically downward. Case: Aluminum alloy Paint Color: Cover and case; Mint green (Munsell 5.6BG 3.3/2.9) Finish: Polyurethane corrosion-resistance coating Weight: Insertion length of 0.4m: Approx. 15 kg (ANSI 150 4) Insertion length of 1.0m: Approx. 17 kg (ANSI 150 4) Insertion length of 1.5m: Approx. 19 kg (ANSI 150 4) Insertion length of 2.0m: Approx.
2.
Model and Suffix code Option code Suffix code Model Integrated type Explosionproof Zirconia Oxygen Analyzer ZR202S Explosion proof Approval ATEX certified flameproof FM certified explosionproof CSA certified explosionproof IECEx certified flameproof -A -B -C -D -040 -070 -100 -150 -200 Wetted material -S -C Flange -A (*1) -B -C -E -F -G -K -L -M -P -R -S -W Auto Calibration Reference air Gas Thread Connection box thread Instruction manual (*11) (*12) 0.4 m 0.7 m 1.0 m 1.5 m 2.
2. Specifications • External Dimensions Model ZR202S Integrated type Zirconia Oxygen Analyzers Unit: mm ±3 ±3 348 L Unit : mm 49 ±2 49 ±2 L (m) tolerance (mm) 0.4 65 256.5 0.7 67 68 FLANGE 1.0 1.5 610 2.0 612 ±3 [ 123 ±3 Rc1/4 or 1/4NPT Reference Air Inlet ±3 25 125 ±2 ±3 48.5 ±2 122 ±3 156 [ 87 ±3 170 ±3 [ 51 ±3 [ 50.
• External Dimensions (1) For HorizontalMounting (-A) Basic spec. code-A : Horizontal mounting 348 ± 3 Unit : mm 156 ± 3 AUTO CALIBRATION UNIT 244 Terminal box 214 44 MAX 40 40 Span gas inlet Rc 1/4 or 1/4 NPT(Female) 258 Display Zero gas inlet Rc 1/4 or 1/4 NPT(Female) 66.5 166.5 Reference gas inlet Rc 1/4 or 1/4 NPT(Female) HORIZONTAL INSTALL Basic spec. code-B : Vertical mounting 166.
2. Specifications ZR202S body Calibration gas Reference gas Check valve Span-gas solenoid valve Zero-gas flowmeter Ratio-gas flowmeter SPAN IN Zero-gas solenoid valve To Air set REF. IN To Zero-gas cylinder Needle valve ZERO IN Auto calibration unit Zero-gas flowmeter F4.11E.EPS • Hood (Option code /H) Unit : mm 150 63 150 63 274 64 Food Material : Aluminum Food Weight : Approx. 800g ZR202G_F.
2.1.3 ZO21R-L 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/s. When using a ZR202S general-use integrated type detector in the horizontal position, be sure to select a probe protector ZO21R-L-hhh-h*B to support the probe. Insertion Length: 1.05 m. Flange: JIS 5K 65A FF equivalent.
2. Specifications 2.2 ZA8F Flow Setting 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 f6 hole 180 Unit: mm 7 140 REFERENCE CHECK ZERO SRAN Zero gas outlet Span gas inlet Zero gas inlet 26 Reference air outlet 222.8 235.8 REFERENCE 20 35 35 35 35 20 8 35 70 4-Rc1/4 Piping connection port 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.
2. Specifications 2.3 ZO21S Standard Gas Unit WARNING Standard GasUnit (Model ZO21S) must not located in hazardous area. This is a handy unit to supply zero gas and span gas to the detector as calibration gas. 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.
253 228 92 Unit: mm Flow checker Span gas valve Zero gas valve 1600 Gas outlet 354 Zero gas cylinder (6 cylinder): E7050BA 2-16 F2.7E.
2. Specifications 2.4 Other Equipment 2.4.1 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 NPT(F) Material: SUS 316 (JIS) Weight: Approx. 80 g Stop valve Part No. Description L9852CB Joint: RC 1/4, Material: SUS316 (JIS) G7016XH Joint: 1/4 NPT, Material: SUS316 (JIS) Nipple Part No.
Unit: mm K9292DN : Rc 1/4(A part),R 1/4(B) K9292DS : 1/4 NPT(Female)(A part),1/4 NPT(Male)(B part) A B Approx.19 Approx.54 F2.11E.EPS 2.4.3 Air Set (part no. K9473XH or K9473XJ) This set is used to lower the pressure when instrument air is used as the reference and span gases. • Part No. K9473XH or K9473XJ Standard Specifications Primary Pressure: Max. 2 MPa G Secondary Pressure: 0 to 250 kPa G Connection: Rc1/4 or 1/4NPT with joint adapter Weight: Approx. 1 kg Part No.
2. Specifications • Part. no. G7004XF or K9473XG Standard Specifications Primary Pressure: Max. 1 MPa G Secondary Pressure: 20 to 500 kPa G Connection: Rc1/4 or 1/4 NPT(F) with joint adapter Weight : Approx. 1kg Part No. Description G7004XF Joint: Rc 1/4, Material: Zinc Alloy K9473XG Joint: 1/4NPT(F) , Material: Zinc Alloy with adapter 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.
2.4.4 Pressure Regulator for Gas Cylinder (G7013XF or G7014XF) This regulator valve is used with the zero gas cylinders. • Standard Specifications Primary pressure: Max. 14.8 MPa G Secondary pressure: 0 to 0.4 MPa G Connection: Inlet W22 14 threads, right hand screw Outlet Rc 1/4 or 1/4 NPT(F) Material: Brass body Approx.
2. Specifications 2.4.5 Model ZR202A Heater Assembly Model Suffix code Option code Description Heater Assembly for ZR202S ZR202A 0.4 m 0.7 m 1m 1.5 m 2m -040 -070 -100 -150 -200 Length (p1) Jig for change with Jig None -A -N Always -A -A (p1) Suffix code of length should be selected as same as ZR202S installed. * The heater is made of ceramic, do not drop or subject it to pressure stress. T2.12E.EPS Unit : mm 30 Ø 45 (K9470BX) K9470BX Jig for change Ø 21.
2-22 IM 11M13A01-04E
3. Installation 3. Installation This chapter describes installation of the following equipment: 3.1 Model ZR202S Zirconia Oxygen Analyzer 3.2 Model ZA8F Flow Setting Unit 3.3 Case Assembly for Calibration-gas Cylinder (E7044KF) 3.1 Installation of the Zirconia Oxygen Analyzer 3.1.1 Area The following should be taken into consideration when installing the probe: (1) Easy and safe access to the probe for checking and maintenance work.
3.1.2 CENELEC ATEX (KEMA) Flameproof Type ZR202S–A Analyzer for use in hazardous area: Note 1: No. KEMA 04ATEX 2156 Type of Protection and Marking Code: EEx d IIB+H2 Group: II Category: 2GD Temperature class: T2, T3008 C Enclosure: IP66 Note 2: Wiring • All wiring shall comply with local installation requirement. • The cable entry devices shall be of a certified flameproof type suitable for the condition of use Note 3: Operation • Keep the “WARNING” label to the Detector.
3. Installation 3.1.3 FM Explosionproof Type ZR202S–B Analyzer for use in hazardous area: Note 1: Explosionproof for Class I, Division 1, Groups B, C and D Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure Rating: NEMA 4X Temperature class: T2 Note 2: Wiring • All wiring shall comply with National Electrical Code ANSI/NEPA 70 and Local Electrical Code. • In hazardous area, wiring shall be in conduits as shown in the figure.
3.1.4 CSA Explosionproof Type ZR202S–C Detector for use in hazardous area: Note 1: Explosionproof for Class I, Division 1, Groups B, C and D Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure Rating: TYPE 4X Temperature class: T2 Note 2: Wiring • All wiring shall comply with Canadian Electrical Code Part 1 and Local Electrical Code. • In hazardous area, wiring shall be in conduits as shown in the figure. WARNING: SEAL ALL CONDUITS WITHIN 50 cm OF THE ENCLOSURE.
3. Installation 3.1.5 IECEx Flameproof Type ZR202S–D Analyzer for use in hazardous area: Note 1: No. IECEx KEM 06.0006 IECEx flameproof type Ex d IIB+H2 T2 Enclosure: IP66 IECEx type of protection "Dust" Ex tD A21 IP66 T3008 C Enclosure: IP66 Note 2: Wiring • All wiring shall comply with local installation requirement. • The cable entry devices shall be of a certified flameproof type suitable for the condition of use Note 3: Operation • Keep the “WARNING” label to the Detector.
3.1.6 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 3.3 for the dimensions. If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards. • The sensor (zirconia cell) at the probe tip may deteriorate due to thermal shock if water drops are allowed to fall on it, as it is always at high temperature.
3. Installation 3.1.7 Installation of the Probe 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. • 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) (2) (3) (4) (5) (6) 3.2.2 Easy access to the unit for checking and maintenance work. Near to the detector and the converter No corrosive gas. An ambient temperature of not more than 55˚C and little changes of temperature. No vibration. Little exposure to rays of the sun or rain.
3. Installation (1) Make a hole in the wall as illustrated in Figure 3.4. Unit: mm 223 140 4 - Ø6 hole, or M5 screw F3.13E.EPS Figure 3.5 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.
3.4 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 MV or more. Remove wiring from the converter and detector. 1.
4. Piping 4. Piping This chapter describes piping procedures in the two typical system configurations for EXAxtZR Integrated-type Explosionproof 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.
4.1 Piping for System 1 Piping in System 1 is illustrated in Figure 4.7. Non-hazardous Area Hazardous Area ZR202S Integrated type Explosionproof Zirconia Oxygen Analyzer ~ Stop valve or Check valve 100 to 240 V AC ZA8F flow setting unit Flowmeter Reference gas Needle valve Air Set Instrument air Calibration gas Span gas (*4) Pressure regulator Zero gas cylinder F06.EPS Figure 4.7 Piping for System 1 System 1 illustrated in Figure 4.
4. Piping 4.1.2 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 ZR202S 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 may not exceed 40˚C. Mount the pressure regulator (recommended by YOKOGAWA) on the cylinder.
4.2 Piping for System 2 Piping in System 2 is illustrated in Figure 4.9. In System 2, calibration is automated; however, the piping is basically the same as that of System 1. Refer to Section 4.1. Adjust secondary pressure of both the air set and the zero gas regulator so that these two pressures are approximately the same. The flow rate of zero and span gases (normally instrument air) are set by a individual needle valve. After installation and wiring, check the calibration contact output (see Sec. 7.9.
4. Piping • Installation of Auto Calibration Unit Unit: mm Horizontal mounting on the ZR202S (-A) 44 MAX 214 Terminal box side 244 258 Display side 40 40 66.5 Zero gas inlet Rc 1/4 or 1/4 NPT(Female) 166.5 Reference air inlet Rc 1/4 or 1/4 NPT(Female) Span gas inlet Rc 1/4 or 1/4 NPT(Female) Vertical mounting on the ZR202S (-B) 166.5 45 60 160 Span gas inlet Rc 1/4 or 1/4 NPT(Female) 180 44 MAX Reference air inlet Rc 1/4 or 1/4 NPT(Female) 40 40 66.
Piping Diagram Piping Diagram of Auto Calibration Unit ZR202S 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 Zero-gas flowmeter F4.11E.EPS Ensure that the furnace gas does not flow into the probe.
5. Wiring 5. Wiring This chapter describes wiring procedures necessary for the EXAxtZR Integrated-type Explosionproof Zirconia Oxygen Analyzer. 5.1 General CAUTION Be sure to read Sections 3.1.2 to 3.1.4 where the important information on wiring is provided. 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.
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. Unit: mm 25 Rc1/4 or 1/4NPT (Reference air inlet) Cable gland Rc1/4 or 1/4NPT (Calibration gas inlet) M2031.5, 1/2 NPT or the like (Wiring connection) F5.3E.EPS Figure 5.3 Cable Gland Mounting 5.2 Wiring for Analog Output This wiring is for transmitting 4 to 20mA DC output signals to a device, e.g. recorder.
5.3 Wiring Power and Ground Terminals Wiring for supplying power to the analyzer and grounding the equipment. Ground 1 DI 2 C DO 1 DO 2 L G FG Grounding to the earth terminal on the equipment case Equipment case Lock washer Grounding terminal FG + AO- Crimp contact of the grounding line N Jumper plate ~ 100~240VAC 50/60Hz 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. Wiring 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. Hazardous Area Analyzer Non-hazardous Area Terminal Box Annunciator or the like DO-1 DO-1 #1 Output DO-2 DO-2 #2 Output F5.6E.EPS Figure 5.6 Contact Output Wiring 5.4.
5.5 Contact Input Wiring The converter can execute specified function when receiving contact signals. To use these contact signals, proceed wiring as follows: Hazardous Area Non-hazardous Area 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-core or 3-core 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 EXAxtZR Integrated type Explosionproof Zirconia Oxygen Analyzer. 6.1 ZR202S Oxygen Analyzer 6.1.1 Integrated type Explosionproof Oxygen Analyzer Terminal box, Explosionproof Flame arrester assembly Flange used to mount the detector. Selectable from JIS or ANSI etc standard models. Probe this part is inserted in the furnace. Selectable of length from 0.4, 0.7, 1.0, 1.5, 2.0m.
6.2 ZA8F Flow Setting Unit, 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 Wirimg 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 measurement 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 > > µMmNkgalbbl % 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, refer to See 7.4.3.
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. Table7.3 Switch operation PASSno 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 Table7.4 Parameter Code Switch operation Password has been entered and the parameter code selection display has appeared. Character A is flashing, indicating that character A can be changed. A01 If you touch the [>] key once, the position of the digit that is flashing will move to the right. his allows you to change 0. A01 Touch the [>] key again to move the position of the digit that is flashing to the right one m ore digit.
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 (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 An example of entering "9.8" is given below. (The currently set value is 0.0) digit to be changed.
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 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 10.6, later in this manual. Table 7.
7.7 Output Range Setting This section sets forth analog output range settings. For details, consult Section 8.2,”Current Output Settings,” later in this manual. 7.7.1 Minimum Current (4 mA) and Maximum Current (20 mA) Settings Use the parameter codes C11 to set the oxygen concentration at 4 mA and C12 to set the oxygen concentration at 20 mA. The following shows where 10% O2 is set at 4 mA and 20% O2 at 20 mA. Table 7.
7. Startup Switch operation . ENT . . ENT . . ENT . . ENT . . ENT . . ENT . . ENT . . ENT . . ENT Display after the password has been entered. C01 Set the oxygen concentration at 4 mA. Change the parameter code to C11. Touch the [ ] key to switch to Group C. C01 Touch the [>] key to move the position of the digit that is flashing to the right. C11 Touch the [ ] key to enter the numeric value 1. 000 Touch the [ENT] key to display the current set value (0% O2 has been set).
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 7.8 Checking Current Loop Switch operation A01 G01 Display after the password has been entered. ENT 00.0 Touch the [ENT] key. The output current remains preset with the output-hold feature (Section 2.3). 10.
7. Startup 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.
7.9.1 Contact Output Check Follow Table 7.10 to check the contact output. The table uses an example with contact output 1. Table 7.10 Checking Contact Output > . > . > . > . > ENT . > ENT ENT . > ENT ENT . > A01 G01 ENT ENT . > Description ENT . > Display ENT G11 Touch the [ENT] key once again to switch to the parameter code selection display. The contact then returns to the original state. .
7. Startup 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 7.11. The table uses an example with a zero-gas solenoid valve. Table 7.
7.9.3 Checking Input Contacts Follow Table 7.12 to check the input contacts. The table uses an example with input contact 1. Table 7.12 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. 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.
Table 7.14 Calibration Setup Procedure . ENT . ENT . ENT . ENT . ENT . ENT > ENT > ENT > > > > > > Description Display after the password has been entered. A01 b01 Set the zero-gas concentration. Switch the parameter code to B01. Here, set 0.98%. 001.00 % Touch the [ENT] key to display the currently set value. 001.00 % Touch the [>] key to move the position of the digit that is flashing to 1. 000.00 % Touch the [ ] key to change to 0. 000.
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 zerogas flow valve is fully closed. Open the zero-gas cylinder pressure regulator so that the secondary pressure will be a measurement gas plus approx. 70 kPa (to be 300 kPa maximum ).
7.10.2.2 Calibration Implementation This manual assumes that the instrument air is the same as the reference gas used for the span gas. Follow the steps below to conduct manual calibration. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it. Table 7.15 Conducting Calibration The symbol [ 7-22 . > . > . > If you touch the [ENT] key again, "CAL" then flashes.
7. Startup Table 7.15 Conducting 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.
7-24 IM 11M13A01-04E
8. Detailed Data Setting 8. 8.1 Detailed Data Setting Setting Display Item Display items are defined as items displayed on the basic panel display. Parameter code A00 or F08 is used to set the display items as shown in Table 8.1. The oxygen concentration is set at the factory before shipment. In addition, if the data initialization is performed, the oxygen concentration will be set. Table 8.
8.2 Current Output Setting This section describes setting of the analog output range. Table 8.2 shows parameter codes for the set items. Table 8.2 Current Output Parameter Codes Set item Current output Parameter code C01 Output mode C03 Min. oxygen concentration Max. oxygen concentration Output damping coefficient C11 C12 C30 Set value 0: Oxygen concentration 1: 4 mA (fixed *1) 2: 4 mA (fixed *1) 0: Linear 1: Logarithm Oxygen concentration at 4 mA Oxygen concentration at 20 mA 0 to 255 seconds T8.2E.
8. Detailed Data Setting 8.2.3 Selection of Output Mode You can select a linear or logarithmic output mode. The former provides linear characteristics between the analog output signal and oxygen concentration. 8.2.4 Default Values When the analyzer is delivered or data are initialized, the output current settings are by default as shown in Table 8.3. Table 8.3 Output Current Default Values Item Min. oxygen concentration Max.
8.3 Output Hold Setting The “output hold” functions retain an analog output signal at a preset value during the equipment’s warm-up time or calibration or if an error arises. Table 8.4 shows the analog outputs that can be retained and the individual states. Table 8.4 Analog Output Hold Setting Equipment status During warm-up 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 > > Switch operations 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 > ENT OPEn/20.84 Output hold time during calibration OPEn/0.89 b10 Measured-value display F8.1E.EPS Figure 8.
8.3.2 Preference Order of Output Hold Value The output hold value takes the following preference order: Preference order (high) During error occurrence During calibration During maintenance During warm-up 8.2.2E.siki For example, if the output current is set to 4 mA during maintenance, and no outputhold output during calibration is preset, the output is held at 4 mA in the maintenance display.
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.
In the example in Figure 8.2, the high-limit 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-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 8.4.4 Default Values When the analyzer is delivered, or if data are initialized, the default alarm set values are as shown in Table 8.8. Table 8.8 Alarm Setting Default Values Set item High-high-limit alarm setpoint Set value 100% O2 High-high limit alarm 100% O2 Low-limit alarm 0% O2 Low-low-limit alarm setpoint 0% O2 Hysteresis Delayed time High-high-limit alarm detection 0.
8.5 Output Contact Setup 8.5.1 Output Contact Mechanical relays provide contact outputs. Be sure to observe relay contact ratings. (For details, consult the specifications). The following sets forth the operation mode of each contact output. Output contact 1 you can select open or closed contact when the contact is "operated.". For output contact 2, output contact 2 is closed. The relay for output contact 1 is energized when its contacts are closed and vice versa.
8. Detailed Data Setting 8.5.2 Setting Output Contact Set the output contacts following Table 8.10. Table 8.
8.5.3 Default Values When the analyzer is delivered, or if data are initialized, output contacts are by default as shown in Table 8.11. Table 8.11 Output Contact Default Settings Item High-high-limit alarm High-limit alarm Low-limit alarm Low-low-limit alarm Error Warm-up Output range change Calibration Maintenance High-limit temperature alarm Calibration-gas pressure drop Unburnt gas detection Operating contact status s : Present Output contact 1 s Output contact 2 s s Open Closed (fixed) T8.11E.
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 Calibration-gas drop Measuring range change Calibration start Unburnt gas detection Function While a contact signal is on, neither semi-automatic nor automatic calibrations can be made.
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 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 8.7.2 Setting Periods over which Average Values are Calculated and Periods over which Maximum and Minimum Values Are Monitored The equipment enables the display of oxygen concentration average values and maximum and minimum values under measurement (see Section 10.1.1, 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.
8.7.3 Setting Fuels 8.7.3.1Input Parameters The analyzer calculates the moisture content contained in exhaust gases. The following sets forth the fuel parameters necessary for calculation and their entries. The moisture quantity may be mathematically expressed by: (water vapor caused by combustion and water vapor contained in the exhaust gas) Moisture quantity = + (water vapor contained in air for combustion) actual exhaust gas(including water vapor) per fuel x 100 = (Gw + Gw1)/G x 100 = Gw + (1.
8. Detailed Data Setting For liquid fuel 3 Amount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} [m /kg] Theoretical amount of air (Ao) = {(12.38 / 10000) x H1} 2 1.36 3 [m /kg] Low calorific power = H1 X value = {(3.37 / 10000) x Hx} 2 2.
40 39 0.046 38 37 36 35 0.044 0.042 0.040 0.038 0.036 34 0.034 33 32 31 30 Wet-bulb temperature, 8C 29 0.032 0.030 0.028 0.026 Absolute humidity, kg/kg 28 27 26 0.024 0.022 25 24 0.020 0.018 22 20 0.016 18 0.014 16 0.012 14 12 0.010 10 0.008 8 4 2 0 6 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, 8C 38 40 0.000 F8.4E.EPS Figure 8.
8. Detailed Data Setting Table 8.16 Fuel Data d For liquid fuel Fuel Specific properties weight kg/l Type Chemical component (weight percentage) C h O Ash Higher Lower order w content order S N Calorific power Theoretical amount of kJ/kg air for combustion Nm3/kg Amount of combustion gas Nm3/kg CO2 H2O SO2 X value N2 Total 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 0.0 45879 43032 11.2 1.
8.7.3.2Procedure Use the parameter code table below to set fuel values. Table 8.17 Setting Fuel Values Set item Amount of water vapor in exhaust gas Theoretical amount of air X value Absolute humidity of the atmosphere Parameter code F20 Set value 0 to 5 Engineering units m3/kg (m3) m3/kg (m3) F21 1 to 20 F22 F23 0 to 19.99 0 to 1 kg/kg T8.17E.EPS 8.7.3.3Default Values When the analyzer is delivered, or if data are initialized, parameter settings are by default, as shown in Table 8.18. Table 8.
9. Calibration 9. Calibration 9.1 Calibration Briefs 9.1.1 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.
120 100 0.51% 02,81.92mV(Zero origin of calibration) 80 60 Cell voltage (mV) 40 20 21.0% O2, 0mV (Span origin of calibration) 0 -20 -40 0.1 0.5 1 5 Oxygen concentration (vol %) 10 21.0 50 100 F9.1E.EPS Figure 9.1 Oxygen Concentration in a Measurement Gas vs. Cell Voltage (21 % Equivalent) The measurement principles of a zirconia oxygen analyzer have been described above. However, the relationship between oxygen concentration and the electromotive force of a cell is only theoretical.
9. Calibration 9.1.3 Compensation The deviation of a measured value from the theoretical cell electromotive force is checked by the method in Figure 9.2 or 9.3. Figure 9.2 shows a two-point calibration using two gases: zero and span. Cell electromotive forces for a span gas with an oxygen concentration p1 and a zero gas with an oxygen concentration p2 are measured while determining the calibration curve passing between these two points.
9.1.4 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. 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-point and span calibrations. 9.2.1 Calibration Setting The following sets forth the required calibration settings: 9.2.1.
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 hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.
9. Calibration When the calibration mode is in automatic: In addition to the above output stabilization time and calibration time, set the interval, start date, and start time. Interval means the calibration intervals ranging from 000 days, 00 hours to 255 days, 23 hours. Set the first calibration date and the start-calibration time to the start date and start time respectively. After the first calibration is carried out, the next calibration will be executed according to the preset calibration intervals.
9.2.1.7Default Values When the analyzer is delivered, or if data are initialized, the calibration settings are by default, as shown in Table 9.2. Table 9.2 Default Settings for Calibration Item Calibration mode Calibration procedure Zero-gas (oxygen) concentration Span-gas (oxygen) concentration Output hold (stabilization) time Calibration time Calibration interval Start date and time Default Setting Manual Span - zero 1.00% 21.
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.
9-10 IM 11M13A01-04E
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”. SEE ALSO Refer to Section 8.1, “Setting Display Item” for parameter code A00.
Table 10.1 Parameter Codes for Detailed Operation Data Parameter Item code A00 A01 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 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)} 3 21 If you use the air ratio data for estimating the combustion efficiency, etc.
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 10.1.9 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. Five minutes maximum Response time mA 100% 90% 10% of analog output span Time Start calibration Calibration complete The response time is obtained after the corrected calibration curve has been found.
10.1.12 Heater On-Time Ratio The probe sensor is heated to and maintained at 750˚C. When the measured gas temperature is high, the amount of heater ON-time decreases. 10.1.13 Oxygen Concentration (with time constant) When the output damping is specified in the mA-output range setting, the corresponding time constant is also displayed. 10.1.14 Maximum Oxygen Concentration The maximum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed.
10. Other Functions 81.92 Zero origin ez Calibration curve before correction Cell electromotive force, mV Previous zero-gas data B A e1 Corrected calibration curve (theoretical calibration curve) es C Span origin 0 21.0 p1 Span-gas concentration 0.51 Oxygen concentration (vol%O2) Zero-gas ratio = (B/A) x 100 (%) Correctable range: 100 – 30% Span-gas ratio = (C/A) x 100 (%) Correctable range: 0 – 18% F10.2E.EPS Figure 10.2 10.1.
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 10.4 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: 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 .
CAUTION • Parameters of blank item are not used for Oxygen Analyzer. Table 10.6 Parameter Codes Display-related Items in Group A Parameter Item code A00 Selection of display items 0: Oxygen concentration 1: Oxygen analyzer (0.0) 2: Oxygen analyzer (0.0) 3: Analog output selected A01 Oxygen concentration A02 A03 A04 A05 A06 Air ratio A07 Cell temperature A08 Cold-junction temperature A09 Meas.
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 B04 Output stabilization time manual calibration 0 minutes, 0 seconds to 60 minutes, 59 MM.
Output-related Items in Group C Code Item Tuning C01 Analog output C03 Output mode C04 Output during warm-up up C05 Output during maintenance 0: Oxygen concentration 1: Amount of moisture content 2: Mixed ratio 0: Linear 1: Logarithm 0: Held at 4 mA 1: Held at 20 mA 2: Set value remains held. 0: Not held 1: Held output just before maintenance service. 2: Set value remains held. 0: Not held 1: Held output just before calibration. 2: Set value remains held.
10. Other Functions Alarm-related Items in Group D Code D01 D02 D03 D04 D05 D06 D07 D08 D11 D12 D13 D14 D30 D31 D32 D33 D41 Item Tuning Engineering unit 0 to 100 % O2 Default setting 100% O2 0 to 100 % O2 100% O2 0 to 100 % O2 0% O2 0 to 100 % O2 0% O2 Oxygen concentration alarm hysteresis 0 to 9.9 % O2 0.
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.
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.EPS 10.
10. Other Functions 10.5.1 Standard Gas Unit Component Identification Carrying case Flow checker Checks the zero- and span-gas flow. Span gas valve Controls the span-gas (air) flow. Zero gas valve regulator Cover screws (six pcs.) Tube connection Gas cylinder Pump Supplies span gas (air) Contains the zero gas. A gas of 7 Nl is charged to 700 kPa Zero gas valve Clamp Attaches to the gas cylinder for use. Clamps the gas cylinder.
(1) Attach the zero gas valves onto the gas cylinder. First, turn the valve regulator of the zero gas valves counterclockwise to completely retract the needle at the top from the gasket surface. Maintaining the valve in this position, screw the valve mounting into the mouthpiece of the gas cylinder. (If screw connection is proper, you can turn the screw manually. Do not use any tool.
10. Other Functions (2) Next, adjust the flow rate to 600 6 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.
10.6 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). 10.6.
10. Other Functions 10.6.4 Treatment After Calibration No special treatment of the instrument is needed after calibration. However, it is recommended that the pressure regulator for the zero-gas cylinders be closed because calibration is not required so often.
10-24 IM 11M13A01-04E
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.
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 100 6 30% or a span-gas ratio of 0 6 18%. In addition, the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement.
(6) 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. Being careful not to cause irregularities in the pitch of the coil spirals (i.e.
11. Inspection and Maintenance Metal O-ring Sensor U-shaped pipe support Bolts (four) Flame arrestor assembly Probe Contact 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.
16 A 14 11 10 A 13 24 9 8 24 7 5 4 6 3 24 2 1 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 11 , following Section 11.1.2, earlier in this manual. Remove the four bolts 10 to remove the converter 16 . Then remove the three connectors to which lead wire from the heater and thermocouple is connected. Loosen screw 19 until it can be removed from hole in heater strut assembly 23 plate. O-ring 18 prevents screw 19 from dropping out.
Apply adhesive here Flame Arrester Assembly Detector Flame Arrester Assembly Detector F11.5E Figure 11-5 Removal of Flame Arresster 11.1.5 Replacement of O-ring The detector uses three different types of O-rings 14 , 21 , and 22 . Two O-ring of each type. 11.1.6 Stopping and Re-starting Operation When operation is stopped, take care of the followings so that the sensor of the detector cannot become unused.
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 Autocalibration 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.
11-12 IM 11M13A01-04E
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 is generated, 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 ↔ 21.0% F12.4E.EPS Figure 12.4 Table 12.
12. Troubleshooting 12.2.2 Measures Taken When Alarms are Generated 12.2.2.1 Alarm 1: Oxygen Concentration Alarm This alarm is generated when a measured value exceeds an alarm set point or falls below it. For details on the oxygen concentration alarm, see Section 8.4, “Setting Oxygen Concentration Alarms” in the chapter on operation. 12.2.2.
(5) If deterioration of the sensor assembly has occurred abruptly, it may show that the check valve, which prevents moisture in the furnace from getting into the calibration gas tubing, has failed. If the gas in the furnace gets into the calibration gas tubing, it condenses and remains in the gas tubing. The sensor assembly is considered to be broken for the reason that the condensation is blown into the sensor assembly by the calibration gas during calibration and so the cell cools quickly.
12. Troubleshooting 12.2.2.4 Alarm 8: EMF Stabilization Time Over This alarm is generated if the sensor (cell) voltage has not stabilized even after the calibration time is up for the reason that the calibration gas (zero gas or span gas) has not filled the sensor assembly of the detector. (1) The flow of the calibration gas is less than normal (a specified flow of 600 6 60 ml/ min). (2) The length or thickness of the calibration gas tubing has been changed (lengthened or thickened).
12.2.2.6 Alarm 11: Thermocouple Voltage Alarm This alarm is generated when the emf (voltage) of the thermocouple falls below -5 mV (about -1708 C) or exceeds 42.1 mV (about 10208 C). Whenever Alarm 11 is generated, Error-2 (heater temperature failure) occurs. (1) Breakage of the heater thermocouple signal wire between the converter and the detector occurred, or the cable is not securely connected to the connecting terminals.
12. Troubleshooting 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.
12.3.2 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. If air at the analyzer installation site is used for the reference gas, large change of moisture content in the air may cause an error in measured oxygen concentration value (vol% O2).
Customer Maintenance Parts List Model ZO21S Zirconia Oxygen Analyzer/ High Temperature Humidity Analyzer, Standard Gas Unit Item Part No. Qty 1 2 3 @ @- 1 1 1 E7050BA E7050BJ 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.
Customer Maintenance Parts List Model ZR202S Zirconia Oxygen Analyzer (Integrated type Explosionproof) A A 13 1 13 View A-A 2 7 6 5 4 3 9 10 11 8 12 Parts No. MS-code Qty.
Hood for ZR202S 1 ZR202G_F.eps CMPL 11M13A01-04E Item Parts No. Qty. Description 1 K9472UF 1 Hood Assy All Rights Reserved, Copyright © 2004, Yokogawa Electric Corporation. 2 nd Edition : Jul.
Customer Maintenance Parts List Automatic Calibration Unit for ZR202S Integrated type Explosionproof Zirconia Oxygen Analyzer High Temperature Humidity Analyzer 4 5 SPAN IN REF IN ZERO IN 8 7 10PSI K9473XC Qty Description 1 Flow Meter All Rights Reserved, Copyright © 2004, Yokogawa Electric Corporation. NUPRO Part No. 8 SS-2C2-10 Item CMPL 11M13A01-12E 1st Edition : Jun.
Revision Record Manual Title : Model ZR202S Integrated type Zirconia Oxygen Analyzer Manual Number : IM 11M13A01-04E Edition Date Remark (s) 1st April. 2005 Newly published 2nd August. 2006 • p. iV, "WARNING": Deleted description. • p. Viii, Explosionproof Approval: Added description. • p. 2-1, Section 2, "WARNING": Deleted description. • p. 2-4, Section 2.1.2, "ZR202S Integrated-type Explosionproof Oxygen Analyzer": Added description. • p. 2-5, Section 2.1.
