Yokogawa ZR202 User Manual

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User’s

Manual

Model ZR202G Integrated type Zirconia Oxygen Analyzer

IM 11M12A01-04E

7th Edition

Introduction

The EXAxt ZR Integrated type Zirconia Oxygen Analyzer has been developed for combustion control in various industrial processes. There are several version of this analyzer so you can select one that matches your application.

Optional accessories are also available to improve measurement accuracy and automate calibration. An optimal control system can be realized by adding appropriate options.

This instruction manual describes almost all of the equipment related to the EXAxt ZR. You may skip any section(s) regarding equipment which is not included in your system.

Regarding the HART Communication Protocol, refer to IM 11M12A01-51E.

IM11M12A01-51E has been published as ''Model EXAxt ZR series HART protocol''.

Regarding Separate type Zirconia Oxygen Analyzer, refer to IM 11M12A01-02E.

< Before using the equipment, please read any descriptions in this manual related to the equipment and system that you have, on appropriate use and operation of the EXAxt ZR. >

Models and descriptions in this manual are listed below.

Model

ZR202G Integrated type Oxygen Analyzer

ZO21R Probe Protector

ZA8F Flow Setting Unit (for manual

ZR20H Automatic Calibration Unit

— Case Assembly for calibration

— Check valve (Part No. K9292DN,

— Dust Filter for the detector (Part

— Dust Guard Protector (Part No.

ZO21S Standard Gas Unit

CMPL: Customer Maintenance Parts List

Product Name

calibration use)

gas cylinder (Part No. E7044KF)

K9292DS)

No. K9471UA)

K9471UC)

Description in this manual

Specication Installation Operation Maintenance CMPL

IM 11M12A01-04E

This manual consists of twelve chapters. Please refer to the reference chapters for installation, operation and maintenance.

Chapter

1. Overview Equipment models and system conguration examples

2. Specications Standard specication, model code (or part number),

3. Installation Installation method for each equipment

4. Piping Examples of piping in three standard system

5. Wiring Wiring procedures such as “Power supply wiring”,

6. Components Major parts and functions are described

7. Startup Basic procedure to start operation of EXAxt ZR.

8. Detailed Data

Setting

9. Calibration Describes the calibration procedure required in the

10. Other

Functions

11. Inspection

and Maintenance

12. Troubleshoot-

ing

CMPL (parts list) User replaceable parts list

: Read and completely understand before operating the equipment. : Read before operating the equipment, and refer to it whenever necessary. : Recommended to read at least once.

dimension drawing for each equipment

congurations

“output signal wiring” or others

Chapter 7enables you to operate the equipment immediately.

Details of key operations and displays

course of operation.

Other functions described

How to conduct maintenance of EXAxt ZR and procedures for replacement of deteriorated parts

This chapter describes measures to be taken when an abnormal condition occurs.

Outline

Relates to

Installation Operation Maintenance

 For the safe use of this equipment

WARNING

CAUTION

EXAxt ZR is very heavy. Be sure not to accidentally drop it. Handle safely to avoid injury.

Connect the power supply cord only after conrming that the supply voltage matches the rating of this equipment. In addition, conrm that the power is switched off when connecting power supply.

Some process gas is dangerous to people. When removing this equipment from the process line for maintenance or other reasons, protect yourself from potential poisoning by using a protective mask or ventilating the area well

The cell (sensor) at the tip of the probe is made of ceramic (zirconia element). Do not drop the equipment or subject it to pressure stress.

iii

• Do NOT allow the sensor (probe tip) to make contact with anything when installing the analyzer.

• Avoid water dropping directly on the probe (sensor) of the analyzer when installing it.

• Check the calibration gas piping before introducing the calibration gas to ensure that there is no leakage of the gas. If there is any leakage of the gas, the moisture drawn from the sample gas may damage the sensor.

• The probe (especially at the tip) becomes very hot. Be sure to handle it with gloves.

(1) About This Manual

 The contents of this manual shall not be reproduced or copied, in part or in whole, without per-

mission.

 This manual explains the functions contained in this product, but does not warrant that those will

suit the particular purpose of the user.

 Every effort has been made to ensure accuracy in the preparation of this manual. However,

should any errors or omissions come to the attention of the user, please contact the nearest

Yokogawa Electric representative or sales ofce.

 This manual does not cover the special specications. This manual may not be changed on any

change of specication, construction and parts when the change does not affect the functions or

performance of the product.

 If the product is used in a manner not specied in this manual, the safety of this product may be

impaired.

IM 11M12A01-04E

WARNING

CAUTION

IMPORTANT

NOTE

(2) Safety and Modication Precautions

Follow the safety precautions in this manual when using the product to ensure protection and

safety of personnel, product and system containing the product.

 The following safety symbols and wordings are used on the product as well as in this manual.

(3) The following safety symbols are used in this manual.

Throughout this user’s manual, you will find several different types of symbols are used to identify different sections of text. This section describes these icons.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Indicates that operating the hardware or software in this manner may damage it or lead to system failure.

Draws attention to information essential for understanding the operation and features.

TIP

Identies additional information.

 NOTICE

• Specication check

When the instrument arrives, unpack the package with care and check that the instrument has not

been damaged during transportation. In addition, please check that the specication matches the order, and required accessories are not missing. Specications can be checked by the model codes on the nameplate. Refer to Chapter 2 specications for the list of model codes.

• Details on operation parameters

When the EXAxt ZR Integrated type Zirconia Oxygen Analyzer arrives at the user site, it will operate based on the operation parameters (initial data) set before shipping from the factory.

Ensure that the initial data is suitable for the operation conditions before conducting analysis.

Where necessary, set the instrument parameters for appropriate operation. For details on setting data, refer to Chapters 7 to 10.

When user changes the operation parameter, it is recommended to note down the changed setting data.

• How to dispose the batteries:

This is an explanation about the new EU Battery Directive (DIRECTIVE 2006/66/EC). This directive is only valid in the EU.

Batteries are included in this product. Batteries incorporated into this product cannot be removed by yourself. Dispose them together with this product.

When you dispose this product in the EU, contact your local Yokogawa Europe B.V.ofce. Do not

dispose them as domestic household waste.

Battery type: silver oxide battery

Notice:

The symbol (see above) means they shall be sorted out and collected as ordained in ANNEX II in DIRECTIVE 2006/66/EC

 After-Sales Warranty

 Do not modify the product.

 During the warranty period, for repair under warranty carry or send the product to the local sales

representative or service ofce. Yokogawa will replace or repair any damaged parts and return

the product to you.

 Before returning a product for repair under warranty, provide us with the model name and serial

number and a description of the problem. Any diagrams or data explaining the problem would also be appreciated.

 If we replace the product with a new one, we won’t provide you with a repair report.

 Yokogawa warrants the product for the period stated in the pre-purchase quotation. Yokogawa

shall conduct dened 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.

 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 Elec-

tric did not supply.

vii

• Failure due to improper or insufcient maintenance by user.

• Failure due to modication, misuse or outside-of-specications operation which Yokogawa

does not authorize.

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

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

• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,

radiation and other natural changes.

 Yokogawa does not warrant conformance with the specic application at the user site. Yokogawa

will not bear direct/indirect responsibility for damage due to a specic application.

 Yokogawa Electric will not bear responsibility when the user congures the product into systems

or resells the product.

 Maintenance service and supplying repair parts will be covered for ve years after the production

ends. For repair for this product, please contact the nearest sales ofce described in this instruc-

tion manual.

IM 11M12A01-04E

viii

IM 11M12A01-04E

Model ZR202G Integrated type Zirconia Oxygen Analyzer

IM 11M12A01-04E 7th Edition

Introduction ..............................................................................................................i

 For the safe use of this equipment .............................................................................. iii

 NOTICE ........................................................................................................................... vi

 After-Sales Warranty .................................................................................................... vii

1. Overview .................................................................................................... 1-1

1.1 <EXAxtZR>SystemConguration ............................................................... 1-1

1.1.1 System 1 ............................................................................................

1.1.2 System 2 ............................................................................................

1.1.3 System 3 ............................................................................................

1.2 < EXAxt ZR > System Components ................................................................

1.2.1 System Components .........................................................................

1.2.2 Oxygen Analyzer and Accessories ....................................................

Toc-1

1-1

1-2

1-3

1-4

2. Specications ........................................................................................... 2-1

2.1 GeneralSpecications ..................................................................................... 2-1

2.1.1 StandardSpecications .....................................................................

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer ..........................

2.1.3 ZO21R Probe Protector .....................................................................

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit ................

2.2.1 ZA8F Flow Setting Unit ....................................................................

2.2.2 ZR20H Automatic Calibration Unit ...................................................

2.3 ZO21S Standard Gas Unit ..............................................................................

2.4 Other Equipment .............................................................................................

2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA) .......................

2.4.2 Dust Guard Protector (part no. K9471UC) ......................................

2.4.3 Stop Valve (part no. L9852CB or G7016XH) ...................................

2.4.4 Check Valve (part no. K9292DN or K9292DS) ................................

2.4.5 Air Set ...............................................................................................

2.4.6 Zero Gas Cylinder (part no. G7001ZC) ...........................................

2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder .......

2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder .................

2.4.9 ZR202A Heater Assembly ...............................................................

2-1

2-2

2-9

2-10

2-12

2-14

2-15

2-16

2-17

2-18

2-19

IM 11M12A01-04E

Toc-2

3. Installation ................................................................................................. 3-1

3.1 Installation of ZR202G Zirconia Oxygen Analyzer ........................................3-1

3.1.1 Installation Location ...........................................................................

3.1.2 Probe Insertion Hole ..........................................................................

3.1.3 Installation of the Probe .....................................................................

3.1.4 Installation of the Dust Filter (K9471UA), Dust Guard Protector

(K9471UC) Probe Protector (ZO21R) ...............................................3-3

3.2 Installation of ZA8F Flow Setting Unit ............................................................

3.2.1 Installation Location ...........................................................................

3.2.2 Mounting of ZA8F Flow Setting Unit ..................................................

3.3 Installation of ZR20H Automatic Calibration Unit .........................................

3.3.1 Installation Location ...........................................................................

3.3.2 Mounting of ZR20H Automatic Calibration Unit .................................

3.4 Installation of the Case Assembly (E7044KF) for

Calibration Gas Cylinder ..................................................................................3-9

3.4.1 Installation Location ...........................................................................

3.4.2 Mounting ............................................................................................

3.5 Insulation Resistance Test .............................................................................

3-1

3-2

3-5

3-6

3-7

3-9

3-10

4. Piping ......................................................................................................... 4-1

4.1 Piping for System 1 ...........................................................................................4-1

4.1.1 Piping Parts for System 1 ..................................................................

4.1.2 Piping for the Calibration Gas ............................................................

4.1.3 Piping for the Reference Gas

4.2 Piping for System 2 ...........................................................................................

4.2.1 Piping Parts for System 2 ..................................................................

4.2.2 Piping for the Calibration Gas ............................................................

4.2.3 Piping for the Reference Gas

4.3 Piping for System 3 ...........................................................................................

4.4 Piping for the Oxygen Analyzer with Pressure Compensation ...................

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation ......

4.4.2 Piping for the Calibration Gas ............................................................

4.4.3 Piping for the Reference Gas

.............................................................4-2

.............................................................4-4

.............................................................4-8

4-2

4-3

4-4

4-6

4-8

5. Wiring ......................................................................................................... 5-1

5.1 General ...............................................................................................................5-1

5.1.1 Terminals for the External Wiring .......................................................

5.1.2 Wiring .................................................................................................

5.1.3 Mounting of Cable Gland ...................................................................

5.2 Wiring for Analog Output .................................................................................

5.2.1 Cable Specications ..........................................................................

5.2.2 Wiring Procedure ...............................................................................

5-2

5-3

IM 11M12A01-04E

5.3 Wiring Power and Ground Terminals .............................................................5-4

5.3.1 Wiring for Power Line .........................................................................

5.3.2 Wiring for Ground Terminals ..............................................................

5.4 Wiring for Contact Output ................................................................................

5.4.1 Cable Specications ..........................................................................

5.4.2 Wiring Procedure ...............................................................................

5.5 Wiring for Contact Input ...................................................................................

5.5.1 Cable Specications ..........................................................................

5.5.2 Wiring Procedure ...............................................................................

Toc-3

5-4

5-5

5-6

6. Components ............................................................................................. 6-1

6.1 ZR202G Zirconia Oxygen Analyzer .................................................................6-1

6.1.1 Integrated type Zirconia Oxygen Analyzer ........................................

6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit ........................

6-1

6-2

7. Startup ....................................................................................................... 7-1

7.1 Checking Piping and Wiring Connections .....................................................7-2

7.2 Valve Setup ........................................................................................................

7.3 Supplying Power to Converter ........................................................................

7.4 Operation of Infrared Switch ...........................................................................

7.4.1 Display and Switches .........................................................................

7.4.2 Display Conguration .........................................................................

7.4.3 Entering Parameter Code Selection Display .....................................

7.4.4 Selecting Parameter Codes ...............................................................

7.4.5 Changing Set Values .........................................................................

7.5 Conrmation of Equipment Type Setting .......................................................

7.6 Selection of Measurement Gas .......................................................................

7.7 Output Range Setting .......................................................................................

7.7.1 Minimum Current (4 mA) and Maximum Current (20 mA) Settings ..

7.8 Checking Current Loop ..................................................................................

7.9 Checking Contact I/O ......................................................................................

7.9.1 Contact Output Check .....................................................................

7.9.2 Checking Calibration Contact Output ..............................................

7.9.3 Checking Input Contacts ..................................................................

7.10 Calibration .......................................................................................................

7.10.1 Calibration Setup .............................................................................

7.10.2 Manual Calibration ...........................................................................

7-2

7-3

7-4

7-5

7-6

7-8

7-9

7-11

7-12

7-13

7-14

7-15

7-17

IM 11M12A01-04E

Toc-4

8. Detailed Data Setting ............................................................................... 8-1

8.1 Setting Display Item ..........................................................................................8-1

8.2 Current Output Setting .....................................................................................

8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum

Oxygen Concentration ( at 20 mA) ....................................................8-2

8.2.2 Entering Output Damping Constants .................................................

8.2.3 Selection of Output Mode ..................................................................

8.2.4 Default Values ....................................................................................

8.3 Output Hold Setting ..........................................................................................

8.3.1 Denition of Equipment Status ..........................................................

8.3.2 Preference Order of Output Hold Value .............................................

8.3.3 Output Hold Setting ............................................................................

8.3.4 Default Values ....................................................................................

8.4 Setting Oxygen Concentration Alarms

8.4.1 Alarm Values ......................................................................................

8.4.2 Alarm Output Actions .........................................................................

8.4.3 Alarm Setting

8.4.4 Default Values ....................................................................................

8.5 Output Contact Setup .......................................................................................

8.5.1 Output Contact ...................................................................................

8.5.2 Setting Output Contact ......................................................................

8.5.3 Default Values ..................................................................................

8.6 Input Contact Settings ....................................................................................

8.6.1 Setting Input Contact .......................................................................

8.6.2 Default Values ..................................................................................

8.7 Other Settings .................................................................................................

8.7.1 Setting the Date-and-Time ...............................................................

8.7.2 Setting Periods over which Average Values are Calculated and Periods

over which Maximum and Minimum Values Are Monitored.............8-13

8.7.3 Setting Fuels ....................................................................................

8.7.4 Setting Purging ................................................................................

......................................................................................8-7

...........................................................8-6

8-1

8-2

8-3

8-5

8-6

8-8

8-9

8-10

8-11

8-12

8-14

8-18

9. Calibration ................................................................................................. 9-1

IM 11M12A01-04E

9.1 Calibration Briefs ..............................................................................................9-1

9.1.1 Principle of Measurement ..................................................................

9.1.2 Calibration Gas ..................................................................................

9.1.3 Compensation ....................................................................................

9.1.4 Characteristic Data from a Sensor Measured During Calibration .....

9.2 Calibration Procedures ....................................................................................

9.2.1 Calibration Setting ..............................................................................

9.2.2 Calibration ..........................................................................................

9-1

9-2

9-4

9-5

9-8

Toc-5

10. Other Functions ...................................................................................... 10-1

10.1 Detailed Display ..............................................................................................10-1

10.1.1 Air Ratio

10.1.2 Cell Temperature ..............................................................................

10.1.3 C. J. Temperature

10.1.4 Amount of Water Vapor in Exhaust Gas ..........................................

10.1.5 Cell Voltage ......................................................................................

10.1.6 Thermocouple Voltage .....................................................................

10.1.7 Cold Junction Voltage ......................................................................

10.1.8 Current Output .................................................................................

10.1.9 Response Time ................................................................................

10.1.10 Cell’s Internal Resistance ...............................................................

10.1.11 Robustness of a Cell .......................................................................

10.1.12 Heater On-Time Ratio .....................................................................

10.1.13 Oxygen Concentration (with time constant) ....................................

10.1.14 Maximum Oxygen Concentration ...................................................

10.1.15 Minimum Oxygen Concentration ....................................................

10.1.16 Average Oxygen Concentration ......................................................

10.1.17 Span and Zero Correction Ratios ...................................................

10.1.18 History of Calibration Time ..............................................................

10.1.19 Time .................................................................................................

10.1.20 Software Revision ...........................................................................

10.2 Operational Data Initialization ......................................................................

10.3 Initialization Procedure ..................................................................................

10.4 Reset .................................................................................................................

10.5 Handling of the ZO21S Standard Gas Unit .................................................

10.5.1 Standard Gas Unit Component Identication ................................

10.5.2 Installing Gas Cylinders .................................................................

10.5.3 Calibration Gas Flow ......................................................................

10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit ...................

10.6.1 Preparation Before Calibration ......................................................

10.6.2 Operating the Span Gas Flow Setting Valve .................................

10.6.3 Operating the Zero Gas Flow Setting Valve ..................................

10.6.4 Treatment After Calibration ............................................................

............................................................................................10-3

10-3

.............................................................................10-3

10-3

10-4

10-5

10-6

10-7

10-8

10-9

10-16

10-17

10-19

10-20

11. Inspection and Maintenance ................................................................. 11-1

11.1 Inspection and Maintenance of the Detector ............................................... 11-1

11.1.1 Cleaning the Calibration Gas Tube ..................................................

11.1.2 Replacing the Sensor Assembly ......................................................

11.1.3 Replacement of the Heater Assembly .............................................

11.1.4 Replacement of Dust Filter ..............................................................

11.1.5 Replacement of O-ring .....................................................................

11.1.6 Stopping and Re-starting Operation ................................................

11-1

11-2

11-4

11-6

IM 11M12A01-04E

Toc-6

11.2 Inspection and Maintenance of the Converter ............................................ 11-8

11.2.1 Replacing Fuses ..............................................................................

11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit ........

11-8

11-10

12. Troubleshooting ..................................................................................... 12-1

12.1 Displays and Measures to Take When Errors Occur .................................. 12-1

12.1.1 What is an Error? .............................................................................

12.1.2 Measures to Take When an Error Occurs .......................................

12.2 Displays and Measures to Take When Alarms are Generated ...................

12.2.1 What is an Alarm? ............................................................................

12.3 Measures When Measured Value Shows an Error ......................................

12.3.1 Measured Value Higher Than True Value ........................................

12.3.2 Measured Value Lower Than True Value ......................................

12.3.3 Measurements Sometimes Show Abnormal Values .....................

12-1

12-2

12-4

12-9

12-10

Customer Maintenance Parts List ........................................CMPL 11M12A01- 04E

Customer Maintenance Parts List ........................................CMPL 11M12A01-12E

Customer Maintenance Parts List ...........................................CMPL 11M3D1- 01E

Revision Information ...............................................................................................i

IM 11M12A01-04E

<1.Overview>

ZR202G Integrated type Zirconia Oxygen Analyzer

ZO21S Standard gas unit

Stop valve

Calibration gas

F1.1E.ai

100 to 240 V AC

100/110/115 200/220/240 V AC

Contact input Analog output, contact output

Digital output (HART)

1. Overview

The EXAxt ZR Integrated type Zirconia Oxygen Analyzer is used to monitor and control the oxygen concentration in combustion gases, in boilers and industrial furnaces, for wide application in industries which consume considerable energy-such as steel, electric power, oil and petrochemical, ceramics, pulp and paper, food, or textiles, as well as incinerators and medium/small boilers. It can help conserve energy in these industries. The EXAxt ZR also contributes to preservation of the earth’s environment in preventing global warming and air pollution by controlling complete combustion to reduce CO2, SOx and NOx.

The EXAxt ZR Integrated type Zirconia Oxygen Analyzer integrates both probe and converter. The

analyzers need not use a sampling device, and allow direct installation of the probe in the wall of a ue

or furnace to measure the concentration of oxygen in the stack gas of the temperature up to 700°C.

The probe uses a high-reliability Zirconia sensor and a heater assembly that can be replaced on site.

The analyzer is equipped with three infrared switches, which enable the user to operate the equipment without opening the cover on site. Analyzer calibration can also be fully automated and the automatic calibration unit is provided. Choose the equipment which best suits your needs so that an optimal combustion control system can be obtained.

Some examples of typical system conguration are illustrated below:

1-1

1.1 <EXAxtZR>SystemConguration

The system configuration should be determined by the conditions; e.g. whether the calibration is to be automated, and whether flammable gas is present and requires safety precautions. The system

conguration can be classied into three basic patterns as follows:

1.1.1 System 1

This is the simplest system consisting of an integrated type analyzer. This system can be implemented for monitoring oxygen concentration in the combustion gases boiler. No piping is required for the reference gas (air) which is fed in at the installation site. The ZO21S standard gas unit is used for calibration.

Zero gas from this unit and span gas (air) is sent to the probe through a tube which is connected during calibration.

Figure1.1 ExampleofSystem1

IM 11M12A01-04E

<1. Overview>

1-2

IM 11M12A01-04E

CAUTION

ZR202G Integrated type Zirconia Oxygen Analyzer

F1.2E.ai

ZA8F flow setting unit

Reference gas

Calibration gas

Needle

valve

Flowmeter

Instrument air

Air Set

Calibration

gas pressure

regulator

Zero gas cylinder

Calibration gas unit case

Stop valve

Check valve

Span gas(Same as Zero gas calibration)

100 to 240 V AC Contact input

Analog output, contact output Digital output (HART)

• As this system uses ambient air for the reference gas, measuring accuracy will be affected by the installation location.

• A stop valve should be connected to the calibration gas inlet of the equipment. The valve should be fully closed unless calibration is in progress.

1.1.2 System 2

This system is for monitoring and controlling oxygen concentration in the combustion gases of a large-size boiler or heating furnace. Instrument air (clean and dry air of oxygen concentration 21%) is used as the reference gas and the span gas for calibration. Zero gas is fed from a cylinder during

calibration. The gas ow is controlled by the ZA8F ow setting unit (for manual valve operation).

Figure 1.2 Example of System 2

<1.Overview>

100 to 240 V AC

Automatic calibration unit

Reference gas

Calibration gas (Zero)

Contact input Analog output, contact output

Digital output (HART)

Air Set

Instrument air

Calibration gas unit case

Calibration

gas pressure

regulator

Zero gas cylinder

ZR202G Integrated type Zirconia Oxygen Analyzer with automatic calibration unit (ZR202G-□-□-□-A-□-□-□-□-A)

F1.3E.ai

Span gas

ZR20H

Note: The installation temperature limits range for integrated type analyzer is -20 to 55°C.

1.1.3 System 3

This example, System 3, represents typical applications in large boilers and heating furnaces, where is a need to monitor and control oxygen concentration. The reference gas and calibration-time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder.

System 3 uses the ZR20H automatic calibration unit, with auto-switching of the calibration gas.

A “combustible gas detected” contact input turns off power to the heater. There’s also contact output from the converter that can be used to operate a purge gas valve to supply air to the sensor.

1-3

*1 Shield cable:

Use shielded signal cables, and connect the shields to the FG terminal of the converter.

*2 Select the desired probe from the Probe Conguration table on page 1-4.

*3 When a zirconia oxygen analyzer is used, 100% N

Use approx. 1 vol% O2 gas (N2-based).

gas cannot be used as the zero gas.

Figure 1.3 Example of System 3

IM 11M12A01-04E

1-4

System Components

ZR202G Integrated type Zirconia Oxygen Analyzers ZO21R Probe Protector for Zirconia Oxygen Analyzers

K9471UA Dust Filter for Oxygen Analyzer

ZO21S Standard Gas Unit ZA8F Flow Setting Unit for manual calibration

ZR20H Automatic Calibration Unit for Integrated type Analyzer

L9852CB, G7016XH Stop Valve for Calibration gas line K9292DN,K9292DS Check Valve for Calibration gas line

G7003XF/K9473XK, G7004XF/K9473XG Air Set

G7001ZC Zero gas Cylinder

G7013XF, G7014XF Pressure Regulator for Gas Cylinder

E7044KF Case Assembly for Calibration gas Cylinder

Integrated type

System configuration

Example 3Example 1

Example 2

( )

T1.1.ai

: Items required for the above system example

: To be selected depending on each application. For details, refer to corresponding chapter.

: Select either

( )

ZR202A Heater Assembly (Spare Parts for ZR202G)

K9471UC Dust Guard Protector

F1.4E.ai

Detector (ZR202G)

Detector(ZR202G)

Probe Protector

(ZO21R)

Dust Filter

(K9471UA)

Dust Guard

Protector

(K9471UC)

Sample gas temperature 0 to 700°C

Mounting

Insertion length

General-use Probe

Application

Horizontal

vertical

Horizontal

vertical

Horizontal

vertical

Vertical

0.4 to

2 m

0.4

2 m

2.5 m

or more

3 m

or less

2.5 m

or more

• Boiler

• Heating furnace

• For pulverized coal boiler with gas flow velocity 10 m/sec or more

• Cement Kiln

• Black liquid recovery boiler

• Cement Kiln

Gas Flow

Sample inlet

<1. Overview>

1.2 < EXAxt ZR > System Components

1.2.1 System Components

1.2.2 Oxygen Analyzer and Accessories

IM 11M12A01-04E

<2. Specications>

2. Specications

This chapter describes the specications for the following:

ZR202G General-use Integrated type Zirconia Oxygen Analyzer (See Section 2.1.2)

ZO21R-L Probe Protector (See Section 2.1.3)

ZA8F Flow Setting Unit (See Section 2.2.1)

ZR20H Automatic Calibration Unit (See Section 2.2.2)

ZO21S Standard Gas Unit (See Section 2.3)

K9471UA Dust Filter for Oxygen Analyzer (See Section 2.4)

2.1 General Specications

2.1.1 Standard Specications

Measured Object: Oxygen concentration in combustion exhaust gas and mixed gas (excluding

inammable gases). May not be applicable corrosive gas such as ammonia,

chlorine is present-check with YOKOGAWA.)

2-1

Measured System: Zirconia system

Oxygen Concentration: 0.01 to 100 vol% O

Output Signal: 4 to 20 mA DC (maximum load resistance 550Ω)

Measurement Range: Any setting in the range of 0 to 5 through 0 to 100 vol% O

partial range

Digital Communication (HART): 250 to 550Ω, depending on number of eld devices connected to the

loop (multi-drop mode).

Note: HART is a registered trademark of the HART Communication Foundation.

Display Range: 0 to 100 vol% O

Warm-up Time: Approx. 20 min.

Repeatability: (Excluding the case where the reference gas is by natural convection)

± 0.5% Maximum value of set range; less than 0 to 25 vol% O2 range

± 1 % Maximum value of set range; 0 to 25 vol%

Linearity: (Excluding standard gas tolerance)

(Excluding the case where the reference gas is by natural convection) (Use oxygen of known concentration (with in the measuring range) as the zero and span calibration gases.) ± 1% Maximum value of set range; less than 0 to 25 vol% O2 range

± 3% Maximum value of set range; 0 to 25 vol% O2 or more and less than 0

± 5% Maximum value of set range; 0 to 50 vol %O2 or more and up to 0 to

(in 1 vol%O2), or

O2 or more and up to 0 to

100 vol% O2 range

(Sample gas pressure: within ± 4.9 kPa)

to 50 vol% O2 range (Sample gas pressure: within ± 0.49 kPa)

100 vol% O2 range (Sample gas pressure: within ± 0.49 kPa)

IM 11M12A01-04E

<2. Specications>

2-2

IM 11M12A01-04E

Drift: (Excluding the rst two weeks in use)

(Excluding the case where the reference gas is by natural convection.) Both zero and span ± 2% Maximum value of set range/month

Response Time: Response of 90% within 5 seconds. (Measured after gas is introduced from

calibration gas inlet and analog output starts changing.)

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer

Can be operated in the eld without opening the cover using optical switches.

Display: 6-digit LCD

Switch: Three optical switches

Output Signal: 4 to 20 mA DC, one point (maximum load resistance 550 Ω)

Digital Communication (HART): 250 to 550 Ω, depending on quantity of eld devices connected to the

loop (multi-drop mode).

Note: HART is a registered trademark of the HART Communication Foundation.

Contact Output Signal: Two points (one is fail-safe, normally open)

Contact Input Signal: Two points

Sample Gas Temperature: 0 to 700°C

It is necessary to mount the cell using Inconel cell-bolts when the temperature measures more than 600°C.

High-temperature service ― greater than 700°C ― is not available.

Sample Gas Pressure: -5 to +250 kPa (When the pressure in the furnace exceeds 3 kPa, it is

recommended to compensate the pressure. When the pressure in the furnace exceeds 5 kPa, you must perform pressure compensation.)

No pressure uctuation in the furnace be allowed.

Note: When the detector is used in conjunction with a check valve and the ZA8F Flow Setting Unit, the maximum pressure of sample

gas is 150 kPa. When with a check valve and the ZR20H Automatic Calibration Unit, it is 200 kPa. If the pressure of your sample gas exceeds these limits, consult with Yokogawa.

Probe Length: 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m

Probe Material: SUS 316 (JIS)

Ambient Temperature: -20 to +55°C (- 5 to +70°C on the case surface)

Storage Temperature: -30 to +70°C

Humidity Range: 0 to 95%RH (non-condensing)

Installation Altitude: 2000 m or less

Category based on IEC 1010: II (Note)

Pollution degree based on IEC 1010: 2 (Note)

Note: Installation category, called over-voltage category, species impulse withstand voltage. Category II is for electrical equipment.

Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric strength. Degree 2 is the normal indoor environment.

Power Supply Voltage: Ratings; 100 to 240 V AC

Acceptable range; 85 to 264 V AC

Power Supply Frequency: Ratings; 50/60 Hz

Acceptable range; 45 to 66 Hz

Power Consumption: Max. 300 W, approx. 100 W for ordinary use.

<2. Specications>

CAUTION

Safety and EMC conforming standards

Safety: EN61010-1, CSA C22.2 No.61010-1,

EMC: EN 61326 Class A,

CISPR 11

KC Marking: Korea Electromagnetic Conformity Standard

This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this instrument in the industrial environment only.

Reference Gas System: Natural Convection, Instrument Air, Pressure Compensation

Instrument Air System (excluding Natural Convection):

Pressure; 200 kPa + the pressure inside the furnace (It is recommended

to use air which is dehumidied by cooling to dew point -20°C or

less, and dust or oil mist are removed.)

Consumption; Approx. 1Nl/min

EN 55011 Class A Group 1, EN 61000-3-2, AS/NZS

UL61010-1

2-3

Material in Contact with Gas: SUS 316 (JIS), Zirconia, SUS 304 (JIS) (ange), Hastelloy B, (Inconel

600, 601)

Construction: Heater and thermocouple replaceable construction. Non explosion-proof JIS

C0920 / equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version.)

Gas Connection: Rc 1/4 or 1/4 FNPT

Wiring Connection: G1/2, Pg13.5, M20 by 1.5mm, 1/2 NPT select one type (4 pieces)

Installation: Flange mounting

Probe Mounting Angle: Horizontal to vertically downward.

When the probe insertion length is 2 m or less, installing at angles from horizontal to vertically downward is available. When the probe insertion length is 2.5m or more, mount vertically downward (within ± 5°), and if installing at angles from horizontal to vertically downward (within ± 5°), use a probe protector.

Case: Aluminum alloy

Paint Color: Cover; Mint green (Munsell 5.6BG3.3/2.9)

Case; Mint green (Munsell 5.6BG3.3/2.9)

Finish: Polyurethane corrosion-resistance coating

Insertion length of 0.4m: approx. 8 kg (JIS 5K 65) / approx. 13 kg (ANSI 150 4)

Insertion length of 1.0m: approx. 10 kg (JIS 5K 65) / approx. 15 kg (ANSI 150 4)

Insertion length of 1.5m: approx. 12 kg (JIS 5K 65) / approx. 17 kg (ANSI 150 4)

Insertion length of 2.0m: approx. 14 kg (JIS 5K 65) / approx. 19 kg (ANSI 150 4)

Insertion length of 3.0m: approx. 17 kg (JIS 5K 65) / approx. 22 kg (ANSI 150 4)

Weight:

IM 11M12A01-04E

<2. Specications>

2-4

IM 11M12A01-04E

Functions

Display Function: Displays values of the measured oxygen concentration, etc.

Alarm, Error Display: Displays alarms such as “AL-06” or errors such as “Err-01” when any such

status occurs.

Calibration Functions: Auto-calibration; Requires the Automatic Calibration Unit. It calibrates

Maintenance Functions: Can operate updated data settings in daily operation and checking. Display

Setup Functions: Initial settings suit for the plant conditions when installing the converter.

Display and setting content:

Display Related Items: Oxygen concentration (vol% O2), Output current value (mA), air ratio,

automatically at specied intervals.

Semi-auto Calibration; Requires the Automatic Calibration Unit. Input

calibration start signal by optical switch or contact, then it calibrates automatically afterwards.

Manual Calibration; Calibration with opening/closing the valve of calibration

gas in operation interactively with the optical switch.

data settings, calibration data settings, test settings (current output loop check, input/output contact check).

Current output data settings, alarm data settings, contact data settings, other settings.

moisture quantity (in hot gases) (vol% H2O), Cell temperature (°C ), thermocouple reference junction temperature (°C ), maximum/minimum/ average oxygen concentration (vol% O2), cell e.m.f. (mV), cell internal

resistance (Ω), cell condition (in four grades), heater on-time rate (%),

calibration record (ten times), time (year/month/day/hour/minute)

Calibration Setting Items: Span gas concentration (vol% O2), zero gas concentration (vol%O2),

calibration mode (auto, semi-auto, manual), calibration type and method (zero-span calibration, zero calibration only, span calibration only), stabilization time (min.sec), calibration time (min.sec), calibration period (day/hour), starting time (year/month/day/hour/minute)

Output Related Items: Analog output/output mode selection, output conditions when warming-up/

maintenance/calibrating/abnormal, 4 mA/20 mA point oxygen concentration (vol% O2), time constant, preset values when warming-up/maintenance/ calibrating/abnormal, output preset values on abnormal

Alarm Related Items: Oxygen concentration high alarm/high-high alarm limit values (vol%

Oxygen concentration low alarm/low-low alarm limit values (vol% O2), Oxygen concentration alarm hysteresis (vol% O2), Oxygen concentration alarm detection, alarm delay (seconds)

Contact Related Items: Selection of contact input 1 and 2, selection of contact output 1 and

2 (abnormal, high-high alarm, high alarm, low alarm, low-low alarm, maintenance, calibrating, range switching, warming-up, calibration gas

pressure decrease, ameout gas detection (answer-back of contact input)

O2),

<2. Specications>

Converter Output: One mA analog output point (4 to 20 mA DC (maximum load resistance of

550Ω)) with mA digital output point (HART) (minimum load resistance of 250Ω).

2-5

Range; Any setting between 0 to 5 through 0 to 100 vol%

O2 in 1 vol% O2, and partial range is available (Maximum range value/minimum range value 1.3 or more) For the log output, the minimum range value is xed at 0.1 vol% O2. 4 to 20 mA DC linear or log can be selected. Input/output isolation.

Output damping; 0 to 255 seconds.

Hold/non-hold selection, preset value setting possible with hold.

Contact Output: Two points, contact capacity 30V DC 3A, 250V AC 3A (resistive load)

One of the output points can be selected to ether normally energized or normally de-energized status. Delayed functions (0 to 255 seconds) and hysteresis function (0 to 9.9 vol% O2) can be added to high/low alarms. The following functions are programmable for contact outputs. (1) Abnormal, (2) High-high alarm, (3) High alarm, (4) Low-low alarm, (5) Low alarm, (6) Maintenance, (7) Calibration, (8) Range switching answerback, (9) Warm-up, (10) Calibration gas pressure decrease (answer-back of contact input), (11) Flameout gas detection (answer-back of contact input).

Contact Input: Two points, voltage-free contacts

The following functions are programmable for contact inputs: (1) Calibration gas pressure decrease alarm, (2) Range switching (switched

range is xed), (3) External calibration start, (4) Process alarm (if this signal

is received, the heater power turns off)

Self-diagnosis: Abnormal cell, abnormal cell temperature (low/high), abnormal calibration,

A/D converter abnormal, digital circuit abnormal

Calibration: Method; zero/span calibration

Calibration mode; Auto, semi-auto and manual (All are operated using

optical switches). Either zero or span can be skipped.

Zero calibration gas concentration setting range; 0.3 to 100 vol% O2 (in 0.01

vol% O2).

Span calibration gas concentration setting range; 4.5 to 100 vol% O2 (in 0.01

vol% O2).

Use nitrogen-balanced mixed gas containing 0 to 10 vol% O2 scale of

oxygen for standard zero gas and 80 to 100 vol% O2 scale of oxygen for standard span gas. Calibration period; date/time setting: maximum 255 days

IM 11M12A01-04E

<2. Specications>

2-6

IM 11M12A01-04E

Model and Codes

Model Sufx code Option code Description

ZR202G - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Integrated type Zirconia Oxygen Analyzer

Length -040

Wetted material -S

Flange (*2)

Auto Calibration -N

Reference gas -C

Gas Thread -R

Connection box thread -P

Instruction manual -J

-- -A - - - - - - - - - - Always -A

Options

Valves

Tag plates

NAMUR NE43 compliant

-070

-100

-150

-200

-250

-300

-C

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-R

-S

-W

-A

-B

-E

-P

-T

-G

-M

-T

-E

-C

*1 For the horizontally installed probe whose insertion length is 2.5 m or more, use the Probe Protector. Be sure to specify

ZO21R-L-200-. Specify the ange sufx code either -C or -K.

*2 The thickness of the ange depends on its dimensions.

*3 Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to 700°C). *4 Specify either /CV or /SV option code. *5 Specify either /SCT or /PT option code. *6 No need to specify the option codes, /CV and /SV, since the check valves are provided with the Automatic Calibration Unit.

Automatic calibration cannot be used when natural convection is selected as reference gas.

*7 Sun shield hood is still effective even if scratched. Hood is necessary for outdoor installation out of sun shield roof. *8 Recommended if sample gas contains corrosive gas like chlorine.

*9 Piping for reference gas must be installed to supply reference gas constantly at a specied ow rate.

*10 Output signal limits: 3.8 to 20.5 mA. Specify either /C2 or /C3 option code.

- - - - - - - - - -

/C Inconel bolt (*3)

/CV /SV

/H Hood (*7)

/F1 /F2

/SCT /PT

/C2

/C3

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m

2.5 m (*1)

3.0 m (*1)

SUS316 Stainless steel with Inconel calibration gas tube (*8)

ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 A SUS304 DIN PN10 DN80 A SUS304 DIN PN10 DN100 A SUS304 JIS 5K 65 FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Westinghouse

Not required Horizontal mounting (*6) Vertical mounting (*6)

Natural convection External connection (Instrument air) (*9) Pressure compensated (*9)

Rc 1/4 1/4 NPT (Female)

G1/2 Pg13.5 M20x1.5 mm 1/2NPT

Japanese English Chinese

Check valve (*4) Stop valve (*4)

Dust Filter Dust Guard Protector

Stainless steel tag plate (*5) Printed tag plate (*5)

Failure alarm down-scale: Output status at CPU failure and hardware error is 3.6 mA or less (*10) Failure alarm up-scale: Output status at CPU failure and hardware error is 21.0 mA or more (*10)

<2. Specications>

F11_01.ai

153 to 164

125

170

252 to 265

48.5

338 to 351

122

L= 0.4, 0.7,

1.0, 1.5, 2.0,

2.5, 3.0 (m)

4-G1/2,2-1/2NPT etc. Cable connection port

Display side

152.4

190.5

228.6 165 200 220 155 175 185 210 229 190 155

120.6

152.4

190.5 125 160 180 130 140 150 175

190.5

152.4 127

4 - Ø19 4 - Ø19 8 - Ø19 4 - Ø18 8 - Ø18 8 - Ø18 4 - Ø15 4 - Ø19 8 - Ø19 8 - Ø19 8 - Ø19 4 - Ø19

4 - Ø11.5

A B C

19 24 24 18 20 20 14 18 18 18 24 24 14

Ø50.8

Rc1/4 or 1/4NPT Reference gas inlet

Rc1/4 or 1/4NPT Calibration gas inlet

Ø123

Terminal side

Flange

• External Dimensions

Model ZR202G Integrated type Zirconia Oxygen Analyzers Unit: mm

2-7

• Standard Accessories

Fuse A1113EF 1 3.15 A

Allen wrench L9827AB 1 For lock screw

Item Parts. No. Q'ty Description

IM 11M12A01-04E

<2. Specications>

2-8

IM 11M12A01-04E

F11_02.EPS

Flange

156 ± 3

125

170

256 ± 4

48.5

Ø123

342 ± 4

122

Terminal side

PIPING:A

PIPING

A B B A B B A A B B B B A

152.4

190.5

228.6 165 200 220 155 175 185 210 229 190 155

120.6

152.4

190.5 125 160 180 130 140 150 175

190.5

152.4 127

4 - Ø19 4 - Ø19 8 - Ø19 4 - Ø18 8 - Ø18 8 - Ø18 4 - Ø15 4 - Ø19 8 - Ø19 8 - Ø19 8 - Ø19 4 - Ø19

4 - Ø11.5

A B C

19 24 24 18 20 20 14 18 18 18 24 24 14

L= 0.4, 0.7,

1.0, 1.5, 2.0,

2.5, 3.0 (m)

4-G1/2,2-1/2NPT etc. Cable connection port

Ø50.8

Rc1/4 or 1/4NPT Reference gas inlet

Rc1/4 or 1/4NPT Calibration gas inlet

Reference gas outlet

Display side

Flange

ØB

Flange

ØA

Flange

Stop

valve

ØA

ØB

274

150

± 4

± 3

F13.ai

Material of HOOD : Aluminum Food Weight : Approx. 800g

Model ZR202G...-P Integrated type Zirconia Oxygen Analyzer with pressure compensation

Unit: mm

• Standard Accessories

• Hood (Option code /H) Unit: mm

Item Parts. No. Q'ty Description

Fuse A1113EF 1 3.15 A Allen wrench L9827AB 1 For lock screw

<2. Specications>

F2-3E.ai

Flange <1> (with bolts, nuts and washer)

gasket (t1.5)

SUS316

Dimensions of holes on opposing surface

ØA

Gas flow

Washer (12)

Mounting nut (M12)

l (Insert length)

l=1050,1550,2050

Ø60.5

2.1.3 ZO21R Probe Protector

This probe protector is required for the general-use detector when it is used for oxygen concentration

measurements in powdered coal boilers or in uidized furnaces to prevent abrasion due to dust particles when gas ow exceeds 10 m/sec.

When probe length of the ZR202G is 2.5 m or more and mounted horizontally, be sure to select a probe protector ZO21R-L-200-*B to support the probe.

Insertion Length: 1.05 m, 1.55 m, 2.05 m.

Flange: JIS 5K 65A FF equivalent, ANSI Class 150 4 FF (without serration)

equivalent or DIN PN10 DN50A equivalent. However, ange thickness is

different.

Material: SUS316 (JIS), SUS304 (JIS) (Flange)

2-9

Weight: 1.05m; Approx. 6/10 kg (JIS/ANSI), 1.55 m; Approx. 9/13 kg

Installation: Bolts, nuts, and washers are provided for detector, probe adapter and

• Model and Codes

Model Sufx code Option code Description

ZO21R -L - - - - - - - - - - - - Probe Protector(0 to 700°C)

Insertion length

Flange ( *1) -J

Style code *B - - - - - - - - - - - - Style B

*1 Thickness of ange depends on dimensions of ange.

• External Dimension

(JIS/ANSI), 2.05 m; Approx. 12/16 kg (JIS/ANSI)

process-side ange.

-100

-150

-200

-A

-E

- - - - - - - - - - - -

1.05 m (3.5 ft)

1.55 m (5.1 ft)

2.05 m (6.8 ft)

JIS 5K 65 FF SUS304 ANSI Class 150 4 FF SUS304 DIN PN10 DN50A SUS304

Unit: mm

Flange<1> A B C t D

JIS 5K 65 FF SUS304 155 130 4 - Ø15 5 40

ANSI Class 150 4 FF SUS304 228.6 190.5 8 - Ø19 12 50

DIN PN10 DN50A SUS304 165 125 4 - Ø18 12 50

IM 11M12A01-04E

<2. Specications>

2-10

IM 11M12A01-04E

NOTE

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit

2.2.1 ZA8F Flow Setting Unit

This ow setting unit is applied to the reference gas and the calibration gas in a system conguration

(System 2).

This unit consists of a owmeter and ow control valves to control the ow of calibration gas and

reference gas.

• Standard Specications

Flowmeter: Calibration gas; 0.1 to 1.0 l/min. Reference gas; 0.1 to 1.0 l/min.

Construction: Dust-proof and rainproof construction

Case Material: SPCC (Cold rolled steel sheet)

Painting: Baked epoxy resin, Dark-green (Munsell 2.0 GY 3.1/0.5 or equivalent)

Tube Connections: Rc1/4 or 1/4FNPT

Reference Gas Pressure: Clean air supply of sample gas pressure plus approx. 50 kPa G (or

sample gas pressure plus approx.150 kPa G when a check valve is used, maximum pressure rating is 300 kPa) (pressure at inlet of the automatic calibration unit)

Air Consumption: Approx. 1.5 l/min

Weight: Approx. 2 kg

Used instrument air for span calibration gas, if without instrument air is used, contact YOKOGAWA.

• Model and Codes

Model Sufx code Option code Description

ZA8F - - - - - - - - - - - - - - - - - - - - - - - Flow setting unit

Joint

Style code *C - - - - - - - - - - - - Style C

-J

-A

- - - - - - - - - - - -

Rc 1/4 With 1/4 NPT adapter

<2. Specications>

CHECK

OUT

REF OUT

REFERENCE

SPAN

ZERO

REFERENCE CHECK

AIR

ZERO

SPAN

CHECK OUT

PIPNG INSIDE THE FLOW SETTING UNIT

Unit : mm (inch)

Weight : Approx. 2.3 kg

Flowmeter Flowmeter

ZERO

GAS IN

AIR IN

Instrument air Approx. 1.5 l/min.

Air Set

REF OUT

SPAN

GAS IN

2035

222.8

235.8

140

180

Reference gas outlet

Calibration gas outlet

ø6 Hole

Span gas inlet

Zero gas inlet

2B mounting pipe

Instrument air inlet

F2.6E.ai

Air pressure ; without check valve ; sample gas pressure + approx.50 kPaG with check valve ; sample gas pressure + approx.150 kPaG

Piping connection port A

ZA8F-J*C

ZA8F-A*C

5 - Rc1/4

5 - 1/4NPT

Model

Piping connection port A

• External Dimensions

2-11

IM 11M12A01-04E

<2. Specications>

2-12

IM 11M12A01-04E

2.2.2 ZR20H Automatic Calibration Unit

This automatic calibration unit is applied to supply specied ow of reference gas and calibration gas during automatic calibration to the detector in a system conguration (System 3).

• Specications

Equipped with the analyzer when automatic calibration is specied in the sufx code of the ZR202G

Integrated type by selecting either “-A (Horizontal mounting)” or “-B (Vertical mounting)”. The ZR20H should be arranged when automatic calibration is to be required after the ZR202G has been installed. Ask Yokogawa service station for its mounting.

Construction: Dust-proof and rainproof construction; NEMA4X/IP67 (excluding owmeter)

Mounting: Mounted on ZR202G, no vibration

Materials: Body; Aluminum alloy, Piping; SUS316 (JIS), SUS304 (JIS), Flowmeter;

Finish: Polyurethane corrosion-resistance coating

Piping Connection: Rc 1/4 or 1/4 NPT

Power Supply: 24V DC (from ZR202G)

Power consumption: Approx.1.3 W

Reference Gas Pressure: Sample gas pressure plus Approx. 150 kPa (690 kPa max.), (Pressure at

Air Consumption: Approx. 1.5 l/min

Weight: Approx. 2 kg

Ambient Temperature: -20 to +55°C, no condensing and freezing

Ambient Humidity: 0 to 95% RH

Storage Temperature: -30 to +65°C

• Model and Codes

Model Sufx code Option code Description

ZR20H - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Gas piping connection-R-T

Reference gas *2 -E

Mounting -A

– -A - - - - - - - - - - - -

*1 Ask Yokogawa service station for additional mounting of ZR20H to the preinstalled ZR202G. *2 Select the appropriate reference gas of ZR20H according to the one of ZR202G.

MA (Methacrylate resin), Bracket; SUS304 (JIS)

Case; Mint green (Munsell 5.6 BG3.3 /2.9) Cover; Mint green (Munsell 5.6 BG3.3/2.9)

inlet of automatic calibration unit)

Automatic calibration unit for ZR202G *1

- - - - - - - - - - - -

-P

-B

- - - - - - - - - - - -

Rc 1/4 1/4 NPT

Instrument air Pressure compensated

Horizontal mounting Vertical mounting

Always -A

<2. Specications>

Rc1/4 or 1/4NPT(Female)

SPAN IN REF IN ZERO IN

AUTO CAL. UNIT

-20 TO 558C

ZR20HMODEL

SUFFIX

STYLE

AMB.TEMP

NO.

SUPPLY 690kPa MAX.

USED WITHZR202G

ZR202GUSED WITH

690kPa MAX.SUPPLY

NO.

AMB.TEMP

STYLE

SUFFIX

MODEL ZR20H

-20 TO 558C

AUTO CAL. UNIT

SPAN IN REF IN ZERO IN

[ 84

166.5

Ø80

243

258

166.5

5644

180MAX444040 66.5

49111

66.540 40

Ø84

Span gas inlet

Zero gas inlet

Reference gas inlet

Zero gas inlet

Reference gas inlet

Span gas inlet

MAX

(2) Vertical Mounting (-B)

Unit: mm

Ø80

SPAN IN

REF. IN

ZERO IN

F4.11E.ai

Calibration gas

Reference gas

ZR202G body

Span gas solenoid valve

Span gas flowmeter

Reference gas flowmeter

To Air set

To Zero gas cylinder

Needle valve

Automatic calibration unit

Zero gas flowmeter

Zero gas solenoid valve

Check valve

External Dimensions

(1) Horizontal Mounting (-A)

2-13

PIPNG INSIDE THE AUTOMATIC CALIBRATION UNIT

IM 11M12A01-04E

<2. Specications>

2-14

IM 11M12A01-04E

228

253

1600

354

Flow checker Span gas valve

Zero gas valve Gas outlet

F24.ai

Zero gas cylinder (6 cylinder): E7050BA

2.3 ZO21S Standard Gas Unit

This is a handy unit to supply zero gas and span gas to the detector in a system conguration based

on System 1. It is used in combination with the detector only during calibration.

• Standard Specications

Function: Portable unit for calibration gas supply consisting of span gas (air) pump, zero

gas cylinder with sealed inlet, ow rate checker and ow rate needle valve.

Sealed Zero Gas Cylinders (6 provide): E7050BA

Capacity: 1 l

Filled pressure: Approx. 686 kPa G (at 35 °C)

Composition: 0.95 to 1.0 vol% O

Power Supply: 100, 110, 115, 200, 220, 240V AC± 10%, 50/60 Hz

Power Consumption: Max. 5 VA

Case material: SPCC (Cold rolled steel sheet)

Paint: Epoxy resin, baked

Paint Color: Mainframe; Munsell 2.0 GY3.1/0.5 equivalent

Piping: Ø6 x Ø4mm exible tube connection

Weight: Approx. 3 kg

Span gas: Internal pump draws in air from atmosphere, and feeds to detector.

* Non CE Mark.

• Model and Codes

Model Sufx code Option code Description

ZO21S - - - - - - - - - - - - - - - - - - - - - Standard gas unit

-2

Power supply

Panel

Style code *A - - - - - - - - - - - Style A

-3

-4

-5

-7

-8

balance

2+N2

Cover; Munsell 2.8 GY6.4/0.9 equivalent

- - - - - - - - - - -

-J

-E

- - - - - - - - - - -

200 V AC 50/60 Hz 220 V AC 50/60 Hz 240 V AC 50/60 Hz 100 V AC 50/60 Hz 110 V AC 50/60 Hz 115 V AC 50/60 Hz

Japanese version English version

• External Dimensions

<2. Specications>

Ø51

Carborundum filter (SiC)

Increasing of insertion length

F31.EPS

Screw

Detector

Attach the filter unit to the tip of the detector by screwing it clockwise.

4-Ø6

122

Ø50.8

100

Increasing of insertion length

F11-1.ai

2.4 Other Equipment

2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA)

This lter is used to protect the detector sensor from corrosive dust components or from a high

concentration of dust when the oxygen concentration in utility boilers or concrete kilns are to be measured.

This lter requires the measuring gas ow of 1 m/sec or faster to replace gas inside zirconia sensor.

• Standard specications

Applicable detector: Standard-type detector for general-use (the sample gas ow should be

approximately perpendicular to the probe.)

Mesh: 30 microns

Material: Carborundum (Filter), SUS316 (JIS)

Weight: Approx. 0.2 kg

Part No. Description

K9471UA Filter

K9471UX Tool

2-15

Unit: mm

2.4.2 Dust Guard Protector (part no. K9471UC)

Recommended to be used when sample gas is likely to ow directly into the cell due to its ow direction in the stack or the like, ammable dust may go into the cell, or water drops are likely to fall

and remain in the cell during downtime or the like due to the installation position.

Material: SUS316 Unit: mm

Weight: Approx. 0.3 kg

IM 11M12A01-04E

<2. Specications>

2-16

IM 11M12A01-04E

F15.ai

(Full open length)

Rc1/4 or 1/4NPT

Ø43

K9292DN : Rc 1/4(A),R 1/4(B) K9292DS : 1/4FNPT(A),1/4NPT(Male)(B)

F30.EPS

Approx. 19 Approx. 54

Unit: mm

2.4.3 Stop Valve (part no. L9852CB or G7016XH)

This valve is mounted on the calibration gas line in the system to allow for one-touch calibration. This

is applied to a system conguration (System 1).

• Standard Specication

Connection: Rc 1/4 or 1/4 FNPT

Material: SUS 316 (JIS)

Weight: Approx. 80 g

Part No. Description

L9852CB Joint: Rc 1/4, Material: SUS316 (JIS)

G7016XH Joint: 1/4 NPT, Material: SUS316 (JIS)

2.4.4 Check Valve (part no. K9292DN or K9292DS)

This valve is mounted on the calibration gas line (directly connected to the detector). This is applied to

a system based on the system conguration (System 2 and 3).

This valve prevents the sample gas from entering the calibration gas line. Although it functions as the stop valve, operation is easier as it does not require opening/closing at each calibration.

Screw the check valve into the calibration gas inlet of the detector instead of the stop valve.

• Standard Specications

Connection: Rc1/4 or 1/4FNPT

Material: SUS304 (JIS)

Pressure: Between 150 kPa G or more 350 kPa G or less

Weight: Approx. 40 g

Part No. Description

K9292DN Joint: Rc 1/4, Material: SUS304 (JIS)

K9292DS Joint: 1/4 NPT, Material: SUS304 (JIS)

<2. Specications>

Ø74

Primary

Secondary

Max. 210

max. 55

Approx. 122

Secondary pressure gauge

Panel (Horizontal mounting)

Panel (Vertical mounting)

G7003XF, G7004XF: Rc 1/4 K9473XK, K9473XG: 1/4NPT connector

ø15

2-ø2.2

+0.5

-0

2-ø6.5

2-M6 screw depth 8

Horizontal mounting

Vertical mounting

Panel cut dimensions

View A

F22_1.ai

Unit : mm

2.4.5 Air Set

This set is used to lower the pressure when instrument air is used as the reference and span gases.

Standard Specications

• Part no. G7003XF or K9473XK

Primary Pressure: Max. 1 MPa G

Secondary Pressure: 0.02 to 0.2 MPa G

Connection: Rc1/4 or 1/4FNPT with joint adapter

Weight: Approx.1 kg

Part No. Description

G7003XF Joint: RC 1/4, Material: Zinc alloy

K9473XK Joint: 1/4 FNPT, Material: Zinc alloy with adapter (SUS316)

• Part. no. G7004XF or K9473XG

Primary Pressure: Max. 1 MPa G

Secondary Pressure: 0.02 to 0.5 MPa G

2-17

Connection: Rc1/4 or 1/4 FNPT with joint adapter

Weight : Approx. 1kg

Part No. Description

G7004XF Joint: RC 1/4, Material: Zinc alloy

K9473XG Joint: 1/4 FNPT, Material: Zinc alloy with adapter (SUS316)

IM 11M12A01-04E

<2. Specications>

2-18

IM 11M12A01-04E

Unit : mm

Weight : Approx. 6 kg

F32.ai

485

325

ø140

Regulator handle

W22 (Righthanded screw)

Stop valve

Approx.112

Unit : mm

* Outlet

Part No.

G7013XF

G7014XF

* Outlet

Rc1/4

1/4 NPT female screw

Secondary pressure gauge

Primary pressure gauge

Secondary safety valve

Primary safety valve

Approx. 82

Approx. 59

Approx. 163 Approx. 174

2.4.6 Zero Gas Cylinder (part no. G7001ZC)

The gas from this cylinder is used as the calibration zero gas and detector purge gas.

• Standard Specications

Capacity: 3.4 l

Filled pressure: 9.8 to 12 MPa G

Composition: 0.95 to 1.0 vol%

O2 remaining N

(Note) Export of such high pressure lled gas cylinder to most countries is prohibited or restricted.

2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder

This regulator valve is used with the zero gas cylinders.

• Standard Specications

Primary Pressure: Max. 14.8 MPa G

Secondary Pressure: 0 to 0.4 MPa G

Connection: Inlet W22 14 threads, right hand screw

Outlet Rc1/4 or 1/4FNPT

Material: Brass body

<2. Specications>

324

496

200 180

Pressure regulator

Zero gas cylinder

2B mounting pipe

( Ø60.5 )

(G7001ZC)

G7013XF/ G7014XF

F23.ai

(Note)The zero gas cylinder and the regulator valve are not included in the E7044KF (case assembly)

(158.3)

(160)

The oblique line is an opening portion.

K9470BX

ZR202A-040

ZR202A-070

ZR202A-100

ZR202A-150

ZR202A-200

ZR202A-250

ZR202A-300

552

852

1152

1652

2152

2652

3152

Approx. 0.8

Approx. 1.2

Approx. 1.6

Approx. 2.2

Approx. 2.8

Approx. 3.4

Approx. 4.0

Jig for change

L±12

(K9470BX)

Ø 21.7

Unit : mm

Ø 45

L: length

Weight (kg)

Model & Code

F2.16.EPS

2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder

This case is used to store the zero gas cylinders.

• Standard Specications

Case Paint: Baked epoxy resin, Jade green (Munsell 7.5 BG 4/1.5)

Installation: 2B pipe mounting

Weight: Approx. 10 kg (including gas cylinder)

(Note) Export of such high pressure lled gas cylinder to most countries is prohibited or restricted.

2-19

2.4.9 ZR202A Heater Assembly

Model Sufx code Option code Description

ZR202A - - - - - - - - - - - - - - - - - - - - Heater Assembly for ZR202G

Length (*1) -040

-070

-100

-150

-200

-250

-300

Jig for change -A

-N

-- -A - - - - - - - - - - - Always -A

*1 Sufx code of length should be selected as same as ZR202G installed.

*2 Jig part no. is K9470BX to order as a parts after purchase. (Note) The heater is made of ceramic, do not drop or subject it to pressure stress.

 External Dimensions

- - - - - - - - - - -

0.4 m

0.7 m 1 m

1.5 m 2 m

2.5 m 3 m

with Jig (*2) None

IM 11M12A01-04E

Blank Page

<3. Installation>

NOTE

CAUTION

3. Installation

This chapter describes installation of the following equipment:

3.1 Model ZR202G Integrated type Zirconia Oxygen Analyzer

3.2 Model ZA8F Flow Setting Unit

3.3 Model ZR20H Automatic Calibration Unit

3.4 Case Assembly (E7044KF) for Calibration gas Cylinder

3.1 Installation of ZR202G Zirconia Oxygen Analyzer

3.1.1 Installation Location

The following should be taken into consideration when installing the probe:

(1) Easy and safe access to the probe for checking and maintenance work.

(2) Ambient temperature of not more than 55°C, and the terminal box should not be affected by

radiant heat.

3-1

(3) A clean environment without any corrosive gases.

A natural convection type analyzer (model ZR202G-----C), which uses ambient air as reference gas, requires that the ambient oxygen concentration be constant. Automatic calibration cannot be used when natural convection is selected as reference gas.

(4) No vibration.

(5) The sample gas satises the specications described in Chapter 2.

(6) No sample gas pressure uctuations.

• The ambient temperature of the ZR202G Integrated type Zirconia Oxygen Analyzer should be between - 20°C and 55°C.

IM 11M12A01-04E

<3. Installation>

3-2

IM 11M12A01-04E

CAUTION

100mm

(vertical)

Bounds of the probe insertion hole location

Flange matches the detector size

(horizontal)

100mm

Four-hole flange

Eight-hole flange

F3101E.ai

*1 Note

Type Outside diameter of detector

With dust filter 51 mm in diameter (Note) With probe protector 60.5 mm in diameter (Note)

Standard 50.8 mm in diameter (Note)

CAUTION

3.1.2 Probe Insertion Hole

• The outside dimension of detector may vary depending on its options. Use a pipe that is large enough for the detector. Refer to Figure 3.1 for the dimensions. If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards.

• When using the detector with pressure compensation, ensure that the ange gasket does not block the reference gas outlet on the detector ange. If the ange gasket blocks the outlet, the detector cannot conduct pressure compensation. Where necessary, make a notch on the ange

gasket.

• The sensor (zirconia cell) at the probe tip may deteriorate due to thermal shock if water drops are allowed to fall on it, as it is always at high temperature.

(1) Do not mount the probe with the tip higher than the probe base.

(2) If the probe length is 2.5 m or more, the detector should be mounted vertically (no more than a 5°

tilt).

(3) The detector probe should be mounted at right angles to the sample gas ow or the probe tip

should point downstream.

(Note) When using the detector with pressure compensation, ensure that the flange gasket does not block the reference gas

outlet on the detector flange. If the flange gasket blocks the outlet, the detector cannot perform pressure compensation.

Where necessary, make a notch in the ange gasket.

Figure 3.1 Illustrates an example of the probe insertion hole

3.1.3 Installation of the Probe

• The cell (sensor) at the tip of the detector is made of ceramic (zirconia). Do not drop the detector, as impact will damage it.

• A gasket should be used between the anges to prevent gas leakage. The gasket material

should be heatproof and corrosion-proof, suited to the characteristics of the sample gas.

<3. Installation>

CAUTION

Ø51

Carborundum filter (SiC)

Increasing of insertion length

F31.EPS

Screw

Detector

Attach the filter unit to the tip of the detector by screwing it clockwise.

The following should be taken into consideration when mounting the general-use detector:

<General-use detector>

(1) Make sure that the cell mounting screws (four bolts) at the probe tip are not loose.

If a dust lter (see Section 2.4.1) is used, make sure it is properly attached to the detector. Refer to Section 3.1.4 for installation of the dust lter.

(2) Where the detector is mounted horizontally, the calibration gas inlet and the reference gas inlet

should face downward.

3.1.4 Installation of the Dust Filter (K9471UA), Dust Guard Protector (K9471UC) Probe Protector (ZO21R)

• The dust lter is used to protect the Zirconia sensor from corrosive dust or a high concentration of dust such as in utility boilers and concrete kilns. If a lter is used in combustion systems other

than these, it may have adverse effects such as response delay. The combustion conditions

should be examined carefully before using a lter.

3-3

• The dust lter requires gas ow of 1 m/sec or faster at the front surface of the lter.

When you specify option code /F1, the detector is shipped with the dust lter mounted.

Follow this procedure when replacing the lter in the detector. It is recommended that you read Chapter 11 prior to lter mounting, for it is necessary to be familiar with the detector’s construction,

especially the sensor assembly.

(1) Mount the dust lter by putting it on the end of the detector and screw the dust lter clockwise.

Put a hook pin wrench (K9471UX), Ø52 to 55 in diameter, into the hole on the dust lter to fasten

or remove it. Apply a heat-resistant coating (see Note 1) to the threads on the detector.

Where mounting dust lter after having once removed it from the detector, reapply the heat-

resistant coating.

Note 1:As the detector is heated to 700°C, it is recommended to use the heat-resistant coating on the threads to prevent seizing up.

Name of heat-resistant coating material: “Never-Seez Nickel Special”.

Figure 3.2.1 Installation of the dust lter

IM 11M12A01-04E

<3. Installation>

3-4

IM 11M12A01-04E

4-Ø6

122

Ø50.8

100

Increasing of insertion length

F11-1.ai

2050

Ø60.5

Notch

Unit: mm

F3103E.ai

Gasket (t1.5)

Calibration gas inlet

Reference gas inlet

Direction of the sample gas flow

Detector top

< Procedures for installing the dust guard protector (K9471UC)>

The ZR202G is shipped with the dust guard protector when the option code /F2 is specied in case

of ordering the detector. The protector should be used when preventing dusts and water drops from lowering the detector performance is desired. Screw the protector on the top of the detector so as to cover the top. When attaching or detaching the protector, perform by hooking holes of its side with a hook pin wrench for Ø52-55 hole( Pin diameter 4.5 mm: P/N K9471UX or the like) or by pass a screwdriver through the holes. When re-attaching the protector after detaching it, apply the “NeverSeez Nickel Special” to it.

Figure 3.2.2 Installation of the dust guard protector

The detector is used with a probe protector to support the probe (ZR202G) when the probe length is

2.5m or more and mounted horizontally.

(1) Put a gasket (provided by the user) between the anges and mount the probe protector in the

probe insertion hole.

(2) Make sure that the sensor assembly mounting screws (four bolts) at the probe tip are not loose.

(3) Mount the detector so that the calibration/reference gas inlet faces downward.

Figure 3.3 Probe protector (supporting the mounting strength)

<3. Installation>

Direction of the sample gas flow

Mount the protector so that the notch is on the downstream side of gas flow.

F3104E.ai

1050,1550, 2050

Gasket (t1.5)

Unit: mm

Detector top

Calibration gas inlet

Reference gas inlet

NOTE

The detector is used with a probe protector to prevent the sensor from being worn by dust particles

when there is a high concentration of dust and gas ow exceeds 10 m/sec (ne-carbon boiler or uid-

bed furnace).

(1) Put the gasket that is provided by user between the anges, and mount the probe protector in

the probe insertion hole. The probe protector should be installed so that the notch comes to the

downstream of the sample gas ow.

(2) Make sure that the sensor assembly mounting screws (four bolts) at the probe tip are not loose.

(3) Where the detector is mounted horizontally, the calibration/reference gas inlet should face

downward.

3-5

Figure 3.4 Mounting of detector with a probe protector (Dust wear protect)

When the probe protector is used in the ZR202G with pressure compensation (-P), instrument air leaking from the probe protector may affect the measured value.

3.2 Installation of ZA8F Flow Setting Unit

3.2.1 Installation Location

The following should be taken into consideration:

(1) Easy access to the unit for checking and maintenance work.

(2) Near to the detector and the converter

(3) No corrosive gas.

(4) An ambient temperature of not more than 55°C and little changes of temperature.

(5) No vibration.

(6) Little exposure to rays of the sun or rain.

IM 11M12A01-04E

<3. Installation>

3-6

IM 11M12A01-04E

F3401E.ai

223

140

F3.13E.ai

4 - Ø6 hole, or M5 screw

Unit: mm

3.2.2 Mounting of ZA8F Flow Setting Unit

The ow setting unit can be mounted either on a pipe (nominal JIS 50 A) or on a wall. It should be positioned vertically so that the owmeter works correctly.

(1) Prepare a vertical pipe of sufcient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting the

ow setting unit. (The unit weighs approximately 2 to 3.5 kg.)

(2) Mount the ow setting unit on the pipe by tightening the nuts with the U-bolt so that the metal

tting is rmly attached to the pipe.

Figure 3.12 Pipe Mounting

(1) Make a hole in the wall as illustrated in Figure 3.13.

Figure 3.13 Mounting holes

<3. Installation>

F3.14E.ai

(2) Mount the ow setting unit. Remove the pipe mounting parts from the mount ttings of the ow

setting unit and attach the unit securely on the wall with four screws.

Figure 3.14 Wall mounting

3.3 Installation of ZR20H Automatic Calibration Unit

3-7

3.3.1 Installation Location

The following should be taken into consideration:

(1) Easy access to the unit for checking and maintenance work.

(2) Near to the detector and the converter

(3) No corrosive gas.

(4) An ambient temperature of not more than 55°C and little change of temperature.

(5) No vibration.

(6) Little exposure to rays of the sun or rain.

3.3.2 Mounting of ZR20H Automatic Calibration Unit

ZR202G -  -  -  -  - A or B is shipped with automatic calibration unit attached.

The automatic calibration unit includes owmeters and solenoid valves, so as to ensure reliable and

accurate operation – Flowmeter should be mounted vertically. The associated probe is designed for horizontal or vertical mounting.

If you buy the automatic calibration unit afterward, and need to install it or replace it, contact our service representative.

IM 11M12A01-04E

<3. Installation>

3-8

IM 11M12A01-04E

Zero gas inlet Rc1/4 or 1/4NPT(Female)

Reference gas inlet Rc1/4 or 1/4NPT(Female)

Terminal box side

Span gas inlet Rc1/4 or 1/4NPT(Female)

166.5

258

243

214 MAX44 66.540 40

Vertical mounting on the ZR202G (-B)

F3.15E.ai

Horizontal mounting on the ZR202G (-A)

Unit: mm

Display side

Zero gas inlet Rc1/4 or 1/4NPT(Female)

Span gas inlet Rc1/4 or 1/4NPT(Female)

Reference gas inlet Rc1/4 or 1/4NPT(Female)

166.5

45 160

66.540 40180 MAX44

Figure 3.15 Automatic Calibration Unit Mounting

<3. Installation>

F3-16E.ai

A pipe to be mounted (nominal JIS 50A : O.D. 60.5 mm)

3.4 Installation of the Case Assembly (E7044KF) for Calibration Gas Cylinder

The case assembly is used to store the G7001ZC zero gas cylinders.

3.4.1 Installation Location

The following should be taken into consideration:

(1) Easy access for cylinder replacement

(2) Easy access for checking

(3) Near to the detector and converter as well as the ow setting unit.

(4) The temperature of the case should not exceed 40°C due to rays of the sun or radiated heat.

(5) No vibration

3.4.2 Mounting

Mount case assembly on a pipe (nominal JIS 50 A) as follows:

(1) Prepare a vertical pipe of sufcient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting

the case assembly. (The sum of the case assembly and the calibration gas cylinder weighs approximately 4.2 kg.)

3-9

(2) Mount the case assembly on the pipe by tightening the nuts with the U-bolt so that the metal

tting is rmly attached to the pipe.

Figure 3.16 Pipe Mounting

IM 11M12A01-04E

3-10

DI-1

DI-2

DI-C4DO-15DO-16DO-27DO-2

(+)

(-)

F3.17E.ai

Remove jumper plate

Insulation

resistance

tester

Insulation

resistance

tester

Crossover wiring

Contact input 1

Contact input 2

Insulation resistance

tester

<3. Installation>

3.5 Insulation Resistance Test

Even if the testing voltage is not so great that it causes dielectric breakdown, testing may cause deterioration in insulation and a possible safety hazard. Therefore, conduct this test only when it is necessary.

The applied voltage for this test shall be 500 V DC or less. The voltage shall be applied for as short a

time as practicable to conrm that insulation resistance is 20 MΩ or more.

Remove wiring from the converter and the detector.

1. Remove the jumper plate located between terminal G and the protective grounding terminal.

2. Connect crossover wiring between L and N.

3. Connect an insulation resistance tester (with its power OFF). Connect (+) terminal to the crossover wiring, and (-) terminal to ground.

4. Turn the insulation resistance tester ON and measure the insulation resistance.

5. After testing, remove the tester and connect a 100 kΩ resistance between the crossover wiring

and ground, to discharge.

6. Testing between the heater terminal and ground, contact output terminal and ground, analog output/input terminal and the ground can be conducted in the same manner.

7. Although contact input terminals are isolated, insulation resistance test cannot be conducted because the breakdown voltage of the surge-preventing arrester between the terminal and ground is low.

8. After conducting all the tests, replace the jumper plate as it was.

IM 11M12A01-04E

<4. Piping>

ZR202G Integrated type Zirconia Oxygen Analyzer

ZO21S Standard gas unit

Stop valve

Calibration gas

F1.1E.ai

100 to 240 V AC

100/110/115/200/220/240 V AC

Contact input Analog output, contact output

Digital output (HART)

CAUTION

4. Piping

This chapter describes piping procedures in the three typical system congurations for EXAxt ZR

Integrated type Zirconia Oxygen Analyzer.

4-1

• Ensure that each check valve, stop valve and joints used for piping are not leaking. Especially, when there is any leakage at piping and joints for the calibration gas, it may cause clogging of the piping or incorrect calibration.

• Be sure to conduct leakage test after setting the piping.

• Basically, apply instrument air (dehumidied to the dew point -20°C or lower, removed any dust,

oil mist and the like) for the reference gas when piping.

• When the instrument applies natural convection for reference gas (Model ZR202GC), ambient air near the probe is used for reference gas; therefore the accuracy of analysis will be affected by ambient humidity changes or the like. If more accurate analysis is necessary, use

instrument air (dehumidied to the dew point -20°C or lower, removed any dust, oil mist and the

like) for reference gas. Stable analyzing can be conducted when using instrument air.

4.1 Piping for System 1

The piping in System 1 is illustrated in Figure 4.1

----

Figure 4.1 Piping for System 1

Piping in System 1 is as follows:

• Place a stop valve through the nipple at the calibration gas inlet of the equipment. Then mount a joint for a 6 mm (O.D.) x 4 mm (I.D.) soft tube at the stop valve connection hole of the inlet side (see Section 4.1.2). The tube is to be connected to this joint only during calibration.

• The stop valve should be connected directly to the equipment. If any piping is present between the analyzer and the stop valve, condensed water may be produced in the pipe, which may cause damage to the sensor by rapid cooling when the calibration gas is introduced.

• The reference gas should have an oxygen concentration identical to that of fresh air (21%).

IM 11M12A01-04E

<4. Piping>

4-2

IM 11M12A01-04E

F4.2E.ai

Stop valve

Tube connection joint

Nipple

4.1.1 Piping Parts for System 1

Check that the parts listed in Table 4.1 are provided.

Table 4.1 Piping Parts

Equipment Piping location Parts Name Description

Oxygen Analyzer Calibration gas inlet Stop valve (L9852CB or G7016XH) recommended by

YOKOGAWA

Nipple * Rc1/4 or 1/4 NPT General parts

Joint for tube connection Rc1/4 (1/4NPT) for a

6x4mm soft tube

Reference gas inlet (Sealed up) (when piping is required, refer to Section 4.1.3)

Note: Parts with marking * are used when required.

General parts can be found on the local market.

General parts

4.1.2 Piping for the Calibration Gas

When carrying out calibration, connect the piping (6(O.D) x 4(I.D.) mm tube) from the standard gas

unit to the calibration gas inlet of the oxygen analyzer. Mount the stop valve (of a quality specied by

YOKOGAWA) through a nipple (found on the local market) as illustrated in Figure 4.2, and mount a joint (also found on the local market) at the stop valve tip. (The stop valve may be mounted on the equipment when the oxygen analyzer is shipped.)

Note: Mount the stop valve in the vicinity of the equipment.

Figure 4.2 Piping for the Calibration Gas Inlet

4.1.3 Piping for the Reference Gas

• Normally, no piping is required for the reference gas inlet when the equipment applies natural convection for reference gas (models ZR202G-----C). Leave the plug as it is. If the air around the probe is polluted and the necessary oxygen concentration (21 vol%O2) cannot be obtained, make instrument air piping as in Section 4.2, System 2.

• When the equipment uses instrument air for the reference gas, piping is required as described in Section 4.2, System 2 (models ZR202G-----E or P).

<4. Piping>

ZR202G Integrated type Zirconia Oxygen Analyzer

F1.2E.ai

ZA8F flow setting unit

Reference gas

Calibration gas

Needle

valve

Flowmeter

Instrument air

Air Set

Pressure

regulator

Zero gas cylinder

Calibration gas unit case

Stop valve

Check valve

Span gas(Same as Zero gas calibration)

100 to 240 V AC

Contact input Analog output, contact output Digital output (HART)

4.2 Piping for System 2

Piping in System 2 is illustrated in Figure 4.7.

Figure 4.7 Piping for System 2

4-3

System 2 illustrated in Figure 4.7 requires piping as follows:

• Mount the check valve or the stop valve through a nipple to the calibration gas inlet of the equipment.

4.2.1 Piping Parts for System 2

Check that the parts listed in Table 4.2 are provided.

Table 4.2 Piping Parts

Equipment Piping location Parts Name Description

Oxygen Analyzer Calibration gas inlet Stop valve or check valve Stop valve (L9852CB or G7016XH

recommended by YOKOGAWA Check valve (K9292DN or K9292DS) provided by YOKOGAWA

Nipple * Rc1/4 or 1/4 NPT General parts

Zero gas cylinder User' s scope

Pressure Regulator (G7013XF or G7014XF) recommended by

YOKOGAWA

Joint for tube connection Rc1/4 or 1/4 NPT General parts

Reference gas inlet Air set (G7003XF/ K9473XK or G7004XF

/ K9473XG) recommended by YOKOGAWA

Joint for tube connection Rc1/4 or 1/4 NPT General parts

Note: Parts with marking * are used when required.

General parts can be found on the local market.

4.2.2 Piping for the Calibration Gas

This piping is to be installed between the zero gas cylinder and the ZA8F ow setting unit, and between the ZA8F ow setting unit and the ZR202G analyzer.

The cylinder should be placed in a case assembly E7044KF or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature may not exceed 40°C.

Mount the pressure regulator (recommended by YOKOGAWA) on the cylinder.

Mount the stop valve or the check valve (recommended by YOKOGAWA) through the nipple (found on the local market) at the calibration gas inlet of the equipment as illustrated in Figure 4.8. (The stop valve or the check valve may have been mounted on the equipment when shipped.) Connect the

ow setting unit and the analyzer to a 6mm (O.D.) x 4mm (I.D.) (or nominal size 1/4 inches) or larger

stainless steel pipe.

IM 11M12A01-04E

<4. Piping>

4-4

IM 11M12A01-04E

F4.8E.ai

Stop valve or check valve

Piping for the reference gas 6mm (O.D.) by 4mm (I.D.) stainless steel pipe

Piping for the calibration gas 6mm (O.D.) by 4mm (I.D.) stainless steel pipe

100 to 240 V AC

Automatic Calibration Unit

Reference gas

Calibration gas (Zero)

Contact input Analog output, contact output

Digital output (HART)

Air Set

Instrument air

Calibration gas unit case

Pressure

regulator

Zero gas cylinder

ZR202G Integrated type Zirconia Oxygen Analyzer with automatic calibration

F1.3E.ai

Span gas

ZR20H

Note: The installation temperature limits range for integrated type analyzer is -20 to 55°C.

Figure 4.8 Piping for the Calibration Gas Inlet

4.2.3 Piping for the Reference Gas

Reference gas piping is required between the air source (instrument air) and the ow setting unit, and between the ow setting unit and the analyzer.

Insert the air set next to the ow setting unit in the piping between the air source and the ow setting

unit.

Use a 6mm (O.D.) x 4mm (I.D.) (or nominal size 1/4 inches) stainless steel pipe between the ow

setting unit and the analyzer.

4.3 Piping for System 3

Piping in System 3 is illustrated in Figure 4.9. In System 3, calibration is automated; however, the piping is basically the same as that of System 2. Refer to Section 4.2.

Adjust secondary pressure of both the air set and the zero gas regulator so that these two pressures

are approximately the same. The ow rate of zero and span gases (normally instrument air) are set

by a individual needle valve. After installation and wiring, check zero gas calibration contact output

(see Sec. 7.9.2), and adjust zero gas regulator and calibration gas needle valve so that zero gas ow

is within the permitted range. Next check span gas calibration contact output and adjust air set so that

span gas ow is within the permitted range.

Figure 4.9 Piping for System 3

<4. Piping>

Zero gas inlet Rc1/4 or 1/4NPT(Female)

Reference gas inlet Rc1/4 or 1/4NPT(Female)

Terminal box side

Span gas inlet Rc1/4 or 1/4NPT(Female)

166.5

258

243

214 MAX44 66.540 40

Vertical mounting on the ZR202G (-B)

F3.15E.ai

Horizontal mounting on the ZR202G (-A)

Unit: mm

Display side

Zero gas inlet Rc1/4 or 1/4NPT(Female)

Span gas inlet Rc1/4 or 1/4NPT(Female)

Reference gas inlet Rc1/4 or 1/4NPT(Female)

166.5

45 160

66.540 40180 MAX44

Piping Diagram

SPAN IN

REF. IN

ZERO IN

F4.11E.ai

Calibration gas

Reference gas

ZR202G body

Span gas solenoid valve

Span gas flowmeter

Reference gas flowmeter

To Air set

To Zero gas cylinder

Needle valve

Automatic Calibration Unit

Zero gas flowmeter

Zero gas solenoid valve

Check

valve

• Installation of ZR20H Automatic Calibration Unit

4-5

IM 11M12A01-04E

<4. Piping>

4-6

IM 11M12A01-04E

NOTE

342±4

F4.12E.ai

ØB

ØA

*1: Dimension may vary depending on the detector type. Ensure that the flange gasket does not block off the reference gas outlet. Where necessary, make a notch on the flange

Rc 1/4 or 1/4 NPT (Reference gas inlet)

4-G1/2, 2-1/2 NPT or the like (Wiring connection)

Rc1/4 or 1/4NPT (Calibration gas inlet)

Stop valve

Reference gas outlet

Flange

PIPING

4.4 Piping for the Oxygen Analyzer with Pressure Compensation

ZR202G-----P Oxygen Analyzer with pressure compensation may be used in System 2 and System 3.

Use this style analyzer whenever the furnace pressure exceeds 5 kPa (see Note). Even if the furnace pressure is high, the detector can measure by adjusting pressure of the probe with the furnace pressure using instrument air. The inside pressure of the probe will be kept identical to the furnace pressure by feeding instrument air at higher pressure than that in the furnace.

The process gas pressure should not be subjected to rapid changes.

Unit: mm

The detector with pressure compensation is illustrated in Figure 4.12.

Figure 4.12 Oxygen Analyzer with Pressure Compensation

Ensure that the furnace gas does not ow into the probe.

Valve operation

1. For safety, stop the furnace that the detector is to be installed in. If furnace internal pressure is high, this is especially dangerous.

2. Before starting instrument air ow, completely shut the stop valve in front of the reference gas

outlet.

3. Check that the reference gas outlet is not blocked by a ange gasket or the like.

<4. Piping>

CAUTION

ZR202G Integrated type Zirconia Oxygen Analyzer with pressure compensation

F1.2E.ai

ZA8F flow setting unit

Reference gas

Calibration gas

Needle

valve

Flowmeter

Instrument air

Air Set

Pressure

regulator

Zero gas cylinder

Calibration gas unit case

Stop valve

Check valve

Span gas(Same as Zero gas calibration)

100 to 240 V AC

Contact input Analog output, contact output

Digital output (HART)

CAUTION

4. Set the instrument air pressure higher than furnace internal pressure.

5. Completely open the stop valve in front of the reference gas outlet and, after turning on

instrument air ow, start furnace operation. As furnace internal pressure rises, conrm that instrument air continues to ow and adjust the valve or increase supply pressure if necessary.

6. After furnace internal pressure stabilizes, adjust ow.

7. If furnace operation is stopped, stop instrument air ow and completely shut the stop valve in front of the reference gas outlet. You may leave reference gas owing if you wish.

• Use suitable cable glands to completely seal the detector. As far as possible do not stop the

instrument air ow, to prevent the sample gas from entering the detector and damaging the

zirconia cell.

4-7

• Connect the stop valve, which is at the calibration gas inlet, directly to the equipment. If piping connections are made between the detector and the needle valve, condensation will result inside the piping and cause the sensor to be damaged when the calibration gas is introduced.

Figure 4.13 illustrates an example of System 2 using the analyzer with pressure compensation.

Supplying the air pressure (ow) may vary depending on the furnace pressure. It is recommended to use a ow gauge and an air set meeting the furnace pressure.

Figure 4.13 Illustrates an example of System 2 using the analyzer with pressure

• When using the ZA8F Flow Setting Unit and the ZR20H Automatic Calibration Unit, please note that

compensation.

the supplying airow (pressure) will vary depending on the furnace pressure.

IM 11M12A01-04E

4-8

<4. Piping>

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation

Check that the parts listed in Table 4.3 are provided.

Table 4.3 Piping Parts

Equipment Piping location Parts Name Description

Oxygen Analyzer with pressure compensation

Note: Use parts with marking * as required.

General parts can be found on the local market.

Calibration gas inlet Check valve or stop

valve

Nipple * Rc1/4 or 1/4 NPT General parts

Zero gas cylinder User's scope

Pressure regulator (G7013XF or G7014XF) recommended by

Joint for tube connection Rc1/4 or 1/4 NPT General parts

Reference gas inlet Air set (G7003XF/ K9473XK or G7004XF / K9473XG)

Joint for tube connection Rc1/4 or 1/4 NPT General parts

Stop valve (L9852CB or G7016XH) recommended by YOKOGAWA Check valve (K9292DN or K9292DS) provided by YOKOGAWA

YOKOGAWA

recommended by YOKOGAWA

4.4.2 Piping for the Calibration Gas

Calibration gas piping is basically identical to that of System 2. See Section 4.2.2.

4.4.3 Piping for the Reference Gas

Reference gas piping is basically identical to that of for System 2. See Section 4.2.3.

IM 11M12A01-04E

<5. Wiring>

CAUTION

NOTE

5. Wiring

This chapter describes wiring procedures necessary for the EXAxt ZR Integrated type Zirconia Oxygen Analyzer.

5.1 General

• Never supply current to the equipment or any other device constituting a power circuit in combination with the equipment, until all wiring is completed.

5-1

• This product complies with CE marking. Where a performance suit for CE marking is necessary, the following wiring procedure is necessary.

1. Install an external switch or circuit breaker to the power supply of the equipment.

2. Use an external switch or circuit breaker rated 5A and conforms to IEC 947-1 or IEC 947-3.

3. It is recommended that the external switch or circuit breaker be mounted in the same room as the equipment.

4. The external switch or circuit breaker should be installed within the reach of the operator, and marked as the power supply switch of this equipment.

Wiring procedure

Wiring should be made according to the following procedure:

1. Be sure to connect the shield of the shielded line to FG terminal of the analyzer.

2. The most outer sheath of the signal line and the power cable should be stripped off to the minimum necessary length.

3. Signal will be affected by noise emission when the signal lines, power cable and heater cable are located in the same conduit. When using a conduit, signal lines should be installed in the separate conduit from power and heater cables. Be sure to ground the metal conduit.

4. Mount the attached two blind plugs to unused cable connection gland(s) of the equipment.

5. The cables indicated in Table 5.1 are used for wiring.

After completing the wiring, screw the cover in the terminal box body and secure it with a lock screw.

Table 5.1 Cable Specications

Terminal name of converter Name Need for shields Cable type Number of wires

L, N,

AO+, AO- Analog output Ο CVVS 2

DO-1, DO-2 Contact output CVV 2 to 4

DI-1, DI-2, DI-C Contact input CVV 3

Note *: When the case is used for protective grounding, use a 2-wire cable.

• Select an appropriate cable O.D. for the cable gland size.

• Protective grounding should have the grounding resistance of 100Ω or less.

Power supply CVV 2 or 3 *

IM 11M12A01-04E

<5. Wiring>

5-2

IM 11M12A01-04E

1 2 C DO DO

DIDI

1 2

L NFG

G FG

F5101.ai

–

DI-12DI-23DI-C4DO-15DO-16DO-27DO-2

9 AO (+)

(-)

F28.EPS

Model ZR202G Integrated type Zirconia Oxygen Analyzer

Contact input 1

Contact output 2

Contact output 1

Analog output 4-20 mA DC

100 to 240 V AC, 50 or 60 Hz

Digital output

Contact input 2

5.1.1 Terminals for the External Wiring

Remove the terminal cover on the opposite side of the display to gain access to the external wiring terminals.

Figure 5.1 Terminals for External Wiring

5.1.2 Wiring

Make the following wiring for the equipment. It requires a maximum of four wiring connections as shown below.

(1) Analog output signal (2) Power and ground (3) Contact output (4) Cont

act input

The protective grounding for the analyzer shall be connected either the protective ground terminal

in the equipment or the ground terminal on the case.

Standard regarding grounding: Ground to earth, ground resistance: 100Ω or less.

Figure 5.2 Wiring Connection

<5. Wiring>

F5.3E.ai

4-G1/2,2-1/2NPT etc. Cable connection port

Cable gland

Rc1/4 or 1/4NPT Reference gas inlet

Rc1/4 or 1/4NPT Calibration gas inlet

AO(+) AO(-)

F5.4E.ai

Shielded cables

Analyzer

Receiver

CAUTION

5.1.3 Mounting of Cable Gland

For each wiring inlet connection of the equipment, mount the conduit appropriate for the screw size or a cable gland.

Figure 5.3 Cable Gland Mounting

5.2 Wiring for Analog Output

This wiring is for transmitting 4 to 20mA DC output signals to a device, e.g. recorder. Maintain the load

resistance including the wiring resistance of 550Ω or less.

5-3

Figure 5.4 Wiring for Analog Output

5.2.1 Cable Specications

Use a 2-core shielded cable for wiring.

5.2.2 Wiring Procedure

(1) M4 screws are used for the terminals. Use crimp-on terminals appropriate for M4 terminal

screws for cable connections. Ensure that the cable shield is connected to the FG terminal of the equipment.

(2) Be sure to connect (+) and (-) polarities correctly.

• Before opening the cover, loosen the lock screw. If the screw is not loosened rst, the cover

will be improperly engaged to the body, and the terminal box will require replacement. When opening and closing the cover, remove any sand particles or dust to avoid gouging the thread.

• After screwing the cover on the equipment body, secure it with the lock screw.

IM 11M12A01-04E

<5. Wiring>

5-4

IM 11M12A01-04E

1 2 C DO DO

DIDI

1 2

L NFG + -

100~240VAC 50/60Hz

F5.5E.ai

Jumper plate

Grounding to the earth terminal on the equipment case

Equipment case

Lock washer

Crimp contact of the grounding line

Grounding terminal

Ground

FGG

5.3 Wiring Power and Ground Terminals

Wiring for supplying power to the analyzer and grounding the equipment.

Figure 5.5 Power and Grounding Wiring

5.3.1 Wiring for Power Line

Connect the power wiring to the L and N terminals of the equipment. For a three-core cable, ground one core appropriately. Proceed as follows:

(1) Use a two-core or three-core cable.

(2) M4 screws are used for the terminals. Use crimp-on terminals appropriate for M4 terminal

screws for cable connections.

5.3.2 Wiring for Ground Terminals

The ground wiring of the analyzer should be connected to either the ground terminal of the equipment case or the terminal inside of the equipment. Proceed as follows:

(1) Keep the ground resistance of 100Ω or less (JIS Class D grounding).

(2) When connecting the ground wiring to the ground terminal of the equipment case, be sure that

the lock washer is in contact with the case surface (see Figure 5.5.).

(3) Ensure that the jumper plate is connected between the G terminal and the FG terminal of the

equipment.

(4) The size of external ground screw thread is M4. Each cable should be terminated corresponding

crimp-on terminals.

<5. Wiring>

DO-1

DO-2

F5.6E.ai

#2 Output

Analyzer

Terminal box

Annunciator or the like

#1 Output

Converter Terminal box

DI-1

DI-C

DI-2

Contact input 1

Contact input 2

F5.7E.ai

5.4 Wiring for Contact Output

The equipment can output a maximum of two contact signals. These contact outputs can be used for different applications such as a low alarm or high alarm.

Do the contact output wiring according to the following requirements.

Figure 5.6 Contact Output Wiring

5.4.1 Cable Specications

The number of cores varies depending on the number of contacts used.

5.4.2 Wiring Procedure

5-5

(1) M4 screws are used for the terminals. Use crimp-on terminals appropriate for M4 terminal

screws for cable connections.

(2) The contact output relays are rated 30 V DC 3A, 250 V AC 3A. Connect a load (e.g. pilot lamp

and annunciator) within these limits.

5.5 Wiring for Contact Input

The converter can execute specied function when receiving contact signals.

To use these contact signals, proceed wiring as follows:

Figure 5.14 Contact Input Wiring

5.5.1 Cable Specications

Use a 2-core or 3-core cable for this wiring. Depending on the number of input(s), determine which cable to use.

IM 11M12A01-04E

5-6

<5. Wiring>

5.5.2 Wiring Procedure

(1) M4 screws are used for the terminal of the converter. Each cable should be equipped with the

corresponding crimp contact.

(2) The ON/OFF level of this contact input is identied by the resistance. Connect a contact input

that satises the descriptions in Table 5.2.

Table 5.2 Identication of Contact Input ON/OFF

Resistance 200 Ω or less 100 kΩ or more

Closed Open

IM 11M12A01-04E

<6. Components>

Terminal box, Non explosion-proof JIS C0920 / equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version.)

Probe this part is inserted in the furnace. Selectable of length from 0.4, 0.7,

1.0, 1.5, 2.0, 2.5 or 3.0m.

Flange used to mount the detector. Selectable from JIS, ANSI, DIN or JPI standard models.

F6.1E.ai

Bolt

Washer

Pipe support

U-shaped pipe

Metal O-ring

Dust filter mounting screw

Sensor (cell)

Contact

Screw

Probe

Calibration gas pipe opening

Filter

6. Components

This chapter describes the names and functions of components for the major equipment of the EXAxt ZR Integrated type Zirconia Oxygen Analyzer.

6.1 ZR202G Zirconia Oxygen Analyzer

6.1.1 Integrated type Zirconia Oxygen Analyzer

6-1

Figure 6.1 Integrated type Zirconia Oxygen Analyzer

IM 11M12A01-04E

6-2

Reference gas flow setting valve

Span gas flow setting valve

Zero gas flow setting valve

Flowmeter for reference gas

Flowmeter for calibration gas

F6-4E.ai

ZERO INREF INSPAN IN ZERO INREF INSPAN IN

F6.3E.ai

Flowmeter for Span gas

Flowmeter for Reference gas

Flowmeter for Zero gas

Horizontal mounting Vertical mounting

Span gas flow setting valve

Reference gas flow setting valve

Zero gas flow setting valve

Span gas flow setting valve

<6. Components>

6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit

Figure 6.2 ZA8F Flow Setting Unit

Figure 6.3 ZR20H Automatic Calibration Unit

IM 11M12A01-04E

<7. Startup>

F7.0E.ai

Place in normal operation

Check piping and wiring connections

Set up valves

Supply power

Confirm converter type setting

Select gas to be measured

Set output ranges

Check current loop

Check contact action

Calibrate analyzer

Set detailed data

7. Startup

The following describes the minimum operating requirements — from supplying power to the

converter to analog output conrmation to manual calibration.

7-1

Figure 7.1 Startup Procedure

For system tuning by HART communication, refer to the IM 11M12A01-51E ''HART Communication Protocol''.

IM 11M12A01-04E

<7. Startup>

7-2

IM 11M12A01-04E

NOTE

CAUTION

7.1 Checking Piping and Wiring Connections

Refer to Chapters 4 and 5, earlier in this manual, for piping and wiring conrmations.

7.2 Valve Setup

Set up valves and associated components used in the analyzer system in the following procedures:

(1) If a stop valve is used in the detector’s calibration gas inlet, fully close this valve.

(2) If instrument air is used as the reference gas, adjust the Air set secondary pressure so that the

air pressure of sample gas pressure plus approx. 50 kPa (plus approx. 150 kPa for with check valve) (300 kPa maximum for the ZA8F, 690 kPa maximum for the ZR20H) is obtained. Turn the

reference gas ow setting valve in the ow setting unit to obtain the ow of 800 to 1000 ml/min. (Turning the valve shaft counterclockwise increases the rate of ow. When turning the valve shaft, if the valve has a lock nut, rst loosen the lock nut.) After completing the valve setup, be

sure to tighten the lock nut.

The calibration gas ow setting will be described later. Fully close the needle valve in the ow setting

unit.

7.3 Supplying Power to Converter

To avoid temperature changes around the sensor, it is recommended that the power be continuously supplied to the Oxygen Analyzer if it is used in an application where its operations and suspensions are periodically repeated.

It is also recommended to ow a span gas (instrument air) beforehand.

Supply power to the converter. A display as in Figure 7.1, which indicates the detector’s sensor temperature, then appears. As the heat in the sensor increases, the temperature gradually rises to 750°C. This takes about 20 minutes after the power is turned on, depending somewhat on the ambient temperature and the sample gas temperature. After the sensor temperature has stabilized at 750°C, the converter is in the measurement mode. The display panel then displays the oxygen concentration as in Figure 7.2. This is called the basic panel display.

Figure 7.1 Display of Sensor Temperature Figure 7.2 Measurement Mode Display

While Warming Up

<7. Startup>

2: Infrared switch

4: Decimal point

1: Data display area

3: Engineering-unit display area

ENT

µ Mm Nk ga lb bl % scftm3 /d /s /h /m

F7.3E.ai

7.4 Operation of Infrared Switch

7.4.1 Display and Switches

This equipment uses an infrared switch that enables operation with the cover closed. Figure 7.3 shows the infrared switch and the display. Table 7.1 shows the three switch (keys) and functions.

Figure 7.3 Infrared switch and the display

1. Data display area: Displays the oxygen concentration, set values, alarm numbers, and error numbers.

7-3

2. Infrared switch: Three switches perform data setting operations.

3. Engineering-unit display area: the percent sign appears when the oxygen concentration is displayed.

4. Decimal point: A decimal point is displayed.

Table 7.1 Switch and Function

Switch Function

ENT 1. Used to change the basic panel display to the parameter selection display.

1. Moves the position of the digit to the right. If you continuously touch the key, the position of the digit will move continuously to the right, nally returning to the leftmost position after reaching the rightmost position of the digit.

2. Selects Yes or No.

3. When you touch this key together with the [ENT] key, the previous display then appears, or the operation will be cancelled.

Used to change values. If you continuously touch this key, the value of the digit will increase continuously, e.g., from 1 to 2 to 3 (for numeric data), or from A to B to C (for alphabetic

characters), and nally return to its original value.

2. Used to enter data.

3. Advances the operation.

The three infrared switches are activated by completely touching the glass surface of the switch. To

touch any of the keys continuously, rst touch the surface and then completely remove your nger

from the surface. Then touch it again.

Infrared switches consist of two elements: an infrared emitting element and an infrared acceptance

element. Infrared light-waves from the element bounces on the operator’s nger and are reected

back to the acceptance element, thereby causing the infrared switch to turn on and off, depending

on the strength of the reected light-waves. From this operating principles, carefully observe the

following:

IM 11M12A01-04E

<7. Startup>

7-4

IM 11M12A01-04E

CAUTION

F7.4E.ai

Group G setup display

Basic panel display

Password entry display

Group A setup display

Group B setup display

Group C setup display

Parameter code selection display

Group D setup display

Group E setup display

Group F setup display

1. Be sure to put the equipment case cover back on. If this is not done, the infrared switch will not

reect the infrared light-waves, and a “dSPErr” error will be issued.

2. Before placing the equipment in operation, be sure to wipe off any moisture or dust on the glass

surface if it is wet or dirty. Also make sure your ngers are clean and dry before touching the

glass surface of the switch.

3. If the infrared switches are exposed to direct sunlight, they may not operate correctly. In such a case, change position of the display or install a sun cover.

7.4.2 Display Conguration

The parameter codes provided for the equipment are used to control the equipment display panels (see below). By selecting appropriate parameter codes, you can conduct calibration and set operation

parameters. Figure 7.4 shows the conguration of display items. The parameter codes are listed in groups of seven; which are briey described in Table 7.2.

To enter parameters, you rst need to enter the password, refer to See 7.4.3.

Touch the [ >] key and [ ENT] key at same time to revert to the main screen.

Figure 7.4 Display Conguration

<7. Startup>

CAUTION

Table 7.2 Display Functions

Display Function and item to be set

Basic panel Displays the oxygen concentration in normal operation, or displays the detector

heater temperature while warming up. If an error or alarm arises,

the corresponding error or alarm number appears. Password entry Enters the password for the parameter code selection display. Group A setup Displays detailed data, such as the cell voltage or temperature. Group B setup Sets and performs calibration. Group C setup Sets analog output. Group D setup Sets an alarm. Group E setup Sets the input and output contacts. Group F setup Selects the type of equipment and sets the parameters for computation. Group G setup Performs the current-loop or contact checks.

7.4.3 Entering Parameter Code Selection Display

This section briey describes the password entry procedure for entering the parameter code selection

display. The password is 1102 - it cannot be changed to a different password.

Switch operation Display Description

> ∧

ENT

21.0%

Warm-up is complete, and the basic panel is now displayed.

7-5

> ∧

∧

> ∧

ENT

PASSno

0000

1000

1100

1102

A01

Continuously touch the [ENT] key for at least three seconds

to display "PASSno."

Touch the [ENT] key again. This allows you to change the leftmost

digit that is ashing.

Set the password 1102. If you touch the [∧] key, the digit that is ashing will

be 1.

Touch the [>] key to move the position of the digit that is ashing to the

right one digit.

Touch the [∧] key to change the numeric value to 1.

Touch the [>] key again to move the position of the digit that is ashing to

the right one more digit. Continuously touch the [>] key, and the position of

the digit that is ashing will move continuously to the right.

Touch the [∧] key to change the numeric value to 2. Continuously touch [∧]

key, and the numeric value increases continuously.

If you touch the [ENT] key, all the digits ash.

Touch the [ENT] key again to display A01 on the parameter code selection

display.

The symbol [ ] indicates that the key is being touched. Light characters indicate that the digits are ashing.

• If no key is touched for at least 20 seconds during password entry, the current display will automatically switch to the basic panel display.

• If no key is touched for at least 10 minutes during parameter code selection, the current display will automatically switch to the basic panel display.

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7-6

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7.4.4 Selecting Parameter Codes

Switch operation Display Description

> ∧

ENT

A01

b01

Password has been entered and the parameter code selection display has

appeared.

Character A is ashing, indicating that character A can be changed.

If you touch the [>] key once, the position of the digit that is ashing will move to

the right.

This allows you to change 0.

Touch the [>] key again to move the position of the digit that is ashing to the right

one more digit. This enables you to change numeric character 1.

Touch the [>] key again to return the position of the digit that is ashing to A.

Continuously touch the [>] key, and the position of the digit that is ashing will

move continuously to the right.

If you touch the [∧] key once, character A will change to B.

> ∧

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

ENT

ENT Set

C01

d01

Value

7.4.5 Changing Set Values

(1) Selecting numeric values from among preset values

Switch operation Display Description

> ∧

∧

ENT

Touch the [∧] key once to change to C.

Continuously touch the [∧] key, and the value of the digit that is ashing will

increase continuously, from D to E to F to G to A. Numeric values will change from

0 to 1 to 2 to 3 … to 8 to 9 and back to 0. However, numbers that are not present

in the parameter codes will be skipped. Each digit is changed independently. Even

though a low-order digit changes from 9 to 0, a high-order digit will not be carried.

After you select the desired character, touch the [ENT] key. The set data will be

displayed.

The set value is displayed after the parameter code selection. An example of how

to select either 0, 1, or 2 as the set value is given below.

(The currently set value is 0.)

Touch the [∧] key once to change the current value from 0 to 1.

Touch the [∧] key again to change to the numeric value 2.

> ∧

ENT

C01

If you touch the [∧] key again, the numeric value will return to 0.

Continuously touch the [∧] key, and the numeric values will change continuously.

Display the desired numeric value and touch the [ENT] key.

The display will then return to the parameter code selection

<7. Startup>

(2) Entering numeric values such as oxygen concentration values and factors

Switch operation Display Description

> ∧

ENT

00.0

09.0

The set value is displayed after the parameter code selection.

An example of entering "9.8" is given below. (The currently set value is 0.0)

Touch the [>] key to move the position of the digit that is ashing to the digit to be

changed.

Continuously touch the [>] key, and the position of the digit that is ashing will

move continuously to the right.

Touch the [∧] key to set the numeric value 9.

Continuously touch the [∧] key, and the numeric value will change in sequence

from 0 to 1 to 2 to 3 … to 8 to 9 and back to 0.

Touch the [>] key to move the position of the digit that is ashing to the right.

7-7

> ∧

(3) If invalid numeric values are entered.

Switch operation Display Description

> ∧

ENT

09.8

C11

98.0

Err

00.0

Touch the [∧] key to set the numeric value 8.

Where the correct numeric value is displayed, touch the [ENT] key.

If you touch the [ENT] key again, the ashing stops and the current set value will

be in effect.

Touch the [ENT] key once again to return to the parameter code selection display.

If an invalid numeric value (beyond the input range specied) is entered,

"Err" will appear for two seconds after touching the [ENT] key.

"Err" appears for two seconds, and the display returns to the rst set value.

Re-enter the numeric value.

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7-8

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CAUTION

7.5 Conrmation of Equipment Type Setting

This equipment can be used for both the Oxygen Analyzer and the Humidity Analyzer. If you choose

optional specication /HS at the time of purchase, the equipment is set for the Humidity Analyzer.

Before setting the operating data, be sure to check that the desired model has been set. Note that if the equipment type setting is changed after operating data are set, the operating data that have been set are then initialized and the default settings remain. Set the equipment type with parameter code 「F01」. See Table 10.7, later in this manual.

Note that if the equipment type is changed, operation data that have already been set are initialized (reverting to the default setting).

Table 7.3 Converter Type Setting Procedure

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

> ∧

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

ENT

ENT Basic

F01

panel display

Touch the [∧] key to switch to Group F. If an unwanted alphabetic character after F

has been entered, continuously touch the [∧] key to return to the original.

Touch the [ENT] key for conrmation. If 0 (zero) is entered, the oxygen analyzer

is already set. If 1 (one) is entered, the humidity analyzer has been set.

Change the setting following the steps below.

Continuously touch the [∧] key, and the position of the digit will change from 1 to 0

to 1 to 0. Release the [ENT] key when 0 is displayed.

Touch the [ENT] key. The numeric value will ash.

Touch the [ENT] key again to stop the numeric value from ashing.

Touch the [ENT] key once again, and the display will change to the parameter

code.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

(This is not required if you proceed to make another setting.) (The displayed

numeric characters indicate the measurement gas concentration.)

<7. Startup>

7.6 Selection of Measurement Gas

Combustion gases contain moisture created by burning hydrogen in the fuel. If this moisture is removed, the oxygen concentration might be higher than before. You can select whether the oxygen concentration in a wet gas is to be measured directly, or compensated for its dry-gas value before use. Use the parameter code 「F02」 to set the measurement gas. For details on the parameter code, see Table 10.7, later in this manual.

Table 7.4 Setting Measurement Gas

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

7-9

> ∧

ENT

ENT Basic

F01

F02

F03

panel display

Touch the [∧] key to switch to Group F. If an unwanted alphabetic character after F

has been entered, continuously touch the [∧] key to return to the original.

Touch the [>] key to move the position of the digit that is ashing to the right.

Touch the [∧] key to change the numeric value to 2. If an unwanted numeric value

has been entered, continuously touch the [∧] key to return to the original.

Touch the [ENT] key for conrmation. If 0 (zero) is entered, the oxygen

concentration in a wet gas is already set. If the oxygen concentration in a dry gas is

to be entered, follow the steps below to set 1 (one).

Continuously touch the [∧] key, and the position of the digit will change from 1 to 0

to 1 to 0. Release the [ENT] key when 1 (one) is displayed.

Touch the [ENT] key. The numeric value will ash.

Touch the [ENT] key again to stop the value from ashing.

Touch the [ENT] key once again, and the display will change to the parameter

code selection panel.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

(This is not required if you proceed to make another setting.) (The displayed

numeric characters indicate the measurement gas concentration.)

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

7.7 Output Range Setting

This section sets forth analog output range settings. For details, consult Section 8.2,”Current Output Settings,” later in this manual.

7.7.1 Minimum Current (4 mA) and Maximum Current (20 mA) Settings

Use the parameter codes 「C11」 to set the oxygen concentration at 4 mA and 「C12」 to set the oxygen concentration at 20 mA. The following shows where 10% O2 is set at 4 mA and 20% O2 at 20 mA.

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7-10

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Table 7.5 Minimum and Maximum Value Setting Procedure

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

> ∧

ENT

C01

C11

000

010

C11

C12

Set the oxygen concentration at 4 mA. Change the parameter code to C11.

Touch the [∧] key to switch to Group C.

Touch the [>] key to move the position of the digit that is ashing to the right.

Touch the [∧] key to enter the numeric value 1.

Touch the [ENT] key to display the current set value (0% O2 has been set).

Touch the [>] key to move the position of the digit that is ashing to the right.

Touch the [∧] key to change the numeric value to 1.

If you touch the [ENT] key, all the digits ash.

Touch the [ENT] key again to stop the ashing.

Touch the [ENT] key once again, and the display will switch to the parameter code

selection display.

Set the oxygen concentration at 20 mA. Touch the [>] key to move the position of

the digit that is ashing to the right.

Touch the [∧] key to enter the numeric value 2.

> ∧

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

ENT

ENT Basic

025

020

C12

panel display

Touch the [ENT] key to display the current set value.

Touch the [>] key to move the position of the digit that is ashing to the right.

Touch the [∧] key to change the numeric value to 0. The numeric value will change

from 5 to 6 ... to 9 and back to 0.

If you touch the [ENT] key, all the digits ash.

Touch the [ENT] key again to stop the ashing.

Touch the [ENT] key once again to switch to the parameter code selection display.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

(This is not required if you proceed to make another setting.)(The displayed

numeric characters indicate the measurement gas concentration.)

<7. Startup>

7.8 Checking Current Loop

The set current can be output as an analog output. This enables the checking of wiring between the converter and the receiving instrument. Current loop checking is performed using parameter code

「G01」.

Table 7.6 Checking Current Loop

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

7-11

> ∧

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

ENT

ENT Basic

G01

00.0

10.0

G01

panel display

Touch the [∧] key to switch to Group G.

Touch the [ENT] key. The output current remains preset with the output-hold

feature (Section 2.3).

Touch the [∧] key to set the numeric value 1 (to set a 10-mA output).

Touch the [ENT] key to have all the digits ash.

Touch the [ENT] key again to stop the ashing.

A 10-mA output is then issued.

Touch the [ENT] key once again to switch to the parameter code selection display.

At that point, the output current returns to the normal value.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

7.9 Checking Contact I/O

Conduct a contact input and output check as well as an operation check of the solenoid valves for the optional automatic calibration unit.

Table 7.7 Parameter Codes for Checking Contact I/O

Check item Parameter code Set value and contact action

Contact output 1 G11 0 Open

1 Closed

Contact output 2 G12 0 Open

1 Closed

Automatic calibration solenoid valve (zero gas)

Automatic calibration solenoid valve (span gas)

Contact input 1 G21 0 Open

Contact input 2 G22 0 Open

G15 0 Off

1 On

G16 0 Off

1 On

1 Closed

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7-12

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CAUTION

7.9.1 Contact Output Check

Follow Table 7.8 to check the contact output. The table uses an example with contact output 1.

Table 7.8 Checking Contact Output

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

> ∧

ENT

ENT Basic

G01

G11

panel display

Touch the [∧] key to switch to Group G.

Touch the [>] key to move the position of the digit that is ashing to the right one

digit.

Touch the [∧] key to enter 1.

Touch the [ENT] key to have 0 (zero) ash. The contact is then open.

Touch the [∧] key to set 1 (one).

Touch the [ENT] key. The ashing continues.

Touch the [ENT] key again to stop the ashing, and the contact will be closed.

Touch the [ENT] key once again to switch to the parameter code selection display.

The contact then returns to the original state.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

(This is not required if you proceed to make another setting.)

(The displayed numeric characters indicate the measurement gas concentration.)

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

• If you conduct an open-close check for the contact output 2, Error 1 (cell voltage failure) or Error 2 (heater temperature abnormal) will occur. This is because the built-in heater power of the detector, which is connected to contact output 2, is turned off during the above check. So, if the above error occurs, reset the equipment or turn the power off and then back on to restart (refer to Section 10.4, “Reset,” later in this manual).

<7. Startup>

7.9.2 Checking Calibration Contact Output

The calibration contacts are used for the solenoid valve drive signals for the Automatic Calibration

Unit. This output signal enables you to check the equipment operation. Check the owmeter gas ow

for that operation.

Follow the steps in Table 7.9. The table uses an example with a zero gas solenoid valve.

Table 7.9 Checking Calibration Contact Output

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

7-13

> ∧

ENT

ENT Basic

G01

G11

G15

panel display

Touch the [∧] key to switch to Group G.

Touch the [>] key to move the position of the digit that is ashing to the right one

digit.

Touch the [∧] key to enter 1.

Touch the [>] key to move the position of the digit that is ashing to the right one

digit.

Touch the [∧] key to enter 5.

Touch the [ENT] key to have 0 ash.

The solenoid valve remains closed.

Touch the [∧] key to enter 1.

Touch the [ENT] key. The ashing continues.

Touch the [ENT] key again to stop the ashing, and the solenoid valve will be open

to let the calibration gas ow.

Touch the [ENT] key once again to switch to the parameter code selection display.

The solenoid valve will then be closed.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

(This is not required if you proceed to make another setting.)

(The displayed numeric characters indicate the measurement gas concentration.)

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

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<7. Startup>

7-14

IM 11M12A01-04E

7.9.3 Checking Input Contacts

Follow Table 7.10 to check the input contacts. The table uses an example with input contact 1.

Table 7.10 Checking Input Contacts

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

> ∧

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

ENT

ENT Basic

G01

G21

panel display

Touch the [∧] key to switch to Group G.

Touch the [>] key to move the position of the digit that is ashing to the right one

digit.

Touch the [∧] key to enter 2.

Touch the [ENT] key. 0 is displayed with the contact open. If the contact is closed,

the display will be 1 (one).

This enables you to check whether or not the wiring connections have been

properly made or not.

Touch the [ENT] key once again to switch to the parameter code selection display.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

<7. Startup>

CAUTION

7.10 Calibration

The converter is calibrated in such a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases.

There are three types of calibration procedures available:

(1) Manual calibration conducting zero and span calibrations, or either of these calibrations in turn.

(2) Semi-automatic calibration which uses the infrared switches or a contact input signal and

conducts calibration operations based on a preset calibration time and stable time.

(3) Automatic calibration conducted at preset intervals.

Manual calibration needs the ZA8F Flow Setting Unit to allow manual supply of the calibration gases. Semi-automatic and automatic calibrations need ZR20H Automatic Calibration Unit to allow automatic supply of the calibration gases. The following sections set forth the manual calibration procedures. For details on semi-automatic and automatic calibrations, consult Chapter 9, “Calibration,” later in this manual

7.10.1 Calibration Setup

Set the following three items before carrying out a calibration. Parameter codes for these set items are listed in Table 7.11.

7-15

(1) Mode setting

There are three calibration modes: manual, semi-automatic, and automatic.

Select the desired mode. This section uses manual mode for calibration.

(2) Oxygen concentration in zero gas

Enter the zero gas oxygen concentration for calibration.

(3) Oxygen concentration in span gas

Enter the span gas oxygen concentration for calibration. If instrument air is used, enter 21 vol %

O2. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.

If instrument air is used for the span gas, dehumidify the air to a dew point of -20°C and remove any oil mist or dust.

Incomplete dehumidifying or unclean air will have an adverse effect on the measurement accuracy.

Table 7.11 Calibration Parameter Codes

Set item Parameter code Set value

Calibration mode B03 0 Manual calibration

1 Semi-automatic calibration

2 Automatic calibration

Zero gas oxygen concentration B01 Enter oxygen concentration.

Span gas oxygen concentration B02 Enter oxygen concentration.

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7-16

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Table 7.12 Calibration Setup Procedure

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

> ∧

ENT

b01

001.00

000.00

000.90

000.98

Set the zero gas concentration. Switch the parameter code to B01.

Here, set 0.98%.

Touch the [ENT] key to display the currently set value.

Touch the [>] key to move the position of the digit that is ashing to 1.

Touch the [∧] key to change to 0.

Touch the [>] key to move the position of the digit that is ashing to the

right one digit.

Touch the [∧] key to change the numeric value to 9.

Touch the [>] key to move the position of the digit that is ashing to the

right one digit.

Touch the [∧] key to change the numeric value to 8.

Touch the [ENT] key to have all the digits ash.

Touch the [ENT] key again to stop the ashing.

> ∧

Set the span gas concentration by above procedure, set 21 %.

> ∧

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

ENT

ENT Basic panel

b01

b03

display

Touch the [ENT] key once again to switch to the parameter code selection

display.

Next, set the calibration mode. Switch the parameter code to B03.

Touch the [ENT] key to display the currently set value.

If it is 0, you can leave it as is. If it is other than 0, change it to 0 (zero).

Touch the [ENT] key. The numeric value will ash.

Touch the [ENT] key again to stop the ashing.

Touch the [ENT] key once again to switch to the parameter code selection

display.

Touch the [>] key together with the [ENT] key to return to the basic panel

display. (This is not required if you proceed to make another setting.)

(The displayed numeric characters indicate the measurement gas

concentration.)

<7. Startup>

7.10.2 Manual Calibration

The following describes how to conduct a calibration.

7.10.2.1 Preliminary

Before conducting a manual calibration, be sure that the ZA8F Flow Setting Unit zero gas ow valve

is fully closed. Open the zero gas cylinder pressure regulator so that the secondary pressure will be a sample gas plus approx. 50 kPa (or sample gas pressure plus approx. 150 kPa when a check valve is used, maximum pressure rating is 300 kPa).

7.10.2.2 Calibration Implementation

This manual assumes that the instrument air is the same as the reference gas used for the span gas. Follow the steps below to conduct manual calibration. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.

Table 7.13 Conducting Calibration

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

7-17

> ∧

ENT

b10

CAL

SPAn Y

21.00

OPEn /20.84

20.84

Switch the parameter code to B10.

(The key operations for this procedure are omitted.)

Touch the [ENT] key, and "CAL" will be displayed.

To cancel the above, touch the [>] key and [ENT] key together to return to

the B10 display.

If you touch the [ENT] key again, "CAL" then ashes.

To cancel the above, touch the [>] key and [ENT] key together, the display

will return to the B10 display.

If you touch the [ENT] key again, "SPAn Y" appears (Y is ashing).

If you omit the span calibration, touch the [>] key, and change "Y" to "N".

If you touch the [ENT] key, the display then jumps to "ZEro Y."

Touch the [ENT] key to display the calibration gas value, in other words,

the span gas concentration set in Section 7.10.1, "Calibration Setup."

To cancel the above, touch the [>] key and [ENT] key together, then the

display returns to "SPAn Y."

If you touch the [ENT] key, "OPEn" and the currently measured value are

displayed alternately. Open the Flow Setting Unit span gas ow valve and

adjust the span gas ow to 600 ± 60 ml/min. To do this, loosen the valve

lock nut and gently turn the valve control (shaft) counterclockwise.

Check the calibration gas owmeter for conrmation.

If the automatic calibration unit is connected, open the span gas solenoid

valve, and the measured value changes to the span gas value.

When the display becomes stable, proceed to the next step.

To cancel the above, touch the [>] key and [ENT] key together, then the

display returns to "SPAn Y."

If you touch the [ENT] key, all the digits ash. At that point, no calibration is

conducted yet.

The symbol [ ] indicates that the key is being touched. Light characters indicates that the digits are ashing.

IM 11M12A01-04E

7-18

<7. Startup>

Table 7.13 Conducting Calibration (Continued)

Switch operation Display Description

> ∧

ENT

ZEro Y

0.98

OPEn

/0.89

ENT

ENT Basic panel

0.89

CALEnd

b10

display

If you touch the [ENT] key again, the ashing stops and "ZEro Y" appears.

Close the span gas ow valve. Secure the span gas lock nut for leakage.

If the automatic calibration unit is connected, close the span gas solenoid

valve.

If zero gas calibration is omitted, touch the [>] key to change "Y" to "N".

Next, if you touch the [ENT] key, the display jumps to "CALEnd."

Touch the [ENT] key to display the calibration gas value.

This value must be the zero gas concentration set in Section 7.10.1,

"Calibration Setup," earlier in this manual.

To cancel the above, touch the [>] key and [ENT] key together, then the

display returns to "ZEro Y."

If you touch the [ENT] key, "OPEn" and the currently measured value are

displayed alternately. Open the Flow Setting Unit zero gas ow valve and

adjust the zero gas ow to 600 ± 60 ml/min. To do this, loosen the valve

lock nut and gently turn the valve control (shaft) counterclockwise.

Check the calibration gas owmeter for conrmation. If the automatic

calibration unit is connected, open the zero gas solenoid valve, and then

the measured value changes to the zero gas value. When the display

becomes stable, proceed to the next step.

To cancel the above, touch the [>] key and [ENT] key together, then the

display returns to "ZEro Y."

If you touch the [ENT] key, all the digits ash. At that point, no calibration is

conducted yet.

Touch the [ENT] key again to get the measured value to agree with the

zero gas concentration. Close the zero gas ow valve.

Secure the valve lock nut for leakage during measurement.

If the automatic calibration unit is connected, close the span gas solenoid

valve. "CALEnd" ashes during the output hold time. If "output hold" is

specied in the Output Hold setting," it remains as an analog output (see

Section 8.3).

When the preset output hold time is up, the calibration is complete.

The output hold time is set to 10 minutes at the factory.

If you touch both the [>] key and [ENT] key at the same time during the

preset Output Hold Time, the calibration is aborted and the parameter

code selection display appears.

If you touch the [>] key and [ENT] key together, then the basic panel

display appears.

The above "display" is a result of switch operations.

The symbol [ ] indicates the keys are being touched, and the light characters indicate "ashing."

"/" indicates that the characters are displayed alternately.

IM 11M12A01-04E

<8. Detailed Data Setting>

CAUTION

8. Detailed Data Setting

8.1 Setting Display Item

Display items are dened as items displayed on the basic panel display.

Parameter code 「A00」 or 「F08」 is used to set the display items as shown in Table 8.1. The oxygen concentration is set at the factory before shipment. In addition, if the data initialization is performed, the oxygen concentration will be set.

Table 8.1 Display Item

Values set with A00 or F08 Items displayed on the basic panel display

0 Indicates the oxygen concentration.

1 or 2 For humidity analyzers only. (if 1 or 2 is set for the oxygen analyzer,

"0.0" is only displayed on the basic panel display.)

3 Displays an item for the current output.

If the output damping has been set for the current output, values involving the output damping are displayed.

8-1

If you set “3” in the parameter code 「A00」 or 「F08」, be sure to select “Oxygen Concentration” in the following mA output setting (see Section 8.2, “Current Output Setting”).

8.2 Current Output Setting

This section describes setting of the analog output range. Table 8.2 shows parameter codes for the set items.

Table 8.2 Current Output Parameter Codes

Set item Parameter code Set value

Analog output C01 0 Oxygen concentration

Output mode C03 0 Linear

Min. oxygen concentration C11 Oxygen concentration at 4 mA

Max. oxygen concentration C12 Oxygen concentration at 20 mA

Output damping constant C30 0 to 255 seconds

*1: For the oxygen analyzer, set 0 (zero) only for parameter code C01. When it is set, the current output is 4-mA xed regardless of

the oxygen concentration.

1 4 mA (xed *1)

2 4 mA (xed *1)

1 Logarithm

IM 11M12A01-04E

<8. Detailed Data Setting>

8-2

IM 11M12A01-04E

CAUTION

8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum Oxygen Concentration ( at 20 mA)

Set the oxygen concentration values at 4 mA and 20 mA.

The minimum concentration of oxygen for the minimum current (4 mA) is 0% O2 or 6% to 76% O2.

The maximum concentration of oxygen for the maximum current (20 mA) ranges from 5% to 100% O2, and must be greater than 1.3 times the concentration of oxygen set for the minimum. If it does not fall within this input range setting, the setting will be invalid, and the previous set values will remain.

Setting example 1

If the setting (for a 4 mA current) is 10% O2, you must set the oxygen concentration for the maximum (20 mA) point at 13% O2.

Setting example 2

If the setting (for a 4 mA current) is 75% O2, you must set the oxygen concentration for the maximum (20 mA) point at 98% O2 (75 × 1.3).

(Numbers after the decimal point are rounded up.)

• When you select logarithmic mode, the minimum output remains constant at 0.1% O2, and the

parameter 「C11」 display remains unchanged.

8.2.2 Entering Output Damping Constants

If a measured value adversely affected by a rapid change in the sample gas oxygen concentration is used for the control means, frequent on-off actions of the output will result. To avoid this, the converter allows the setting of output damping constants ranging from 0 to 255 seconds.

8.2.3 Selection of Output Mode

You can select a linear or logarithmic output mode. The former provides linear characteristics between the analog output signal and oxygen concentration.

8.2.4 Default Values

When the analyzer is delivered or data are initialized, the output current settings are by default as shown in Table 8.3.

Table 8.3 Output Current Default Values

Item Default setting

Min. oxygen concentration

Max. oxygen concentration

Output damping constant 0 (seconds)

Output mode Linear

0% O

25% O

• When you select logarithmic mode, the minimum output remains constant at 0.1% O2, and the

parameter 「C11」 display remains unchanged.

<8. Detailed Data Setting>

8.3 Output Hold Setting

The “output hold” functions retain an analog output signal at a preset value during the equipment’s warm-up time or calibration or if an error arises.

Table 8.4 shows the analog outputs that can be retained and the individual states.

Table 8.4 Analog Output Hold Setting

8-3

Equipment status

Output hold values available

4 mA O

20 mA O

Without hold feature O O O

Retains output from just before occurrence

Set value (2.4 to 21.6 mA)

O: The output hold functions are available. *1: The output hold functions on error occurrence are unavailable when option code "/C2" or "/C3" (NAMER NE 43 compliant) is

specied.

During warm-up During

O O O

8.3.1 Denition of Equipment Status

(1) During warm-up

“During warm-up” is the time required after applying power until the sensor temperature stabilizes at 750°C, and the equipment is in the measurement mode. This status is that the sensor temperature is displayed on the basic panel.

(2) During maintenance

“During maintenance” is the time from when a valid password is entered in the basic panel display to enable the parameter code selection display until the display goes back to the basic panel display

During calibration Error occurrence

maintenance

O O O

(*1)

(3) During calibration (see Chapter 9, Calibration)

In the manual calibration, proceed with the calibration operation with the parameter code

「B10」 to display the span gas conrmation display for the rst span calibration, thus starting the

calibration time when the [ENT] key is touched. After a series of calibrations is complete and the preset output stabilization time has elapsed, the calibration time will be up. Figure 8.1 shows the

denition of “during calibration” in the manual calibration.

IM 11M12A01-04E

<8. Detailed Data Setting>

8-4

IM 11M12A01-04E

Output hold time during calibration

Switch operation Display

> ∧

ENT

b10

> ∧

ENT

CAL

SPAn Y

21.00

OPEn/20.84

20.84

ZEro Y

0.98

OPEn/0.89

0.89

> ∧

Figure 8.1 Denition of During Calibration

In a semi-automatic calibration, “during calibration” is the time, starting when a calibration

instruction is executed with an infrared switch or a contact input, to make a series of calibrations, until the preset output stabilization time elapses.

In an automatic calibration, “during calibration” is the time, starting when automatic calibration is

carried out at the calibration start time, until the preset output stabilization time elapses.

(4) “Error” appears when Error 1 to Error 4 are being issued

ENT

CALEnd

b10

Measured-value display

<8. Detailed Data Setting>

During error occurrence

During calibration

During maintenance

During warm-up

Preference order (high)

8.3.2E.siki

8.3.2 Preference Order of Output Hold Value

The output hold value takes the following preference order:

For example, if the output current is set to “4 mA” during maintenance, and “without hold” output during calibration is preset, the output is held at 4 mA in the maintenance display. However, the output hold is released at the time of starting the calibration, and the output will be held again at 4 mA after completing the calibration and when the output stabilization time elapses.

8.3.3 Output Hold Setting

Table 8.5 lists parameter codes with set values for individual set items.

Table 8.5 Parameter Codes for Output Holding

Set items Parameter code Set value

During warm-up C04 0 4 mA

1 20 mA

2 Holds Set value

During maintenance C05 0 Without hold feature

1 Last measured value.

2 Holds set values.

During calibration C06 0 Without hold feature

1 Last measured value.

2 Holds set values.

During error occurrence C07 0 Without hold feature

1 Last measured value.

2 Holds set values.

Note: "C07" is not displayed when option code "/C2" or "/C3" (NAMUR NE 43 compliant) is specied.

8-5

8.3.4 Default Values

When the analyzer is delivered, or if data are initialized, output holding is by default as shown in Table

8.6.

Table 8.6 Output Hold Default Values

Status Output hold (min. and max. values) Preset value

During warm-up 4 mA 4 mA

Under maintenance Holds output at value just before maintenance started. 4 mA

Under calibration or blow-back Holds output at value just before starting calibration 4 mA

On Error occurrence Holds output at a preset value. 3.4 mA

IM 11M12A01-04E

<8. Detailed Data Setting>

8-6

IM 11M12A01-04E

Delayed time: 5 seconds

7.5%

High alarm setpoint

5.5%

Oxygen concentration

Alarm output

ON OFF

Hysteresis

2.0%

Alarm range

Delayed time: 5 seconds

F8.2E.ai

8.4 Setting Oxygen Concentration Alarms

The analyzer enables the setting of four alarms high-high, high, low, and low-low alarms depending upon the oxygen concentration. The following section sets forth the alarm operations and setting procedures.

8.4.1 Alarm Values

(1) High-high and high alarm values

High-high alarms and high alarms are issued when they are set to be detected with parameter codes 「D41」 and 「D42」, and if the measured values exceed the preset oxygen concentration values specied with 「D01」 and 「D02」.

The oxygen alarm set values can range from 0 to 100% O

(2) Low and low-low alarm values

Low alarms and low-low alarms are issued when they are set to be detected with parameter codes 「D43」 and 「D44」, and if the measured values are lower than the preset oxygen concentration values specied with 「D03」 and 「D04」.

The oxygen alarm set values can range from 0 to 100%

8.4.2 Alarm Output Actions

If the measured values of the oxygen concentration uctuate between normal (steady-state) values

and alarm setting, there may be a lot of alarm-output issuing and canceling. To avoid this, set the delay time and allow for hysteresis for alarm canceling under the alarm output conditions, as Figure

8.2 shows. When the delay time is set, an alarm will not be issued so quickly even if the measured value differs from the steady-state and enters the alarm setpoint range. If the measured value remains within the alarm setpoint range for a certain period of time (for the preset delay time), an alarm will result. On the other hand, there will be a similar delay each time the measured value returns to the steady state from the alarm setpoint range (canceling the alarm status). If hysteresis is set, alarms will be canceled when the measured value is less than or more than the preset hysteresis values. If both the delay time and hysteresis are set, an alarm will be issued if the measured value is in the alarm setpoint range and the delay time has elapsed. When the alarm is reset (canceled), it is required that the measured value be beyond the preset hysteresis value and that the preset delay time. Refer to Figure 8.2 for any further alarm output actions. The delay time and hysteresis settings are common to all alarm points.

O2.

Figure 8.2 Alarm Output Action

<8. Detailed Data Setting>

CAUTION

In the example in Figure 8.2, the high alarm point is set to 7.5% O2, the delayed time is set to ve seconds, and hysteresis is set to 2% O2.

Alarm output actions in this gure are expressed as follows:

(1) Although oxygen concentration measurement “A” has exceeded the high alarm setpoint, “A” falls

lower than the high alarm setpoint before the preset delayed time of ve seconds elapses. So,

no alarm is issued.

(2) Oxygen concentration measurement “B” exceeds the high alarm setpoint and the delayed time

has elapsed during that measurement. So, an alarm results.

(3) Although oxygen concentration measurement “C” has fallen lower than the hysteresis set value,

that measurement exceeds the hysteresis set value before the preset delayed time has elapsed. So, the alarm is not canceled.

(4) Oxygen concentration measurement “D” has fallen below the hysteresis set value and the preset

delayed time during measurement has elapsed, so the alarm is canceled.

8.4.3 Alarm Setting

Set the alarm setpoints following Table 8.7 listing parameter codes.

Table 8.7 Parameter Codes for Oxygen Concentration Alarms

8-7

Set item Parameter code Set value

Oxygen concentration high-high alarm setpoint

Oxygen concentration high alarm setpoint

Oxygen concentration low alarm setpoint

Oxygen concentration low-low alarm setpoint

Oxygen concentration alarm hysteresis

Delayed alarm action D33 0-255 seconds

Oxygen concentration high-high alarm detection

Oxygen concentration high alarm detection

Oxygen concentration low alarm detection

Oxygen concentration low-low alarm detection

D01 0-100% O

D02 0-100% O

D03 0-100% O

D04 0-100% O

D30 0-9.9% O

D41 0 Not detected

1 Detected

D42 0 Not detected

1 Detected

D43 0 Not detected

1 Detected

D44 0 Not detected

1 Detected

Even with alarms set, if “Not detected” has been set in the above alarm detection, no alarm is issued. Be sure to set “Detected” in the above alarm detection if you use alarm features.

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<8. Detailed Data Setting>

8-8

IM 11M12A01-04E

8.4.4 Default Values

When the analyzer is delivered, or if data are initialized, the default alarm set values are as shown in Table 8.8.

Table 8.8 Alarm Setting Default Values

Set item Set value

High-high alarm setpoint 100% O

High alarm setpoint 100% O

Low alarm setpoint 0% O

Low-low alarm setpoint 0% O

Alarm hysteresis 0.1% O

Delayed alarm action 3 seconds

High-high alarm detection Not detected

High alarm detection Not detected

Low alarm detection Not detected

Low-low alarm detection Not detected

8.5 Output Contact Setup

8.5.1 Output Contact

Mechanical relays provide contact outputs. Be sure to observe relay contact ratings. (For details, see

Section 2.1, "General Specications.") The following sets forth the operation mode of each contact

output. Output contact 1 you can select open or closed contact when the contact is "operated". For output contact 2, contact is closed. The relay for output contact 1 is energized when its contacts are closed and vice versa. Accordingly, when no power is supplied to the equipment, those contacts remain open. In addition, the relay for output contact 2 is energized when the corresponding contact is open and de-energized when that contact is closed.

Table 8.9 Setting Output Contacts

Operating state When no power is applied to this equipment

Output contact 1 Open (de-energized) or closed

(energized) selectable.

Output contact 2 Closed (de-energized) only. Closed

Open

<8. Detailed Data Setting>

WARNING

8.5.2 Setting Output Contact

Set the output contacts following Table 8.10.

Table 8.10 Parameter Codes for Output Contact Setting

8-9

Set item Parameter

code

Output contact 1

Operation E10 0 Operated in closed status. (Normally de-energized)

1 Operated when open. (Normally energized) (Note 1)

Error E20 0 Not operated if an error occurs.

1 Operated if an error occurs.

High-high alarm E21 0 Not operated if a high-high alarm occurs.

1 Operated if a high-high alarm occurs. (Note 2)

High alarm E22 0 Not operated if a high alarm occurs.

1 Operated if a high alarm occurs. (Note 2)

Low alarm E23 0 Not operated if a low alarm occurs.

1 Operated if a low alarm occurs. (Note 2)

Low-low alarm E24 0 Not operated if a low-low alarm occurs.

1 Operated if a low-low alarm occurs. (Note 2)

Maintenance E25 0 Not operated during maintenance.

1 Operated during maintenance (see Section 8.3.1).

Calibration E26 0 Not operated during calibration.

1 Operated during calibration (see Section 8.3.1).

Measurement range change

Warm-up E28 0 Not operated during warming up.

Calibration gas pressure

Unburnt gas detection

decrease

E27 0 Not operated when changing ranges.

1 Operated when changing ranges. (Note 3)

1 Operated during warming up.

E29 0

E32 0 Not operated while a unburnt gas detection contact is being closed.

Not operated while a calibration gas pressure decrease contact is being closed.

Operated while a calibration gas pressure closed. (Note 4)

Operated while a unburnt gas detection contact is being closed. (Note 5)

Set value

decrease

contact is being

Note 1: Output contact 2 remains closed. Note 2: The oxygen concentration alarm must be preset (see Section 8.4). Note 3: Range change answer-back signal. For this action, the range change must be preset during the setting of input contacts

(see Section 8.6).

Note 4: Calibration gas pressure decrease answer-back signal. Calibration gas pressure decrease must be selected beforehand

during the setting of input contacts.

Note 5: Non-combusted gas detection answer-back signals. “Non-combusted gas” detection must be selected during the setting of

input contacts.

• Output contact 2 is linked to the detector’s heater power safety switch. As such, if output contact 2 is on, the heater power stops and an Error 1 (cell voltage abnormal) or Error 2 (heater temperature abnormal) occurs.

IM 11M12A01-04E

<8. Detailed Data Setting>

8-10

IM 11M12A01-04E

NOTE

8.5.3 Default Values

When the analyzer is delivered, or if data are initialized, output contacts are by default as shown in Table 8.11.

Table 8.11 Output Contact Default Settings

Item Output contact 1 Output contact 2

High-high alarm

High alarm

Low alarm

Low-low alarm

Error O

Warm-up O

Output range change

Calibration

Maintenance O

High limit temperature alarm

Calibration gas pressure

Unburnt gas detection

Operating contact status Open Closed (xed)

O: Present

decrease

The above blank boxes indicate the items have been set off.

<8. Detailed Data Setting>

CAUTION

8.6 Input Contact Settings

The converter input contacts execute set functions by accepting a remote (contact) signal. Table 8.12 shows the functions executed by a remote contact signal.

Table 8.12 Input Contact Functions

Set item Function

Calibration gas pressure decrease

Measuring range change While contact input is on, the analog output range is switched to 0-25% O2.

Calibration start If a contact signal is applied, semi-automatic calibration starts (only if the semi-

Unburnt gas detection If a contact signal is on, the heater power will be switched off. (An one-to 11-

While a contact signal is on, neither semi-automatic nor automatic calibrations can be made.

automatic or automatic mode has been setup). Contact signal must be applied for at least one second. Even though a continuous contact signal is applied, a second calibration cannot be made. If you want to make a second calibration, turn the contact signal off and then back on.

second time interval single-output signal is available as a contact signal.) If this operation starts, the sensor temperature decreases and an error occurs. To restore it to normal, turn the power off and then back on, or reset the analyzer.

8-11

• Measurement range switching function by an external contact input is available for analog output

1 only and the range is xed to 0-25%O2.

• To conduct a semi-automatic calibration, be sure to set the Calibration setup mode to “Semiautomatic” or “Automatic”.

8.6.1 Setting Input Contact

To set the input contacts, follow the parameter codes given in Table 8.13.

Table 8.13 Parameter Codes for Input Contact Settings

Set item Parameter code Set value

Input contact 1 (function) E01 0 Invalid

Input contact 2 (function) E02 0 Invalid

Input contact 1 (action) E03 0 Operated when closed

Input contact 2 (action) E04 0 Operated when closed

1 Calibration gas pressure decrease

2 Measuring range change

3 Calibration

4 Unburnt gas detection

1 Calibration gas pressure decrease

2 Measuring range change

3 Calibration

4 Unburnt gas detection

1 Operated when open

8.6.2 Default Values

When the analyzer is delivered, or if data are initialized, the input contacts are all open.

IM 11M12A01-04E

<8. Detailed Data Setting>

8-12

IM 11M12A01-04E

8.7 Other Settings

8.7.1 Setting the Date-and-Time

The following describe how to set the date-and-time. Automatic calibration works following this setting.

Use parameter code 「F10」 to set the date-and-time.

Table 8.14 Data-and-time Settings

Switch operation Display Description

> ∧

ENT

F10

Select the parameter code F10.

> ∧

∧

ENT

00.01.01

00.06.01

00.06.21

07.18

14.30

If you touch the [ENT] key, the current date will be displayed. The display

on the left indicates the date - January 1, 2000. To set June 21, 2000,

follow the steps below:

Touch the [>] key to move the position of the digit that is ashing to the

right.

Touch the [∧] key to change to 6.

Touch the [>] key to move the position of the digit that is ashing to the

right one digit.

Touch the [∧] key to change to 2.

Touch the [>] key to move the position of the digit that is ashing to the

right one digit.

Let the rightmost character ash, and touch the [>] key to display the time.

Continuously touch the [>] key, then the date and time are alternately

displayed. Displayed on the left is 7:18 a.m.

Omitted here.

Touch the [∧] key and enter the current time in same way as the date has

been entered, on a 24-hour basis. 2:30 p.m.

Displayed on the left means 2:40 p.m.

If you touch the [ENT] key, all the digits ash.

> ∧

The symbol ( ) indicates that the corresponding keys are being touched, and the light characters indicate ashing.

ENT

14.30

F10

Touch the [ENT] key again to set the time.

If you touch the [>] and [ENT] keys together, the parameter code selection

display appears.

<8. Detailed Data Setting>

8-13

8.7.2 Setting Periods over which Average Values are Calculated and Periods over which Maximum and Minimum Values Are Monitored

The equipment enables the display of oxygen concentration average values and maximum and minimum values under measurement (see Section 10.1, later in this manual). The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored.

8.7.2.1 Procedure

Use the parameter-code table below to set the average, maximum and minimum oxygen concentration values. Periods over which average is calculated and periods over which maximum and minimum values are monitored can be set, ranging from 1 to 255 hours. If the set ranges are beyond

the limits specied, an “Err” will be displayed.

Table 8.15 Parameter Codes for Average, Maximum and Minimum Values

Set item Parameter code Set range Units

Periods over which average values are calculated

Periods over which maximum and minimum values are monitored

F11 1 to 255 Hours

F12 1 to 255 Hours

8.7.2.2 Default Value

When the analyzer is delivered, or if data are initialized, periods over which average values are calculated are set to one hour, and periods over which maximum and minimum values are monitored are set to 24 hours.

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<8. Detailed Data Setting>

8-14

IM 11M12A01-04E

Moisture quantity =

where,

Ao : Theoretical amount of air per unit quantity of fuel, m3 /kg (or m3 /m3 ) ............ 2 in Table 8.16

G: Actual amount of exhaust gas (including water vapor) per unit quantity of fuel, m3/kg (or m3 /m3)

Gw : Water vapor contained in exhaust gas per unit quantity of fuel (by hydrogen

and moisture content in fuel), m3 /kg (or m3 /m3 ) ............ 1 in Table 8.16

Gw1: Water vapor contained in exhaust gas per unit quantity of fuel (moisture content in air), m3 /kg (or m3 /m3 )

Go: Theoretical amount of dry exhaust gas per unit quantity of fuel, m3 /kg (or m3 /m3 )

m: Air ratio

X : Fuel coefficient determined depending on low calorific power of fuel, m3 /kg (or m3 /m3 ) ... 3 in Table 8.16

Z : Absolute humidity of the atmosphere, kg /kg ....... Figure 8.4

(water vapor caused by combustion and water vapor contained in the exhaust gas)

actual exhaust gas(including water vapor) per fuel

+ (water vapor contained in air for combustion)

x 100

Gw + (1.61 x Z x m x Ao)

Go + Gw + (m - 1) Ao + (1.61 x Z x m x Ao)

x 100

Gw + (1.61 x Z x m x Ao )

X + Ao x m

x 100

Gw + Gw1

x 100

..... Equation 1

............ Equation 2

8.7.3 Setting Fuels

8.7.3.1 Input Parameters

The analyzer calculates the moisture content contained in exhaust gases. The following sets forth the fuel parameters necessary for calculation and their entries. The moisture quantity may be mathematically expressed by:

Fill in the boxes with fuel parameters in Equation 2 above to calculate the moisture content. Use Ao, Gw and X shown in Table 8.16. If there are no appropriate fuel data in Table 8.16, use the following equations for calculation.

Find the value of “Z” in Equations 1 and 2 using Japanese Standard JIS B 8222. If a precise measurement is not required, obtain the value of “Z” using a graph for the absolute humidity indicated by a dry and wet bulb hygrometer.

<8. Detailed Data Setting>

For liquid fuel

Amount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} (m /kg)

Theoretical amount of air (Ao) = 12.38 x (Hl/10000) – 1.36 (m /kg)

Low calorific power = Hl

X value = (3.37 / 10000) x Hx – 2.55 (m /kg)

where, Hl: low calorific power of fuel

h: Hydrogen in fuel (weight percentage)

w: Moisture content in fuel (weight percentage)

Hx: Same as numeric value of Hl

For gas fuel

Amount of water vapor in exhaust gas (Gw) = (1/100) {(h2) + 1/2 ∑y (Cx Hy) + wv} (m /m )

Theoretical amount of air (Ao) = 11.2 x (Hl/10000) (m /m )

Low calorific power = Hl

X value = (1.05 / 10000) x Hx (m /m )

where, Hl: low calorific power of fuel

CxHy: Each hydrocarbon in fuel (weight percentage)

h2: Hydrogen in fuel (weight percentage)

wv: Moisture content in fuel (weight percentage)

Hx: Same as numeric value of Hl

For solid fuel

Amount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} (m /kg)

Theoretical amount of air (Ao) = 1.01 x (Hl / 1000) + 0.56 (m /kg)

Low calorific power = Hl = Hh – 25 (9h + w) (kJ/kg)

X value = 1.11 - (0.106 / 1000 ) x Hx (m /m )

where, w: Total moisture content in use (weight percentage)

h: Hydrogen content (weight percentage)

The average hydrogen content of coal mined in Japan, which is a dry ash-free type, is

5.7 percent. Accordingly, "h" may be expressed mathematically by:

h = 5.7 [{100 – (w + a)} / 100] x (100 – w) / (100 – w1)

where, a: Ash content (%)

w1: Moisture content (%), analyzed on a constant humidity basis

Hh: Higher calorific power of fuel (kJ/kg)

Hl: Low calorific power of fuel (kJ/kg)

Hx: Same numeric value of Hl

8-15

Figure 8.3 Calculation Formula

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<8. Detailed Data Setting>

8-16

IM 11M12A01-04E

0.046

0.044

0.042

0.040

0.038

0.036

0.034

0.032

0.030

0.028

0.026

0.024

0.022

0.020

0.018

0.016

0.014

0.012

0.010

0.008

0.006

0.004

0.002

0.000

6 8

12 14 16 18 20 22

26 28 30 32 34 36

-2

Wet-bulb temperature, °C

Absolute humidity, kg/kg

Dry-bulb temperature, °C

F8.4E.ai

Figure 8.4 Absolute Humidity of Air



For liquid fuel

C H O

2 H

2N2

0.78~

0.83

0.81~

0.84

0.85~

0.88

0.83~

0.89

0.90~

0.93

0.93~

0.95

0.94~

0.96

0.92~

1.00

0.94~

0.97

85.7

85.6

85.9

84.6

84.5

86.1

84.4

86.1

83.0

14.0

13.2

12.0

11.8

11.3

10.9

10.7

10.9

10.5

0.7

0.4

0.5

0.4

0.5

1.2

0.5

2.0

3.0

1.5

3.5

1.5

3.5

0.0 0.0

0.3

0.4

0.5

0.6

2.0

0.05

0.1

46465

45879

45544

45125

43827

43952

43116

43660

43032

43535

43032

42739

42320

41274

41441

40646

41190

40604

11.4

11.2

10.9

10.8

10.7

10.5

10.7

10.3

1.59

1.60

1.58

1.61

1.58

1.61

1.55

1.56

1.47

1.34

1.32

1.27

1.22

1.20

1.22

1.18

0.00

0.01

0.02

0.01

0.02

0.01

0.02

9.02

8.87

8.61

8.53

8.44

8.43

8.32

8.43

8.18

12.17

11.93

11.55

11.44

11.31

11.27

11.12

11.27

10.93

0.96

0.91

0.89

0.86

0.77

0.79

0.72

0.77

0.72

CO TotalH

CO2CH

CmH

O2N

2 CO

H2O

0.544

1.369

0.796

2.030

2.530

1.43

1.25

0.09

1.25

1.96

0.72

1.34

1.25

1.97

2.59

3H8

90%, C4H1010%

3H8

10%, C4H1090%

C2H

C3H

C4H

9.0

2.0 88.4 3.2 1.6 4.2

25.0

2.0

20.0 53.0

50.5

25.92.6 3.9

0.1

8.0

20428 18209

3391 3349

37883 34074

102055 93976

125496 115868

12767

12642

39750

69638

62991

99070

128452

10758

12642

35820

63744

59060

91255

118623

4.455

0.603

9.015

24.63

30.37

2.390

9.570

16.74

14.35

23.91

31.09

0.45

0.98

3.10

3.90

1.0

2.0

1.0

3.0

4.0

1.10

0.02

1.88

4.10

4.90

1.0

2.0

3.0

2.0

4.0

5.0

3.60

1.01

7.17

19.5

24.0

1.89

7.57

13.2

11.4

18.9

24.6

5.15

1.48

10.03

26.7

32.8

2.89

10.6

18.2

15.4

25.9

33.6

0.46

0.08

0.86

2.36

2.91

0.27

0.32

0.90

1.60

1.48

2.29

2.98



For gas fuel

Specific

weight

kg/l

Chemical component

(weight percentage)

Calorific power

kJ/kg

Theoretical

amount of

air for

combustion

Nm3/kg

Amount of combustion

gas Nm

/kg

Ash

content

Higher

order

Lower

order

value

Total

Theoretical amount of air

Combustion

product, Nm

/ m

Calorific power

kJ/Nm

Chemical component

(weight percentage)

Specific

weight

kg/Nm

Theoretical

amount of

air for

combustion

Higher

order

Lower

order

value

Kerosene

Light oil

Heavy

oil

class

Heavy oil

class 2

Heavy

oil

class

No.1

No.2

No.1

No.2

No.3

No.4

Fuel

properties

Type

Coke oven gas

Blast furnace gas

Natural gas

Propane

Butane

(Gases)

Oxygen

Nitrogen

Hydrogen

Carbon monoxide

Carbon dioxide

Methane

Ethane

Ethylene

Propane

Butane

(Molecular Formula)

Fuel

properties

Type

T8.8E.ai

<8. Detailed Data Setting>

Table 8.16 Fuel Data

8-17

IM 11M12A01-04E

Yokogawa ZR202 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

 For the safe use of this equipment

 NOTICE

 After-Sales Warranty

CONTENTS

1. Overview

1.1.1 System 1

1.1.2 System 2

1.1.3 System 3

1.2 < EXAxt ZR > System Components

1.2.1 System Components

1.2.2 Oxygen Analyzer and Accessories

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer

2.1.3 ZO21R Probe Protector

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit

2.2.1 ZA8F Flow Setting Unit

2.2.2 ZR20H Automatic Calibration Unit

2.3 ZO21S Standard Gas Unit

2.4 Other Equipment

2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA)

2.4.2 Dust Guard Protector (part no. K9471UC)

2.4.3 Stop Valve (part no. L9852CB or G7016XH)

2.4.4 Check Valve (part no. K9292DN or K9292DS)

2.4.5 Air Set

2.4.6 Zero Gas Cylinder (part no. G7001ZC)

2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder

2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder

2.4.9 ZR202A Heater Assembly

3. Installation

3.1 Installation of ZR202G Zirconia Oxygen Analyzer

3.1.1 Installation Location

3.1.2 Probe Insertion Hole

3.1.3 Installation of the Probe

3.1.4 Installation of the Dust Filter (K9471UA), Dust Guard Protector (K9471UC) Probe Protector (ZO21R)

3.2 Installation of ZA8F Flow Setting Unit

3.2.1 Installation Location

3.2.2 Mounting of ZA8F Flow Setting Unit

3.3 Installation of ZR20H Automatic Calibration Unit

3.3.1 Installation Location

3.3.2 Mounting of ZR20H Automatic Calibration Unit

3.4 Installation of the Case Assembly (E7044KF) for Calibration Gas Cylinder

3.4.1 Installation Location

3.4.2 Mounting

3.5 Insulation Resistance Test

4. Piping

4.1 Piping for System 1

4.1.1 Piping Parts for System 1

4.1.2 Piping for the Calibration Gas

4.1.3 Piping for the Reference Gas

4.2 Piping for System 2

4.2.1 Piping Parts for System 2

4.2.2 Piping for the Calibration Gas

4.2.3 Piping for the Reference Gas

4.3 Piping for System 3

4.4 Piping for the Oxygen Analyzer with Pressure Compensation

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation

4.4.2 Piping for the Calibration Gas

4.4.3 Piping for the Reference Gas

5. Wiring

5.1 General

5.1.1 Terminals for the External Wiring

5.1.2 Wiring

5.1.3 Mounting of Cable Gland

5.2 Wiring for Analog Output

5.2.2 Wiring Procedure

5.3 Wiring Power and Ground Terminals

5.3.1 Wiring for Power Line

5.3.2 Wiring for Ground Terminals

5.4 Wiring for Contact Output

5.4.2 Wiring Procedure

5.5 Wiring for Contact Input

5.5.2 Wiring Procedure

6. Components

6.1 ZR202G Zirconia Oxygen Analyzer

6.1.1 Integrated type Zirconia Oxygen Analyzer

6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit