User's Manual Model ZR22S, ZR402G Separate type Explosionproof Zirconia Oxygen Analyzer IM 11M13A01-02E IM 11M13A01-02E 2nd Edition
Introduction The EXAxtZR Separate type Explosionproof Zirconia Oxygen Analyzer has been developed for combustion control in various industrial processes. This analyzer basically consists of a detector and a converter. You can select between several versions, based upon your application. Optional accessories are also available to improve measurement accuracy and automate calibration. An optimal control system can be realized by adding appropriate options.
This manual consists of twelve chapters. Please refer to the reference chapters for installation, operation and maintenance. Table of Contents Chapter Outline 1. Overview Equipment models and system configuration examples 2. Specifications Standard specification, model code (or part number), 3. Installation dimension drawing for each equipment Installation method for each equipment 4. Piping 5.
r ATEX Documentation This procedure is only applicable to the countries in European Union. SF 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. Kaikkien ATEX Ex -tyyppisten tuotteiden käyttöhjeet ovat saatavilla englannin-, saksan- ja ranskankielisinä.
r For the safe use of this equipment WARNING Requirements for explosionproof use: The ZR22S is connected to a ZR402G or AV550G*1 that is mounted in a non-hazardous area. The ambient temperature is in the range -20 to +608C. The surface temperature of the ZR22S is not over the temperature class T2 (3008C)*2. *1: Refer to IM 11M12D01-01E *2: The terminal box temperature does not exceed 1508C. CAUTION The cell (sensor) at the tip of the detector is made of ceramic (zirconia element).
• Every effort has been made to ensure accuracy in the preparation of this manual. However, should any errors or omissions come to the attention of the user, please contact the nearest Yokogawa Electric representative or sales office. • This manual does not cover the special specifications. This manual may not be changed on any change of specification, construction and parts when the change does not affect the functions or performance of the product.
(3) The following safety symbols are used on the product as well as in this manual. DANGER This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injury electric shock, or fatalities. The manual describes what special care the operator must exercise to avoid such risks.
r Precautions in Handling Explosionproof Zirconia Oxygen Analyzer The explosionproof zirconia oxygen analyzer (Model ZR22S) 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 ZR22S) 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 ................... vii NOTICE ...........................
3.2 Installation of the Detector (Model ZR22S-h-015) ........................................ 3-8 3.2.1 Installation Location ................................................................................ 3-8 3.2.2 Usage of the High-temperature Probe Adapter (Model ZO21P-H) ....... 3-8 3.2.3 Probe Insertion Hole ................................................................................ 3-9 3.2.4 Mounting of the High-Temperature Detector ....................................... 3-10 3.
6. Components .................................................................................................................. 6-1 6.1 ZR22S Detector ............................................................................................... 6-1 6.1.1 Explosionproof Detector (except for Model ZR22S-h-015) .................. 6-1 6.1.2 High-Temperature Detector (Model ZR22S-h-015) ............................... 6-2 6.2 ZR402G Converter ..................................................................
8.5.2 Setting Procedure ................................................................................... 8-15 8.5.3 Default Values ....................................................................................... 8-15 8.6 Other Settings ................................................................................................ 8-16 8.6.1 Setting the Date-and-Time .................................................................... 8-16 8.6.
11.1.6 Cleaning the High-temperature Probe Adapter ..................................... 11-9 11.1.7 Stopping and Re-starting Operation ...................................................... 11-9 11.2 Inspection and Maintenance of the Converter ............................................ 11-10 11.2.1 Replacing Fuses ................................................................................... 11-10 11.2.2 Cleaning .......................................................................................
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1. Overview 1. Overview The EXAxtZR Separate-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 energy2such 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 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 there is a need to monitor and control oxygen concentration. The reference gas and calibration-time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder. System 2 uses the ZR40H 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 Separate type System config. System Components Ex.1 Ex.
2. Specifications 2. Specifications This chapter describes the specifications for the following: ZR22S Separate-type explosionproof detector (See Section 2.2.1) ZO21R-L Probe protector (See Section 2.2.2) ZR22S (0.15 m) High-temperature separate-type detector (See Section 2.3.1) ZO21P-H Adapter for High temperature probe (See Section 2.3.2) ZR402G Separate type converter (See Section 2.4) ZA8F Flow setting unit (See Section 2.5.1) ZR40H Automatic calibration unit (See Section 2.5.
2.1 General Specifications 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. Measurement System: Zirconia system Oxygen concentration: 0.
2. Specifications 2.2 Separate-type Explosionproof Detector and Related Equipment Separate-type Explosionproof detector ZR22S can be used in combination with the probe protector ZO21R-L (see Section 2.2.2). 2.2.1 ZR22S Separate-type Explosionproof Detector Flameproof Type CENELEC ATEX (KEMA): ZR22S-A No.
IECEx Flameproof: ZR22S-D IECEx flameproof type Ex d IIB+H2 T2 Enclosure: IP66 IECEx type of protection "Dust" Ex tD A21 IP66 T3008 C Enclosure: IP66 NAME PLATE ZIRCONIA DETECTOR MODEL SUFFIX ZR22S MODEL : Specified model code SUFFIX : Specified suffix code STYLE : Style code AMB. TEMP : Ambient temperature NO. : Serial No. and year of production*1 YOKOGAWAr : The manufacturer name Tokyo 180-8750 JAPAN : The manufacturer address*2 STYLE AMB.TEMP -20 TO 608C NO. Tokyo 180-8750 JAPAN No. IECEx KEM 06.
2. Specifications Terminal Box Paint Color: Case; Mint green (Munsell 5.6BG3.3/2.9) Cover; Mint green (Munsell 5.6BG3.3/2.9) Finish: Polyurethane corrosion-resistant coating Gas Connection: Rc1/4 or 1/4 NPT Wiring Connection: ATEX; M20 by 1.5 mm or 1/2 NPT select one type (2 pieces) FM; 1/2 NPT (2 pieces) CSA; 1/2 NPT (2 pieces) IECEx; M20 by 1.5 mm or 1/2 NPT select one type (2 pieces) Installation: Flange mounting Probe Mounting Angle: Horizontal to vertically downward.
Option code Suffix code Model ZR22S Description Separate type Explosionproof Zirconia Oxygen Analyzer, Detector ATEX certified flameproof FM certified explosionproof CSA certified explosionproof IECEx certified flameproof Explosion -A proof -B Approval -C -D Length -015 -040 -070 -100 -150 -200 (*12) 0.15 m (for high temperature use) 0.4 m 0.7 m 1.0 m 1.5 m 2.
2. Specifications EXTERNAL DIMENSIONS Model ZR22S Separate type Explosionproof Zirconia Oxygen Analyzer, Detectors 24 63 63 f 87 63 t 85 63 f 50.8 f 51 63 Unit : mm 311 63 L tolerance (mm) 64 65 67 68 610 612 95 63 156 63 Rc1/4 or 1/4NPT Reference air inlet 2-M2031.5 or 2-1/2NPT Cable connection port 63 f124 63 25 62 L (m) 0.15 0.4 0.7 1.0 1.5 2.
2.2.2 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 ZR22S separate-type explosionproof detector in the horizontal position, be sure to select a probe protector ZO21R-L-hhh-h*B to support the probe. Insertion Length: Flange: Material: Weight: Installation: Model 1.05 m.
2. Specifications 2.3 High-Temperature Separate-type Detector and Related Equipment 2.3.1 ZR22S (0.15m) High-Temperature Separate-type Detector Standard Specifications Construction: Water-resistant Probe length: 0.15 m Terminal box: Aluminium alloy Probe material: Probe material in contact with gas: SUS 316, SUS 316L (JIS) (Probe), SUS 304 (JIS) (Flange), Zirconia (Sensor), Hastelloy B, (Inconel 600, 601) Weight: Approx.
2.3.2 ZO21P-H Adapter for High-Temperature Probe The probe adapter is used to lower the sample gas to a temperature below 7008C (below 3008C at probe adapter surface) before it is fed to the detector. Insertion length: 1 m, 1.
2. Specifications Unit: mm Approx. 351 Sample gas outlet R1/2 (Note2) Flange (Thickness 5) JIS 5K 32 FF 180 fA Flange 110 f115 f60.5 170 f60.5 t Approx. 215 Gasket (Thickness 3) Approx. 100 (Insertion length) (Note1) Detector (ZR22S) Approx. 48 Flange provided by customer f52 over High temperature Probe f30 n-[C (Note 1) 1000 or 1500 (mm) (Note 2) If the sample gas pressure is negative, connect the auxiliary ejector.
2.4 ZR402G Separate-type Converter WARNING Converter (Model ZR402G) must not be located in hazardous area. 2.4.1 Standard Specification The ZR402G Separate-type Converter can be controlled by LCD touchscreen on the converter. Display: LCD display of size 320 by 240 dot with touchscreen.
2. Specifications 2.4.2 Functions Display Functions: Value Display; Displays values of the measured oxygen concentration, etc Graph Display; Displays trends of measured oxygen concentration Data Display; Displays various useful data for maintenance, such as cell temperature, reference junction temperature, maximum/minimum oxygen concentration, or the like Status Message; Indicates an alarm or error occurrence with flashing of the corresponding icon.
Output Related Items: Analog output/output mode selection, output conditions when warming-up/maintenance/calibrating (during blowback)/abnormal, 4 mA/20 mA point oxygen concentration (vol% O2), time constant.
2. Specifications Calibration: Method; zero/span calibration Calibration mode; automatic, semi-automatic and manual (All are operated interactively with an LCD touchpanel). Either zero or span can be skipped. Zero calibration-gas concentration setting range: 0.3 to 100 vol% O2 (in increments of 0.01 vol% O2 in smallest units). Span calibration-gas concentration setting range: 4.5 to 100 vol% O2 (in increments of 0.01 vol% O2 in smallest units).
d External Dimensions Unit: mm 1 to 6 (Panel Thickness) 2-inch mounting pipe 4 - [6 holes for Wall mounting 8 10 228 57.3 36 54.7 136.3 40 40 40 (1/2NPT) 120.2 100 126.5 280 EXA ZR402G 111 46 23 8-G1/2, 8-1/2NPT etc (Wiring connection) (for wall mounting) 4 - [ 6 holes 126.5 274 +2 0 38 24 14 38 4-R8 to R10 or 4-C5 to C8 +2 190 Wall mounting 183 0 Panel Cut-out 243 64 205.5 64 123 63 155.5 63 39 62 55 62 251.5 64 94.
2. Specifications 2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit 2.5.1 ZA8F Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration (System 1). This unit consists of a flow meter and flow control valves to control the flow of calibration gas and reference air. Standard Specifications FIowmeter: Calibration gas; 0.1 to 1.0 l/min. Reference air; 0.1 to 1.0 l/min.
d External Dimensions Unit: mm f6 hole 180 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 REF OUT Flow meter AIR IN ZERO GAS IN SPAN GAS IN Instrument air Approx 1.5 l/min. Airset Air pressure ; without check valve ; measured gas pressure 1 approx.
2. Specifications 2.5.2 ZR40H Automatic Calibration Unit WARNING Automatic Calibration Unit (Model ZR40H) must not be located in hazardous area. 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 2). • Specifications Used when auto calibration is required for the separate type and instrument air is provided. The solenoid valves are provided as standard.
d External Dimensions Unit : mm 2B pipe mounting example wiring inlet ; 2-G1/2,Pg13.5,M2031.5 or 1/2NPT (wiring inlet is at same position on rear) 90 26 116.5 54 *1 4- f 6.5 41.2 140 12 41.2 71.5 49.5 Flowmeter 223 250 OCK Setting Valve for reference air Setting Valve for calibration gas Zero gas inlet Rc1/4 or 1/4 NPT 26 42 46 102 16 58 MAX calibration gas outlet Rc1/4 or 1/4 NPT reference air outlet Rc1/4 or 1/4 NPT 40 30 47.
2. Specifications d Piping Diagram REF OUT CHECK OUT EV1 flow meter flow meter *2 *2 EV2 F2.7E.EPS ZERO GAS IN AIR IN Instrument air Approx. 1.5 l/min. Air set *2 Needle valve is supplied as accessory with flow meter.
2.6 ZO21S Standard Gas Unit WARNING Standard Gas Unit (Model ZO21S) must not be 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.
2. Specifications d External Dimensions 253 228 92 Unit : mm Flow checker Span gas valve Zero gas valve 1600 Gas outlet 354 Zero gas cylinder (6 cylinder): E7050BA F2.8E.
2.7 Other Equipments 2.7.1 Auxiliary Ejector for High Temperature (Part No. E7046EC or E7046EN) This ejector is used where pressure of measured gas for high temperature detector is negative. This ejector consists of an ejector assembly, a pressure gauge and a needle valve. Standard Specifications Ejector Assembly Ejector Inlet Air Pressure: 29 to 68 kPa G Air Consumption: Approx.
2. Specifications E7046EC ; Piping connections, Rc1/4( p part) or R1/4( pp part ), E7046EN ; Piping connections,1/4NPT female ( p part) or 1/4NTP male( pp part ) Pressure gauge 39 f63f4 or 1/4 inch, conduit (stainless) Needle valve f43 Approx.88 Ejector assembly Height when fully open Approx.67 lnstrument air inlet R1/2 Approx. 70 pp Detector 38 p p p 40 Not included in high temperature use auxiliary ejector. 20 Auxiliary ejector for high-temperature mounting place use.
< Pressure setting for the auxiliary ejector for high-temperature use > Pressure supply for the auxiliary ejector should be set so that the suction flow of the measured gas becomes approximately 5 l/min. To set this, proceed as follows: (1) In Graph 4, draw a horizontal line from the 5 l/min point. on the vertical axis (Suction flow: Qg) toward the gas pressure line to be used, to find the point of intersection.
2. Specifications 2.7.2 Stop Valve (Part No. L9852CB or G7016XH) This valve mounted on the calibration gas line in the system to allow for one-touch calibration. This is applies to the system configuration shown for system 1 in section 1. Standard Specifications Connection: Rc 1/4 or 1/4 NPT Material: SUS 316 (JIS) Weight: Approx. 80 g Stop valve Part No. Description L9852CB Joint: Rc1/4, Material: SUS 316 (JIS) G7016XH Joint: 1/4NPT, Material: SUS316 (JIS) Nipple Part No.
2.7.3 Check Valve (Part No. K9292DN or K9292DS) This valve is mounted on the calibration gas line (directly connected to the detector). This is applied to a system based on the (System 2 and 3) system configuration . This valve prevents the process gas from entering the calibration gas line. Although it functions as a stop valve, operation is easier than a stop valve as it does not require opening/closing at each calibration.
2. Specifications 2.7.4 Air Set 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. Description K9473XH Joint: Rc 1/4, Material: Aluminum K9473XJ Joint: 1/4 NPT (F), Material: Body; Aluminum, Adapter; Zinc alloy T2.11E.
Horizontal mounting 22 Unit : mm View A Panel cut dimensions Vertical mounting [15 40 +0.5 2-2.2 -0 40 2-[6.5 max. 55 2-[6 screw depth 10 Max. 210 [74 Panel (Horizontal mounting) Secondary pressure gauge Panel (Vertical mounting) Secondary A 88 Primary G7004XF: Rc 1/4 K9473XG: 1/4NPT connector Approx. 122 F2.13E.EPS 2.7.5 Cylinder Regulator Valve (Part No. G7013XF or G7014XF) This regulator valve is used with the zero gas cylinders. Standard Specifications Primary pressure : Max. 14.
2. Specifications 2.7.6 Model ZR22A Heater Assembly Model Suffix code Description Option code ZR22A Heater Assembly for ZR22S Length -015 -040 (*1) -070 -100 -150 -200 0.15 m 0.4 m 0.7 m 1m 1.5 m 2m -A -N Jig for change -A with Jig (*2) None Always -A T2.13E.EPS *1: Suffix code of length should be selected as same as ZR22S installed. *2: Jig part no. is K9470BX to order as a parts after purchase. (Note) The heater is made of ceramic, do not drop or subject it to pressure stress.
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3. Installation 3. Installation This chapter describes installation of the following equipment: Section 3.1 Detector (except model ZR22S-h -015) Section 3.2 Detector (model ZR22S-h -015) Section 3.3 ZR402G Converter Section 3.4 ZA8F Flow Setting Unit Section 3.5 ZR40H Automatic Calibration Unit WARNING Converter (Model ZR402G) and Automatic Calibration Unit (Model ZR40H) must not be located in hazardous area.
Hazardous area Non-hazardous area ZR22S DETECTOR AV550G Solenoid Valve Solenoid Valve Needle Valve Needle Valve Regulator Solenoid Valve Instrument Air Regulator Stop Valve Span Gas Zero Gas Flow meter F3.01E.EPS Figure 3.1 Connection with AV550G Regarding the AV550G installation procedure, refer to IM 11M12D01-01E. 3.1 Installation of the Detector 3.1.
3. Installation • Take care not to generate mechanical sparking when accessing to the detector and peripheral devices in hazardous location Note 4: Maintenance and Repair • The detector modification or parts replacement by other than authorized representative of Yokogawa Electric Corporation is prohibited and will void CENELEC ATEX (KEMA) Flameproof Certification. Note 5: Cable Entry • The type of cable entry is marked near the cable entry port according to following codes.
3.1.4 CSA Explosionproof Type ZR22S-C Detector for use in hazardous locations: 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 location, 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 ZR22S-D Detector for use in hazardous locations: Note 1: IECEx KEM 06.0006 IECEx flameproof type Ex d IIB+ H2 T2 Enclosure: IP66 IECEx type of protection "Dust" Ex tD A21 IP66 T3008C 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 Includes those analyzers equipped with a probe supporter and probe protector. When preparing the probe insertion hole, the following should be taken into consideration: 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 3.4 for the dimensions. • If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards.
3. Installation 3.1.7 Installation of the Detector CAUTION • The cell (sensor) at the tip of the detector is made of ceramic (zirconia). Do not drop the detector, as impact will damage it. • 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 the Detector (Model ZR22S-h-015) 3.2.1 Installation Location This model detector is used with the High-temperature Probe Adapter (Model ZO21P-H) when the temperature of sample gas exceeds 7008 C, or when it is required due to maintenance spaces. The following should be taken into consideration when installing the detector: (1) Easy and safe access to the detector for checking and maintenance work.
3. Installation (4) To prevent temperature rises due to radiant heat, insert heat insulator between the wall of the furnace and the probe adapter. (5) To prevent temperature rises from thermal conduction, place the mounting flange as far from the wall of the furnace as possible. CAUTION When a heater is used in hazardous area, then be sure to use appropriate explosionproof heater and wiring conduit.
3.2.4 Mounting of the High-Temperature Detector Note Ceramic (zirconia) is used in the sensor (cell) portion on the detector probe tip. Care should be taken not to drop the detector during installation. The same applies to a probe made of silicon carbide (SiC). A gasket should be used on the flange surface to prevent gas leakage. The gasket material should be selected depending on the characteristics of the measurement gas. It should be heatproof and corrosion-proof.
3. Installation 3.3 Installation of the Converter WARNING Converter (Model ZR402G) must not be located in hazardous area. 3.3.1 Location The following should be taken into consideration when installing the converter: (1) Readability of the indicated values of oxygen concentration or messages on the converter display. (2) Easy and safe access to the converter for operating keys on the panel. (3) Easy and safe access to the converter for checking and maintenance work.
dMounting procedure 1. Put four bolts in the holes on the fitting. 2. Clamp the pipe with the fitting and a bracket, with the four bolts passing through the bracket holes. 3. Secure the fitting and the bracket tightly to the pipe with four washers and nuts. A pipe to be mounted (nominal JIS 50A) Bracket *Fitting Nut *Washer *Screw Bolt * Note: These fittings are attached to the equipment when it is delivered. Washer F3.08E.EPS Figure 3.
3. Installation (1) Cut out the panel according to Figure 3.11. Unit: mm +2 274 0 +2 183 0 F3.11E.EPS Figure 3.11 Panel cutout sizes (2) Remove the fitting from the converter by loosening the four screws. (3) Insert the converter case into the cutout hole of the panel. (4) Attach the mounting fitting which is once removed in step (2) again to the converter. (5) Firmly fix the converter to the panel. Fully tighten the two clamp screws to hold the panel with the fitting.
3.4 Installation of ZA8F Flow Setting Unit 3.4.1 Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector and the converter (3) No corrosive gas. (4) An ambient temperature of not more than 558 C and little changes of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain. 3.4.
3. Installation (1) Make a hole in the wall as illustrated in Figure 3.14. Unit : mm 223 140 4 - f6.5 hole, or M6 screw F3.14E.EPS Figure 3.14 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. F3.15E.EPS Figure 3.
3.5 Installation of ZR40H Automatic Calibration Unit WARNING Automatic Calibration Unit (Model ZR40H) must not be located in hazardous area. 3.5.1 Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector and the converter (3) No corrosive gas. (4) An ambient temperature of not more than 558 C and little change of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain.
3. Installation (1) Make a hole in the wall as illustrated in Figure 3.17. Unit : mm 223 140 4 - f6.5 hole, or M6 screw F3.14E.EPS Figure 3.17 Mounting holes (2) Mount the Automatic Calibration Unit. Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit on the wall with four screws. When setting it with M5 bolts, use washers. 4-[6.5 F3.18E.EPS Figure 3.
3.6 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 the detector. 1.
4. Piping 4. Piping This chapter describes piping procedures based on two typical system configurations for EXAxt ZR Separate-type Explosionproof Zirconia Oxygen Analyzer. • Ensure that each check valve, stop valve and joint used for piping do not allow leakage. Especially, if there is any leakage of the calibration gas from pipes and joints, it may cause clogging of the pipes or incorrect calibration. • Be sure to conduct leakage test after piping.
4.1 Piping for System 1 Piping in System 1 is illustrated in Figure 4.1. Hazardous area Non-hazardous area ZR402G Converter ZR22S Separate type Explosionproof Zirconia Oxygen Analyzer, Detector Stop valve or Check valve EXA ZR402G ~ 100 to 240 V AC ZA8F flow setting unit flowmeter Reference gas Needle valve Air Set Instrument air Span gas (*) Calibration gas Pressure regulator Zero gas cylinder * Calibration gas unit same as for zero gas. F1.1E.EPS Figure 4.
4. Piping 4.1.1 Piping Parts for System 1 Check that the parts listed in Table 4.1 are ready. Table 4.1 Detector General-use detector Piping location Calibration gas inlet Parts Stop valve or check valve Nipple * Zero gas cylinder Gas pressure regulator High-temperature Detector (0.
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 ZR22S detector. The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 408 C. Mount a regulator valve (specified by YOKOGAWA) on the cylinder.
4. Piping 4.1.5 Piping to the High-temperature Probe Adapter • The measured gas should be at a temperature below 7008 C before reaching the detector sensor. If the gas is under negative pressure, it should be fed to the detector by suction. • For usage of the probe adapter when using high-temperature detector, refer to Section 3.2.2. • If the measured gas is under negative pressure, connect the auxiliary ejector (E7046EC/E7046EN) as illustrated in Figure 4.3.
In cases where condensation is likely to occur in the probe adapter when the sample gas is cooled, protect the probe adapter with an insulating material as illustrated in Figure 4.5. Cover flange Sample gas outlet Adapter for high temperature probe Detector Insulating material Probe F4.5E.EPS Figure 4.
4. Piping 4.2 Piping for System 2 Piping in System 2 is illustrated in Figure 4.7. 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 reducing valve so that these two pressures are approximately the same. The flow rate of zero and span gases (normally instrument air) are set by a single needle valve.
Hazardous area Non-hazardous area ZR402G Converter ZR22S Separate type Explosionproof Zirconia Oxygen Analyzer, Detector EXA ZR402G *1 Check valve Signal (6-core shield cable) ~ Heater (2-core) flowmeter 100 to 240 V AC Contact input Analog output, contact output Digital output (HART) Needle valve Reference gas Air Set Calibration gas Instrument air Pressure regulator ZR40H Auto Calibration unit *2 Calibration gas unit case Zero gas cylinder F1.2E.
4. Piping The following parts are required for blowback piping. • Blow pipe (to be prepared as illustrated in Figure 4.9.) • Two-way solenoid valve: “ Open “ when electric current is on. (Found on the open market) • Air set (recommended by YOKOGAWA, K9473XH / K9473XJ or G7004XF / K9473XG) Manufacture the blow pipe as illustrated in Figure 4.9, and mount it on the hightemperature probe adapter. Unit : mm Rc1/4 Blind flange of the adapter for high temperature probe Welded 8 (O.D.
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5. Wiring 5. Wiring In this Chapter, the wiring necessary for connection to the EXAxtZR Separate-type Explosionproof Zirconia Oxygen Analyzer is described. 5.1 General CAUTION • NEVER supply current to the converter or any other device constituting a power circuit in combination with the converter, until all wiring is completed. • This product complies with CE marking. Where compliance with CE marking is necessary, the following wiring procedure is necessary. 1.
CAUTION • Select suitable cable O.D. to match the cable gland size. • Protective grounding should be connected in ways equivalent to D style (Class 3) grounding (the grounding resistance is 100V or less). • Special consideration of cable length should be taken for the HART communication, For the detail, refer to Section 1.1.2 of the IM 11M12A01-51E " Communication Line Requirement ". 5.1.
5. Wiring 5.1.2 Wiring Connect the following wiring to the converter. It requires a maximum of eight wiring connections as shown below. (1) Detector output (connects the converter with the detector.) (2) Detector heater power (connects the converter with the detector.
5.1.3 Mounting of Cable Gland For each cable connection opening of the converter, mount a conduit that matches the thread size, or a cable gland. EXA ZR402G 8-G1/2, 8-1/2NPT or the like (Wiring connection) Ground terminal (M4) Adaptor for 1/2 NPT thread F5.3E.EPS Figure 5.
5. Wiring 5.2 Wiring for Detector Output This wiring enables the converter to receive cell output from the detector, output from a thermocouple and a reference junction compensation signal. Install wires that allow for 10V of loop resistance or less. Keep detector wiring away from power wiring. Separate signal and power wiring. CAUTION Be sure to read Section 3.1.2 to 3.1.5 where the important information on writing is provided.
5.2.1 Cable Specifications During operation of the process, the terminal box may get quite hot and may reach temperatures of up to 1508 C. The cable may be exposed to even higher temperatures, so be sure to use suitably heat-resistant cable. Basically, PVC sheathed PVC insulated cable (six core) is used for this wiring. When the ambient temperature of the detector exceeds 808 C, install a terminal box, and connect with the detector using six-piece 600V silicon rubber insulated glass braided wire. 5.2.
5. Wiring 5.2.3 Connection to the Converter To connect the wiring to the converter, proceed as follows: (1) M4 screws are used for the terminals of the converter. Each wire in the cable should be terminated in the corresponding size crimp-on terminal. (2) When a rubber insulated glass braided wire is used for wiring to the detector, use a terminal box. For wiring between the terminal box and the converter, basically use cable, e.g. PVC sheathed PVC insulated cable, rather than individual wires.
5.3 Wiring for Power to Detector Heater This wiring provides electric power from the converter to the heater for heating the sensor in the detector. CAUTION Refer to section 3.1.
5. Wiring (3) The size of the terminal screw threads is M3.5. Each cable should be terminated in the corresponding size crimp-on terminals contact (*1) respectively. *1 If the terminal box's surface temperature at the detector installation site exceeds 608 C, use a “ bare crimp-on terminal”. CAUTION • Before opening the detector cover, loosen the lock screw. If the screw is not loosened first, the screw will damage the cover, and the terminal box will require replacement.
5.4 Wiring for Analog Output This wiring is for transmitting 4 to 20 mA DC output signals to a device, e.g. recorder. Maintain the load resistance including the wiring resistance at 550V or less. ZR402G Converter Receiver 1 1 2 AO1(+) AO1(-) AO2(+) AO2(-) Receiver 2 Shielded cable FG 1 2 F5.8E.EPS Figure 5.8 Wiring for analog output 5.4.1 Cable Specifications For this wiring, use a 2-core or a 4-core shielded cable. 5.4.2 Wiring Procedure (1) M4 screws are used for the terminal of the converter.
5. Wiring 5.5 Power and Grounding Wiring This wiring supplies power to the converter and grounds the converter/detector. ZR402G Converter ZR22S Detector L N G Grounding to the ground terminal on the converter case Converter case Ground Jumper plate FG terminal Lock washer Crimp-on terminal of the ground wire 100 - 240VAC 50/60Hz F5.9E.EPS Figure 5.9 Power and Grounding wiring 5.5.1 Power Wiring Connect the power wiring to the L and N terminals of the converter.
5.6 Contact Output Wiring Contact outputs 1 to 3 can be freely assigned to "low limit alarm", "high limit alarm", etc. user selectable, but the assignment of contact output 4 is fixed ("error output"). And the action (contact closed on error output) also cannot be changed. When using these contact outputs, install the wiring as follows: Converter Terminal box Annunciator or the like DO-1 DO-1 DO-2 #1 Output #2 Output DO-2 DO-3 #3 Output DO-3 DO-4 DO-4 #4 Output F5.10E.EPS Figure 5.
5. Wiring 5.7 Wiring for ZR40H Automatic Calibration Unit This wiring is for operating the solenoid valve for the zero gas and the span gas in the ZR40H Automatic Calibration Unit, in a system where the calibration gas flow rate is automatically controlled (e.g. System configuration 2). When installing this wiring, proceed as follows: Wiring inlet 2-G1/2, Pg13.
5.7.2 Wiring Procedure M4 screws are used for the terminals of the converter. Each cable should be terminated in the corresponding crimp-on terminals. M4 screws are used for the terminals of the solenoid valve as well. ZR402G Converter AC-Z ZR40H Automatic Calibration unit Zero AC-S AC-C Span F5.12E.EPS Figure 5.
5. Wiring 5.8 Contact Input Wiring The converter can execute specified function when receiving contact signals. To use these contact signals, wire as follows: ZR402G Converter Terminal box DI-1 Contact input 1 DI-2 DI-C Contact input 2 F5.13E.EPS Figure 5.13 Contact Input Wiring 5.8.1 Cable Specifications Use 2-core or 3-core cable for this wiring. Depending on the number of input(s), determine which cable to use. 5.8.2 Wiring Procedure (1) M4 screws are used for the terminals of the converter.
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6. Components 6. Components In this Chapter, the names and functions of components are described for the major equipment of the EXAxt ZR Separate-type Explosionproof Zirconia Oxygen Analyzer. 6.1 ZR22S Detector 6.1.1 Explosionproof Detector (except for Model ZR22S-h-015) Probe this part is inserted in the furnace. Select length from 0.15, 0.4, 0.7, 1.0, 1.5 or 2.0 m. Contact Flange used to mount the detector. Select from JIS or ANSI standard models.
6.1.2 High-Temperature Detector (Model ZR22S-h-015) Sample gas outlet When a negative measurement gas pressure is used, connect the auxiliary ejector assembly. When the measurement gas is high-temperature and high-pressure, and does not fall below 7008C, connect a pressure control valve (e.g. a needle valve). (Refer to Section 3.
6. Components 6.2 ZR402G Converter Complete Operation Display d Interactive operations along with operation display d A variety of display modes2enabling you to Typical Converter Displays d Example of basic display select the operation mode freely d Back-lit LCD display allows viewing even in areas of low lighting d Error codes and details of errors are displayed no need to refer to instruction manual d Password for security This data display provides for interactive operation.
6.3 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve Flow meter for reference gas Flow meter for calibration gas F6.4E.EPS Figure 6.4 ZA8F Flow Setting Unit Flow meter for calibration gas Flow meter for reference gas Reference gas flow setting valve Terminal Box Made in Japan REF.OUT CAL.OUT SPAN IN ZERO IN Calibration gas flow setting valve F6.5E.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. System tuning by the HART communicator, refer to IM11M12A01-51E " HART Communication Protocol ". 7.1 Checking Piping and Wiring Connections Check that the piping and wiring connections have been properly completed in accordance with Chapter 4, “Piping,” and Chapter 5, “Wiring.” 7.
7.3 Supplying Power to the Converter CAUTION To avoid temperature changes around the sensor, it is recommended that (rather than turning it on and off) power be continuously supplied to the Oxygen Analyzer if it is used in an application where it is used periodically. It is also recommended to flow a span gas (instrument air) beforehand. Supply power to the converter. A display as in Figure 7.1, which indicates the detector’s sensor temperature, then appears.
7. Startup 7.4 Touchpanel Switch Operations 7.4.1 Basic Panel and Switch The converter uses a touchpanel switch which can be operated by just touching the panel display. Figure 7.3 shows the basic panel display. The switches that appear in the switch display area vary depending on the panel display, allowing all switch operations. Table 7.1 shows the switch functions. Tag name display area Tag: 21.0 Primary value % O2 Secondary value Tertiary value 17.43mA -Output1 17.
7.4.2 Display Configuration (for Oxygen Analyzer) Figure 7.3.1 shows the configuration. A password the displays positioned below enables display Execution/Setup to be protected. If a password has not been set, press the [Enter] key to proceed to the next panel display. The Home key enables you to return to Execution/Setup from any panel display.
7. Startup 7.4.3 Display Functions Individual panel displays in the display configuration provide the following functions: (1) Basic panel display: Displays the values measured in three selected items (see Section 7.9, “Setting Display Item”). (2) Execution/Setup display: Selects the calibration, maintenance and setup items. (3) Detailed-data display: This allows you to view such detailed data as the cell electromotive force and cell temperature (see Section 10.1.
Operation Press the [ABC] key once. Press and hold the [ABC] key. Display A2 AA B C AB2 Release the [ABC] key when the character B appears in the cursor position. Enter the character C in the same manner as above. Press the [other] key. ABC2 Press and hold the [$%&] key and enter %. Then press the [0-9] key. ABC%2 Enter the numeric characters 1, 2 and 3 in turn. Press the [Enter] key to complete the entry. ABC%1232 Ex7.
7. Startup 7.5 Confirmation of Converter Type Setting This converter can be used for both the Oxygen Analyzer and the Humidity Analyzer. Before setting the operating data, be sure to check that the desired converter model has been set. Note that if the converter type setting is changed, the operating data that have been set are then initialized and the default settings remain. To set the desired operating data, follow these steps: (1) Press the setup key. (2) Use the.
7.6 Confirmation of Detector Type Setting Check that the detector in Figure 7.7 is the one for this equipment. WARNING • If this converter is to be used in conjunction with the ZO21D*, the power requirements are limited to 115 V AC or less, 50 Hz or 60 Hz (it cannot be used with a 125 V or greater, or in the EEC). • If detector settings are to be changed, first disconnect the wiring connections between the detector and the converter. Then change detector settings appropriately.
7. Startup 7.9 Setting Display Item This section briefly describes the display item settings shown in Figure 7.11, “Basic Panel Display.” Tag name Tag: 21.0 Primary value %O2 Secondary value Tertiary value 17.43mA -Output1 17.43mA -Output2 F7.11E.EPS Figure 7.11 Basic Panel Display (1) Press the Setup key in the basic panel display to display the Execution/Setup display. Then select Maintenance in the Execution/Setup display.
Table 7.2 Display Items Item Primary value Secondary and tertiary values Oxygen concentration s s s s Air ratio Moisture quantity Current output 1 s s s Current output 2 s Output 1 item Output 2 item s s Display Oxygen concentration during measurement Current computed air ratio Moisture quantity (%H2O) in the exhaust gas Oxygen concentration with the equipment set for oxygen analyzer (See *1 below.) Oxygen concentration with the equipment set for oxygen analyzer (See *1 below.
7. Startup 7.10 Checking Current Loop The set current can be output as an analog output. (1) Press the Setup key on the basic panel display to display the Execution/Setup display. Then select Maintenance in the Execution/Setup display. (2) Select “mA-output loop check” in the Maintenance panel display to display the “mAoutput loop check” display, enabling you to check “mA-output1” and “mA-output2.” Select the desired output terminal for current-loop checking (see Figure 7.15.1).
7.11 Checking Contact I/O Conduct the contact input and output checking as well as operational checking of the solenoid valves for automatic calibration. 7.11.1 Checking Contact Output To check the contact output, follow these steps: (1) Press the Setup key in the basic panel display to display the Execution/Setup display. Select Maintenance in that display. (2) Select Contact check then contact output in the Maintenance panel display to display the Output contact check display (see Figure 7.15.2).
7. Startup 7.11.2 Checking Calibration Contact Output The calibration contacts are used for solenoid valve drive signals for the ZR40H Automatic Calibration Unit. When using the ZR40H Automatic Calibration Unit, use the calibration contact output to check that the wiring connections have been properly completed and check equipment operation. (1) Referring to Section 7.11.1, display the contact check display. (2) Select the Calibration contacts to display the panel display as Figure 7.15.3 shows.
7.12 Calibration The converter is calibrated in such a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases. There are three types of calibration procedures available: (1) Manual calibration conducting zero and span calibrations, or either of these calibrations in turn.
7. Startup (2) Span-gas concentration With “Span gas conc” selected in the Calibration setup display, display the Numericdata Entry display and enter an oxygen concentration value for the span-gas calibration; If instrument air is used, enter 02100 for a 21 vol% O2 value. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.
(3) Follow the display message in Figure 7.19 to turn on span gas flow. Open the spangas flow valve for the Flow Setting Unit by loosening the valve lock-nut and slowly turning the valve shaft counterclockwise to flow the span gas at 600 ml/min. ± 60 ml/min. Use the calibration gas flowmeter to check the flow. Manual calibration Manual calibration Open span gas valve. 21.00% Set flow span gas to 0.5min./div 600ml/min. Valve opened r Cancel calibration 1.00% Enter 21.0 %O2 CAL. TIME F7.19E.
7. Startup (7) Follow the instructions in the display as in Figure 7.23 to turn on the zero gas flow. To do this, open the zero-gas flow valve for the Flow Setting Unit and adjust that valve to obtain a flow of 600 ml/min. ± 60 ml/min. (The valve should be adjusted by loosening its lock nut and slowly turning the valve shaft counterclockwise. Use the calibration gas flowmeter to check the flow.) Manual calibration Open zero gas valve. Set flow zero gas to 600ml/min.
(9) After the measured value has stabilized, press the [Enter] key to display the “zerocalibration complete” display shown in Figure 7.26. At this point, the measured value is corrected to equal the zero-gas concentration, setting are made to agree. Close the zero-gas flow valve. The valve lock-nut should be tightened completely so that the zero gas does not leak. Manual calibration Zero calibration Close the zero gas valve. Span calibration r End Enter F7.26E.EPS Figure 7.
8. Detailed Data Setting 8. 8.1 Detailed Data Setting Current Output Setting This section describes setting of the analog output range. 8.1.1 Setting Minimum Current (4 mA) and Maximum Current (20 mA) To set the minimum and maximum currents, proceed as follows: (1) Select Setup in the Execution/Setup display. (2) Select the mA-output setup in the Setup display. (3) Select mA-output1 in the mA-output display. (4) Select Min. oxygen conc. in the mA-output1 range display and press the [Enter] key.
Maximum oxygen concentration, %O2 (for a maximum current of 20 mA) Setting example 2 If the setting (for a 4 mA current) is 75% O2, you must set the oxygen concentration for the maximum (20 mA) point at more than 98% O2 (75 3 1.3). (Numbers after the decimal point are rounded up.) 95 85 75 Ranges over which oxygen concentrations can be set 65 55 45 Outside ranges 35 25 15 5 5 15 25 35 45 55 Minimum oxygen concentration, %O2 (for a minimum current of 4 mA) 8.1.3 65 75 F8.0E.
8. Detailed Data Setting 8.1.5 Default Values When the analyzer is delivered or reset to defaults, the output current default settings by as shown in Table 8.1.1. Table 8.1.1 Output Current Default Values Item Default setting Min. oxygen concentration 0% O2 Max. oxygen concentration 25% O2 Output damping constant 0 (seconds) Output mode Linear T8.1.1E.
8.2 Output Hold Setting The “output hold” functions hold an analog output signal at a preset value during the equipment’s warm-up time or calibration or if an error arises. Outputs 1 and 2 can be set individually. Table 8.1.2 shows the analog outputs that can be retained and the individual states. Table 8.1.
8. Detailed Data Setting For semi-automatic calibration, “under calibration” is the time required from entering calibration instructions to perform a, either by using the touchpanel or by a contact input, calibration until the output stabilization time elapses. For automatic calibration, “under calibration” is the time required, after performing an appropriate calibration until the output stabilization time elapses. (4) During “Blowback” (see Section 10.
8.2.3 Output Hold Setting To set the output hold, follow these steps: (1) Press the Setup key in the basic panel display to display the Execution/Setup display. Then select Setup in the Execution/Setup display. Next, select the mA-output setup and then the mA-output preset display as shown in Figure 8.2. mA-outputs presets mA-outputs presets Warm up: 4mA r Preset value: 4 . 0 mA r Maintenance: Hold r Preset value: 4 . 0 mA r Cal.blowback: Hold r Preset value: 4 . 0 mA r Error: Preset r Preset value: 3 .
8. Detailed Data Setting 8.3 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 out the alarm operations and setting procedures. 8.3.1 Alarm Values (1) High-high and high alarm values If high-high and high alarm values are set to ON, then alarms occur if measured valves exceed the alarm set values.
In the example in Figure 8.4, the high-limit alarm point is set to 7.5% O2, the delay time is set to five seconds, and hysteresis is set to 2% O2. Alarm output actions in this figure are as follows: (1) In “A” Although oxygen concentration value exceed the high-limit alarm setpoint, it falls lower than the high-limit alarm setpoint before the preset delay time of five seconds elapses. So, no alarm is issued.
8. Detailed Data Setting Oxygen alarms Alarms setup Parameter: High High alarm: OFF r Set value: 1 0 0 . 0 % O2 r High alarm: ON r Set value: 1 0 0 . 0 % O2 r Low alarm: OFF r Set value: 0 . 0 % O2 r Low Low alarm: OFF r Set value: 0 . 0 % O2 Oxygen r Hysteresis: r Contact delay: 0.1%O2 3s r Setpoints Enter Figure 8.5 Alarms Setup Display 8.3.4 Enter F8.6E.EPS F8.5E.EPS Figure 8.
8.4 Output Contact Setup 8.4.1 Output Contact Mechanical relays provide contact outputs. Be sure to observe relay contact ratings. (For details, consult the specifications requirements.) The operation modes of each contact output are as follows. For output contacts 1 to 3 you can select open or closed contact when the contact is “operated.” Default is closed. For output contact 4, contact is closed. When power fails, contact outputs 1 to 3 are open, and 4 is closed. Table 8.
8. Detailed Data Setting Output contact 1 Contact setup Output contact 1 Alarms r Others r During power-off the contact is open and in condition it is Open r Output contact 2 r Output contact 3 r lnput contacts Enter F8.7E.EPS Figure 8.7 Contact Setup Display Contact1 r r r r r r r Enter F8.8E.EPS Figure 8.8 Output Contact 1 Display Others Warm up: Range change: Calibration: Maintenance: Blow back: Temp.input high: Cal.gas press.low: Process up set: ON OFF OFF ON OFF OFF OFF OFF Enter F8.9E.
Table 8.5 Output Contact Settings Item to be selected High-highlimit alarm High-limit alarm Alarm and Error settings Low-limit alarm Low-low-limit alarm Calibration coefficient alarm Startup power stabilization timeout alarm Error Warm-up Output range change Other settings Calibration Maintenance Blow-back High-limit temperature alarm Calibrationgas press. low Process upset Brief description If "high-high alarm ON" is selected, contact output occurs when the high-high-limit alarm is issued.
8. Detailed Data Setting 8.4.3 Default Values When the analyzer is delivered, or if data are initialized, alarm and other setting defaults are as shown in Table 8.6. Table 8.
8.5 Input Contact Settings 8.5.1 Input Contact Functions The converter input contacts execute set functions by accepting a remote dry-contact (“voltage-free contact”) signal. Table 8.7 shows the functions executed by a remote contact signal. Table 8.7 Input Contact Functions Item Function Calibration-gas pressure drop While the contact signal is on, neither semi-automatic nor automatic calibration is possible.
8. Detailed Data Setting 8.5.2 Setting Procedure The following are set so that semi-automatic calibration starts when input contact open is applied to “Input1.” Proceed as follows: (1) Press the Setup key in the Basic panel display to display the Execution/Setup display. (2) Select Setup in the Execution/Setup display to display the “Commissioning” (Setup) display. (3) Select “Contact setup” in the “Commissioning” (Setup) display. (4) Select “Input contacts” in the Contact setup display.
8.6 Other Settings 8.6.1 Setting the Date-and-Time The following describe how to set the date-and-time. Automatic calibration or blowback works following this setting. Proceed as follows: (1) Press the Setup key in the Basic panel display to display the Execution/Setup display. (2) Select Setup in the Execution/Setup display to display the “Commissioning” (Setup) display. (3) Select Others in the “Commissioning” (Setup) display. The Others display then appears, as shown in Figure 8.13. (4) Select Clock.
8. Detailed Data Setting 8.6.2.2Default Values When the analyzer is delivered, or if data are initialized, the average-value calculation periods and maximum- and minimum-value monitoring periods are by default one hour and 24 hours respectively. Averaging Set period over which average is calculated: 1h r Set period over which maximum and minimum is stored: 24h Enter F8.15E.EPS Figure 8.15 Setting Average-Value Calculation Periods and Maximum- and Minimum-Value Monitoring Periods 8.6.3 Setting Fuels 8.
Fill in the boxes with fuel parameters in Equation 2 above to calculate the moisture content. Use A0, Gw and X shown in Table 8.8. If there are no appropriate fuel data in Table 8.8, use the following equations for calculation. Find the value of “Z” in Equations 1 and 2 using Japanese Standard JIS B 8222. If a precise measurement is not required, obtain the value of “Z” using a graph Figure 8.17 for the absolute humidity indicated by a dry and wet bulb hygrometer.
8. Detailed Data Setting 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 F8.17E.EPS Figure 8.
Table 8.8 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 1.59 1.47 0.00 8.87 11.93 0.
8. Detailed Data Setting 8.6.3.2Procedure To make a fuel setting, follow these steps: (1) Press the Setup key in the basic panel display to display the Execution/Setup display. (2) Select Setup in the Execution/Setup display. The “Commissioning” (Setup) display then appears. (3) Select Others in that display and then the Fuel setup shown in Figure 8.18. (4) Choose the Theoretical air quantity and the Content of moisture in the exhaust gas in turn. The numeric-data entry display then appears.
8.6.4 Setting Purging Purging is to remove condensed water in the calibration gas pipe by supplying a span calibration gas for a given length of time before warm-up of the detector. This prevents cell breakage during calibration due to condensed water in the pipe. Open the solenoid valve for the automatic calibration span gas during purging and after the purge time has elapsed, close the valve to start warm-up.
8. Detailed Data Setting 8.6.5 Setting Passwords The converter enables password settings to prevent unauthorized switching from the Execution/Setup menu lower level menu displays. Set passwords for calibration, blowback and maintenance use and for setup use individually. Proceed as follows: (1) Press the Setup key in the basic panel display to display the Execution/Setup display. (2) Choose Setup to display the “Commissioning” (Setup) display.
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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% O2 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.
81.92 Zero origin ez Cell electromotive force, mV Calibration curve before correction 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 (percent oxygen by volume) Zero-point correction factor = (B/A) x 100 (percent) Correctable range: 100 ± 30 percent Span correction factor = (C/A) x 100 (percent) Correctable range: 0 ± 18 percent F9.3E.EPS Figure 9.
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.
9.2.1.2Calibration Procedure Select both span and zero calibrations or span calibration only or zero calibration only. Usually select span and zero calibrations. Select Points from the Calibration setup display and then you can select “Both,” “Span” or “Zero” (see Figure 9.5 below). Calibration setup Calibration setup Mode: Manual r Points: Semi_Auto Auto r Zero gas conc: 1.00% r Span gas conc: 2 1 . 0 0 % r Points: Both r Zero gasSpan conc: 1.00% Zero r Span gas conc: 21 .
9. Calibration 9.2.1.5Setting Calibration Time • When the calibration mode is in manual: First set the output stabilization time. This indicates the time required from the end of calibration to entering a measurement again. This time, after calibration, the measurement gas enters the sensor to set the time until the output returns to normal. The output remains held after completing the calibration operation until the output stabilization time elapses.
(1) Select the “Calibration timing” display. A panel display as shown in Figure 9.7 appears. (2) Select each item for the calibration to display the numeric-data entry display. Enter the desired numeric values for the calibration. Calibration timing Hold time: 1 0 min 0 0 s r Csl time: 1 0 min 0 0 s r lnterval: 30d 00h r Start date: 0 1 / 0 1 / 0 0 r Start time: 00:00 Enter F9.7E.EPS Figure 9.
9. Calibration 9.2.3 Calibration 9.2.3.1Manual Calibration For manual calibration, consult Section 7.12, “Calibration” earlier in this manual. 9.2.3.2Semi-automatic Calibration To start calibration, follow these steps: (1) Press the Setup key in the basic panel display to display the Execution/Setup display. Then select Calibration from the Execution/Setup display. The Calibration display shown in Figure 9.8 appears.
9.2.3.3Automatic Calibration No execution operations are required for automatic calibration. Automatic calibration starts in accordance with a preset start date and time. Calibration is then executed at preset intervals. CAUTION Before conducting a semi-automatic or automatic calibration, run the automatic calibration unit beforehand to obtain a calibration flow of 600 ± 60 ml/min.
10. Other Functions 10. Other Functions 10.1 Display 10.1.1 Detailed Display Press the Detailed-data key on the basic panel display to display the detailed operation data as shown in Figure 10.1. Pressing the . or m key, you can advance the page or go back to your desired page. • Detailed-data display There are ten panel displays for viewing detailed data. The following briefly describe the operational data displayed on the detailed-data display. Tag: Span gas ratio: 0.0% Zero gas ratio 100.
10.1.1.2 Response Time The cell’s response time is obtained in the procedure shown in Figure 10.3. 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. Other Functions 10.1.1.6 Cell Voltage The cell (sensor) voltage will be an index to determine the amount of degradation of the sensor. The cell voltage corresponds to the oxygen concentration currently being measured. If the indicated voltage approximates the ideal value (corresponding to the measured oxygen concentration), the sensor will be assumed to be normal. The ideal value of the cell voltage (E), when the oxygen concentration measurement temperature is controlled at 7508 C.
10.1.1.11 Maximum Oxygen Concentration The maximum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed. If the setup period elapses, the maximum oxygen concentration that has been displayed so far will be cleared and a new maximum oxygen concentration will be displayed. If the setup period of time is changed, the current maximum oxygen concentration will be displayed (for more details, see Section 8.6.2 earlier in this manual). 10.1.1.
10. Other Functions 10.1.2 Trend Graph Press the Graph display key in the basic panel display to switch to the graph display. This will help grasp the measured-value trend. Touching anywhere on the graph display will return to the basic panel display. To set the trend graph display, follow the steps in Section 10.1.2.1. 10.1.2.1 Setting Display Items (1) Press the Setup key in the Basic panel display to display the Execution/Setup display. Select Maintenance from the Execution/Setup display.
25.0%O2 10min./div Upper limit set Time per graduation, calculated by the set sampling period Lower limit set 0.0%O2 12.3%O2 60 data items Currently measured value Sampling period F10.5E.EPS Figure 10.5 Plotting Graph for Sampling Period 10.1.2.3 Setting Upper and Lower Limit Values on Graph Set upper- and lower-limit values on the graph in the following procedure: Press Upper limit in the Trend graph display. The numeric-data entry key appears. Enter the upper-limit value.
10. Other Functions 10.1.3 Auto(matic) Revert Time While the Execution/Setup display, or any other display that is positioned lower than the Execution/Setup display (see Figure 7.3.1, earlier in this manual), is displayed, if there is no key entry from the touchpanel for a certain time, the current display will automatically return to the basic panel display. This action is referred to as “auto return.” The “auto return” time setting starts from no key entry to the return to automatic return.
Display setup r Display item r Trend graph r Auto return time: 0 min Language: English Deutsch Francias Enter F10.7E.EPS Figure 10.7 Display Setup Display 10.2 Blowback d Blowback Setup The following sections describe the blowback setup procedures required for carrying out blowback. 10.2.1 Mode There are three blowback modes available: (1) No function – blowback disabled.
10. Other Functions 10.2.2 Operation of Blowback Figure 10.9 shows a timing chart for the operation of blowback. To execute blowback with a contact input, use a contact input with an ON-time period of one to 11 seconds. Once blowback starts, a contact output opens and closes at ten-second intervals during the preset blowback time. After the blowback time elapses, the analog output remains held at the preset status until the hold time elapses (refer to Section 8.1, earlier in this manual).
In the Blowback setup display shown in Figure 10.10, if you choose “Mode: No function” or “Semi-auto blowback,” the Interval, Start Date, and Start Time for these are not displayed. CAUTION • If the blowback is executed with an input contact, it must be preset in the Input contacts setting (for more details, see Section 8.5, earlier in this manual). • In Section 8.4, “Output Contact Setup,” earlier in this manual, set the contact used as the blowback switch beforehand.
10. Other Functions 10.3 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 function-by-function initialization. Table 10.5 lists the initialization items and default values. To initialize the set data, follow these steps: (1) Press the Setup key in the Basic panel display to display the Execution/Setup display. Then choose Setup.
Table 10.
10. Other Functions Item Data to be initialized Parameter Alarm setting Hysteresis Alarm data Alarm set value Contacts Output contact 1 Output contact 2 Other settings Output contact 3 Default setting Oxygen concentration 0.
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 10.5 Handling of the ZO21S Standard Gas Unit (Non CE Mark) The following describe how to flow zero and span gases using the ZO21S Standard Gas Unit. Operate the ZO21S Standard Gas Units, according to the procedures that follow. 10.5.1 Standard Gas Unit Component Identification Carrying case Flow checker Checks the zero- and span-gas flow. Span gas valve Controls the span-gas (air) flow. Zero gas valve regulator Cover screws (six pcs.
10.5.2 Installing Gas Cylinders Each ZO21S Standard Gas Unit comes with six zero-gas cylinders including a spare. Each gas cylinder contains 7-liters of gas with a 0.95 to 1.0 vol% O2 (concentration varies with each cylinder) and nitrogen, at a pressure of 700 kPaG (at 358 C). The operating details and handling precautions are also printed on the product. Please read them beforehand. To install the gas cylinder, follow these steps: (1) Attach the zero gas valves onto the gas cylinder.
10. Other Functions The standard gas unit is used only when manual calibration is employed. Therefore, the timing for flowing span gas (air) is included in the manual calibration flowchart described in Section 10.5.2. For operation of the converter, see Section 7.12, earlier in this manual. (1) When the message “Open span gas valve” is displayed on the converter display during calibration, plug the power cord into the power supply socket to start the pump of the standard gas unit.
(1) Use the needle of the zero gas valve “ CHECK GAS “ to puncture a hole in the gas cylinder installed as described in Section 10.5.2. Fully clockwise turn the valve regulator by hand. (2) Next, adjust the flow rate to 600 ± 60 ml/min (the flow check ball stops floating on the green line when the valve is slowly opened). Turn the regulator of the zero-gas valves back slowly counterclockwise. At that time, the flow rate also decreases as the inner pressure of the gas cylinder decreases.
10. Other Functions 10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F Flow Setting Unit is used as a calibration device for a system conforming to System 2. Calibration in such a system is to be manually operated. So, you have to operate the valve of the Flow Setting each time calibration is made (starting and stopping the calibration gas flow and adjusting the flow rate). This applies even if you are using the ZR40H Autocalibration Unit. For operation of the converter, see Section 7.
10.6.3 Operating the Zero Gas Flow Setting Valve Operate the zero gas flow setting valve during zero-point calibration in the following procedures: (1) When the display shown in Figure 10.17 appears during calibration, open the zero gas flow setting valve of the flow setting unit and adjust the flowrate to 600 ± 60 ml/min. To rotate the valve shaft, if the valve has a lock nut loosen the lock nut and slowly turn it counterclockwise. To check the flowrate, monitor the calibration gas flow meter.
11. Inspection and Maintenance 11. Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxtZR 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 (600 ± 60 ml/min) , clean the calibration gas tube.
11. Inspection and Maintenance 11.1.2 Replacing the Sensor Assembly The performance of the sensor (cell) deteriorates as its surface becomes soiled during operation. Therefore, you have to replace the sensor when its life expectancy expires, for example, when it can no longer satisfy a zero-gas ratio of 100630 percent or a span-gas ratio of 0618 percent. In addition, the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement.
3. Part assembly procedure (1) First, install the contact. Being careful not to cause irregularities in the pitch of the coil spirals (i.e., not to bend the coil out of shape), place it in the ringed groove properly so that it forms a solid contact. Groove in which the contact (E7042BS) is placed F11.2E.EPS Figure 11.2 Installing the Contact (2) Next, make sure that the O-ring groove on the flange surface of the sensor is clean.
11. Inspection and Maintenance Metal O-ring Sensor U-shaped pipe support Bolts (four) 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.
14 A 13 11 10 12 A 22 8 9 ( 22 ) 7 4 5 3 6 ( 22 ) 2 1 21 TC +(with Si TUBE) TC - 32 CELL + View A - A 26 24 16 27 25 15 1 17 23 ( 12 ) CELL 2 3 TC 4 5 CJ 28 31 29 30 6 7 H T R 8 20 ( 13 ) 18 19 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 terminal box 14 6 , following Section 11.1.2, earlier in this manual. Open the and remove the three terminal connections – CELL +, TC + and TC -. Before disconnect the HTR terminals, remove the terminal block screw 26 . Keeping the other terminal remaining to be connected. Disconnect the two HTR connections. (These terminals have no polarity.
11.1.4 Replacement of flame arrester assembly If it takes longer for the analyzer to return to read the concentration of a sample gas after calibration, the flame arrester may have become clogged. Inspect the flame arrester and if necessary, clean or replace it. Set the flame arrester assembly 1 in place using a special pin spanner (with a pin 4.5 mm in diameter: part no. K9471UX or equivalent).
11. Inspection and Maintenance 11.1.6 Cleaning the High-temperature Probe Adapter CAUTION • Do NOT subject the probe of the High-temperature Probe Adapter (ZO21P-H-A) to shock. This probe uses silicon carbide (SiC) which may become damaged if it is subjected to a strong shock or thermal shock. The high-temperature detector is structured so that the gas to be measured is directed toward the detector with the high-temperature probe adapter.
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. A dirty touchpanel should be wiped off with a soft dry cloth. 11.2.1 Replacing Fuses The converter incorporates a fuse, as indicated in Figure 11.6. If the fuse blows out, replace it in the following procedure.
11. Inspection and Maintenance To replace the fuse, follow these steps: (1) Turn off the power to the converter for safe replacement. (2) Remove the fuse from its holder. With the appropriate flat-blade screwdriver that just fits the holder cap slot (Figure 11.7), turn the fuse holder cap 908 counterclockwise. By doing so, you can remove the fuse together with the cap. Cap Flat-blade screwdriver Socket Fuse F11.7E.EPS Figure 11.
11.2.3 Adjust LCD screen contrast An LCD is built in the ZR402G converter. The contrast of this LCD is affected by its ambient temperature. For this reason, the LCD is shipped, after adjusting the contrast so as to become the most suitable in a room temperature(20-308 C). However, when display on the LCD is hard to see, adjust the LCD contrast by change the resistance of the variable resistor; its position is shown in Fig. 11.8 Variable resistor Figure 11.
11. Inspection and Maintenance 11.3 Replacing Flow meter in ZR40H Autocalibration Unit (1) Remove piping and wiring, and remove the ZR40H from the 2B pipe or wall mounting. (2) Remove four M6 bolts between brackets. (3) Remove piping extension (4) Remove bolts holding flow meter, and replace it. A white back plate (to make the float easy to see) is attached. The end of the pin holding down the back plate must be on the bracket side. (5) Replace piping, and fix M6 bolts between brackets.
C D Two screws fix flow meter Connect piping pairs A-A', B-B', C-C', D-D' A' A C' B' D' B F11.10E.eps Fig. 11.
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).
12. Troubleshooting 12.1.2.2 Error-2: Heater Temperature Failure This error occurs if the detector heater temperature does not rise during warm-up, or if the temperature falls below 7308C or exceeds 7808C after warm-up is completed. In addition, when error-2 occurs, alarm 10 (cold junction temperature alarm) or alarm 11 (thermocouple voltage alarm) may be generated at the same time.
CAUTION • Measure the thermocouple resistance value after the difference between the detector tip temperature and the ambient temperature decreases to 508C or less. If the thermocouple voltage is large, accurate measurement cannot be achieved. 12.1.2.3 Error-3: A/D Converter Failure/Error-4: Writing-to-memory Failure • A/D Converter Failure It is suspected that a failure has occurred in the A/D converter mounted in the electrical circuits inside the converter.
12. 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. Tag: Tag: 21.0 Alarm 6 :Zero conc.ratio %O2 17.42mA -Output1 17.42mA -Output2 F12.3E.EPS Figure 12.3 F12.4E.EPS Figure 12.4 Table 12.
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 8.3, “Setting Oxygen Concentration Alarms,” in the chapter on operation. 12.2.2.2 Alarm 6: Zero-point Calibration Coefficient Alarm In calibration, this alarm is generated when the zero correction factor is out of the range of 100 6 30% (refer to Section 9.1.
12. Troubleshooting (4) Confirm whether deterioration of or damage to the sensor assembly that caused the alarm has occurred abruptly during the current calibration in the following procedure: a. Call up the detailed data display. b. Display “Calibration time history” by pressing the . key (Figure 12.6). Since the ten previous span-correction factor and zero-correction factor values can be checked in this display, changes in deterioration of the sensor can be seen. Tag: Tag: Cell voltage: 0 . 6 mV 4 2 .
12.2.2.3 Alarm 7: Span-point Calibration Coefficient Alarm In calibration, this alarm is generated when the span correction factor is out of the range of 0 6 18% (refer to Section 9.1.3, “Compensation”). The following are suspected as the cause: (1) The oxygen concentration of the span gas does not agree with the value of the span gas set “Calibration setup.” (2) The flow of the span gas is out of the specified flow value (600 mL/min 660 mL/ min).
12. Troubleshooting 12.2.2.5 Alarm 10: Cold Junction Temperature Alarm This alarm is generated when the temperature of the cold junction located at the terminal block of the detector falls below -258C or exceeds 1558C. Check the following: Display “C.J.Temperature” in the detailed data display. If “C.J.Temperature” is indicated as 2008C or -508C, the following can be considered.
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 -1708C) or exceeds 42.1 mV (about 10208C). 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 Countermeasures When Measured Value Shows Error The causes that the measured value shows an abnormal value is not always due to instrument failures. There are rather many cases where the causes are those that measuring gas itself is in abnormal state or external causes exist, which disturb the instrument operation. In this section, causes of and measures against the cases where measured values show the following phenomena will be described.
12.3.2 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 detector 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 ZR22S Zirconia Oxygen Analyzer, Detector (Separate type Explosionproof) A 13 A 1 13 View A-A 2 7 6 5 4 3 9 10 11 8 12 F02E.EPS Parts No. MS-code Qty.
Customer Maintenance Parts List Model ZR402G Zirconia Oxygen Analyzer/High Temperature Humidity Analyzer,Converter 1 Hood for ZR402G ZR402G 2 Item Parts No. Qty. 1 2 A1113EF K9471UF 1 1 Description Fuse (3.15A) Hood All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. CMPL 11M12C01-01E 2nd Edition : Feb.
Customer Maintenance Parts List Model ZR40H Separate type Zirconia Oxygen Analyzer/ High Temperature Humidity Analyzer, Automatic Calibration Unit 6 LOCK ZERO LOCK COMMON SPAN ZERO 10 9 AUTO CALIBRATION UNIT MODEL SUFFIX ZR40H STYLE S1 SUPPLY 690kPa MAX. AMB.TEMP-20 TO 558C USED WITHZR402G NO. Made in Japan REF.OUT Item Part No. 6 K9473XC Qty Description 1 Flowmeter CAL.OUT SPAN IN ZERO IN All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation.
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 E7046EC/E7046EN Zirconia Oxygen Analyzer Auxiliary Ejector (for Model ZO21P-H) 1 3 2 4 5 Item 1 2 3 4 5 6 7 6 7 Parts No. Qty.
Customer Maintenance Parts List Model ZO21P-H Zirconia Oxygen Analyzer High Temperature Probe Adaptor 5,6 4 7 3 8,9,10 ZR22G 2 1 Item Parts No. Qty. Description 1 E7046AL E7046BB E7046AP E7046AQ E7046AD 1 1 1 1 1 Probe (SiC, L=1.0m) Probe (SiC, L=1.5m) Probe (SUS, L=1.0m) Probe (SUS, L=1.
Revision Record Manual Title : Model ZR22S, ZR402G Separate type Explosionproof Zirconia Oxygen Analyzer Manual Number : IM 11M13A01-02E Edition Date Remark (s) 1st Apr. 2005 Newly published 2nd Jul. 2006 • p. iv, p. 2-1, p. 3-1. Warning about Explosionproof: Deleted description. • p. vii, Explosionproof Approval: Added description. • p. 2-3, Section 2.2.1, "ZR22S Separate-type Explosionproof Detector": Added description. • p. 2-4, Section 2.2.
