YOKOGAWA ZR202S User Manual

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User ’s Manual

Model ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

IM 11M13A01-04E

6th Edition

Introduction

Thank you for purchasing the ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer.

Please read the following respective documents before installing and using the ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer.

The related documents are as follows.

General Specications

Model ZR22S and ZR202S Explosion-proof Direct In Situ Zirconia Oxygen Analyzer

* the “E” in the document number is the language code.

User’s Manual

Model ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

Model ZR22A, ZR202A Heater Assembly

Model EXAxt ZR Series HART Protocol

* the “E” or “EN” in the document number is the language code.

Contents Document number Note

GS 11M13A01-01E

Contents Document number Note

IM 11M13A01-04E (This manual)

IM 11M12A01-21E

IM 11M12A01-51E

An exclusive User’s Manual might be attached to the products whose sufx codes or option codes contain the code “Z” (made to customers' specications). Please read it along with this manual.

The EXAxt ZR Integrated type Explosion-proof 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 Explosion-proof Zirconia Oxygen Analyzer, refer to IM 11M13A01-02E.

< 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. >

IM 11M13A01-04E

Models and descriptions in this manual are listed below.

Model

ZR202S Integrated type Explosion-proof

Zirconia Oxygen Analyzer

ZO21R-L Probe Protector

ZA8F Flow Setting Unit

(for manual calibration use)

— Automatic Calibration Unit

— Calibration Gas Unit Case (Part No.

E7044KF)

— Check Valve

(Part No. K9292DN, K9292DS)

ZO21S Standard Gas Unit

CMPL: Customer Maintenance Parts List

Product Name

Specication

Description in this manual

Installation

Operation

Maintenance

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

Table and Contents

Chapter

1. Overview Equipment models and system conguration examples

Outline

Installation Operation

Relates to

Maintenance

CMPL

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

dimension drawing for each equipment

3. Installation Installation method for each equipment

4. Piping Examples of piping in two standard system

congurations

5. Wiring Wiring procedures such as “Power supply wiring”, “Output signal wiring” or others

6. Components Major parts and functions are described

7. Startup Basic procedure to start operation of EXAxt ZR. Chapter 7 enables you to operate the equipment immediately.

8. Detailed Data

Setting

9. Calibration Describes the calibration procedure required in the

10. Other

Functions

11. Inspection and

Maintenance

12. Troubleshooting This chapter describes measures to be taken when an

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.

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

abnormal condition occurs

IM 11M13A01-04E

 ATEX Documentation

This is only applicable to the countries in the European Union.

iii

EST

SLO

IM 11M13A01-04E

 Precautions in Handling Explosion-proof Zirconia Oxygen Analyzer

The explosion-proof zirconia oxygen analyzer (Model ZR202S) are designed as explosion-proof instruments.

When using either of these instruments in an explosion-susceptible hazardous area, note the following and observe the given precautions:

Use only the supplied, the explosion-proof zirconia oxygen analyzer (Model ZR202S) and

accessories, or any explosion-proof certication may be invalidated.

For the details, refer to the system congurations in the manual.

CAUTION

Only trained persons use this instrument in industrial locations.

Explosion-proof Approval followings:

ZR202S-A (ATEX); Ex db IIB+H2 T2 Gb, Ex tb IIIC T300°C Db

ZR202S-B (FM); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,

Groups E, F and G, T2

ZR202S-C (CSA); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,

Groups E, F and G, T2

ZR202S-D (IECEx); Ex db IIB+H

T2 Gb, Ex tb IIIC T300°C Db

 For the safe use of this equipment

WARNING

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

CAUTION

Requirements for explosion-proof use:

The ambient temperature is in the range of -20 to +55ºC. The surface temperature of the ZR202S is not over the temperature class T2 (300ºC)*

* The surface temperature of the amplier box does not exceed 70ºC.

Oxygen concentration of sample/reference /calibration gas shall not exceed that found in normal air, typically 21 vol%.

IM 11M13A01-04E

NOTE

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.

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

• Avoid any 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

• This manual should be passed on to the end user.

• The contents of this manual are subject to change without prior notice.

• The contents of this manual shall not be reproduced or copied, in part or in whole, without permission.

• 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.

NOTE

This instrument is tested and certied as explosion-proof type. Please note that the construction of the

instrument, installation, external wiring, maintenance or repair is strictly restricted, and non-observation or negligence of this restriction would result in dangerous condition.

(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.

IM 11M13A01-04E

(3) The following safety symbols are used on the product as well as in this manual.

WARNING

This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injury electric shock, or fatalities. The manual describes what special care the operator must exercise to avoid such risks.

CAUTION

This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring.

NOTE

This symbol draws attention to information essential for understanding the operation and functions.

Protective Ground Terminal

Function Ground Terminal (Do not use this terminal as the protective

ground terminal.)

Alternating current

IM 11M13A01-04E

 Special descriptions in this manual

This manual indicates operation keys, displays and drawings on the product as follows:

• Operation keys, displays on the panel Enclosed in [ ]. (Ex. “MODE” key)

(Ex. message display → “BASE”)

(Ex. data display → “102” lit, “102” ashing)

• Drawing for ashing

vii

Indicated by gray characters (Flashing)

(lit)

• Displays on the LCD display panel

Alphanumerics Alphanumerics AlphanumericsLED Display LED Display LED Display

IM 11M13A01-04E

viii

 NOTICE

l 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.

l Details on operation parameters

When the EXAxt ZR Integrated type Explosion-proof 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 of setting data, refer to chapters 7 to 10. When user changes the operation parameter, it is recommended to note down the changed setting data.

l Product Disposal:

The instrument should be disposed of in accordance with local and national legislation/regulations.

 Trademark Acknowledgments

• All other company and product names mentioned in this user’s manual are trademarks or registered trademarks of their respective companies.

• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this user’s manual.

IM 11M13A01-04E

u CE marking products

 Authorized Representative in EEA

The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2, 3825 HD Amersfoort, The Netherlands).

 Identication Tag

This manual and the identication tag attached on packing box are essential parts of the product. Keep them together in a safe place for future reference.

 Users

This product is designed to be used by a person with specialized knowledge.

l 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: Manganese dioxide lithium battery

Notice:

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

IM 11M13A01-04E

u After-Sales Warranty

l Do not modify the product.

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

Yokogawa shall conduct dened warranty service based on its standard.

l 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.

l In the following cases, customer will be charged repair fee regardless of warranty period.

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

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

supply.

• Failure due to improper or 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.

l 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 applica-

tion.

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

or resells the product.

l 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 instruction manual.

IM 11M13A01-04E

IM 11M13A01-04E

Model ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

IM 11M13A01-04E 6th Edition

CONTENTS

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

u CE marking products ..................................................................................ix

u After-Sales Warranty ....................................................................................x

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

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

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

1.1.2 System 2 ............................................................................................ 1-2

1.2 < EXAxt ZR > System Components ................................................................ 1-2

1.2.1 System Components ......................................................................... 1-2

1.2.2 Oxygen Analyzer and Installation ......................................................1-2

Toc-1

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

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

2.1.1 Standard Specications ..................................................................... 2-1

2.1.2 ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer 2-4

2.1.3 ZO21R Probe Protector ................................................................... 2-11

2.2 ZA8F Flow Setting Unit ................................................................................... 2-12

2.3 ZO21S Standard Gas Unit .............................................................................. 2-14

2.4 Other Equipment ............................................................................................. 2-15

2.4.1 Stop Valve (L9852CB, G7016XH) ...................................................2-15

2.4.2 Check Valve (K9292DN, K9292DS) ................................................ 2-15

2.4.3 Air Set ...............................................................................................2-16

2.4.4 Pressure Reducing Valve for Gas Cylinder (G7013XF, G7014XF) . 2-17

2.4.5 ZR202A Heater Assembly ...............................................................2-17

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

3.1 Installation of ZR202S Zirconia Oxygen Analyzer ......................................... 3-1

3.1.1 Installation Location ........................................................................... 3-1

3.1.2 ATEX Flameproof Type ...................................................................... 3-2

3.1.3 FM Explosion-proof Type ................................................................... 3-3

3.1.4 CSA Explosion-proof Type ................................................................. 3-4

3.1.5 IECEx Flameproof Type ..................................................................... 3-5

3.1.6 Probe (Detector) Insertion Hole ......................................................... 3-7

3.1.7 Installation of the Probe (Detector) .................................................... 3-7

3.1.8 Installation of the Probe Protector (ZO21R) ...................................... 3-8

IM 11M13A01-04E

Toc-2

3.2 Installation of ZA8F Flow Setting Unit ............................................................ 3-8

3.2.1 Installation Location ........................................................................... 3-8

3.2.2 Mounting of ZA8F Flow Setting Unit .................................................. 3-9

3.3 Insulation Resistance Test ............................................................................. 3-10

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

4.1 Piping for System 1 ........................................................................................... 4-2

4.1.1 Piping Parts for System 1 .................................................................. 4-2

4.1.2 Piping for the Calibration Gas Inlet .................................................... 4-3

4.1.3 Piping for the Reference Gas Inlet ..................................................... 4-3

4.1.4 Piping for the Reference Gas Outlet .................................................. 4-3

4.2 Piping for System 2 ........................................................................................... 4-4

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

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

5.1.1 Terminals for the External Wiring ....................................................... 5-2

5.1.2 Wiring ................................................................................................. 5-3

5.1.3 Mounting of Cable Gland ................................................................... 5-3

5.2 Wiring for Analog Output ................................................................................. 5-4

5.2.1 Cable Specications ..........................................................................5-4

5.2.2 Wiring Procedure ............................................................................... 5-4

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

5.3.1 Wiring for Power Line ......................................................................... 5-5

5.3.2 Wiring for Ground Terminals .............................................................. 5-5

5.4 Wiring for Contact Output ................................................................................ 5-6

5.4.1 Cable Specications ..........................................................................5-6

5.4.2 Wiring Procedure ............................................................................... 5-6

5.5 Wiring for Contact Input ................................................................................... 5-6

5.5.1 Cable Specications ..........................................................................5-6

5.5.2 Wiring Procedure ............................................................................... 5-7

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

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

IM 11M13A01-04E

6.1 ZR202S Zirconia Oxygen Analyzer ................................................................. 6-1

6.2 ZA8F Flow Setting Unit, Automatic Calibration Unit ..................................... 6-2

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

7.2 Valve Setup ........................................................................................................ 7-2

7.3 Supplying Power to Analyzer .......................................................................... 7-2

7.4 Operation of Infrared Switch ........................................................................... 7-3

7.4.1 Display and Switches ......................................................................... 7-3

7.4.2 Display Conguration ......................................................................... 7-4

7.4.3 Entering Parameter Code Selection Display ..................................... 7-5

7.4.4 Selecting Parameter Codes ............................................................... 7-6

7.4.5 Changing Set Values .........................................................................7-7

7.5 Conrmation of Equipment Type Setting ....................................................... 7-8

7.6 Selection of Measurement Gas ....................................................................... 7-9

7.7 Output Range Setting ....................................................................................... 7-9

7.8 Checking Current Loop .................................................................................. 7-11

7.9 Checking Contact I/O ...................................................................................... 7-11

7.9.1 Checking Contact Output ................................................................. 7-12

7.9.2 Checking Calibration Contact Output .............................................. 7-13

7.9.3 Checking Contact Input ................................................................... 7-14

7.10 Calibration ....................................................................................................... 7-15

7.10.1 Calibration Setup .............................................................................7-15

7.10.2 Manual Calibration ........................................................................... 7-17

Toc-3

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

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

8.2 Current Output Setting ..................................................................................... 8-1

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

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

8.2.2 Entering Output Damping Constants ................................................. 8-2

8.2.3 Selection of Output Mode .................................................................. 8-2

8.2.4 Default Values .................................................................................... 8-2

8.3 Output Hold Setting .......................................................................................... 8-3

8.3.1 Denition of Equipment Status .......................................................... 8-3

8.3.2 Preference Order of Output Hold Value ............................................. 8-5

8.3.3 Output Hold Setting ............................................................................ 8-5

8.3.4 Default Values .................................................................................... 8-5

8.4 Oxygen Concentration Alarms Setting........................................................... 8-6

8.4.1 Setting the Alarm Values .................................................................... 8-6

8.4.2 Alarm Output Actions ......................................................................... 8-6

8.4.3 Alarm Setting...................................................................................... 8-7

8.4.4 Default Values .................................................................................... 8-8

8.5 Contact Output Setting ..................................................................................... 8-8

8.5.1 Contact Output ................................................................................... 8-8

8.5.2 Setting Contact Output....................................................................... 8-9

8.5.3 Default Values .................................................................................. 8-10

8.6 Contact Input Setting ...................................................................................... 8-11

8.6.1 Setting Contact Input ....................................................................... 8-11

8.6.2 Default Values .................................................................................. 8-11

8.7 Other Settings ................................................................................................. 8-12

8.7.1 Setting the Date-and-Time ............................................................... 8-12

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 .................................................................................... 8-14

8.7.4 Setting Purging ................................................................................ 8-18

IM 11M13A01-04E

Toc-4

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

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

9.1.1 Principle of Measurement .................................................................. 9-1

9.1.2 Calibration Gas .................................................................................. 9-2

9.1.3 Compensation .................................................................................... 9-3

9.1.4 Characteristic Data from a Sensor Measured During Calibration ..... 9-4

9.2 Calibration Procedures .................................................................................... 9-5

9.2.1 Calibration Setting .............................................................................. 9-5

9.2.2 Calibration .......................................................................................... 9-8

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

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

10.1.1 Air Ratio............................................................................................10-3

10.1.2 Cell Temperature ..............................................................................10-3

10.1.3 C. J. Temperature.............................................................................10-3

10.1.4 Amount of Water Vapor in Exhaust Gas .......................................... 10-3

10.1.5 Cell Voltage ...................................................................................... 10-4

10.1.6 Thermocouple Voltage ..................................................................... 10-4

10.1.7 Cold Junction Voltage ......................................................................10-4

10.1.8 Current Output ................................................................................. 10-4

10.1.9 Response Time ................................................................................ 10-5

10.1.10 Cell’s Internal Resistance ...............................................................10-5

10.1.11 Robustness of a Cell ....................................................................... 10-5

10.1.12 Heater On-Time Ratio ..................................................................... 10-6

10.1.13 Oxygen Concentration (with time constant) ....................................10-6

10.1.14 Maximum Oxygen Concentration ................................................... 10-6

10.1.15 Minimum Oxygen Concentration .................................................... 10-6

10.1.16 Average Oxygen Concentration ......................................................10-6

10.1.17 Span and Zero Correction Ratios ................................................... 10-6

10.1.18 History of Calibration Time .............................................................. 10-7

10.1.19 Time .................................................................................................10-7

10.1.20 Software Revision ........................................................................... 10-7

10.2 Operational Data Initialization ......................................................................10-8

10.3 Initialization Procedure ..................................................................................10-9

10.4 Reset ...............................................................................................................10-10

10.5 Handling of the ZO21S Standard Gas Unit .................................................10-17

10.5.1 Standard Gas Unit Component Identication ................................ 10-17

10.5.2 Installing Gas Cylinders ................................................................. 10-18

10.5.3 Calibration Gas Flow ......................................................................10-18

10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit ................... 10-21

10.6.1 Preparation Before Calibration ......................................................10-21

10.6.2 Operating the Span Gas Flow Setting Valve .................................10-21

10.6.3 Operating the Zero Gas Flow Setting Valve ..................................10-21

IM 11M13A01-04E

10.6.4 Treatment After Calibration ............................................................ 10-21

Toc-5

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

11.1 Inspection and Maintenance of the Detector ............................................... 11-2

11.1.1 Cleaning the Calibration Gas Tube .................................................. 11-2

11.1.2 Replacing the Sensor Assembly ...................................................... 11-2

11.1.3 Replacement of the Heater Assembly ............................................. 11-5

11.1.4 Replacement of Flame Arrestor Assembly ...................................... 11-7

11.1.5 Replacement of O-ring ..................................................................... 11-8

11.1.6 Stopping and Re-starting Operation ................................................ 11-8

11.2 Inspection and Maintenance of the Analyzer ............................................... 11-9

11.3 Replacement of Flowmeter for Automatic Calibration Unit .................... 11-11

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

12.1 Displays and Remedies When Errors Occur ...............................................12-1

12.1.1 Error Types ....................................................................................... 12-1

12.1.2 Remedies When an Error Occurs ....................................................12-2

12.2 Displays and Remedies When Alarms are Generated ................................ 12-4

12.2.1 Alarm types ...................................................................................... 12-4

12.2.2 Remedies When Alarms are Generated ..........................................12-5

12.3 Measures When Measured Value Shows an Error ...................................... 12-9

12.3.1 Measured Value Higher Than True Value ........................................12-9

12.3.2 Measured Value Lower Than True Value ......................................12-10

12.3.3 Measurements Sometimes Show Abnormal Values ..................... 12-10

Customer Maintenance Parts List ......................................CMPL 11M13A01-04E

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

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

IM 11M13A01-04E

Blank Page

<1.Overview>

ZR202S Integrated type Explosion-proof

Hazardous Area

unit case

1. Overview

The EXAxt ZR Integrated type Explosion-proof 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 Explosion-proof 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 flue 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.

1-1

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

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 two basic patterns as follows:

1.1.1 System 1

This system is for monitoring and controlling oxygen concentration in the combustion gases of a large-size boiler or heating furnace. 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).

Zirconia Oxygen Analyzer

Stop valve

Check valve

Reference gas

Calibration gas

Flowmeter

Needle

valve

Air Set

Instrument air Span gas

Non-hazardous Area

100 to 240 V AC

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

Figure 1.1 Example of System 1

Note: The installation temperature limits range for integrated type analyzer is -20 to 55°C. *1 Shield cable:

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

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

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

ZA8F

Flow Setting Unit

gas cannot be used as the zero gas.

Pressure

reducing

valve

Calibration gas

Zero gas cylinder

F1-1E.ai

IM 11M13A01-04E

1-2

<1. Overview>

1.1.2 System 2

This example, System 2, represents typical applications in large boilers and heating furnaces, where is a need to monitor and control oxygen concentration. Instrument air (clean, dry) is used as the reference gas and span gas for calibration. Zero gas is supplied from a gas cylinder.

System 2 uses the 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 analyzer that can be used to operate a purge gas valve to supply air to the sensor.

ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

Automatic

Calibration Unit

Reference gas

Span gas

Calibration gas (Zero)

Hazardous Area

Air Set

Instrument air

Pressure reducing

valve

Calibration gas unit case

Zero gas cylinder

Non-hazardous Area

100 to 240 V AC

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

Figure 1.2 Example of System 2

1.2 < EXAxt ZR > System Components

1.2.1 System Components

System Components

ZR202S Integrated type Zirconia Oxygen Analyzers

ZO21R Probe Protector for Zirconia Oxygen Analyzers ZO21S Standard Gas Unit

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

G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder

ZR202A Heater Assembly (Spare Parts for ZR202S)

: Items required for the above system example

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

( )

: Select either

F1-2E.ai

Integrated type

System configuration

Example 1

( )

Example 2

T1-1.ai

1.2.2 Oxygen Analyzer and Installation

Sample gas temperature 0 to 700ºC

Mounting Insertion length General-use Probe Application

Horizontal

vertical

IM 11M13A01-04E

0.4 to 2 m

Integrated type Analyzer (ZR202S)

Boiler, Heating furnace

  <2.Specications>

2. Specications

This chapter describes the specications for the following:

ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer (See Subsection 2.1.2)

ZO21R-L Probe Protector (See Subsection 2.1.3)

ZA8F Flow Setting Unit (See Subsection 2.2.1)

Automatic Calibration Unit (See Subsection 2.2.2)

ZO21S Standard Gas Unit (See Section 2.3)

Other equipments (See Section 2.4)

CAUTION

Requirements for explosion-proof use:

The ambient temperature is in the range of -20 to +55°C. The surface temperature of the ZR202S is not over the temperature class T2 (300°C)(*)

(*) The surface temperature of the amplier box does not exceed 70°C.

2-1

Oxygen concentration of sample/reference/calibration gas shall not exceed that found in normal air, typically 21 vol%.

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

and chlorine is present - Contact with YOKOGAWA and its agency.

Measurement System: Zirconia system

Measurement Range: 0.01 to 100 vol%O

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

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

or partial range

Digital Communication (HART): 250 to 550 Ω, 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

(in 1 vol%O2),

Warm-up Time: Approx. 20 min.

Explosion-proof Approval:

ATEX Flameproof: ZR202S-A;

Applicable Standard: EN 60079-0: 2012+A11: 2013, EN 60079-1: 2014,

EN 60079-31: 2014

Certicate Number: KEMA 04ATEX2156 X

Type of protection: Ex db IIB+H

T2 Gb, Ex tb IIIC T300°C Db

IM 11M13A01-04E

2-2

<2. Specications>

Eqipment Group: II Category: 2GD Temperature class for Ex “db”: T2

The maximum surface temperature for Ex “tb”: T300°C

Degree of protection of enclosure: IP66

NAME PLATE

MODEL : Specified model code SUFFIX : Specified suffix code STYLE : Style code AMB. TEMP : Ambient temperature NO. : Serial No. and year of production*

Yokogawa Electric Corporation : The manufacturer name Tokyo 180-8750 JAPAN : The manufacturer address*

No. KEMA 04ATEX2156 X Ex db IIB+H2 T2 Gb, Ex tb IIIC T300°C Db

FM Explosion-proof: ZR202S-B

Applicable Standard: FM3600 1998, FM3615 1989, FM3810 2005, ANSI/NEMA 250 1991 Type of protection: Explosion-proof for Class I, Division 1, Groups B, C and D Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure Rating: NEMA 4X Temperature Class: T2

CSA Explosion-proof: ZR202S-C

Applicable Standard: C22.2 No.0-M1991, C22.2 No.0.4-04, C22.2 No.0.5-1982,

Certicate Number: 1649642

Type of protection: Explosion-proof for Class I, Division 1, Groups B, C and D Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure: Type 4X Temperature Class: T2

The country of origin

*1: The third to seventh gure from the last shows the year of production.

e.g. 27D327560 2005.02

The year of production

*2: “180-8750” is a zip code which represents the following address.

2-9-32 Nakacho, Musashino-shi, Tokyo Japan

C22.2 No.25-1966, C22.2 No.30-M1986, C22.2 No.94-M91, C22.2-No.61010-1-04

IECEx Flameproof: ZR202S-D

IM 11M13A01-04E

Applicable Standard: IEC 60079-0: 2011, IEC 60079-1: 2014, IEC 60079-31: 2013

Certicate Number: IECEx KEM 06.0006X

Type of protection: Ex db IIB+H Temperature class for Ex “db”: T2 The maximum surface temperature for Ex “tb”: T300°C Degree of protection of enclosure: IP66

T2 Gb, Ex tb IIIC T300°C Db

  <2.Specications>

NAME PLATE

MODEL : Specified model code SUFFIX : Specified suffix code STYLE : Style code AMB. TEMP : Ambient temperature NO. : Serial No. and year of production* Yokogawa Electric Corporation : The manufacturer name Tokyo 180-8750 JAPAN : The manufacturer address*

2-3

No. IECEx KEM 06.0006X Ex db IIB+H2 T2 Gb, Ex tb IIIC T300°C Db

*1: The third to seventh gure from the last shows the year of production.

*2: “180-8750” is a zip code which represents the following address.

The country of origin

e.g. 27D327560 2005.02

The year of production

2-9-32 Nakacho, Musashino-shi, Tokyo Japan

Safety, EMC, and RoHS conformity standards

Installation altitude based on IEC 61010: 2000 m or less

Category based on IEC 61010: II (Note)

Pollution degree based on IEC 61010: 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.

Safety: Conforms to EN 61010-1, EN 61010-2-030, CAN/CSA-C22.2 No. 61010.1 certied,

UL Std. No. 61010-1 certied

EMC: Conforms to EN 61326-1*, Class A, Table 2,

EN 61326-2-3, EN 61000-3-2

*: Inuence of immunity environment (Criteria A ): ±20% of F. S.

EMC Regulatory Arrangement in Australia and New Zealand (RCM) EN61326-1 Class A

Korea Electromagnetic Conformity Standard

RoHS: EN 50581

CAUTION

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.

Repeatability: ± 0.5% Maximum value of set range; Range from 0 to 5 vol%O

less than 0 to 25 vol%O2 range

± 1 % Maximum value of set range; Range from 0 to 25 vol%O2 or more and

up to 0 to 100 vol%O

or more and

IM 11M13A01-04E

2-4

<2. Specications>

Linearity: (Excluding standard gas tolerance)

(Use oxygen of known concentration (with in the measuring range) as the zero and span calibration gases.) ± 1% Maximum value of set range; Range from 0 to 5 vol%O2 to 0 to 25

vol%O2. (Sample gas pressure: within ± 4.9 kPa)

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

less than 0 to 50 vol%O2. (Sample gas pressure: within ± 0.49 kPa)

± 5% Maximum value of set range; Range from 0 to 50 vol%O2 to 0 to 100

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

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

Both zero and span ± 2% Maximum value of range set/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 ZR202S Integrated type Explosion-proof 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. A ame arrestor may corrode if sample gas contains the following corrosive gases

under 380°C or over. Greater than 5000 ppm SO

Greater than 1000 ppm NO Greater than 50 ppm HCl

Sample Gas Pressure: -5 to +5 kPa

No pressure uctuation in the furnace should be allowed.

Oxygen concentration of sample gas:

For explosion-proof use, not more than that found in normal air, typically 21 vol%

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

Probe Material: 316 SS (JIS)

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

Storage Temperature: -30 to +70°C

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

Power Supply Voltage: Ratings; 100 to 240 V AC, Acceptable range; 85 to 264 V AC

Power Supply Frequency:

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

Reference Gas System: Instrument Air

IM 11M13A01-04E

Ratings; 50/60 Hz, Acceptable range; 45 to 66 Hz

  <2.Specications>

Instrument Air System:

Pressure; 50 kPa + the pressure inside the furnace

150 kPa + the pressure inside the furnace with automatic calibration unit or

check valve. (It is recommended to use air which has been dehumidied by

cooling to dew point -20°C or less, and dust or oil mist are removed.)

Consumption; Approx. 1.5 Nl/min

Oxygen concentration of calibration gas:

For explosion-proof use, not more than that found in normal air, typically 21 vol%

Wetted Material: 316 SS (JIS), Zirconia, 304 SS (JIS) (ange),

Hastelloy B, (Inconel 600, 601)

Construction: Heater and thermocouple replaceable construction. Equivalent to NEMA 4X/IP66

(Achieved when pipes are installed at calibration gas and reference gas inlets and exhaust pipe is installed so that reference gas can be exhausted to clean atmosphere. Excluding probe top.) (Achieved when the cable entry is completely sealed with a cable gland.)

Gas Connection: Rc 1/4 or 1/4 NPT(F)

Wiring Connection: ATEX: M20 by 1.5 mm, 1/2 NPT select one type (4 pieces)

FM: 1/2 NPT (4 pieces) CSA: 1/2 NPT (4 pieces) IECEx: M20 by 1.5 mm, 1/2 NPT select one type (4 pieces)

2-5

Installation: Flange mounting

Probe Mounting Angle: Horizontal to vertically downward.

Case: Aluminum alloy

Finish: Polyurethane corrosion-resistance coating

Weight: Insertion length of 0.4m: approx. 15 kg (ANSI 150 4)

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

Calibration Functions:

Insertion length of 1.0m: approx. 17 kg (ANSI 150 4) Insertion length of 1.5m: approx. 19 kg (ANSI 150 4) Insertion length of 2.0m: approx. 21 kg (ANSI 150 4)

status occurs.

Automatic Calibration; Requires the Automatic Calibration Unit. It calibrates

automatically at specied intervals.

Semi-automatic 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.

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

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

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

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

IM 11M13A01-04E

2-6

<2. Specications>

Display and setting content:

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

moisture quantify (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%O

), zero gas concentration (vol%O2),

calibration mode (automatic, semi-automatic, 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%

), time constant.

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

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)

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

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

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

in 1 vol%O2, or 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 30 V DC 3 A, 250 V AC 3 A (resistive load)

Contact Input: Two points, voltage-free contacts

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

IM 11M13A01-04E

One of the output points can be selected to either normally energized or normally de-energized status. Delayed functions (0 to 255 seconds) and hysteresis function (0 to 9.9 vol%O

) 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 answer-back, (9) Warm-up, (10) Calibration gas pressure decrease (answer-back of contact input), (11) Flameout gas detection (answer-back of contact input).

Contact output 2 is set to normally operated, xed error status.

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)

converter abnormal, digital circuit abnormal

  <2.Specications>

Calibration: Method; zero/span calibration

Calibration mode; Automatic, semi-automatic 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/23 hours

2-7

IM 11M13A01-04E

2-8

<2. Specications>

Model and Codes

Model Sufx code Option code Description

ZR202S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Integrated type Explosion-proof Zirconia Oxygen Analyzer

Explosionproof Approval (*13)

Length -040

Wetted material -S

Flange (*1)

Automatic Calibration -N

Reference gas -E - - - - - - - - - - External connection (Instrument air) (*8)

Gas Thread -R

Connection box thread -M

Instruction manual -E - - - - - - - - - - English

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

Options

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

*2 Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to700°C). *3 Specify either /CV or /SV option code. *4 Specify either /SCT or /PT option code. *5 No need to specify the option codes, /CV and /SV, since the check valves are provided with the Automatic Calibration Unit. *6 Sun shield hood is still effective even if scratched. Hood is necessary for outdoor installation out of sun shield roof. *7 Recommended if sample gas contains corrosive gas like chlorine.

*8 Piping for reference gas must be installed to supply reference gas constantly at a specied ow rate. *9 When selecting code -B (FM certied explosion-proof) or -C (CSA certied explosion-proof), select code -T(1/2 NPT). *10 Conrm inside diameter of pipe attached to customer’s ange in case that -A or -E is selected.

*11 The cable entry devices (cable glands etc.) and blind plugs shall be in type of protection Ex “db” or Ex “tb”, suitable for the

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

*13 When using ZR202S as CE marking compliance product, select -A (ATEX certied ameproof).

*14 "-Q" is the explosion-proof type of EAC with Pattern Approval for Russia. "-R" is the explosion-proof type of EAC for

-A

-B

-C

-D

-Q

-R

-070

-100

-150

-200

-C

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-R

-S

-W

-A

-B

NAMUR NE43 compliant

-T

Valves

Tag plates

- - - - - - - - - -

/C Inconel bolt (*2)

/CV /SV

/H Hood (*6)

/SCT /PT

/C2

/C3

ATEX certied ameproof (*11) FM certied explosion-proof CSA certied explosion-proof IECEx certied ameproof (*11) EAC with PA certied explosion-proof (*14) EAC certied explosion-proof (*14)

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m

SUS316 Stainless steel with Inconel calibration gas tube (*7)

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

Not required Horizontal mounting (*5) Vertical mounting (*5)

Rc 1/4 1/4 NPT (Female)

M20x1.5 mm 1/2NPT (*9)

Check valve (*3) Stop valve (*3)

Stainless steel tag plate (*4) Printed tag plate (*4)

Failure alarm down-scale: Output status at CPU failure and hardware error is 3.6 mA or less (*12) Failure alarm up-scale: Output status at CPU failure and hardware error is 21.0 mA or more (*12)

conditions of use and correctly installed. They shall provide a degree of ingress protection of at least IP66.

Kazakhstan and Belarus.

Standard Accessories

Item Parts No. Q'ty Description Item Parts No. Q'ty Description

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

IM 11M13A01-04E

  <2.Specications>

±3

348

±3

127

4 -

11.5

Unit : mm

• External Dimensions

ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzers

±2

±3

50.8 Ø

±3 52 Ø

tolerance (mm)L (m)

0.4

0.7

1.0

1.5

2.0

±5

±7

±8

±10

±12

256.5

FLANGE

Rc1/4 or 1/4 NPT (F) Reference Gas Inlet

±3

156

±3

±3 87

Ø±3123

±2

48.5

2-9

Unit : mm

±3

170

±3

122

Flange

ANSI Class 150 2 RF 304 SS (JIS) ANSI Class 150 3 RF304 SS (JIS) ANSI Class 150 4 RF 304 SS (JIS) DIN PN10 DN50 304 SS (JIS) DIN PN10 DN80 304 SS (JIS) DIN PN10 DN100 304 SS (JIS) JIS 5K 65 FF 304 SS (JIS) JIS 10K 65 FF 304 SS (JIS) JIS 10K 80 FF 304 SS (JIS) JIS 10K 100 FF 304 SS (JIS) JPI Class 150 4 RF 304 SS (JIS) JPI Class 150 3 RF 304 SS (JIS) Westinghouse

With sun shield hood (option code /H)

±2

Rc1/4 or 1/4 NPT (F) Calibration Gas Inlet

Rc1/4 or 1/4 NPT (F) Reference Gas Outlet

A B C

152.4

120.6

190.5

152.4

228.6

190.5

165

125

200

160

220

180

155

130

175

140

185

150

210

175

229

190.5

190

152.4

155

± 4 ± 3

274

4 - Ø19

4 -

8 -

4 -

8 -

4 -

4 8 -

8 8 -

4 -

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

±3

125

4-M20 ×1.5 or 4-1/2 NPT Cable Connection Port (Female)

n-Ø C

FLANGE

150

F2-1E.ai

± 3

150

F2-2E.ai

Material of hood : Aluminum

IM 11M13A01-04E

2-10

<2. Specications>

• External Dimensions

With Automatic Calibration Unit (Horizontal Mount)

156 ±3

348 ±3

AUTOMATIC CALIBRATION UNIT

Display Terminal box

244

Unit : mm

258

MAX44214

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

HORIZONTAL INSTALL

With Automatic Calibration Unit (Vertical Mount)

AUTOMATIC CALIBRATION UNIT

160

● ●

166.5

66.540

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

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

180

• Standard Accessories

Fuse A1113EF 1 3.15 A

Allen wrench L9827AB 1 For lock screw

IM 11M13A01-04E

66.540

MAX44

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

● ●

VERTICAL INSTALL

Item Parts. No. Q'ty Description

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

F2-3E.ai

  <2.Specications>

2.1.3 ZO21R Probe Protector

Used when sample gas ow velocity is approx. 10 m/sec or more and dust particles wears the detector in cases such as pulverized coal boiler of uidized bed furnace (or burner) to protect the

detector from wearing by dust particles.

Insertion Length: 1.05, 1.55, 2.05 m.

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

However, ange thickness is different.

Material: 316 SS (JIS), 304 SS (JIS) (Flange)

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

1.55 m; Approx. 9/13 kg (JIS/ANSI),

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

Installation: Bolts, nuts, and washers are provided for detector, probe protector and process-side

ange.

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.

-100

-150

-200

-A

- - - - - - - - - -

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

2-11

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

Gasket (Thickness 3.0)

ØA

Dimensions of holes on opposing surface

ØB

Gas flow

Washer (M12)

Mounting nut (M12)

316 SS (JIS)

Ø60.5

l (Insert length)

l=1050,1550,2050

Flange<1> A B C t D

JIS 5K 65 FF 304 SS (JIS) 155 130 4 - Ø15 5 40 ANSI Class 150 4 FF 304 SS (JIS) 228.6 190.5 8 - Ø19 12 50

Unit: mm

F2-4E.ai

IM 11M13A01-04E

2-12

<2. Specications>

2.2 ZA8F Flow Setting Unit

 ZA8F Flow Setting Unit

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

(System 1). Used when instrument air is provided.

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

reference gas.

Standard Specications

Construction: Dust-proof and rainproof construction

Case Material: SPCC (Cold rolled steel sheet)

FIowmeter Scale: Calibration gas; 0.1 to 1.0 Lmin.

Reference gas; 0.1 to 1.0 L/min.

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 kPaG

(or sample gas pressure plus approx. 150 kPaG when a check valve is used). Pressure at inlet of the Flow Setting Unit.(Maximum 300 kPaG)

Reference Gas Consumption: Approx. 1.5 L/min

Calibration Gas (zero gas, span gas) Consumption: Approx. 0.7 L/min (at calibration time only)

Weight: Approx. 2.3 kg

NOTE

Use instrument air for span calibration gas, if no instrument air is available, 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

IM 11M13A01-04E

  <2.Specications>

• External Dimensions

2-13

ø6 Hole

235.8

222.8

Calibration gas outlet

Reference gas outlet

REFERENCE CHECK

Span gas inlet

CHECK

REF

OUT

180

140

REFERENCE

SPAN

AIR

SPAN

Instrument air inlet

ZERO

Zero gas inlet

Piping connection port A

ZERO

2035

Model

ZA8F-J*C

ZA8F-A*C

Unit : mm

JIS 50A (60.5mm) mounting pipe

Piping connection port A

5 - Rc1/4

5 - 1/4 NPT

Weight : Approx. 2.3 kg

PIPNG INSIDE THE FLOW SETTING UNIT

CHECK OUT

Flowmeter Flowmeter

ZERO

GAS IN

SPAN

GAS IN

REF OUT

AIR IN

Air Set

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

Instrument air Approx. 1.5 L/min.

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IM 11M13A01-04E

2-14

<2. Specications>

2.3 ZO21S Standard Gas Unit

CAUTION

Standard Gas Unit (Model ZO21S) must not be located in hazardous area.

This is a handy unit to supply zero gas and span gas to the detector as calibration gas. It is used in combination with the detector only during calibration.

The ZO21S does not conform to CE marking.

Standard Specications

Function:

Sealed Zero Gas Cylinders (6 provided): E7050BA Capacity: 1 l Filled pressure: Approx. 686 kPaG (at 35°C) Composition: 0.95 to 1.0 vol%O Power Supply: 100, 110, 115, 200, 220, 240 V AC ±10%, 50/60 Hz Power Consumption: Max. 5 VA Case material: SPCC (cold rolled steel sheet) Paint Color: Mainframe; Munsell 2.0 GY3.1/0.5 equivalent

Piping: Ø6 х Ø4 mm exible tube connection Weight: Approx. 3 kg

Model and Codes

Model Sufx code Option code Description

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

Power supply

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

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.

2 + N2 balance

Cover; Munsell 2.8 GY6.4/0.9 equivalent

-2

-3

-4

-5

-7

-8

-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

Zero gas cylinder (6 cylinder): E7050BA

IM 11M13A01-04E

1600

354

228

253

Unit: mm

Flow checker Span gas valve

Zero gas valve Gas outlet

F2-6E.ai

  <2.Specications>

2.4 Other Equipment

2.4.1 Stop Valve (L9852CB, G7016XH)

This valve mounted on the calibration gas line in the system using ZA8F ow setting unit for manual

calibration.

Standard Specications

Material: 316 SS (JIS)

Connection: Rc 1/4 or 1/4 FNPT

Weight: Approx. 200 g

Part No. Description

L9852CB Joint: Rc 1/4, Material: 316 SS (JIS)

G7016XH Joint: 1/4 FNPT, Material: 316 SS (JIS)

Unit : mm

2-15

Analyzer

Approx. 100

Nipple G7209XA 2-Rc1/4 K9470ZN 2-1/4NPT

Ø48

2.4.2 Check Valve (K9292DN, K9292DS)

This valve is mounted on the calibration gas line (directly connected to the detector). This valve prevents the sample gas from entering the calibration gas line. Although it functions as a stop valve, operation is easier than a stop valve as it does not require opening/closing at each calibration. Screw a check valve, instead of a stop valve into the calibration gas inlet of the detector.

Standard Specications

Material: 304 SS (JIS)

(Full open length) L9852CB 2-Rc1/4 G7016XH 2-1/4NPT

F2-7.1E.ai

Connection: Rc1/4 or 1/4 FNPT

Pressure: 150 kPaG or more and 350 kPaG or less

Weight: Approx. 90 g

Part No. Description

K9292DN Joint: Rc 1/4, Material: 304 SS (JIS) K9292DS Joint: 1/4 FNPT, Material: 304 SS (JIS)

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

Approx. 19

Approx. 54

Unit: mm

F2-8E.ai

IM 11M13A01-04E

2-16

<2. Specications>

2.4.3 Air Set

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

Standard Specications

• G7003XF, K9473XK

Primary Pressure: Max. 1 MPaG

Secondary Pressure: 0.02 to 0.2 MPaG

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

Weight: Approx.1 kg

Part No. Description

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

K9473XK Joint: 1/4 FNPT (with joint adapter), Material: Zinc alloy, Adapter: 316 SS (JIS)

• G7004XF, K9473XG

Primary Pressure: Max. 1 MPaG

Secondary Pressure: 0.02 to 0.5 MPaG

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

Weight: Approx. 1 kg

Part No. Description

G7004XF Joint: Rc 1/4, Material: Zinc alloy K9473XG Joint: 1/4 FNPT (with joint adapter), Material: Zinc alloy, Adapter: 316 SS (JIS)

External Dimensions

Panel cut dimensions

Horizontal mounting

ø15

+0.5

-0

2-ø2.2

Ø74

Vertical mounting

2-ø6.5

max. 55

Secondary pressure gauge

Unit : mm

View A

2-ø6 screw depth 8

Panel (Horizontal mounting)

Panel (Vertical mounting)

IM 11M13A01-04E

Primary

Secondary

Max. 210

Approx. 122

G7003XF, G7004XF: Rc 1/4 K9473XK, K9473XG: 1/4 FNPT (with joint adapter)

F2-9E.ai

  <2.Specications>

2.4.4 Pressure Reducing Valve for Gas Cylinder (G7013XF, G7014XF)

This pressure reducing 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 1/4 FNPT

Material: Brass body

Secondary pressure gauge Primary pressure gauge

2-17

Unit : mm

Reducing valve handle

Approx.112

Approx. 59

Approx. 163

2.4.5 ZR202A Heater Assembly

Model and Codes

Model Sufx code Option code Description

ZR202A - - - - - - - - - - - - - - - - - - - - Heater Assembly for ZR202S

Length (*1) -040

Jig for change -A

— -A - - - - - - - - - - - Always-A

*1 Sufx code of length should be selected as same as ZR202S installed.

(Note) The heater is made of ceramic, do not drop or subject it to pressure stress.

-070

-100

-150

-200

-N

- - - - - - - - - - -

* Outlet

Primary safety valve

Part No.

G7013XF G7014XF

0.4 m

0.7 m 1 m

1.5 m 2 m

with Jig None

Stop valve

Approx. 174

* Outlet Rc1/4 1/4 NPT female with adapter

W22 (Right hand screw)

Secondary safety valve

Approx. 82

F2-10E.ai

Inlet

IM 11M13A01-04E

2-18

<2. Specications>

External Dimensions

Ø 45

Jig for change

(K9470BX)

Model & Codes

ZR202A-040

ZR202A-070

ZR202A-100

ZR202A-150

ZR202A-200

Ø21.7

552

852

1152

1652

2152

K9470BX

Weight (kg)

Approx. 0.8

Approx. 1.2

Approx. 1.6

Approx. 2.2

Approx. 2.8

Unit : mm

L±12

F2-11E.ai

IM 11M13A01-04E

<3. Installation>

3. Installation

This chapter describes installation of the following equipment:

3.1 Model ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

3.2 Model ZA8F Flow Setting Unit

3.3 Case Assembly (E7044KF) for Calibration gas Cylinder

3.1 Installation of ZR202S Zirconia Oxygen Analyzer

3.1.1 Installation Location

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

(1) Easy and safe access to the analyzer 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) A clean environment without any corrosive gases.

3-1

(4) No vibration.

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

(6) No sample gas pressure uctuations.

CAUTION

• The ambient temperature of the ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer should be between - 20°C and 55°C.

IM 11M13A01-04E

3-2

<3. Installation>

3.1.2 ATEX Flameproof Type

ZR202S–A Analyzer for use in hazardous area:

Note 1: Applicable Standard: EN 60079-0: 2012+A11: 2013, EN 60079-1: 2014,

Certicate Number: KEMA 04ATEX2156 X

The symbol “X” placed after certicate number indicates that the equipment is subjected to

Type of protection: Ex db IIB+H2 T2 Gb, Ex tb IIIC T300°C Db

Equipmant Group: II

Category: 2GD

Temperature class for Ex “db”: T2

The maximum surface temperature for Ex “tb”: T300°C

Degree of protection of enclosure: IP66

Note 2: Wiring

• All wiring shall comply with local installation requirement.

Note 3: Operation

EN 60079-31: 2014

special conditions for safe use. Refer to Note 6.

• Keep to “WARNING” on the Analyzer.

WARNING: DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE IS PRESENT

POTENTIAL ELECTROSTATIC CHARGING HAZARD-READ USER’S MANUAL (IM11M13A01-04) FOR INSTALLATION AND SAFE USE, READ IM11M13A01-04 USE AT LEAST 80°C HEAT RESISTANT CABLES & CABLE GLANDS

• Take care not to generate mechanical sparking when accessing to the analyzer and peripheral devices in hazardous area.

Note 4: Maintenance and Repair

• The analyzer modication or parts replacement by other than authorized representative of Yokogawa Electric Corporation is prohibited and will void the certication.

Note 5: Cable Entry

• The threaded type of cable entry is marked beside the cable entry according to the following markings.

Threaded type : Marking

M20x1.5 : M

1/2 NPT : N

• The cable entry devices (cable glands etc.) and blind plugs shall be in type of protection Ex “db” or Ex “tb”, suitable for the conditions of use and correctly installed. They shall provide a degree of ingress protection of at least IP66.

Note 6: Special conditions for safe use

IM 11M13A01-04E

Electrostatic charge may cause an explosion hazard. Avoid any actions that cause the generation of electrostatic charge, such as rubbing with a dry cloth.

If it is mounted in the area where the use of Ex “tb” apparatus is required, it shall be installed in such a way that the risk from electrostatic discharges and propagating brush discharges caused by rapid

ow of dust is avoided.

<3. Installation>

Note 7: Special fastener

Hexagon socket head cap screws below are special fastener according to EN60079-0: 2012+A11:

2013 (see the gure below). Material property classes of them are A2-50 or better.

Special fastener

Figure 3.1 Special fastener

3.1.3 FM Explosion-proof Type

3-3

ZR202S–B Analyzer for use in hazardous area:

Note 1: Applicable Standard: FM3600 1998, FM3615 1989, FM3810 2005, ANSI/NEMA 250 1991

Type of protection: Explosion-proof for Class I, Division 1, Groups B, C and D

Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G

Enclosure Rating: NEMA 4X

Temperature Class: T2

Note 2: Wiring

• All wiring shall comply with National Electrical Code ANSI/NEPA 70 and Local Electrical Code.

• In hazardous area, wiring shall be in conduits as shown in the gure.

WARNING: SEAL ALL CONDUITS WITHIN 18 INCHES OF THE ENCLOSURE.

Hazardous Area Division 1

Non-hazardous Area

18 inches (475mm) MAX.

Non-hazardous Area

Conduit

Figure 3.2 Wiring of ZR202S-B

Sealing Fitting

F3-1E.ai

IM 11M13A01-04E

3-4

<3. Installation>

Note 3: Operation

• Keep the “WARNING” label to the Analyzer.

WARNING: OPEN CIRCUIT BEFORE REMOVING COVER. INSTALL IN

ACCORDANCE WITH THE INSTRUCTION MANUAL IM 11M13A01–04E. USE AT LEAST 80°C HEAT RESISTANT CABLES.

• Take care not to generate mechanical sparking when accessing to the analyzer and peripheral devices in hazardous area.

Note 4: Maintenance and Repair

• The analyzer modication or parts replacement by other than authorized representative of

Yokogawa Electric Corporation is prohibited and will void Factory Mutual Explosion-proof Approval.

3.1.4 CSA Explosion-proof Type

ZR202S–C Analyzer for use in hazardous area:

Note 1: Applicable Standard: C22.2 No.0-M1991, C22.2 No.0.4-04, C22.2 No.0.5-1982,

C22.2 No.25-1966, C22.2 No.30-M1986, C22.2 No.94-M91, C22.2-No.61010-1-04

Certicate Number: 1649642

Type of protection: Explosion-proof for Class I, Division 1, Groups B, C and D

Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G

Enclosure: Type 4X

Temperature Class: T2

Note 2: Wiring

• All wiring shall comply with Canadian Electrical Code Part 1 and Local Electrical Code.

• In hazardous area, wiring shall be in conduits as shown in the gure.

WARNING: SEAL ALL CONDUITS WITHIN 50 cm OF THE ENCLOSURE.

UN SELLE DOIT ÊTRE INSTALLÊ Á MOINS DE 50 cm DU BîTIER.

Hazardous Area Division 1

Non-hazardous Area

50cm MAX.

Conduit

50cm MAX.

Sealing Fitting

Non-hazardous Area

Figure 3.3 Wiring of ZR202S-C

IM 11M13A01-04E

F3-2E.ai

<3. Installation>

Note 3: Operation

• Keep the “WARNING” label to the Analyzer.

WARNING: OPEN CIRCUIT BEFORE REMOVING COVER. REFER TO

IM 11M13A01–04E. USE AT LEAST 80°C HEAT RESISTANT CABLES.

OUVRIR LE CIRCUIT AVANT D’ENLEVER LE COUVERCLE. UTILISEZ DES CÁBLES RÊSISTANTS Á 80°C MINIMUM. VEUILLEZ VOUS RÊFÊRER AU IM 11M13A01–04E.

• Take care not to generate mechanical sparking when accessing to the analyzer and peripheral devices in hazardous area.

Note 4: Maintenance and Repair

• The analyzer modication or parts replacement by other than authorized representative of

Yokogawa Electric Corporation is prohibited and will void Canadian Standards Explosion-proof

Certication.

3.1.5 IECEx Flameproof Type

ZR202S–D Analyzer for use in hazardous area:

Note 1: IECEx ameproof type

Applicable Standard: IEC 60079-0: 2011, IEC 60079-1: 2014, IEC 60079-31: 2013

3-5

Certicate Number: IECEx KEM 06.0006X

The symbol “X” placed after certicate number indicates that the equipment is subjected to

special conditions for safe use. Refer to Note 6.

Type of protection: Ex db IIB + H2 Gb, Ex tb IIIC T300ºC Db

Temperature class for Ex “db”: T2

The maximum surface temperature for Ex “tb”: T300ºC

Degree of protection of enclosure: IP66

Note 2: Wiring

• All wiring shall comply with local installation requirement.

Note 3: Operation

• Keep to “WARNING” on the Analyzer.

WARNING: DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE IS PRESENT

POTENTIAL ELECTROSTATIC CHARGING HAZARD-READ USER’S MANUAL (IM11M13A01-04) FOR INSTALLATION AND SAFE USE, READ IM11M13A01-04 USE AT LEAST 80ºC HEAT RESISTANT CABLES & CABLE GLANDS

• Take care not to generate mechanical sparking when accessing to the analyzer and peripheral devices in hazardous area.

Note 4: Maintenance and Repair

• The analyzer modication or parts replacement by other than authorized representative of Yokogawa Electric Corporation is prohibited and will void the certication.

IM 11M13A01-04E

3-6

<3. Installation>

Note 5: Cable Entry

• The threaded type of cable entry is marked beside the cable entry according to the following markings.

Threaded type : Marking

M20x1.5 : M 1/2 NPT : N

• In case of ANSI 1/2 NPT plug, ANSI hexagonal wrench should be applied to screw in.

Note 6: Special conditions for safe use

Electrostatic charge may cause an explosion hazard. Avoid any actions that cause the generation of electrostatic charge, such as rubbing with a dry cloth.

ow of dust is avoided.

Note 7: Special fastener

Hexagon socket head cap screws below are special fastener according to IEC 60079-0: 2011 (see

the gure below). Material property classes of them are A2-50 or better.

Special fastener

Figure 3.4 Special fastener

IM 11M13A01-04E

<3. Installation>

3.1.6 Probe (Detector) Insertion Hole

CAUTION

• The outside dimension of the probe may vary depending on its options. Use a pipe that is large enough for the probe. Refer to Subsection 2.1.2 for the dimensions.

• If the probe is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards.

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

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

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

downstream.

3-7

(vertical)

100 mm

Bounds of the probe insertion hole area

Flange matches the detector size

(horizontal)

100 mm

Figure 3.5 Example of forming probe insertion hole

3.1.7 Installation of the Probe (Detector)

CAUTION

*1 Type Outside diameter of probe Standard 52 mm in diameter With probe protector 60.5 mm in diameter

Four-hole flange Eight-hole flange

F3-3E.ai

• The cell (sensor) at the tip of the probe is made of ceramic (zirconia). Do not drop the probe, 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.

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

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

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

should face downward.

IM 11M13A01-04E

3-8

<3. Installation>

3.1.8 Installation of the Probe Protector (ZO21R)

The probe of the analyzer 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/s (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) When the probe is mounted horizontally, the calibration gas and reference gas inlet should face

downward.

1050, 1550, 2050

Direction of the sample gas flow

Probe top

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

Gasket (t1.5)

Figure 3.6 Mounting of probe with a probe protector (Dust wear protect)

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 analyzer

(3) No corrosive gas.

Unit: mm

Calibration gas inlet Reference gas inlet

F3-4E.ai

IM 11M13A01-04E

(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.

<3. Installation>

3.2.2 Mounting of ZA8F Flow Setting Unit

The ow setting unit can be mounted either on a pipe (nominal JIS 50A) 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.

3-9

F3.5E.ai

Figure 3.7 Pipe Mounting

(1) Make a hole in the wall as illustrated in Figure 3.8.

Unit: mm

223

140

4 - Ø6 hole, or M5 screw

F3-6E.ai

Figure 3.8 Mounting holes

(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 3.9 Wall mounting

F3-7E.ai

IM 11M13A01-04E

3-10

<3. Installation>

3.3 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 analyzer.

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 arrestor between the terminal and ground is low.

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

Contact input 1

Insulation

resistance

tester

DI-1

Contact input 2

DI-2

(+)

Crossover wiring

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

(-)

Crossover wiring

Remove jumper plate

Figure 3.10 Insulation Resistance Test

IM 11M13A01-04E

Insulation resistance

tester

Insulation

resistance

tester

F3-8E.ai

<4. Piping>

CAUTION

4. Piping

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

Integrated type Explosion-proof Zirconia Oxygen Analyzer.

• Ensure that each check valve, stop valve and joints used for piping are not leaking. Especially, if 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 by cooling to the dew point -20°C or lower, and

removing any dust, oil mist and the like) for the reference gas.

Do not loosen or remove any Flame Arrestor of gas inlet/outlet during piping.

The detector modication or parts replacement by other than authorized representative of Yokogawa Electric Corporation is prohibited and will void ATEX Certication, FM Approval, CSA Certication and IECEx Certication.

4-1

Flame Arrestor

F4-0E.ai

IM 11M13A01-04E 3rd Edition : Dec.15,2014-00

4-2

<4. Piping>

4.1 Piping for System 1

The piping in System 1 is illustrated in Figure 4.1

ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

Stop valve

Check valve

Reference gas

Calibration gas

ZA8F

Needle

valve

Flowmeter

Flow Setting Unit

Hazardous Area

Air Set

Instrument air Span gas

Pressure

reducing

valve

Calibration gas unit case

Zero gas cylinder

Non-hazardous Area

Figure 4.1 Piping for System 1

Piping in System 1 is as follows:

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

100 to 240 V AC

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

F4-1E.ai

4.1.1 Piping Parts for System 1

Referring to Table 4.1, check that the parts required for your system are ready.

Table 4.1 Piping Parts

Equipment Piping location Parts Name Description

Integrated type Explosion-proof Zirconia Oxygen Analyzer

Note: Parts with marking * are used when required. General parts can be found on the local market.

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 * R1/4 or 1/4 NPT General parts Zero gas cylinder User’s scope Pressure reducing valve (G7013XF or G7014XF) recommended by

YOKOGAWA Joint for tube connection * R1/4 or 1/4 NPT General parts

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

recommended by YOKOGAWA Joint for tube connection * R1/4 or 1/4 NPT General parts

IM 11M13A01-04E 3rd Edition : Dec.15,2014-00

<4. Piping>

4.1.2 Piping for the Calibration Gas Inlet

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 ZR202S analyzer.

The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature may not exceed 40°C. Mount the pressure reducing valve (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 4.2. (The stop valve or the check valve may have been mounted on the equipment when shipped.)

Connect the ZA8F ow setting unit and the ZR202S analyzer to a 6 mm (O.D.) x 4 mm (I.D.) (or

nominal size 1/4 inches) or larger stainless steel pipe.

Piping for the reference gas outlet 6mm (O.D.) by 4mm (I.D.)

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

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

Stop valve or check valve

Stainless steel pipe

4-3

Figure 4.2 Piping for the Calibration Gas Inlet

4.1.3 Piping for the Reference Gas Inlet

Reference gas piping is required between the air source (instrument air) and the ZA8F ow setting unit, and between the ow setting unit and the ZR202S 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 6 mm (O.D.) x 4 mm (I.D.) (or nominal size 1/4 inch) stainless steel pipe between the ow

setting unit and the analyzer.

4.1.4 Piping for the Reference Gas Outlet

If the ZR202S is exposed to rain or water splash, connect the pipe outlet on downward.

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IM 11M13A01-04E 3rd Edition : Dec.15,2014-00

4-4

<4. Piping>

4.2 Piping for System 2

Piping in System 2 is illustrated in Figure 4.3. In System 2, calibration is automated; however, the piping is basically the same as that of System 1. Refer to Section 4.1.

Adjust secondary pressure of both the air set and the zero gas pressure reducing valve 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 the calibration contact output (see Sec. 7.9.2), and adjust zero gas pressure reducing valve 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.

ZR202S Integrated type Explosion-proof

Hazardous Area

Zirconia Oxygen Analyzer

Automatic

Calibration Unit

Reference gas

Span gas

Calibration gas (Zero)

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

Air Set

Pressure

reducing

valve

Calibration gas unit case

Figure 4.3 Piping for System 2

Instrument air

Zero gas cylinder

Non-hazardous Area

100 to 240 V AC

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

F4-3E.ai

IM 11M13A01-04E 3rd Edition : Dec.15,2014-00

<4. Piping>

Automatic Calibration Unit

• Installation of Automatic Calibration Unit

Horizontal mounting on the ZR202S (-A)

AUTOMATIC CALIBRATION UNIT

Display

Terminal box

244

Unit: mm

258

4-5

214

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

MAX44

HORIZONTAL INSTALL

Vertical mounting on the ZR202S (-B)

AUTOMATIC CALIBRATION UNIT

180 MAX44

● ●

166.5

160

406066.540

● ●

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

Zero gas inlet

66.540 Rc1/4 or 1/4NPT(Female)

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

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

F4-4E.ai

Piping Diagram

Calibration gas

Reference gas

Check

valve

ZR202S body

Span gas solenoid valve

Zero gas solenoid valve

Span gas flowmeter

Reference gas flowmeter

Needle valve

Zero gas flowmeter

SPAN IN

To Air set

REF. IN

To Zero gas cylinder

ZERO IN

F4-5E.ai

IM 11M13A01-04E 3rd Edition : Dec.15,2014-00

<5. Wiring>

5. Wiring

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

5.1 General

CAUTION

Be sure to read Subsections 3.1.2 to 3.1.5 where the important information on wiring is provided.

CAUTION

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

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

5-1

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

2. Use an external switch or circuit breaker rated 5 A 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 analyzer Name Need for shields Number of wires

L, N, AO+, AO- Analog output Ο 2 DO-1, DO-2 Contact output 2 to 8 DI-1, DI-2, DI-C Contact input 3

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

Power supply 2 or 3 *

IM 11M13A01-04E

5-2

WARNING

<5. Wiring>

Cables that withstand temperatures at least 80°C should be used for wiring.

NOTE

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

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

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.

2CDO-2 DO-1 1

F FG

L NFG

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Figure 5.1 Terminals for External Wiring

IM 11M13A01-04E

<5. 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) Contact input

5-3

Contact input 1

Contact input 2

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

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: 100 Ω or less.

(+)

Analog output 4-20 mA DC Digital output

Contact output 1

(-)

100 to 240 V AC, 50 or 60 Hz

Figure 5.2 Wiring Connection

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.

Contact output 2

13 G

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

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

Figure 5.3 Cable Gland Mounting

M20 x1.5, 1/2 NPT or the like (Wiring connection)

Unit: mm

Cable gland

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IM 11M13A01-04E

5-4

<5. Wiring>

5.2 Wiring for Analog Output

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

resistance including the wiring resistance of 550 Ω or less.

Analyzer

AO(+)

AO(

Shielded cables

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.

Receiver

F5-4E.ai

CAUTION

• 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 11M13A01-04E

<5. Wiring>

5.3 Wiring Power and Ground Terminals

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

Ground

5-5

Grounding to the earth terminal on the equipment case

Equipment case

Crimp on terminal of the ground wire

Grounding terminal

Lock washer

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 a three-core cable.

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

screws for cable connections.

1 2 C DO DODI1 2

100~240 V AC 50/60 Hz

+AO

FGL N GFG

Jumper plate

F5-5E.ai

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 (M5) or the terminal inside of the equipment (M4). Proceed as follows:

(1) Keep the ground resistance of 100 Ω or less (JIS D style (Class 3) 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 M5.

Each cable should be terminated corresponding crimp-on terminals.

(5) No intermediate parts are used for the ground terminal inside of the equipment. Use crimping

terminal for connection to the ground terminal inside of the equipment in order to avoid corrosion by high contact potentials.

(6) In order to prevent the earthing conductor from loosening, the conductor must be secured to the

terminal, tightening the screw with torque of approx. 1.2 N•m (for M4) or 2.0 N•m (for M5).

(7) Care must be taken not to twist the conductor.

IM 11M13A01-04E

5-6

<5. Wiring>

5.4 Wiring for Contact Output

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

Do the contact output wiring according to the following requirements.

Hazardous Area

Analyzer

DO-1

DO-2

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

(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.

Non-hazardous Area

Terminal Box

Annunciator or the like

#1 Output

#2 Output

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5.5 Wiring for Contact Input

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

To use these contact signals, proceed wiring as follows:

Hazardous Area

Analyzer Terminal box

DI-1

DI-2

DI-C

Figure 5.7 Contact Input Wiring

5.5.1 Cable Specications

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

Non-hazardous Area

Contact input 1

Contact input 2

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IM 11M13A01-04E

<5. Wiring>

5.5.2 Wiring Procedure

(1) M4 screws are used for the terminal of the analyzer. 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

Closed Open

Resistance 200 Ω or less 100 kΩ or more

5-7

IM 11M13A01-04E

Blank Page

<6. Components>

Terminal box,

Flame arrestor assembly mounting screw

Flame arrestor assembly

6. Components

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

6.1 ZR202S Zirconia Oxygen Analyzer

 Integrated type Explosion-proof Zirconia Oxygen Analyzer

Explosion-proof

Flame arrestor assembly

6-1

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

Screw

Bolt

Pipe support

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

1.0, 1.5, 2.0 m.

U-shaped pipe

Washer

Calibration gas pipe opening

Contact

Metal O-ring

Sensor (cell)

Filter

Figure 6.1 Integrated type Explosion-proof Zirconia Oxygen Analyzer

Probe

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IM 11M13A01-04E

6-2

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Flowmeter for Span gas

Horizontal

Vertical

<6. Components>

6.2 ZA8F Flow Setting Unit, Automatic Calibration Unit

Reference gas flow setting valve

Span gas flow setting valve

Zero gas flow setting valve

Flowmeter for reference gas

Flowmeter for calibration gas

Figure 6.2 ZA8F Flow Setting Unit

mounting

Flowmeter for Reference gas

Flowmeter for Zero gas

Span gas

ZERO INREF INSPAN IN ZERO INREF INSPAN IN

flow setting valve

Flowmeter for Span gas

Span gas flow setting valve

mounting

Flowmeter for Reference gas

F6-2E.ai

Flowmeter for Zero gas

Zero gas flow setting valve

Figure 6.3 Automatic Calibration Unit

IM 11M13A01-04E

Span gas flow setting valve

Reference gas flow setting valve

<7. Startup>

7. Startup

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

to analog output conrmation to manual calibration.

7-1

Check piping and wiring connections

Set up valves

Supply power

Confirm equipment type setting

Select gas to be measured

Set output ranges

Check current loop

Check contact action

Calibrate analyzer

Set detailed data

Place in normal operation

F7-1E.ai

Figure 7.1 Startup Procedure

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

IM 11M13A01-04E

7-2

<7. Startup>

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 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) is obtained. Turn the reference gas ow setting valve in the ZA8F 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.

NOTE

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

unit.

7.3 Supplying Power to Analyzer

CAUTION

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 analyzer. A display as in Figure 7.2, 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 analyzer is in the measurement mode. The display panel then displays the oxygen concentration as in Figure 7.3. This is called the basic panel display.

F7-2E.ai

Figure 7.2 Display of Sensor Temperature Figure 7.3 Measurement Mode Display

While Warming Up

F7-3E.ai

IM 11M13A01-04E

<7. Startup>

7.4 Operation of Infrared Switch

7.4.1 Display and Switches

This equipment uses an infrared switch that enables operation with the cover closed. Figure 7.4 shows the infrared switch and the display. Table 7.1 shows the three switch (keys) and functions.

4: Decimal point

7-3

1: Data display area

2: Infrared switch

F7-4E.ai

3: Engineering-unit display area

µMmNkgalbbl % scftm3 /d /s /h /m

ENT

Figure 7.4 Infrared switch and the display

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

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 11M13A01-04E

7-4

<7. Startup>

CAUTION

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 7.5 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 Subsection 7.4.3.

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

Basic panel display

Password entry display

Group A setup display

Group B setup display

Group C setup display

Group D setup display

Parameter code selection display

Figure 7.5 Display Conguration

IM 11M13A01-04E

Group E setup display

Group F setup display

Group G setup display

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<7. Startup>

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 contact inputs and contact outputs. 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 subsection 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.

Table7.3 Parameter Code Selection

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.

IM 11M13A01-04E

7-6

<7. Startup>

CAUTION

• 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.

7.4.4 Selecting Parameter Codes

Table7.4 Parameter Code

Switch operation Display Description

> ∧

ENT

A01

Password has been entered and the parameter code selection display has

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

> ∧

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

ENT

ENT Set

A01

b01

C01

d01

Value

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 value to 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.

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.

IM 11M13A01-04E

<7. Startup>

7.4.5 Changing Set Values

(1) Selecting numeric values from among preset values

Switch operation Display Description

> ∧

ENT

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.

7-7

> ∧

(2) Entering numeric values such as oxygen concentration values and factors

Switch operation Display Description

> ∧

ENT

C01

00.0

09.0

09.8

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

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

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 to 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.

Touch the [∧] key to set the numeric value to 8.

> ∧

(3) If invalid numeric values are entered.

Switch operation Display Description

> ∧

ENT

09.8

C11

98.0

Err

00.0

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.

IM 11M13A01-04E

7-8

<7. Startup>

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.

CAUTION

Note that if the equipment type is changed, operation data that have already been set are initialized (reverting to the default setting).

Table 7.5 Equipment 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 values indicate the measurement gas concentration.)

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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 7.6 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.

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 Setting”, later in this manual.

 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. Startup>

Table 7.7 Minimum and Maximum Current Setting Procedure

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

> ∧

ENT

C01

C11

000

010

C11

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 to 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.

> ∧

ENT

ENT Basic

C11

C12

025

020

C12

panel 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 to 2.

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 values 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>

7.8 Checking Current Loop

The set current can be output as an analog output. This enables the checking of wiring between the analyzer and the receiving instrument. Current loop checking is performed using parameter code [G01].

Table 7.8 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 current output remains preset with the output-hold feature (Section 2.3).

Touch the [∧] key to set the numeric value to 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 current output 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 7.9 Parameter Codes for Checking Contact I/O

Check item Parameter code Set value and contact

Contact output 1 G11 0 Open

Contact output 2 G12 0 Open

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

G16 0 Off

action

1 Closed

1 On

1 Closed

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<7. Startup>

7.9.1 Checking Contact Output

Follow Table 7.10 to check the contact output. The table uses an example with contact output 1.

Table 7.10 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 output 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 output will be

closed.

Touch the [ENT] key once again to switch to the parameter code selection display. The contact output then returns to the original state.

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

CAUTION

• If you conduct an open-close check for the contact output 2, Err-01 (cell voltage failure) or Err02 (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).

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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 7.11. The table uses an example with a zero gas solenoid valve.

Table 7.11 Checking Calibration Contact Output

Switch operation Display Description

> ∧

ENT

A01

Display after the password has been entered.

7-13

> ∧

ENT

G01

G11

G15

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.

> ∧

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

ENT

ENT Basic

G15

panel display

Touch the [ENT] key once again to switch to the parameter code selection display. The solenoid valve will then be closed.

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<7. Startup>

7.9.3 Checking Contact Input

Follow Table 7.12 to check the contact input. The table uses an example with contact input 1.

Table 7.12 Checking Contact Input

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 input open. If the contact input

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 the parameter code selection display.

Touch the [>] key together with the [ENT] key to return to the basic panel display.

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<7. Startup>

7.10 Calibration

The analyzer 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 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 7.13.

(1) Mode setting

There are three calibration modes: manual, semi-automatic, and automatic. Select the desired mode. This section uses manual mode for calibration.

7-15

(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%

. 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.

CAUTION

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 7.13 Calibration Parameter Codes

Set item Parameter code Set value

Calibration mode B03 0 Manual calibration

1 Semi-automatic, Manual calibration

2 Automatic, Semi-automatic, Manual calibration Zero gas oxygen concentration B01 Enter oxygen concentration. Span gas oxygen concentration B02 Enter oxygen concentration.

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<7. Startup>

Table 7.14 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.

> ∧

Set the span gas concentration by above procedure, set 21%.

> ∧

ENT

ENT Basic panel

000.98

b01

b03

display

Touch the [ENT] key again to stop the ashing.

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 (manual calibration), 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.

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

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<7. Startup>

7.10.2 Manual Calibration

The following describes how to conduct a calibration.

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 reducing value 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).

Calibration Implementation

This manual assumes that the instrument air is the same as the reference gas used for the span gas. Follow the steps below to conduct manual calibration. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.

Table 7.15 Conducting Calibration

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 Subsection 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.

Continue to the next page

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<7. Startup>

Switch operation Display Description

> ∧

ENT

ZEro Y

0.98

OPEn

/0.89

0.89

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 Subsection 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.

> ∧

The above “display” is a result of switch operations.

The symbol [

“/” indicates that the characters are displayed alternately.

[Cancel] indicates the procedure to stop the key operations.

ENT

ENT Basic

] indicates the keys are being touched, and the light characters indicate “ashing.”

CALEnd

b10

panel display

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 zero 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.

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<8. Detailed Data Setting>

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

CAUTION

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

1 4 mA (xed *1) 2 4 mA (xed *1)

Output mode C03 0 Linear

1 Logarithm 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.

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<8. Detailed Data Setting>

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%O

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%O

, 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%O

, 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.)

CAUTION

• 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 analyzer 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 current output settings are by default as shown in Table 8.3.

Table 8.3 Current Output Default Values

Item Default setting

Min. oxygen concentration Max. oxygen concentration Output damping constant 0 (seconds) Output mode Linear

0% 25%

CAUTION

IM 11M13A01-04E

• 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

Equipment

status

Output hold values available

4 mA O 20 mA O Without hold feature O O O Retains output from just

before occurrence Preset 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

O O O

During maintenance

O O O

During calibration During error

8-3

occurrence (*1)

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

(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.

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8-4

<8. Detailed Data Setting>

Switch operation Display

> ∧

ENT

b10

> ∧

ENT

CAL

SPAn Y

21.00

OPEn/20.84

20.84

ZEro Y

0.98

OPEn/0.89

Output hold time during calibration

> ∧

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 Err-01 to Err-04 are being issued

ENT

0.89

CALEnd

b10

Basic panel display

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<8. Detailed Data Setting>

8.3.2 Preference Order of Output Hold Value

The output hold value takes the following preference order:

During error occurrence

During calibration

Preference order (high)

During maintenance

During warm-up

8.3.2E.siki

For example, if the current output 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 During maintenance Holds output at value just before maintenance started 4 mA During calibration Holds output at value just before starting calibration 4 mA During error occurrence Holds output at a preset value 3.4 mA

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8-6

<8. Detailed Data Setting>

8.4 Oxygen Concentration Alarms Setting

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 Setting the 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%O2.

(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 be set in the range of 0 to 100%O

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.

Alarm range

Hysteresis

2.0%

7.5%

High limit alarm setpoint

5.5%

Alarm output

Figure 8.2 Alarm Output Action

IM 11M13A01-04E

Oxygen concentration

ON OFF

Delayed time: 5 seconds

F8-2E.ai

<8. Detailed Data Setting>

In the example in Figure 8.2, the high alarm point is set to 7.5vol%O2, the delayed time is set to ve seconds, and hysteresis is set to 2vol%O2.

Alarm output actions in this gure are expressed as follows:

A. Although the oxygen concentration value exceeds the high limit alarm setpoint, it falls below the

high limit alarm setpoint before the preset delay time of ve seconds elapses. So, no alarm is

issued.

B. The oxygen concentration value exceeds the high limit alarm setpoint and the delay time elapses

during that measurement. So, an alarm is issued.

C. Although the oxygen concentration value falls below the hysteresis set value, the value rises

again and exceeds the hysteresis set value before the preset delay time elapses. So, the alarm is not canceled.

D. The oxygen concentration value falls below the hysteresis set value and the preset delay time

elapses, 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

CAUTION

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.

IM 11M13A01-04E

8-8

<8. Detailed Data Setting>

8.4.4 Default Values

When the analyzer is delivered, or if data are initialized, the default alarm set values are as shown in Table 8.8.

Table 8.8 Alarm Setting Default Values

Set item 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 Contact Output Setting

8.5.1 Contact Output

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. Contact output 1 you can select open or closed contact when the contact is “operated”. For contact output 2, contact is closed. The relay for contact output 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 contact output 2 is energized when the corresponding contact is open and de-energized when that contact is closed.

Table 8.9 Setting Contact Outputs

Operating state When no power is applied to this equipment

Contact output 1 Open (de-energized) or closed

(energized) selectable.

Contact output 2 Closed (de-energized) only. Closed

Open

IM 11M13A01-04E

<8. Detailed Data Setting>

8.5.2 Setting Contact Output

Set the contact outputs following Table 8.10.

Table 8.10 Parameter Codes for Contact Output Setting

Set item Parameter code Set value

Contact output 1

Operation E10 0 Operated in closed status.

Error E20 0 Not operated if an error occurs.

High-high alarm E21 0 Not operated if a high-high alarm

High alarm E22 0 Not operated if a high alarm

Low alarm E23 0 Not operated if a low alarm

Low-low alarm E24 0 Not operated if a low-low alarm

During maintenance E25 0 Not operated during

During calibration E26 0 Not operated during calibration.

Output range change E27 0 Not operated when changing

During warm-up E28 0 Not operated during warming up.

Calibration gas pressure

decrease

Unburnt gas

E29 0 Not operated while a calibration

E32 0 Not operated while an unburnt

detection

Note 1: Contact output 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 contact inputs

Note 4: Calibration gas pressure decrease answer-back signal. Calibration gas pressure decrease must be selected beforehand

Note 5: Non-combusted gas detection answer-back signals. “Non-combusted gas” detection must be selected during the setting of

(see Section 8.5).

during the setting of contact inputs.

contact inputs.

(Normally de-energized)

1 Operated when open. (Normally

energized)

(Note 1)

1 Operated if an error occurs.

occurs.

1 Operated if a high-high alarm

occurs.

(Note 2)

occurs.

1 Operated if a high alarm occurs.

(Note 2)

occurs.

1 Operated if a low alarm occurs.

(Note 2)

occurs.

1 Operated if a low-low alarm

occurs.

(Note 2)

maintenance.

1 Operated during maintenance

(see Subsection 8.3.1).

1 Operated during calibration (see

Subsection 8.3.1).

ranges.

1 Operated when changing

ranges.

(Note 3)

1 Operated during warming up.

gas pressure decrease, contact is being closed.

1 Operated while a calibration gas

pressure decrease, contact is being closed.

(Note 4)

gas detection, contact is being closed.

1 Operated while an unburnt

gas detection, contact is being closed.

(Note 5)

8-9

IM 11M13A01-04E

8-10

<8. Detailed Data Setting>

WARNING

• Contact output 2 is linked to the detector’s heater power safety switch. As such, if contact output 2 is on, the heater power stops and an Err-01 (cell voltage abnormal) or Err-02 (heater temperature abnormal) occurs.

8.5.3 Default Values

When the analyzer is delivered, or if data are initialized, contact outputs are by default as shown in Table 8.11.

Table 8.11 Contact Output Default Settings

Item Contact output 1 Contact output 2

High-high alarm High alarm Low alarm Low-low alarm Error O During warm-up O Output range change During calibration During maintenance O Calibration gas pressure Unburnt gas detection Operating contact status Open Closed (xed)

O: Present

decrease

NOTE

The above blank boxes indicate the items have been set off.

IM 11M13A01-04E

<8. Detailed Data Setting>

8.6 Contact Input Setting

The analyzer contact inputs execute set functions by accepting a remote (contact) signal. Table 8.12 shows the functions executed by a remote contact signal.

Table 8.12 Contact Input 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%O 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

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.

11-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

CAUTION

• To conduct a semi-automatic calibration, be sure to set the Calibration setup mode to “Semi-automatic” or “Automatic”.

8.6.1 Setting Contact Input

To set the contact inputs, follow the parameter codes given in Table 8.13.

Table 8.13 Parameter Codes for Contact Input Settings

Set item Parameter code Set value

Contact input 1 (function) E01 0 Invalid

Contact input 2 (function) E02 0 Invalid

Contact input 1 (action) E03 0 Operated when closed

Contact input 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 contact inputs are all open.

IM 11M13A01-04E

8-12

<8. Detailed Data Setting>

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.

IM 11M13A01-04E

> ∧

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 Subsection 10.1.1, later in this manual). The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored.

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

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.

IM 11M13A01-04E

8-14

<8. Detailed Data Setting>

8.7.3 Setting Fuels

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:

(water vapor caused by combustion and water vapor contained in the exhaust gas)

Moisture quantity =

Gw + Gw1

+ (water vapor contained in air for combustion)

actual exhaust gas(including water vapor) per fuel

x 100

where,

Ao : Theoretical amount of air per unit quantity of fuel, m

G: Actual amount of exhaust gas (including water vapor) per unit quantity of fuel, m

Gw : Water vapor contained in exhaust gas per unit quantity of fuel (by hydrogen and moisture content in fuel), m

Gw1: Water vapor contained in exhaust gas per unit quantity of fuel (moisture content in air), m

Go: Theoretical amount of dry exhaust gas per unit quantity of fuel, m

m: Air ratio

X : Fuel coefficient determined depending on low calorific power of fuel, m

Z : Absolute humidity of the atmosphere, kg/kg ....... Figure 8.17

Gw + (1.61 x Z x m x Ao )

/kg (or m3 /m3)

/kg (or m3 /m3 )

Gw + (1.61 x Z x m x Ao)

Go + Gw + (m - 1) Ao + (1.61 x Z x m x Ao)

X + Ao x m

/kg (or m3 /m3 ) ............ 1 in Table 8.8

x 100

/kg (or m3 /m3 ) ............ 2 in Table 8.8

............ Equation 1

............ Equation 2

/kg (or m3 /m3 )

/kg (or m3 /m3 ) ... 3 in Table 8.8

8.7.3E.siki

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 Industrial Standards 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.

IM 11M13A01-04E

<8. Detailed Data Setting>

8-15

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 / 10000) x H1} – 1.36 [m /kg]

Low calorific power = H1

X value = {(3.37 / 10000) x Hx} – 2.55 [m /kg]

where, H1: low calorific power of fuel

h: Hydrogen in fuel (weight %)

w: Moisture content in fuel (weight %)

Hx: Same as numeric value of H1

For gaseous fuel

Amount of water vapor in exhaust gas = (1/100) {(h2) + 1/2 ∑y (Cy hy) + w} [m /m ]

Theoretical amount of air = 11.2 x (H1/10000) [m /m ]

Low calorific power = H1

X value = (1.05 / 10000) x Hx [m /m ]

where, H1: low calorific power of fuel

h: Hydrogen in fuel (weight %)

w: Moisture content in fuel (weight %)

Hx: Same as numeric value of H1

For solid fuel

Amount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} [m /kg]

Theoretical amount of air = {(1.01 x (H1 / 1000)} + 0.56 [m /kg]

Low calorific power = H1 = 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 %)

h: Hydrogen content (weight %)

The average hydrogen content of coal mined in Japan, which is a dry ash-free type, is

5.7 %. 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]

H1: Low calorific power of fuel [kJ/kg]

Hx: Same numeric value of H1

F8-3E.ai

Figure 8.3 Fuel Calculation Formula

IM 11M13A01-04E

8-16

<8. Detailed Data Setting>

0.046

Wet-bulb temperature, °C

-2

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

Absolute humidity, kg/kg

Figure 8.4 Absolute Humidity of Air

IM 11M13A01-04E

2 4 6 8

10 12 14 16 18 20 22 24 26 28 30 32 34 36

Dry-bulb temperature, °C

0.000

F8-4E.ai

<8. Detailed Data Setting>

Table 8.16 Fuel Data

For liquid fuel

•

properties

Type

Kerosene

Light oil

Heavy

oil

class

Heavy oil

class 2

Heavy

oil

class

Fuel

No.1

No.2

No.1

No.2

No.3

No.4

Specific

weight

kg/l

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

Chemical component

(weight percentage)

C H O

14.0

85.7

85.6

13.2

12.0

11.8

11.3

10.9

10.7

10.9

10.5

0.7

0.4

0.5

85.9

84.6

84.5

86.1

84.4

86.1

83.0

0.5

0.4

0.5

1.2

0.5

2.0

3.0

1.5

3.5

1.5

3.5

Ash

content

0.0 0.0

0.3

0.05

0.4

0.05

0.5

0.05

0.5

0.1

0.5

0.1

0.6

0.1

2.0

0.1

Calorific power

kJ/kg

Higher

order

46465

45879

45544

45125

43827

43952

43116

43660

43032

Lower

order

43535

43032

42739

42320

41274

41441

40646

41190

40604

Theoretical

amount of

air for

combustion

Nm3/kg

11.4

11.2

10.9

10.8

10.7

10.5

10.7

10.3

Amount of combustion

gas Nm3/kg

2 H

1.59

1.56

1.59

1.47

1.60

1.34

1.58

1.32

1.27

1.58

1.61

1.22

1.58

1.20

1.61

1.22

1.55

1.18

0.00

0.01

0.02

0.01

0.02

0.01

0.02

2N2

9.02

8.87

8.61

8.53

8.44

8.43

8.32

8.43

8.18

Total

12.17

11.93

11.55

11.44

11.31

11.27

11.12

11.27

10.93

8-17

value

0.96

0.91

0.89

0.86

0.77

0.79

0.72

0.77

0.72

For gas fuel

•

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

Specific

weight

kg/Nm

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

Chemical component

(weight percentage)

CO TotalH

9.0

CO2CH

50.5 25.92.6 3.9 0.1 8.0 20428 18209

CmH

O2N

25.0 2.0 20.0 53.0

2.0 88.4 3.2 1.6 4.2

3H8

90%, C4H

10%, C4H

10%

90%

(Molecular Formula)

C2H

C3H

C4H

Calorific power

kJ/Nm

Higher

2 CO

order

3391 3349

37883 34074

102055 93976

125496 115868

12767

12642

39750

69638

62991

99070

118623

128452

Lower

order

10758

12642

35820

63744

59060

91255

Theoretical

amount of

air for

combustion

3/m3

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

3.0

4.0

Combustion

product,

/ m

H2O

1.10

0.02

1.88

4.10

4.90

1.0

3.60

1.01

7.17

19.5

24.0

1.89

7.57

2.0

13.2

3.0

11.4

2.0

18.9

4.0

24.6

5.0

5.15

1.48

10.03

26.7

32.8

2.89

10.6

18.2

15.4

25.9

33.6

value

0.46

0.08

0.86

2.36

2.91

0.27

0.32

0.90

1.60

1.48

2.29

2.98

T8-16E.ai

IM 11M13A01-04E

8-18

Procedure

Use the parameter code table below to set fuel values.

Table 8.17 Setting Fuel Values

Amount of water vapor in exhaust gas

Theoretical amount of air F21 1 to 20 m X value F22 0 to 19.99 Absolute humidity of the

atmosphere

Default Values

When the analyzer is delivered, or if data are initialized, parameter settings are by default, as shown in Table 8.18.

Table 8.18 Default Settings of Fuel Values

Amount of water vapor in exhaust gas 1.00 m Theoretical amount of air 1.00 m X value 1.00 Absolute humidity of the atmosphere 0.1000 kg/kg

<8. Detailed Data Setting>

Set item Parameter code Set value Engineering units

F20 0 to 5 m

F23 O to 1 kg/kg

Item Default setting

/kg (m3)

8.7.4 Setting Purging

Purging is to remove condensed water in the calibration gas pipe by supplying a span calibration gas for a given length of time before warm-up of the detector. This prevents cell breakage during calibration due to condensed water in the pipe.

Open the solenoid valve for the automatic calibration span gas during purging and after the purge time has elapsed, close the valve to start warm-up.

Purging is enabled when the cell temperature is 100°C or below upon power up and the purge time is set in the range of 1 to 60 minutes.

Displayed alternately

Figure 8.5 Display during Purging

Procedure

Use the parameter-code table below to set the purging time. The allowable input ranges from 0 to 60 minutes.

Table 8.19 Purging Time

F8-5E.ai

Purging time F15 0 to 60 minutes

Default Value

When the analyzer is delivered, or if data are initialized, purging time is set to 0 minutes.

IM 11M13A01-04E

Set item Parameter code Set range Units

<9. Calibration>

9. Calibration

9.1 Calibration Briefs

9.1.1 Principle of Measurement

This subsection sets forth the principles of measurement with a zirconia oxygen analyzer before detailing calibration.

A solid electrolyte such as zirconia allows the conductivity of oxygen ions at high temperatures. Therefore, when a zirconia-plated element with platinum electrodes on both sides is heated up in contact with gases having different oxygen partial pressures on each side, the element shows the action of the concentration cell. In other words, the electrode in contact with a gas with a higher oxygen partial pressure acts as a negative electrode. As the gas comes in contact with the zirconia element in this negative electrode, oxygen molecules in the gas acquire electrons and become ions. Moving in the zirconia element, they eventually arrive at the positive electrode on the opposite side. There, the electrons are released and the ions return to the oxygen molecules. This reaction is indicated as follows:

Negative electrode: O

Positive electrode: 2 O 2- O2 + 4 e

+ 4e 2 O

9-1

The electromotive force E (mV) between the two electrodes, generated by the reaction, is governed by Nernst’s equation as follows:

E = -RT/nF ln Px/Pa......................................................Equation (1)

where, R: Gas constant

T: Absolute temperature

n: 4

F: Faraday’s constant

Px: Oxygen concentration in a gas in contact with the negative zirconia electrode (%)

Pa: Oxygen concentration in a gas in contact with the positive zirconia electrode (%)

Assuming the zirconia element is heated up to 750°C, then we obtain equation (2) below:

E = -50.74 log Px/Pa......................................................Equation (2)

With this analyzer, the sensor (zirconia element) is heated up to 750°C, so Equation (2) is valid. At that point, the relationship as in Figure 9.1 is effected between the oxygen concentration of the measurement gas in contact with the positive electrode and the electromotive force of the sensor (cell), where a comparison gas of air is used on the negative electrode side.

IM 11M13A01-04E

YOKOGAWA ZR202S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

u CE marking products

u After-Sales Warranty

1. Overview

1.1.1 System 1

1.1.2 System 2

1.2 < EXAxt ZR > System Components

1.2.1 System Components

1.2.2 Oxygen Analyzer and Installation

2.1.2 ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer

2.1.3 ZO21R Probe Protector

2.2 ZA8F Flow Setting Unit

2.3 ZO21S Standard Gas Unit

2.4 Other Equipment

2.4.1 Stop Valve (L9852CB, G7016XH)

2.4.2 Check Valve (K9292DN, K9292DS)

2.4.3 Air Set

2.4.4 Pressure Reducing Valve for Gas Cylinder (G7013XF, G7014XF)

2.4.5 ZR202A Heater Assembly

3. Installation

3.1 Installation of ZR202S Zirconia Oxygen Analyzer

3.1.1 Installation Location

3.1.2 ATEX Flameproof Type

3.1.3 FM Explosion-proof Type

3.1.4 CSA Explosion-proof Type

3.1.5 IECEx Flameproof Type

3.1.6 Probe (Detector) Insertion Hole

3.1.7 Installation of the Probe (Detector)

3.1.8 Installation of the 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 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 Inlet

4.1.3 Piping for the Reference Gas Inlet

4.1.4 Piping for the Reference Gas Outlet

4.2 Piping for System 2

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 ZR202S Zirconia Oxygen Analyzer

6.2 ZA8F Flow Setting Unit, Automatic Calibration Unit

7. Startup

7.1 Checking Piping and Wiring Connections

7.2 Valve Setup

7.3 Supplying Power to Analyzer

7.4 Operation of Infrared Switch

7.4.1 Display and Switches

7.4.3 Entering Parameter Code Selection Display

7.4.4 Selecting Parameter Codes

7.4.5 Changing Set Values

7.6 Selection of Measurement Gas

7.7 Output Range Setting

7.8 Checking Current Loop

7.9 Checking Contact I/O

7.9.1 Checking Contact Output

7.9.2 Checking Calibration Contact Output

7.9.3 Checking Contact Input

7.10 Calibration

7.10.1 Calibration Setup

7.10.2 Manual Calibration