Yokogawa IR200 User Manual

User's Manual

IR200 Infrared Gas Analyzer

IM 11G02M01-01E

3rd Edition

PREFACE

We are grateful for your purchase of Yokogawa’s Infrared Gas Analyzer (Model : IR200).

• First read this instruction manual carefully until an adequate understanding is acquired, and then proceed to installation, operation and maintenance of the analyzer. Wrong handling may cause an accident or injury.

• The specifications of this analyzer are subject to change without prior notice for further product improvement.

• Modification of this analyzer is strictly prohibited unless a written approval is obtained from the manufacturer. Yokogawa will not bear any responsibility for a trouble caused by such a modification.

• This instruction manual shall be stored by the person who actually uses the analyzer.

• After reading the manual, be sure to store it at a place easier to access.

• This instruction manual should be delivered to the end user without fail.

Manufacturer: Yokogawa Electric Corporation. Type: Described in Yokogawa’s company nameplate on main frame Date of manufacture: Described in Yokogawa’s company nameplate on main frame Product nationality: Japan

Request

• It is prohibited to transfer part or all of this manual without Yokogawa’s permission.

• Description in this manual is subject to change without prior notice for further improvement.

iIM 11G02M01-01E

CAUTION ON SAFETY

First of all, read this “Caution on safety” carefully, and then use the analyzer in the correct way.

• The cautionary descriptions listed here contain important information about safety, so they should always be observed. Those safety precautions are ranked in 3 levels, “DANGER”, “CAUTION” and “PROHIBITION”.

Wrong handling may cause a dangerous situation, in which

DANGER

CAUTION

there is a risk of death or heavy injury.

Wrong handling may invite a dangerous situation, in which there is a possibility of medium-level trouble or slight injury or only physical damage is predictable.

PROHIBITION

Caution on installation and transport of gas analyzer

DANGER

CAUTION

Items which must not be done are noted.

• This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent explosion, fire or other serious accidents.

• For installation, observe the rule on it given in the instruction manual and select a place where the weight of gas analyzer can be endured.

Installation at an unsuited place may cause turnover or fall and

there is a risk of injury.

• For lifting the gas analyzer, be sure to wear protective gloves. Bare hands may invite an injury.

• Before transport, fix the casing so that it will not open. Otherwise, the casing may be separated and fall to cause an injury.

• During installation work, care should be taken to keep the unit free from cable chips or other foreign objects. Otherwise, it may cause fire, trouble or malfunction of the unit.

ii IM 11G02M01-01E

Caution on piping

DANGER

CAUTION

In piping, the following precautions should be observed. Wrong piping may cause gas leakage.

If the leaking gas contains a toxic component, there is a risk of serious accident being induced.

Also, if combustible gas is contained, there is a danger of explosion, fire or the like occurring.

• Connect pipes correctly referring to the instruction manual.

• Exhaust should be led outdoors so that it will not remain in the locker and installation room.

• Exhaust from the analyzer should be relieved in the atmospheric air in order that an unnecessary pressure will not be applied to the analyzer. Otherwise, any pipe in the analyzer may be disconnected to cause gas leakage.

• For piping, use a pipe and a pressure reducing valve to which oil and grease are not adhering. If such a material is adhering, a fire or the like accident may be caused.

Caution on wiring

• Wiring work must be performed with the main power set to

OFF to prevent electric shocks.

• Enforce construction of class-D grounding wire by all means.

If the specified grounding construction is neglected, a shock hazard or fault may be caused.

• Wires should be the proper one meeting the ratings of this

instrument. If using a wire which cannot endure the ratings, a fire may occur.

• Be sure to use a power supply of correct rating. Connection of

power supply of incorrect rating may cause fire.

DANGER

CAUTION

Caution on use

• For correct handling of calibration gas or other reference gases, carefully read their instruction manuals beforehand. Otherwise, carbon monoxide or other hazardous gases may cause an intoxication particularly.

• Before leaving unused for a long time or restarting after left at such a status for an extended length of time, follow the directions of each instruction manual because they are different from normal starting or shutdown. Otherwise, the performance may be poor and accidents or injuries may be caused.

• Do not operate the analyzer for a long time with its door left open. Otherwise, dust, foreign matter, etc. may stick on internal walls, thereby causing faults.

iiiIM 11G02M01-01E

• Do not allow metal, finger or others to touch the input/output

PROHIBITION

Caution on maintenance and check

DANGER

CAUTION

terminals in the instrument. Otherwise, shock hazard or injury may occur.

• Do not smoke nor use a flame near the gas analyzer. Otherwise, a fire may be caused.

• Do not allow water to go into the gas analyzer. Otherwise, hazard shock or fire in the instrument may be caused.

• When doors are open during maintenance or inspection, be sure to purge sufficiently the inside of the gas analyzer as well as the measuring gas line with nitrogen or air, in order to prevent poisoning, fire or explosion due to gas leak.

Be sure to observe the following for safe operation avoiding the shock hazard and injury.

• Remove the watch and other metallic objects before work.

• Do not touch the instrument wet-handed.

Caution on use

CAUTION

• If the fuse is blown, eliminate the cause, and then replace it with the one of the same capacity and type as before. Otherwise, shock hazard or fault may be caused.

• Do not use a replacement part other than specified by the instrument maker. Otherwise, adequate performance will not be provided. Besides, an accident or fault may be caused.

• Replacement parts such as a maintenance part should be disposed of as incombustibles. For details, follow the local ordinance.

Others

• If the cause of any fault cannot be determined despite reference to the instruction manual, be sure to contact your dealer or Fuji Electric’s technician in charge of adjustment. If the instrument is disassembled carelessly, you may have a shock hazard or injury.

iv IM 11G02M01-01E

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.

d If we replace the product with a new one, we won’t provide you with a repair report. d Yokogawa warrants the product for the period stated in the pre-purchase quotation.

Yokogawa shall conduct defined warranty service based on its standard. When the customer site is located outside of the service area, a fee for dispatching the maintenance engineer will be charged to the customer.

d In the following cases, customer will be charged repair fee regardless of warranty

period.

• Failure of components which are out of scope of warranty stated in instruction manual.

• Failure caused by usage of software, hardware or auxiliary equipment, which Yokogawa did not supply.

• Failure due to improper or insufficient maintenance by user.

• Failure due to misoperation, misuse or modification which Yokogawa does not authorize.

• Failure due to power supply (voltage, frequency) being outside specifications or abnormal.

• Failure caused by any usage out of scope of recommended usage

• Any damage from fire, earthquake, a storm and flood, lightning, disturbance, riot, warfare, radiation and other natural changes.

d Yokogawa does not warrant conformance with the specific application at the user

site. Yokogawa will not bear direct/indirect responsibility for damage due to a specific application.

d Yokogawa will not bear responsibility when the user configures the product into

systems or resells the product.

d Maintenance service and supplying repair parts will be covered for five years after

the production ends. For repair this product, please contact the nearest sales office described in this instruction manual.

vIM 11G02M01-01E

PREFACE.............................................................................................................................. i

CAUTION ON SAFETY .................................................................................................... ii

r After - Sales Warranty ................................................................................................... v

1. OVERVIEW ................................................................................................................. 1-1

2. NAME AND DESCRIPTION OF EACH PART ..................................................... 2-1

2.1 Description of each unit.................................................................................. 2-1

3. INSTALLATION ......................................................................................................... 3-1

3.1 Selection of installation location ..................................................................... 3-1

3.2 Installation of analyzer.................................................................................... 3-2

3.3 Piping ............................................................................................................... 3-2

3.4 Sampling.......................................................................................................... 3-3

3.5 Wiring method ................................................................................................ 3-6

4. OPERATION ...............................................................................................................4-1

4.1 Preparation for operation ................................................................................ 4-1

4.2 Warm-up operation and regular operation ...................................................... 4-1

5. DESCRIPTION OF DISPLAY AND OPERATION PANELS .............................. 5-1

5.1 Name and description of operation panel....................................................... 5-1

5.2 Overview of display and operation panel....................................................... 5-2

5.3 Overview of display screen ............................................................................. 5-3

5.4 General operation ............................................................................................ 5-6

6. SETTING AND CALIBRATION .............................................................................. 6-1

6.1 Changeover of range ....................................................................................... 6-1

6.2 Calibration setting ........................................................................................... 6-2

6.2.1 Setting of calibration concentration ........................................................ 6-2

6.2.2 Setting of calibration gas......................................................................... 6-4

6.2.3 Setting of manual zero calibration .......................................................... 6-6

6.2.4 Setting of calibration range ..................................................................... 6-8

6.2.5 Setting of auto-calibration component .................................................. 6-10

6.3 Alarm setting ................................................................................................. 6-12

6.3.1 Setting of alarm values.......................................................................... 6-12

6.3.2 Hysteresis setting................................................................................... 6-14

6.4 Setting of auto calibration............................................................................. 6-15

6.4.1 Auto calibration ..................................................................................... 6-15

6.4.2 Forced stop of auto calibration ............................................................. 6-17

6.5 Setting of auto zero calibration..................................................................... 6-19

6.5.1 Auto zero calibration ............................................................................. 6-19

6.5.2 Forced stop of auto zero calibration ..................................................... 6-21

6.6 Peak alarm setting ......................................................................................... 6-23

6.7 Parameter setting ........................................................................................... 6-25

6.8 Maintenance mode ........................................................................................ 6-29

6.9 Calibration ..................................................................................................... 6-32

6.9.1 Zero calibration ..................................................................................... 6-32

6.9.2 Span calibration ..................................................................................... 6-33

vi IM 11G02M01-01E

7. MAINTENANCE ......................................................................................................... 7-1

7.1 Daily check ...................................................................................................... 7-1

7.2 Daily check and maintenance procedures ...................................................... 7-1

7.3 Replacement of power fuse ............................................................................. 7-2

7.4 Moisture interference compensation adjustment ............................................ 7-3

7.5 Cleaning of measuring cell ............................................................................. 7-4

7.5.1 Disassembly and assembly of measuring cell ........................................ 7-4

7.5.2 How to clean cell..................................................................................... 7-9

7.6 Inspection and maintenance of limited service-life components ................... 7-9

8. TROUBLESHOOTING .............................................................................................. 8-1

8.1 Error message.................................................................................................. 8-1

8.2 Other Troubleshooting .................................................................................... 8-3

9. SPECIFICATIONS...................................................................................................... 9-1

9.1 Specifications .................................................................................................. 9-1

9.2 Model and Suffix codes .................................................................................. 9-5

9.3 External Dimensions .................................................................................... 9-10

Customer Maintenance Parts List ............................................... CMPL 11G02M01-01E

Revision Record .................................................................................................................... i

viiIM 11G02M01-01E

1. OVERVIEW

The infrared gas analyzer (IR200) measures the concentrations of CO2, CO, CH4, SO2, NO and O2 contained in sample gas.

2, CO, CH4, SO2, and NO are measured by non-dispersion infrared method, while O2 is measured by

CO paramagnetic or fuel cell method. Up to 4 components including O of components other than O

2) can be measured simultaneously.

A high-sensitivity mass flow sensor is used in the detector unit of infrared method. Due to use of single beam system for measurement, maintenance is easy and an excellent stability is ensured for a long period of time.

In addition, a microprocessor is built in and a large sized liquid crystal display is provided for easier operation, higher accuracy and more functions.

This analyzer is thus optimum for combustion control of various industrial furnaces, botanical study and global atmospheric research.

2 (3 at the maximum for measurement

1 - 1IM 11G02M01-01E

2. NAME AND DESCRIPTION OF EACH PART

2.1 Description of each unit

INFRARED GAS ANALYZER

(1) Handle (2) Power switch

POWER

MODE

ESC

ENT

(11) Terminal block 5 (10) Terminal block 4

(13) Connector 2

(7) Terminal block 1 (8) Terminal block 2 (9) Terminal block 3

ZERO

SPAN

(3) Display and operation panel

(6) Purge gas inlet (5) Sampling gas outlet

(4) Sampling gas inlet

(12) Power inlet

Name Description

(1) Handle Draws the analyzer unit from the case. (2) Power switch Turns ON/OFF this analyzer. (3) Display/Operation panel Liquid crystal display and keys for various operational settings are arranged. (4) Sampling gas inlet Port for connecting the sample gas injection pipe (5) Sampling gas outlet Port for connecting the pipe for discharging the gas after analysis (6) Purge gas inlet Port for connecting the purge gas pipe (7) Terminal block 1 Analog output terminals (8) Terminal block 2 O2 analyzer signal and contact input terminals (9) Terminal block 3 Contact input/output terminals (10) Terminal block 4 Contact output terminal (11) Terminal block 5 Alarm output terminal (12) Power inlet Used to connect the power cable. (13) Connector for Used to connect the communication cable.

communication

Fig. 2-1 Name and description of each unit

2 - 1IM 11G02M01-01E

3. INSTALLATION

DANGER

This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent

explosion, fire or other serious accidents.

CAUTION

•For installation, observe the rule on it given in the instruction manual and select a place where the weight of gas analyzer can be endured. Installation at an unsuited place may cause turnover or fall and there is a risk of injury.

•For lifting the gas analyzer, be sure to wear protective gloves. Bare hands may invite an injury.

•Before transport, fix the casing so that it will not open. Otherwise, the casing may be separated and fall to cause an injury.

•The gas analyzer is heavy. It should be transported carefully by two or more persons if manually required. Otherwise, body may be damaged or injured.

•During installation work, care should be taken to keep the unit free from cable chips or other foreign objects. Otherwise, it may cause fire, trouble or malfunction of the unit.

3.1 Selection of installation location

To install the analyzer for optimum performance, select a location that meets the following conditions;

(1) Use this instrument indoors. (2) A vibration-free place (3) A place which is clean around the analyzer.

(4) Power supply

Voltage rating ;100 V AC to 240 V AC Allowable range ; 85 to 264 V AC Frequency ; 50 Hz / 60 Hz Power consumption; 70 VA max. Inlet ; Conform to EN60320

Protection Class 1

(5) Operation conditions

Ambient temperature : -5 to 45°C Ambient humidity : 90% RH or less, no condensation

3 - 1IM 11G02M01-01E

3.2 Installation of analyzer

There are two methods of installing the analyzer. For detailed dimensions, see Chapter 9.3.

Types

External dimensions

Mounting dimensions

(Unit:mm)

Mounting method

Guide rail

Slide rail

19 inch rack mounting (Note)

INFRARED GAS ANALYZER

POWER

MODE

ZERO

ESC

ENT

SPAN

429 483

177

101.6

450 or more

465

Guide rail

Slide rail

Note) The mounting method should be selected to meet the installation requirements since the top

cover must be detached from the gas analyzer for maintenance and check.

Mounting method

Slide rail Guide rail Maintenance space is provided at the top.

Recommended slide rail: 305A-20, Accuride International Inc.

No maintenance space is provided at the top.

Conditions

These methods must be rigid enough to withstand the mass (about 10 kg) of the gas analyzer.

Remarks

3.3 Piping

CAUTION

Caution on piping

In piping, the following precautions should be observed. Wrong piping may cause gas leakage.

If the leaking gas contains a toxic component, there is a risk of serious accident being induced.

Also, if combustible gas is contained, there is a danger of explosion, fire or the like occurring.

• Connect pipes correctly referring to the instruction manual.

• Exhaust should be led outdoors so that it will not remain in the locker and installation room.

• For piping, use a pipe and a pressure reducing valve to which oil and grease are not adhering. If such a material is adhering, a fire or the like accident may be caused.

3 - 2 IM 11G02M01-01E

Observe the following when connecting the gas pipes.

• The pipes should be connected to the gas inlet and outlet at the rear panel of the analyzer, respectively.

• Connect the sampling system to the instrument by using corrosion-resistant tube such as Teflon, stainless steel, or polyethylene. In case where there is no danger of corrosion, don't use rubber or soft vinyl tube. Analyzer indication may become inaccurate due to the adsorption of gases.

• Piping connections are Rc1/4 (1/4 NPT) female-threaded. Cut the pipe as short as possible for quick response. Pipe of ø 4mm (inside diameter) is recommendable .

• Entry of dust in the instrumant may cause operation fault. Use clean pipes and couplings.

Purge gas inlet Sampling gas outlet

Sampling gas inlet

Sampling gas inlet: Connect the pipe so that zero/span calibration standard gas or

Sampling gas outlet: Measured gas is exhausted after measurement.

Purge gas inlet: It is used for purging the inside of the total gas analyzer. When the

3.4 Sampling

(1) Conditions of sample gas

1. The dust contained in sample gas should be eliminated completely with filters. The filter at the final stage should be capable of eliminating dust of 0.3 microns.

2. The dew point of sample gas must be lower than the ambient temperature for preventing formation of drain in the analyzer. If water vapor is contained in sample gas, its dew point should be reduced down to about 0°C through a dehumidifier.

3. If SO

4. If a large amount of highly corrosive gas such as Cl

5. Sample gas temperature is allowed within a range from 0 to 50°C. Pay attention not to flow

3 mist is contained in sample gas, the mist should be eliminated with a mist filter,

cooler, etc. Eliminate other mist in the same way.

the service life of analyzer will be shortened. So, avoid such gases.

hot gas directly into the analyzer.

Fig. 3-1 Piping

measured gas pretreated with dehumidification is supplied properly. The gas flow rate should be kept constant within the range of 1 ± 0.5L/min.

Connect the pipe so that the gas may escape through the gas outlet into the atmosphere.

analyzer must be purged, refer to Item 3.4, Purging inside Analyzer. Use dry gas N

2 or instrumentation air for purge gas. (flow rate of

1L/min or more should be used and no dust or mist is contained).

2, F2 or HCl is contained in sample gas,

3 - 3IM 11G02M01-01E

(2) Sampling gas flow rate

A flow rate of sampling gas must be 1 ± 0.5L/min. A flow meter should be provided as shown in Fig. 3-2 to measure flow rate values.

(3) Preparation for standard gas

Prepare the standard gas for zero/span calibration.

Without O

Zero gas

Span gas except for O

Span gas for O

* We recommend you to feed the zero gas shown above by humidifying it, if NO or SO

components to be analyzed.

gas

Gas with concentration of 90% or more of full scale

Analyzer Built in O2 Analyzer

gas Dry air, air or gas in

Gas with concentration of 90% or more of full scale

Gas with concentration of 90% or more of full scale or atmospheric air (21%)

Externally mounted

zirconia O

concentration of 80% or higher of the O be contained in zero gas if CO meter is provided.)

Gas with concentration of 90% or more of full scale

1 to 2% O

range (CO2 should not

Analyzer

gas

is included in

(Note) It is understood to influence the calibration model of the infrared gas analyzer when a lot of H

2 ,

He, and Ar are included in the measurment gas (pressure broadening). The span gas must use a gas near the composition of the measurement gas when you measure the

gas like the above-mentioned.

(4) Reduction of moisture interference

NO and SO

2 measurement is subject to moisture interference.

As shown by the configuration example on the next page, provide a device for humidifying zero calibration gas, thus controlling the moisture content at a constant level (moisture content in sample gas should also be controlled here) in configuring a sampling system. That allows the same moisture content as in the case of measurement to be contained in zero gas for calibration.

(5) Purging of instrument inside

The inside of instrument need not be purged generally except for the following cases.

1. A combustible gas component is contained in sample gas.

2. Corrosive gas is contained in the atmospheric air at the installation site.

3. The same gas as the sample gas component is contained in the atmospheric air at the installation site.

In such cases as above, the inside of analyzer should be purged with the air for instrumentation

2. Purging flow rate should be about 1L/min.

or N If dust or mist is contained in purging gas, it should be eliminated completely in advance.

(6) Pressure at sampling gas outlet

Pressure at the sampling gas outlet should be set to atmospheric pressure.

3 - 4 IM 11G02M01-01E

(7) Example of sampling system configuration

Pump

4-way selector cock

Primary filter

Safety drain trap

Electronic dehumidifier

Drain pot

Standard gas

for zero calibration

Standard gas for span calibration

Ball valve

Drain

Sample gas inlet

Flow meter

Exhaust (atmospheric pressure)

Secondary filter

Gas

analyzer

(IR200)

External

O2 analyzer

F03.EPS

Measurement of sample gas with low moisture content (room-temperature saturation level or below): CO, CO

and CH4 measurement

A dehumidifier must be used for CO (0-200 ppm) and SO

measurements (to prevent saturation at 28C). Even in any other gas measurements, if sample gas has a high moisture content or if condensation is likely to occur, a safety drain trap and a dehumidifier should be used.

The system configuration may vary depending upon the nature of measured gas, coexistent gases or application. A typical configuration diagram is shown in Fig. 3-2. Since a system configuration depends upon measured gas, consult with Yokogawa.

Measurement of sample gas with high moisture content or NO, SO2, or CO (0-200 ppm range) measurement

Primary filter

Pump

Atmosphere

Safety dran trap

Drain

A dehumidifier must be used for NO, SO2, and CO (0-200 ppm) measurements (to prevent saturation at 28C). Use either atmospheric air or cylinder gas as a zero calibration gas and supply it through a bubbler (humidifying) to reduce interference of water.

Solenoid

valve

Standard gas for zero calibration

Pump

3-way solenoid valve

Bubbler

Electronic dehumidifier

Drain pot

Ball valve

Solenoid valve

Flow meter

Solenoid valve

Standard gas for span calibration

NO2/NO

converter

Secondary filter

Gas analyzer

(IR200)

External O2 analyzer

Exhaust (atmospheric pressure)

No.

Primary filter (mist filter) Remove dust and mist

Safety drain trap

Pump

Electronic dehumidifier

Drain pot

Ball valve

4-way selector cock

Standard gas for calibration

Flow meter

Secondary filter (membrane filter) Remov fine dust

10 11

NO2/NO converter Convert NO2 gas into NO gas 3-way solenoid valve Used for introducing humidified gas

Bubbler Humidify calibration gas

Solenoid valve Used for switching sampling and calibration lines

Item

Fig. 3-2 A typical example of sampling system

Separate and discharges drain Suck in sample ga Dehumidify sample gas Collect discharged water from dehumidifier Used for discharging drain Used for switching sampling and calibration lines Used for zero/span calibration Adjust and monitor sample gas flow rate

Description

T03.EPS

3 - 5IM 11G02M01-01E

3.5 Wiring method

Caution on wiring

• Wiring work must be performed with the main power set to OFF to prevent electric shocks.

CAUTION

Each external terminal is provided on the rear panel of the analyzer. (See Fig. 3-3) Wire each terminal, referring to Fig. 3-3 and (1) to (7).

• Enforce construction of class-D grounding wire by all means, 100V or less. If the specified grounding construction is neglected, a shock hazard or fault may be caused.

• Wires should be the proper one meeting the ratings of this instrument. If using a wire which cannot endure the ratings, a fire may occur.

• Be sure to use a power supply of correct rating. Connection of power supply of incorrect rating may cause fire.

Terminal block 4

Terminal block 5 Terminal block 3 Terminal block 2

Terminal block 1

Connector for communication

Fig. 3-3 Rear panel

(1) Power inlet

When using supplied power cable, connect the female side to the power inlet at the rear panel of the analyzer, and insert the male side into a receptacle matching the rating.

Power inlet (3 pins)

Female side

Supplied power cable

(

Fig. 3-4

)

Male side

100 to 240V AC 50/60Hz

3 - 6 IM 11G02M01-01E

When noise source is in the vicinity

Do not install the instrument near an electric device that generates noise from the power supply (such as high-frequency furnace and electric welder). If there is no other choice but to install it near such devices, provide completely separate power line to eliminate noise.

IR200 power supply

Varistor or spark killer

Locate and connect in close proximity

In case noise may enter from a relay, solenoid valve, etc. through power supply, connect a varistor or

Noise source

spark killer to the noise source as shown below. If the varistor or spark killer is located away from the noise source, no effect is obtainable. So, locate near the noise source.

(2) Analog output signal (AO): terminal block 1, 1 to 10, 15 to 20.

Output signal: 4 to 20 mA DC or 0 to 1 V DC (selected when ordering)

Non-insulated output

Allowable load: 4 to 20 mA DC, 550Ω or less

0 to 1 V DC, 100kΩ or more

• Analog output is provided from each terminal corresponding to the channel displayed in the

measurement screen.

Note) All of analog output signals for the instrument are not isolated. It is recommended to

isolate signals individually to prevent interference from unnecessary signals or to prevent external interference, especially leading the cable of more than 30 meters to

outdoor.

2 sensor input: terminal block 2,

(3) O

– 2.

Input signal:

External zirconia O External O

2 analyzer: 0 to 1 V DC (DC input resistor of 1MΩ or more)

• It is used when the external zirconia O

• To connect to the output of the external Zirconia analyzer or external O

2 analyzer: Zirconia O2 sensor signal (ZX8D*C output)

2 analyzer or external O2 analyzer is specified as order.

2 analyzer prepared

separately.

• In case of an external O

2 analyzer, input a signal of 0 to 1 V DC with respect to O2 full scale

of the analyzer.

• In case of built-in O

Note) O

2 senser input is not isolated. It is recommended to isolate input signal to prevent

2 analyzer, do not use the terminals.

inter ference from unnecessary signals or to prevent external interference. Zirconia O

2 sensor should be installed at a location that is as close to this instrument

as possible.

3 - 7IM 11G02M01-01E

(4) Contact input (DI): terminal block 2, 13 to 20, terminal block 3, 5 to 10.

• It is for a contact input at no voltage. An input is provided when switching to short circuit

(on) or open (off).

• No voltage is applied to the terminals.

(5) Contact output (DO): terminal block 3,

to 20, terminal block 4 and terminal block 5

• Contact rating: 250 V AC/2 A, load resistance

• An output is for a relay contact output. An output is provided when switching to conductive

(on) or open (off).

Note) The wires of analog output signals, O2 senser input and contact input should be fixed

separately from power supply wiring and contact output wiring.

(6) Communication interface: connector for communication (RS-232C interface)

• Please refer to the manual (IM 11G02P01-01E) about communication function.

3 - 8 IM 11G02M01-01E

(7) List of terminal blocks 1 to 5

CH5 output

(AO)

CH4 output

(AO)

CH3 output

(AO)

CH2 output

(AO

CH1 output

(AO)

Unused

Remote hold input

Average value reset

Auto calibration

(DI)

input (DI)

remote start

input (DI)

Terminal block 1

<TN1>

2 1

(M3.5 screw)

Terminal block 3

<TN3>

(M3.5 screw)

Unused

CH8 output

2 1

(AO)

CH7 output

2 1

(AO)

CH6 output

2 1

(AO)

Instrument error (DO)

CH4 range identification signal output (DO)

CH3 range identification signal output (DO)

CH2 range identification signal output (DO)

CH1 range identification signal output (DO)

Terminal block 2

Unused

2 1

2 sensor input

Terminal block 4

Contact output for CH4

span calibration

(DO)

Contact output for CH3

span calibration

(DO)

Contact output for CH2

span calibration

(DO)

Contact output for CH1

span calibration

(DO)

Contact output for

zero calibration

(DO)

<TN2>

(M3.5 screw)

<TN4>

(M3.5 screw)

Unused

CH4 remote range changeover input (DI)

CH3 remote range changeover input (DI)

CH2 remote range changeover input (DI)

CH1 remote range changeover input (DI)

Unused

Auto calibration status contact output (DO)

Calibration error contact output (DO)

Pump ON/OFF contact output (DO)

Unused

CH3 alarm output

CH2 alarm output

CH1 alarm output

(DO)

Terminal block 5

<TN5>

(M3.5 screw)

Unused

Peak count alarm output (DO)

CH4 alarm output (DO)

*1) Unused terminals are used for internal connection.

So they should not be used as repeating terminals either.

sensor input is used when an external O2 analyzer is selected.

*2) O

3 - 9IM 11G02M01-01E

(8) Description on terminal block

Terminal block 1

<TN1>

CH5 output

(AO)

CH4 output

(AO)

CH3 output

(AO)

CH2 output

(AO

CH1 output

(AO)

2 1

2 3

4 5

6 7

8 9

(M3.5 screw)

Unused

12 13

Unused

14 15

CH8 output

2 1

(AO)

16 17

CH7 output

2 1

(AO)

18 19

CH6 output

2 1

(AO)

Terminal block 1 <TN1>

Terminal block for analog output (non-isolated output) Output : 4 to 20 mA or 0 to 1 V DC Between 1 – 2 : CH5 output Between 3 – 4 : CH4 output Between 5 – 6 : CH3 output Between 7 – 8 : CH2 output Between 9 – 10 : CH1 output Between 11 to 14 : For internal connection. Must not be

wired. (Must not be used as junction

terminal.) Between 15 – 16 : CH8 output Between 17– 18 : CH7 output Between 19– 20 : CH6 output

Terminal block 2 <TN2>

sensor input

Terminal block 2

2 1

Unused

<TN2>

(M3.5 screw)

Unused

CH4 remote range changeover input (DI)

CH3 remote range changeover input (DI)

CH2 remote range changeover input (DI)

CH1 remote range changeover input (DI)

Between 1– 2 : For O

2 sensor input. (Input for our

Zirconia oxygen sensor or exernal

2 sensor. Must not be used unless 2 meter is added.)

O Between 3 to12 : For internal connection. Must not be

wired. (Must not be used as junction

terminal.) Between 13 – 14 : CH4 remote range changeover input Between 15 – 16 : CH3 remote range changeover input Between 17– 18 : CH2 remote range changeover input Between 19– 20 : CH1 remote range changeover input

Note) High range is selected when

open. Low range is selected when short-circuited. For details of action, refer to “6.1 Changeover of range”.

3 - 10 IM 11G02M01-01E

Unused

Remote hold input

Average value reset

Auto calibration

(DI)

input (DI)

remote start

input (DI)

Terminal block 3

<TN3>

(M3.5 screw)

Instrument error (DO)

CH4 range identification signal output (DO)

CH3 range identification signal output (DO)

CH2 range identification signal output (DO)

CH1 range identification signal output (DO)

Terminal block 3 <TN3>

Between 1 to 4 : For internal connection. Must

not be wired. (Must not be used as junction terminal.)

Between 5 – 6 : Remote hold input. No hold

when open. Output hold when short-circuited.

Between 7 – 8 : Average value reset input.

Short-circuiting the contact input (for at 1.5 sec or more) resets O average and O2 correction average simultaneously. Opening it restarts the average value.

Between 9 – 10 : Automatic calibration remote

start input. Open input after strapping for at least 1.5 seconds starts the automatic calibration whether automatic calibration setting is ON or OFF.

Between 11 – 12 : Conductive when analyzer unit

error is producted. Normally

open. Between 13 – 14 : CH4 range identification signal Between 15 – 16 : CH3 range identification signal Between 17– 18 : CH2 range identification signal Between 19– 20 : CH1 range identification signal

Note) Range identification

signal is conductive at Low range or open at High range. In case of 1-range system, the signal remains open.

3 - 11IM 11G02M01-01E

Terminal block 4

Contact output for CH4

span calibration

Contact output for CH3

span calibration

Contact output for CH2

span calibration

Contact output for CH1

span calibration

Contact output for

(DO)

zero calibration

(DO)

<TN4>

(M3.5 screw)

Unused

Auto calibration status contact output (DO)

Calibration error contact output (DO)

Pump ON/OFF contact output (DO)

Unused

Terminal block 4 <TN4>

Between 1 – 2 : CH4 span calibration contact

output

Between 3 – 4 : CH3 span calibration contact

output

Between 5 – 6 : CH2 span calibration contact

output

Between 7 – 8 : CH1 span calibration contact

output

Between 9 – 10 : Zero calibration contact output

When the calibration contact output is measured with manual calibration, the calibration contact corresponding to cali-

bration channel is conductive.

For the automatic calibration,

they are worked sequentially according to “6.4 Auto calibration setting”. If calibration is not performed, all of them are open.

Between 11– 12 : For internal connection. Must

not be wired. (Must not be used as junction terminal.)

Between 13– 14 : Automatic calibration in

progress, contact output. Conductive during automatic calibration. Open otherwise.

Between 15– 16 : Calibration error contact output.

Conductive when error is produced at zero or span calibration. Normally open.

Between 17– 18 : Pump ON/OFF contact output.

(Used for turning ON/OFF the pump. Conductive during measurement and open at zero span calibration.)

For the output of calibration contacts, see

Note:

Item 3.5 (9) “Timing of calibration contact output”.

3 - 12 IM 11G02M01-01E

Unused

CH3 alarm output

CH2 alarm output

CH1 alarm output

(DO)

Terminal block 5

<TN5>

(M3.5 screw)

Unused

Peak count alarm output (DO)

CH4 alarm output (DO)

Terminal block 5 <TN5>

1 and 11 – 14 : For internal connection. Must not

be wired. (Must not be used as

junction terminal.) Between 2– 3 and 3– 4

: CH3 alarm output. Conductive at 2–

3 and open at 3–

4 when set value is

exceeded. Open at 2– 3 and conduc-

tive at 3– 4 otherwise. Between 5– 6 and 6– 7

: CH2 alarm output. Conductive at 5–

6 and open at 6– 7 when set value is

exceeded. Open at 5– 6 and conduc-

tive at 6– 7 otherwise. Between 8– 9 and 9– 10

: CH1 alarm output. Conductive at 8–

9 and open at 9– 10 when set value

is exceeded. Open at 8– 9 and

conductive at 9– 10 otherwise. Between 15–16 and 16– 17

: Peak count alarm contact output.

Conductive at 15 – 16 and open at

16 – 17 when preset peak count is

exceed. Otherwise, open at 15 – 16

and conductive at 16 – 17. For

setting and action, refer to instruc-

tion manual “6.6 Peak Alarm

Setting”. Between 18–19 and 19– 20

: CH4 alarm output. Conductive at

18– 19 and open at 19– 20 when set

value is exceeded. Open at 18– 19

and conductive at 19– 20 otherwise.

3 - 13IM 11G02M01-01E

(9) Timing of calibration contact output

1. Manual calibration (See “6.9 Calibration”).

•

Zero calibration

Pump ON/OFF contact

Zero calibration contact

CH1 to CH4 span calibration contact

Output hold function (with hold ON setting)

• Span calibration

Pump ON/OFF contact Zero calibration contact

Span 1 calibration contact

Span 2 calibration contact

ZERO

SPAN

When selecting CH2 using and keys.

ENT ENT

Output signal hold

ENT ENT

Calibration end

Hold extension time

Calibration end

on off

off

on off

off off

on off

Output hold function (with hold ON setting)

Output signal hold

2. In case of automatic calibration (example shown in 6.4.1, Automatic calibration settings)

Pump ON/OFF contact

Zero calibration contact

CH1 span calibration contact

CH2 span calibration contact

CH3 span calibration contact

Automatic calibration

start

Zero gas

350s

Zero

calibration

CH1 span gas

CH1 span

calibration

350s

CH2 span gas

CH2 span

calibration

350s

CH3 span gas

350s

Hold extension time

The hold extension time

Note)

depends on the gas flow time of the automatic calibration settings.

CH3 span calibration

(automatic calibration end)

Automatic calibration contact

Output hold function

(With hold ON setting)

Output signal hold

Hold extension time

3 - 14 IM 11G02M01-01E

4. OPERATION

4.1 Preparation for operation

(1) Check of gas sampling tube, exhaust tube and wiring

Check that the pipes are correctly connected to the gas sampling port and drain port. Check that the analyzer is correctly wired as specified.

4.2 Warm-up operation and regular operation

(1) Operation procedure

1. Turn ON the power switch at the left of the front panel. In one or two seconds, the measurement screen will appear at the front panel.

2. About 2 hour warm-up operation About 2 hours are needed until the operating performance is stabilized. Warm-up operation

should be continued with the power ON.

3. Setting of various set values Set required set values according to Chapter 6, “Setting and calibration”.

4. Zero and span calibration Perform zero calibration and span calibration after warm-up operation. See Chapter 6.9, “Calibration”.

5. Make moisture interference compensation adjustment (NO Analyzer and SO (See “6.8 Maintenance mode” and “7.4 Moisture interference compensation adjustment” for details.)

Be sure to perform individual moisture interference compensation adjustment according to the system in the case of NO Analyzer and SO affected by moisture interference.

6. Introduction and measurement of measured gas Start measurement by introducing measured gas into the analyzer.

2 Analyzer. Otherwise measurement is

2 Analyzer).

Note) While in warm-up operation, the concentration reading may be beyond the

upper limit of the range (range-over) or below the lower limit (range-under) .

But this is not an error.

4 - 1IM 11G02M01-01E

DESCRIPTION OF DISPLAY AND OPERATION PANEL

This section describes the display and operation panel of the gas analyzer. It also explains the name and description of function on the operation panel. See Fig. 5-1.

5.1 Name and description of operation panel

Display

INFRARED GAS ANALYZER

Power switch

POWER

Controls

(1)MODE key

MODE

ZERO

ESC

ENT

SPAN

• Display : The measurement screen and the setting items are displayed.

• Controls : The configuration is as shown below.

(3)UP key

MODE ESC ZERO

(2)SIDE key

(4)DOWN key

(5)ESCAPE key

(7)ZERO key

ENT SPAN

(8)SPAN key

(6)ENTRY key

Name

(1) MODE key

(2) SIDE key

(3) UP key

(4) DOWN key

Description

Used to switch the mode.

Used to change the selected item (by moving the cursor) and numeral digit.

Used to change the selected

Name

(5) ESCAPE key

(6) ENTRY key

(7) ZERO key

Used to return to a previous screen or cancel the setting midway.

Used for confirmation of selected items or values, and for execution of calibration.

Used for zero calibration.

Description

item (by moving the cursor) and to increase numeral value.

Used to change the selected

(8) SPAN key

Used for span calibration. item (by moving the cursor) and to decrease numeral value.

Fig. 5-1 Name and description of operation display and panel

5 - 1IM 11G02M01-01E

+ 71 hidden pages

Yokogawa IR200 User Manual

PREFACE

CAUTION ON SAFETY

r After - Sales Warranty

CONTENTS

1. OVERVIEW

2. NAME AND DESCRIPTION OF EACH PART

2.1 Description of each unit

3. INSTALLATION

3.1 Selection of installation location

3.2 Installation of analyzer

3.3 Piping

3.4 Sampling

3.5 Wiring method

4. OPERATION

4.1 Preparation for operation

4.2 Warm-up operation and regular operation

DESCRIPTION OF DISPLAY AND OPERATION PANEL

5.1 Name and description of operation panel