Yokogawa IR400 User Manual

User's Manual

IR400 Infrared Gas Analyzer

IM 11G02N01-01E

Yokogawa Electric Corporation

IM 11G02N01-01E

3rd Edition

PREFACE

We are grateful for your purchase of Yokogawa’s Infrared Gas Analyzer, Model:IR400.

• 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 in written format.

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

IM 11G02N01-01E

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”.

DANGER

CAUTION

PROHIBITION

Caution on installation and transport of gas analyzer

DANGER

CAUTION

Improper handling may cause dangerous situations that may result in death or serious injury.

Improper handling may cause dangerous situations that may result in medium-level troubles, minor injury, or property damage.

Items which must not be done are noted.

• The unit is not of explosion-proof specifications. Do not use it in an atmosphere of explosive gases. Otherwise serious accidents such as explosion or fire may result.

• Install the analyzer, observing the rules provided in this manual, in a place that endures the weight of the analyzer. Installation in an inadequate place may cause turnover or fall, resulting in injury.

• Be sure to wear protective gloves when lifting the analyzer. Lifting it with bare hands may result in injury.

• Be sure to fix the casing before transporting the analyzer. Transportation in unstable state may result in injury.

• The gas analyzer is heavy. Two or more persons should carry it, while exercising due care. Otherwise unexpected harm to your body or injury may result.

• Take care not to let cable chips and other foreign objects enter the unit during installation work. Otherwise fire, failure, or malfunction may result.

IM 11G02N01-01E

DANGER

Caution on piping

Be sure to observe the following precautions while installing piping. Improper piping may result in gas leakage.

If the leaking gas contains a toxic component, serious accidents may result. If it contains combustible gases, explosion or fire may result.

• Connect pipes correctly referring to the instruction manual.

• Discharge the exhaust gas outdoors to prevent it from remaining within the sampling device or indoors.

• Relieve the exhaust gas from the analyzer to the atmospheric pressure to prevent buildup of undesirable pressure to the analyzer. Otherwise piping within the analyzer may be disconnected, resulting in gas leakage.

• Use pipes and pressure reducing valves to which no oil/grease is attached for piping. Otherwise, fire may result.

Caution on wiring

CAUTION

DANGER CAUTION

• Be sure to turn off the power before installing wiring.

Otherwise electric shock may result.

• Be sure to perform class D grounding work. Otherwise,

electric shock or failure may result.

• Select a proper wiring material that satisfies the ratings of the

instrument. Otherwise, electric shock or fire may result.

• Be sure to connect a power supply of correct rating.

Otherwise, fire may result.

Caution on use

• Be sure to read the instruction manual for reference gases before handling reference gases such as calibration gas to use them properly.

• Leaving the analyzer unused for a long time or restarting it after long-term suspension requires procedures different from normal operation or suspension procedures. Be sure to follow the instructions in each instruction manual. Otherwise, intended performance may not be achieved, or accidents or injury may result.

• 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.

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iii

Caution on use

• Do not touch the input/output terminals with metal or finger.

PROHIBITION

Caution on maintenance and check

DANGER

CAUTION

Otherwise, electric shock or injury may result.

• Do not smoke or use flames near the analyzer. Otherwise, fire may result.

• Do not allow water to enter the analyzer. Otherwise, electric shock or internal fire may result.

• Before performing work with the cover of the analyzer kept open for maintenance and check, be sure to purge completely not only within the analyzer but also measuring gas lines with nitrogen or air. Otherwise, poisoning, fire, or explosion may result due to gas leakage.

Be sure to observe the following to perform work safely, avoiding electric shock or injury.

• Remove the watch and other metallic objects before work.

• Do not touch the instrument wet-handed.

CAUTION

• If the fuse is blown, eliminate the cause and replace it with the one of the same capacity and type. Otherwise, electric shock or accidents may result.

• Do not use replacement parts other than those specified by the manufacturer. Otherwise, intended performance may not be achieved, or accidents or failures may result.

• Dispose replacement parts such as maintenance parts as incombustibles according to the local waste disposal regulations.

Others

• If the cause of a fault cannot be identified by referring to the instruction manual, be sure to contact your dealer or Yokogawa technician in charge of adjustment. Disassembling the instrument carelessly may result in electric shock or injury.

IM 11G02N01-01E

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.

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

Caution on safety ................................................................................................................. ii

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

Contents ............................................................................................................................... vi

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

2. NAME and description of eaCH UNIT .....................................................................2-1

2.1 Name and description of main unit ................................................................ 2-1

2.2 Input/Output terminal module ......................................................................... 2-2

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

3.1 Installation conditions ..................................................................................... 3-1

3.2 Installation ....................................................................................................... 3-2

3.2.1 Installation of nanlyzer main frame ..............................................................

3.2.2 Mounting input/output terminal module ................................................. 3-3

3.3 Piping ............................................................................................................... 3-4

3.4 Sampling.......................................................................................................... 3-7

3.4.1 Conditions of sampling gas ..................................................................... 3-7

3.4.2 Sampling gas flow ................................................................................... 3-7

3.4.3 Preparation of standard gas ..................................................................... 3-7

3.4.4 Reduction of moisture interference ......................................................... 3-7

3.4.5 Purging of instrument inside ................................................................... 3-7

3.4.6 Pressure at sampling gas outlet ............................................................... 3-8

3.4.7 Example configuration of gas sampling system ..................................... 3-8

3.5 Wiring.............................................................................................................. 3-9

3.5.1 Power inlet ............................................................................................... 3-9

3.5.2 Input/output terminal module .................................................................. 3-9

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 panels ..................................................... 5-2

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

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

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

6.1 Switch of range ............................................................................................... 6-1

6.1.1 Setting of range switch mode.................................................................. 6-1

6.1.2 Manual range switch ............................................................................... 6-2

6.2 Calibration setting ........................................................................................... 6-3

6.2.1 Setting of calibration concentration ........................................................ 6-3

6.2.2 Setting of manual zero calibration .......................................................... 6-5

6.2.3 Setting of calibration range ..................................................................... 6-7

6.2.4 Setting of auto calibration component/range .......................................... 6-9

6.3 Alarm setting ................................................................................................. 6-11

6.3.1 Setting of alarm values.......................................................................... 6-11

6.3.2 Hysteresis setting................................................................................... 6-13

6.4 Setting of auto calibration............................................................................. 6-14

6.4.1 Auto calibration ..................................................................................... 6-14

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

6.5 Setting of auto zero calibration..................................................................... 6-20

6.5.1 Autozero calibration .............................................................................. 6-20

6.5.2 Forced run/stop of auto zero calibration ............................................... 6-22

6.6 Peak alarm setting ......................................................................................... 6-25

6.7 Parameter setting ........................................................................................... 6-27

6.8 Maintenance mode ........................................................................................ 6-34

6.9 Calibration ..................................................................................................... 6-40

6.9.1 Zero calibration ..................................................................................... 6-40

6.9.2 Span calibration ..................................................................................... 6-41

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

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

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

7.3 Maintenance of analyzer unit.......................................................................... 7-2

7.3.1 Cleaning method for sample cell (pipe cell)........................................... 7-2

7.3.2 Cleaning method for sample cell (block cell)......................................... 7-4

7.3.3 Optical zero adjustment method (optical balance adjustment)............... 7-6

7.3.4 Moisture interference compensation adjustment method ....................... 7-7

7.3.5 Replacement of fuse on analyzer unit..................................................... 7-8

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

8. Trouble shooting for analyzer ....................................................................................8-1

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

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

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

9.1 General specifications ..................................................................................... 9-1

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

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

Dedicated relay board (Option code: /R).............................................. 9-14

Customer Maintenance Parts List ................................................ CMPL 11G02N01-01E

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

1. OVERVIEW

This infrared gas analyzer (type: IR400) measures the concentration of NO, SO2, CO2, CO and CH

contained in sampling gas on the principle that different atomic molecules have an absorption spectrum in the wave band of infrared rays, and the intensity of absorption is determined by the Lambert-Beer law.

Since this instrument incorporates a compact paramagnetic O components simultaneously by using the built-in O

sensor (up to 4 components if O2 sensor is excluded).

sensor, it allows measuring up to 5

Furthermore, use of a microprocessor or large sized liquid crystal display realizes improvement of operability, accuracy and multi-functions.

This instrument is optimum for measuring combustible gas exhausted from boilers or incinerators, and it is effective for steel gas analysis (blast furnace, steel converter, thermal treatment furnace, sintering (Pellet equipment), coke furnace), storage and maturity of vegetable and fruit, biochemistry (microbe), [fermentation], air pollution [incinerator, exhaust gas desulfurization, denitration], automotive emission (excluding tester), protection against disasters [detection of explosive gas and toxic gas, combustion gas analysis of new building material], growth of plants, chemical analysis [petroleum refinery plant, petroleum chemistry plant, gas generation plant], environment [landing concentration, tunnel concentration, parking lot, building management] and various physical and chemical experiments.

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2. NAME AND DESCRIPTION OF EACH UNIT

2.1 Name and description of main unit

Front panel

POWER

(1) Handle

(2) Power switch

(3) Display/operation panel

Back panel

(6) Sector motor

(7) Light source cover

Name

(1) Handle

Used for withdrawing the main unit from the panel.

Description

Fig. 2-1

(6) Sector motor

(4) Sampling gas inlet (5) Sampling gas outlet (4) Sampling gas inlet (5) Sampling gas outlet

(or purge gas inlet)

(10) Protective cover

(9) Power inlet (8) Input/output terminal connector

Name

For measuring unit 1

For measuring unit 2

Description

For driving the rotation of sector

(2) Power switch

(3) Display/opera tion

(4) Sampling gas inlet

(5) Sampling gas outlet

IM 11G02N01-01E

Used for ON/OFF the analyzer.

Liquid crysral diaplay and keys for setting various functions

For connecting to the measuring gas tube

Connect to the exhaust line. (A pair of sampling gas inlet/outlet is provided for each measuring unit. When ordered with purge, the piping to measuring unit 2 is built inside. In this case, the sample gas outlet for measuring unit 2 is used for purge gas inlet.)

(7) Light source cover

(8) Input/output ter minal connector

(9) Power inlet

(10) Protective cover

Infrared light source is arranged in the cover.

For connecting to the external input/output terminal module

For connecting the power cable

Protective cover for the light source and the motor. May be removed during operation.

2 - 1

2.2 Input/Output terminal module

This analyzer provides input/output of various signals from the supplied input/outpt terminal module by connecting the instrument to this module.

Input/Output terminal module

(2) Input/Output terminal block (TN1 to TN5)

(1) Mounting hole (φ4.5, 6 places)

TN1 TN2 TN3 TN4 TN5

(6) Communication connector (CN2)

Name

(1) Mounting

hole

(2) Input/output

terminal block (TN 1 to TN

(3) Cable

connection connector

(3) Cable connection connector (CN1)

(4) Analyzer main unit

Input/Output terminal module connection cable (1m)

Fig. 2-2

Description

Used for mounting input/output terminal module.

φ φ

φ 4.5, 6 places

φ φ

Input/output terminal for signals of analog output, range identification contact, alarm contact output, etc.

Used for connecting the analyzer main unit and the input/output terminal module (4).

(5) Calibration solenoid valve drive signal output connector (CN3)

Name

(4) Input/output

terminal module connection cable

(5) Calibration

solenoid valve drive signal output connector

(6) Communication

connector

Description

Used for connecting the analyzer main unit to the input/ output terminal module.

Cable connector for connecting the analyzer to the relay board for automatic calibration.

Connect communication cable. *Please refer to another manual (IM 11G02P01-01E) about communication function.

2 - 2

IM 11G02N01-01E

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

•Entrust the installation, movement or re-installation to a specialist or the supplier. A poor installation may cause accidental tipover, shock hazard, fire, injury, etc.

•The gas analyzer is heavy. It should be installed with utmost care. Otherwise, it may tip over or drop, for example, causing accident or injury.

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

•This unit should be installed in a place which conforms to the conditions noted in the instruction manual. Otherwise, it may cause electric shocks, fire or malfunction of the unit.

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

3.1 Installation conditions

To install the analyzer for optimum performance, select a location that meets the following conditions; (1) This instrument is system built in type. This instrument should be used while embedded in a panel, locker, or enclosure of steel sheet. (2) Use this instrument indoors. (3) A vibration-free place (4) A place which is clean around the analyzer. (5) Power supply Rated voltage : 100 V to 240 V AC Operating voltage : 85 V to 264 V AC

Rated frequency : 50/60 Hz Power consumption : 250 VA max. Inlet : Comformity to EN60320 class I type 3-pin inlet

(6) Operation conditions

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

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3 - 1

3.2 Installation

3.2.1 Installation of analyzer main frame

Installation methods for the analyzer main unit are divided into 2 types;

(

Unit : mm

Type External dimensions Mounting dimensions Mounting method

19 inch rack mounting guide rail method

19 inch rack mounting slide

429 483

177

450 or more

465

101.6

Slide rail (Supports mass)

rail method

Slide rail (Supports mass)

Note 1 Check and maintenance of the analyzer main unit may be carried out with the top cover detached.

The guide rail method may be used if a space accessible for maintenance is provided at the top of the main unit. If maintenance space is not provided specially, it is recommended to use the slide rail method.

Recommended slide rail: Product No.: 305A-24 manufactured by Accuride International Co.

Note 2 For 19 inch rack mounting, the weight of the analyzer is supported with the bottom of the case

(with the side of the case in case of slide rail method). For mounting dimensions of the slide rail, see “Item 9.3 External diagram”.

Don’t install the analyzer at a place which is exposed to direct sunlight. The analyzer should be installed at a place where ambient temperature is within -5 to 45˚C, and

temperature fluctuation during use is minimum.

)

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IM 11G02N01-01E

3.2.2 Mounting input/output terminal module

Mount the input/output terminal module on the panel; observing the following method. (Note) To avoid the effect of noise generated from external units, mount the I/O terminal module

mounting plate on the panel for continuity at the mounting surface and connect the panel to the same ground as the analyzer main unit.

External dimensions Mounting dimensions Mounting method

4.5 mounting hole (× 6 places)

164

316

M4 screw (× 6 places)

150 150

154

Rectangular hole

302

Note) How to ground analyzer main unit and I/O terminal module

To avoid the effect of noises, etc. from external units, it is recommended to ground them by the procedure described below.

Bring I/O terminal module sheet metal and panel into continuity at ///// portion.

Bring analyzer main unit and panel into continuity at ///// portion or rail mounting portion. (No grounding is required at the power terminal).

Terminal

142142

Screwed to panel

Panel plate

Connection cable

To analyzer rear panel

IM 11G02N01-01E

Mount the analyzer and I/O terminal module on the same panel.

Ground the panel casing.

Don’t separate the analyzer and I/O terminal module, and be sure to

* ground them together.

3 - 3

3.3 Piping

Piping should be connected to the gas inlets and outlets of the front panel of the analyzer.

• Use a corrosion resistant tube of Teflon, stainless or polyethylene to connect the instrument to

a sampling system. Even if there is a danger of corrosion, refrain from using a tube of rubber or soft vinyl. The instrument provides inaccurate indication due to gas absorption by piping materials.

• Pipe connection port is Rc1/4 female thread (or 1/4 NPT). Piping should be cut as short as

possible for a quick response. About 4 mm inner diameter is recommended.

• Entry of dust into the instrument may result in defective operation. Use a clean piping or

coupling.

Connect the gas tube by the following method.

Sampling gas outlet

For measuring unit 1

Sampling gas inlet

Sampling gas outlet (Purge gas inlet)

For measuring unit 2

Sampling gas inlet: Attach the gas tube to introduce gas to be measured such as one that has

completed dehumidification process and standard gases for zero and span calibration to this inlet. Gas flow to be introduced should be constant within the range of 0.5 ± 0.2 L/min.

Sampling gas outlet: Exhaust measured gas through the outlet. Attach the tube to exhaust mea-

sured gas outdoors or to the atmosphere.

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

lyzer must be purged, refer to Item 3.3.4 Purging of instrument inside. Use dry gas N

or instrumentation air for purge gas. (flow rate of 1L/min or

more should be used and no dust or mist is contained).

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IM 11G02N01-01E

Internal piping diagram

Measuring unit 2

Measuring unit 1

Built-in

sensor

Built-in O

sensor

OUTLET INLET OUTLET INLET

Sampling cell

Note) 2 cells may be used by combination of

Sampling gas inlet Sampling gas outlet

For measuring unit 2

For measuring unit 1

range.

Note) When the purge gas inlet is provided, the piping to measuring unit 2 is built inside.

Correspondence of measured components and measuring units

Measuring components 1-component Analyzer for

NO, SO

, CO2, CO and CH

2-component Analyzer for NO-SO

and CO2-CO

2-component Analyzer for NO-CO

3-component Analyzer for NO-SO2-CO

4-component Analyzer for NO-SO

-CO2-CO

Measuring unit 1 Each component

NO-SO CO2-CO

NO-SO

Note) When there are two measuring units, the built-in O2 sensor must be connected to the measuring unit 2.

Measuring unit 2 None

None

-CO

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Example of connecting each measuring unit

One pair of gas inlet/outlet

Sampling gas

Flow meter

0.5L/min

Two pair of gas inlet/outlet - (1)

Sampling gas

NO2/NO

converter

Flow meter

0.5L/min

Filter

Flow meter

0.5L/min

Filter

IR400

Sampling gas inlet

Sampling gas outlet

Release to atmosphere.

IR400

Sampling gas inlet

Sampling gas outlet

Sampling gas inlet

Sampling gas outlet

Exhaust

For measuring unit 1

For measuring unit 2

Note) The NO when NO measurement is used for NOx measurement.

Two pair of gas inlet/outlet - (2)

Sampling gas

Note) The NO when NO measurement is used for NOx measurement.

/NO converter is used

Filter

Flow meter

0.5L/min

/NO converter is used

/NO

converter

Filter

Sampling gas inlet

Sampling gas outlet

Sampling gas inlet

Sampling gas outlet

Exhaust

Release to atmosphere.

IR400

For measuring unit 1

For measuring unit 2

Exhaust

Release to atmosphere.

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3.4 Sampling

3.4.1 Conditions of sampling gas

1. Dust contained in the sampling gas should be completely removed with a filter. For the final stage filter, use a filter that allows removing dust particles of 0.3mm.

2. Dew point of sampling gas must be lower than the ambient temperature to avoid occurrence of drain in the gas analyzer. If vapor is contained in the sampling gas, dew point should be lowered to 0°C by using a dehumidifier.

3. If SO

4. Corrosive gases such as Cl

5. Temperature of sampling gas should be within 0 to 50°C. Provide a means that prevents

3.4.2 Sampling gas flow

Flow of sampling gas should be 0.5 ± 0.2L/min. Avoid flow fluctuation during measurement. Observe the flow reading by a flowmeter provided as shown in the example of the sampling

system configuration (Item 3.4.6).

3.4.3 Preparation of standard gas

mist is contained in the sampling gas, use a mist filter or cooler to remove SO3 mist.

Other mists should be removed by using a mist filter or cooler.

erable amounts, will shorten the life of instruments.

entry of hot gas directly into the instrument.

, F2 and HCl, if they are contained in the sampling gas in consid-

Routine calibration is required by standard gas for keeping this instrument under normal operation condition (once a week). Prepare a standard gas cylinder for zero calibration and span calibration.

Zero gas

Span gas other than for O measurement

Span gas for O measurement

Analyzer without O measurement

N2 gas

Gas with concentration of 90% or more of full scale

Analyzer with built-in O

sensor

N2 gas

Gas with concentration of 90% or more of full scale

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

3.4.4 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.

3.4.5 Purging of instrument inside

Analyzer with external zirconia O

sensor Dry air or atmospheric air (Note)

Gas with concentration of 90% or more of full scale

1 to 2% O

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 installa-

tion site.

In such cases as above, the inside of analyzer should be purged with the air for instrumentation or N2. Purging flow rate should be about 1L/min. If dust or mist is contained in purging gas, it should be eliminated completely in advance.

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3.4.6 Pressure at sampling gas outlet

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

3.4.7 Example configuration of gas sampling system

The following illustrates a typical system configuration for five component gas measurement for monitoring combustion exhaust gas from boiler, refuse incinerator, etc.

Contact Yokogawa for system configuration matching the particular use or further information.

(1) Gas extractor

φ10/φ8 Teflon tube

or larger

(2) Mist filter

(4) Gas aspirator

2-way solenoid valve

(5)

Electronic gas cooler

(8) Flowmeter

Infrared gas analyzer

main unit CO,CO

(7) Membrane filter

(O2)

(11) NO converter

(7)

Membrane filter

Infrared gas analyzer

main unit NO, SO

IR400

/NO

Name

(1) Gas extractor

(2)

Mist filter

(3) Safety drain trap

(4) Gas aspirator (5) Electronic gas

cooler

(6)

Solenoid valve

(7) Membrane filter

(3) Safety drain

trap

Drain

Description

Gas extractor with a heating type stainless steel filter of standard mesh 40 m

Removes drain, mist, and dust. The safety drain trap divided

into two rooms for positive and negative pressure. It monitors and adjusts the sample gas pressure.

For aspiration of sample gas Dries the moisture in sample

gas to a dew point of approx. 2˚C.

Used for introducing calibration gas.

PTFE filter used to eliminate fine dust particles and permit monitoring of dust adhering condition on the front panel of the gas analyzer.

ZERO NO SO

Air

Name

(8) Flowmeter

(9) Standard gas

(10)Zirconia O

sensor

(11)NO2/NO con-

verter

NO /N

Pressure reducing valve

(6) Solenoid valve

CO O

(9) Standard gas

CO /N

Description

Adjusts and monitors the flow rate of sample gas.

Reference gas used for calibrating zero and span of the analyzer. Total 6 cylinders required for zero gas air, span gas NO,

, CO, CO2 and O2.

External zirconia oxygen sensor used for measuring the oxygen concentration in sample gas. (This is not necessary in case when O

sensor is built-in.)

Added to NOx analyzer. A special catalyst material for efficient conversion of NO gas to NO is used.

(10) Zirconia O

senor

(ZX8D)

Exhaust

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IM 11G02N01-01E

3.5 Wiring

3.5.1 Power inlet

The power inlet is provided at the rear panel. Connect supplied power cable to this power inlet.

Rear panel

Power inlet

Input/output terminal connector

Grounding 2-pole plug

When noise source is in the vicinity

• Avoid installing this instrument near an electrical unit (high frequency furnace or electric welder)

that generates much electrical noise. If using the instrument near such a noise generating unit is

unavoidable, use a different power line to avoid noise.

Main unit

power supply

Varistor or spark killer

• Mount a noise suppressor such as varister or spark killer

as shown at right figure to the noise generating unit when noise is generated from relays or solenoid valves. Mount the suppressor near the noise generating source, or it will have no effect.

3.5.2 Input/output terminal module

This analyzer should be connected to the input/output terminal module by supplied exclusive cable.

Plug this cable connector into the receptacle at the rear panel of the analyzer and the receptacle on the PC board of the input/output module.

Connect the exclusive cable so that the ferrite core attached to the cable comes to the analyzer side.

Ferrite core (to analyzer side)

Install (connect) near the source.

Noise

generating

source

IM 11G02N01-01E

Analyzer

Exclusive cable

(1 meter long)

Input/output

terminal module

3 - 9

(1) Analog output signal (AO): terminal block 1, 1 to 20, terminal block 2, 3 to 6.

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.

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 or to outdoor.

(2) O

sensor input: terminal block 2, 1 to 2.

Input signal:

External zirconia O External O

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

analyzer: Zirconia O2 sensor signal (ZX8Dp C output)

analyzer or external O2 analyzer is specified as order.

analyzer prepared

separately.

• In case of an external O

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

sensor input is not isolated. It is recommended to isolate when an external O2 analyzer is

installed apart from this analyzer. Zirconia O

analyzer, do not use the terminals.

sensor Yokogawa make IR400 should be

installed at a location that is as close to this instrument as possible.

(3) Contact input (DI): terminal block 2, 1 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.

(4) Contact output (DO): terminal block 3, 11 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).

3 - 10

Wiring of analog output signal, O

sensor input and contact input should be fixed separately

from the wiring of power supply and contact output.

Note) To avoid the effect of noise generated from external units, be sure to ground the

analyzer main unit. Continue between the I/O module mounting plate and the panel and connect the panel casing to the same ground as the analyzer.

IM 11G02N01-01E

(5) List of terminal blocks

Ch5 output

(Ch5_OUT)

Ch4 output

(Ch4_OUT)

Ch3 output

(Ch3_OUT)

Ch2 output

(Ch2_OUT)

Ch1 output

(Ch1_OUT)

Unassigned

Remote hold input

(R_HOLD)

Average value reset

input (RESET)

Auto calibration

remote start

input (R_CAL)

Terminal block 1

<TN1>

— +

(M3.5 screw)

— +

Terminal block 3

<TN3>

(M3.5 screw)

Ch10 output (Ch10_OUT)

Ch9 output (Ch9_OUT)

Ch8 output (Ch8_OUT)

Ch7 output (Ch7_OUT)

Ch6 output (Ch6_OUT)

Ch5 range identification contact output (RNG_ID Ch5)

Ch4 range identification contact output (RNG_ID Ch4)

Ch3 range identification contact output (RNG_ID Ch3)

Ch2 range identification contact output (RNG_ID Ch2)

Ch1 range identification contact output (RNG_ID Ch1)

Note 1

sensor input

_IN)

Ch12 output

(Ch12_OUT)

Ch11 output

(Ch11_OUT)

Unassigned

Note 1 : For external O

Peak count alarm

output (PEAK_ALM)

Auto calibration

status/

contact

output (CAL)

Pump ON/OFF

contact output (PUMP)

Calibration error

contact output

(CAL_ALM)

Instrument error

contact output

(FAULT)

Terminal block 2

<TN2>

(M3.5 screw)

sensor input.

—

Terminal block 4

<TN4>

(M3.5 screw)

Ch5 remote range switch input (R_RNG_Ch5)

Ch4 remote range switch input (R_RNG_Ch4)

Ch3 remote range switch input (R_RNG_Ch3)

Ch2 remote range switch input (R_RNG_Ch2)

Ch1 remote range switch input (R_RNG_Ch1)

Unassigned

Alarm 3 output

(ALM_3)

Alarm 2 output

(ALM_2)

Alarm 1 output

(ALM_1)

IM 11G02N01-01E

Terminal block 5

<TN5>

(M3.5 screw)

Unassigned

Alarm 6 output (ALM_6)

Alarm 5 output (ALM_5)

Alarm 4 output (ALM_4)

Connector

<CN3>

Solenoid valve drive signal output for calibration

Contact output for

sample gas selection

Contact output for

zero calibration

Contact output for Ch1

span calibration

Contact output for Ch2

span calibration

(Transister output)

1 2 3 4 5

<D-sub 9P>

Contact output for Ch3

span calibration Contact output for Ch4

span calibration Contact output for Ch5

span calibration

Power for relay drive 5V DC

3 - 11

(6) Description on terminal block

Terminal block 1

<TN1>

Ch5 output

(Ch5_OUT)

Ch4 output

(Ch4_OUT)

Ch3 output

(Ch3_OUT)

Ch2 output

(Ch2_OUT)

Ch1 output

(Ch1_OUT)

— +

2 3

— +

4 5

— +

6 7

— +

8 9

— +

(M3.5 screw)

12 13 14 15 16 17 18 19 20

Terminal block 2

Note 1

sensor input

_IN)

Ch12 output

(Ch12_OUT)

Ch11 output

(Ch11_OUT)

Unassigned

Note 1: For external O2 sensor input.

<TN2>

—

2 3

—

4 5

—

6 7 8 9

(M3.5 screw)

11 12 13 14 15 16 17 18 19 20

Ch10 output

— +

(Ch10_OUT)

Ch9 output

— +

(Ch9_OUT)

Ch8 output

— +

(Ch8_OUT)

Ch7 output

— +

(Ch7_OUT)

Ch6 output

— +

(Ch6_OUT)

Ch5 remote range changeover input (R_RNG_Ch5)

Ch4 remote range changeover input (R_RNG_Ch4)

Ch3 remote range changeover input (R_RNG_Ch3)

Ch2 remote range changeover input (R_RNG_Ch2)

Ch1 remote range changeover input (R_RNG_Ch1)

Terminal block 1 <TN1> Terminal block for analog output (non-isolated output) Between 1–2: Ch5 output Between 3–4: Ch4 output Between 5–6: Ch3output Between 7–8: Ch2 output Between 9–10: Ch1 output Between 11–12: Ch10 output Between 13–14: Ch9 output Between 15–16: Ch8 output Between 17–18: Ch7 output Between 19–20: Ch6 output

Terminal block 2 <TN2> Between 1–2: O

sensor input

(For input of Fuji’s zirconia oxygen sensor or externally oxygen sensor. Must not be used unless external O

sensor is

provided.) Between 3–4: Ch12 output Between 5–6: Ch11 output Between 7–10 For internal connection. Must not

be wired. (Must not be used as

junction terminal). Between 11–12: Ch5 remote range switch input Between 13–14: Ch4 remote range switch input Between 15–16: Ch3 remote range switch input Between 17–18: Ch2 remote range switch input Between 19–20: Ch1 remote range switch input

3 - 12

Action of remote range switch

High range is selected when open.

Low range is selected when short-

circuited. For details of action, see

“Item 6.1 Switch of range.”

IM 11G02N01-01E

Unassigned

Remote hold input

(R_HOLD)

Average value reset

input (RESET) Auto calibration

remote start

input (R_CAL)

Terminal block 3

<TN3>

(M3.5 screw)

Ch5 range identification contact output (RNG_IDCh5)

Ch4 range identification contact output (RNG_IDCh4)

Ch3 range identification contact output (RNG_IDCh3)

Ch2 range identification contact output (RNG_IDCh2)

Ch1 range identification contact output (RNG_IDCh1)

Terminal block 3 <TN3> Between 1–4: 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.

For details, refer to “Item 6.7

Parameter setting, Output Hold”.

Between 7–8: Average value reset input. short-

circuitting the contact input (for at 1.5 sec min.) resets O and O

corrected average simulta-

average

neously. Opening it restarts the average value.

For details, refer to “Item 6.7 Parameter setting, Average Value Resetting”

Between 9–10: Automatic calibration remote

start input

After shorting for 1.5 sec. or more, automatic calibration is started by the opening input whether the automatic calibration setting is ON/OFF.

For details, refer to “Item 6.4 Setting of auto calibration”

Between 11–12: Ch5 range identification contact

output

Between 13–14: Ch4 range identification contact

output

Between 15–16 Ch3 range identification contact

output

Between 17–18: Ch2 range identification contact

output

Between 19–20: Ch1 range identification contact

output

IM 11G02N01-01E

Action of range identification signal

Range identification contact is

conductive at low range and open

at high range.

3 - 13

Peak count alarm

output (PEAK_ALM)

Auto calibration status/contact

contact output (PUMP)

output (CAL)

Pump ON/OFF

Calibration error

contact output

(CAL_ALM)

Instrument error

contact output

(FAULT)

Terminal block 4

<TN4>

(M3.5 screw)

Unassigned

Terminal 4 <TN4> Between 1–2: Peak count alarm contact output

It is conductive when peak count exceeds the setting time. It remains open below the setting time. For setting and operation, refer to “Item 6.6 Peak alarm setting”.

Between 3–4: Contact output of auto calibration

status When the auto calibration is

carried out and remote hold is ON, it is conductive. Remains open otherwise.

Between 5–6: Pump ON/OFF contact output

Used when turning ON/OFF the pump. It is open during auto and manual calibration status and conductive during measurement.

Between 7–8: Calibration error contact output

It is conductive when an error occurs during zero calibration or span calibration. It is normally open.

Between 9–10: It is conductive when an error

occurs to the analyzer unit. It is normally open.

Between 11–20: For internal connection, wiring is

not allowed. (Do not use it as junction terminal).

3 - 14

IM 11G02N01-01E

Unassigned

Ch3 alarm output

(ALM_Ch3)

Ch2 alarm output

(ALM_Ch2)

Ch1 alarm output

(ALM_Ch1)

Terminal block 5

<TN5>

(M3.5 screw)

Unassigned

Power disconnection alarm output (POWER_OFF)

Ch5 alarm output (ALM_Ch5)

Ch4 alarm output (ALM_Ch4)

Terminal 5 <TN5> Between 2, 3 and 4:

Ch3 alarm output When the output exceeds the set value,

it is conductive between 2 and 3, and open between 3 and 4. Otherwise, it is open between 2 and 3 and conductive between 3 and 4.

Between 5, 6 and 7:

Ch2 alarm output When the output exceeds the set value,

it is conductive between 5 and 6, and open between 6 and 7. Otherwise, it is open between 5 and 6, and conductive between 6 and 7.

Between 8, 9 and 10:

Ch1 alarm output When the output exceeds the set value,

it is conductive between 8 and 9, and open between 9 and 10. Otherwise, it is open between 8 and 9.

Between 12, 13 and14:

Analyzer unit power OFF output When the analyzer unit is turned ON,

it is conductive between 12 and 13, and open between 13 and 14. When the analyzer unit is turned OFF, it is open between 12 and 13, and conductive between 13 and 14.

Between 15, 16 and 17:

Ch5 alarm output When the output exceeds the set value,

it is conductive between 15 and 16, and open between 16 and 17. Otherwise, it is open between 15 and 16, and conductive between 16 and 17.

Between 18, 19 and 20:

Ch4 alarm output When the output exceeds the set value,

it is conductive between 18 and 19, and open between 19 and 20. Otherwise, it is open between 18 and 19, and conductive between 19 and 20.

For detailed action of the alarm contact, refer to “Item 6.3 Alarm setting”.

IM 11G02N01-01E

3 - 15

Connector <CN3>

Solenoid valve drive signal output for calibration

Connector

<CN3>

(Transister output)

Contact output for

sample gas selection

Contact output for

zero calibration

Contact output for Ch1

span calibration

Contact output for Ch2

span calibration

1 2 3 4 5

<D-sub 9P>

Contact output for Ch3

span calibration Contact output for Ch4

span calibration Contact output for Ch5

span calibration Power for relay drive

5V DC

Connector <CN3> provides outputs in combination with calibration action during auto calibration and manual calibration.

An output is from a transistor (ratings: 5 V/50 mA). A transistor is turned ON before starting each calibration. Sample selection output is ON during measurement and OFF during calibration. If calibration is not performed, the other transistors are OFF. In case of auto calibration, sequential output is ON/OFF according to the setting. Refer to “Item 6.4 Setting of auto calibration”.

Note) No. 9 pin is for solenoid valve ON/OFF relay drive power (5 V DC/0.5 A, max).

Use No. 9 with reference to the diagram.

Example of using solenoid valve drive signal output for calibration

SV4

Ch1

span

Contact relay

Relay board

Ch2

span

I/O terminal module

Electronic gas cooler

9 1 3 4 5

Cable

CN3

Flowmeter

Membrane filter

SV3

SV2SV1

Zero

Standard gas for calibration

SV1 SV2 SV3 SV4

Solenoid valve drive power

SV1 to SV4: solenoid valves

Refer to Item 3.4.7 Example configuration of gas sampling system .

3 - 16

Relay board and exclusive cable (D-sub 9p straight cable: 1.5 meters) are available on request.

IM 11G02N01-01E

¥ Zero calibration

¥ Span calibration

Zero calibration

output

Zero calibration

output

Pump ON/OFF contact

Sample selection

output

Ch1 to 5 span

calibration output

Ch1 span

calibration

Output hold function

Sample selection

output

(with hold ON setting)

ZERO ENT

ENT

Hold extension time.

Calibration gas flow

Output signal hold

Calibration end

on off

off

Output hold function

(with hold ON setting)

SPAN ENT

ENT

Hold extemsion time.

Note)

When selecting Ch2 using and keys.

Ch2 span calibration

The hold extension time depends on the gas flow time of the automatic calibration settings.

(7) Timing of solenoid valve drive signal for calibration

1. Manual calibration (see “Item 6.9 Calibration”.)

IM 11G02N01-01E

3 - 17

+ 84 hidden pages

Yokogawa IR400 User Manual

PREFACE

CAUTION ON SAFETY

CONTENTS

1. OVERVIEW

2. NAME AND DESCRIPTION OF EACH UNIT

2.2 Input/Output terminal module

3. INSTALLATION

3.1 Installation conditions

3.2 Installation

3.2.1 Installation of analyzer main frame

3.2.2 Mounting input/output terminal module

3.3 Piping

3.4 Sampling

3.4.1 Conditions of sampling gas

3.4.2 Sampling gas flow

3.4.4 Reduction of moisture interference

3.4.5 Purging of instrument inside

3.4.6 Pressure at sampling gas outlet

3.4.7 Example configuration of gas sampling system

3.5 Wiring

3.5.1 Power inlet

3.5.2 Input/output terminal module