Yokogawa ZR22, ZR402 User Manual

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User's Manual

Model ZR22G, ZR402G Separate type Zirconia High Temperature Humidity Analyzer

IM 11M12A01-03E

7th Edition

Introduction

The EXAxt ZR Separate-type Zirconia High-temperature Humidity Analyzer has been developed for humidity control in various industrial processes. This analyzer basically consists of a detector and a converter. You can select between several versions based upon your application.

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

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

Regarding the HART communication protocol,refer to the IM 11M12A01-51E. IM 11M12A01-51E has been published as Model EXAxt ZR Series HART Protocol The all-in-one version (with sensor and analyzer integrated in one body) is described in

IM 11M12A01-05E < Before using the equipment, please read any related descriptions in this manual for the

equipment and the system you have, on appropriate use and operation of the EXAxt ZR. > Models and descriptions in this manual are as follows:

Models and descriptions in this manual

Description in this manual

Model Product Name Specification Installation Operation Maintenance CMPL

ZR22G General-use detector s s s s ZR402G Converter s s s s s ZH21B Dust protector s s ZA8F Flow setting unit (for manual calibration use) s s s ZR40H Automatic Calibration unit s s s s

- Calibration gas unit case (Part No. E7044KF) s s

- Check valve (Part No. K9292DN, K9292DS) s s ZO21S Standard gas unit s s s s

T.Int.1E

CMPL : Customer Maintenance Parts List

IM 11M12A01-03E

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

Table of Contents

References

Chapter Outline Installation Operation Maintenance

1. Overview Equipment models and system configuration examples

2. Specifications Standard specification, model code (or part number), dimension drawing for each equipment

3. Installation Installation method for each equipment

4. Piping Examples of piping in three standard system configurations

5. Wiring Wiring procedures such as Power supply wiring , output signal wiring or others

6. Components These are described in this manual

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

8. Detailed Data Setting Details of key operations and displays

9. Calibration Describes the calibration procedure required in the course of operation.

10. Other Functions Other functions described

11. Inspection and How to conduct maintenance of EXAxt ZR and procedures

Maintenance for replacement of deteriorated parts

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

CMPL (parts list) User replaceable parts list

: Read and completely understand before operating the equipment.

: Read before operating the equipment, and refer to whenever necessary.

: Recommended to read it at least once.

T.Int.2E

IM 1M12A01-03E

r For the safe use of this equipment

CAUTION

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

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

• Avoid any water dropping directly on the probe (sensor) of the detector 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 measuring gas can damage the sensor.

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

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

DANGER

(1) About This Manual

Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment. In addition, confirm 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 poisoningby using a protective mask or ventilating the area well.

• 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 office.

• This manual does not cover the special specifications. This manual may not be changed on any change of specification, construction and parts when the change does not affect the functions or performance of the product.

• If the product is used in a manner not specified in this manual, safety of this product may be impaired.

IM 11M12A01-03E

iii

(2) Safety and Modification 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.

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

DANGER

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

WARNING

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.

CAUTION

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

Tip

This symbol gives information that complements the present topic.

SEE ALSO

This symbol identifies a source to which to refer.

Protective Ground Terminal

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

terminal.)

Alternating current

IM 1M12A01-03E

• Special descriptions in this manual

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

• Operation keys, Enclosed in [ ], displays on the panel 0 0.

• Drawing for flashing

Indicated by gray characters. (Flashing) (lit)

(Ex. [MODE] key) (Ex. message display 0 BASE 0)

(Ex. data display 0 102 0 lit, 0 102 0 flashing)

IM 11M12A01-03E

r NOTICE

• Specification 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 specification matches the order, and required accessories are not missing. Specifications can be checked by the model codes on the nameplate. Refer to Chapter 2 Specifications for the list of model codes.

• Details on operation parameters When the EXAxt ZR Separate-type High Temperature Humidity Analyzer arrives at the user site, it will operate based set before shipping parameters (initial data) on the departure 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.

r After -Sales Warranty

d Do not modify the product.

d During the warranty period, for repair under warranty carry or send the product to the

local sales representative or service office. Yokogawa will replace or repair any damaged parts and return the product to you.

d Before returning a product for repair under warranty, provide us with the model

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

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

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

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

period.

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

manual.

• Failure caused by usage of software, hardware or auxiliary equipment, which

Yokogawa Electric did not supply.

• Failure due to improper or insufficient maintenance by user.

• Failure due to modification, misuse or outside-of-specifications operation which

Yokogawa does not authorize.

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

abnormal.

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

• Any damage from fire, earthquake, storms and floods, lightning, disturbances, riots,

warfare, radiation and other natural changes.

IM 1M12A01-03E

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

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

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

into systems or resells the product.

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

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

IM 11M12A01-03E

vii

Contents

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

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

r NOTICE.........................................................................................................................vi

r After-Sales Warranty ................................................................................................... vi

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

1.1 < EXAxt ZR > System Configuration............................................................ 1-2

1.1.1 System 1 .................................................................................................. 1-2

1.1.2 System 2 .................................................................................................. 1-3

1.1.3 System 3 .................................................................................................. 1-4

1.2 < EXAxtZR > System Components ............................................................... 1-5

1.2.1 System Components ................................................................................ 1-5

1.2.2 Detectors and Accessories ....................................................................... 1-5

2. Specifications ............................................................................................................... 2-1

2.1 General Specifications .................................................................................... 2-1

2.1.1 Standard Specifications ........................................................................... 2-1

2.2 General-use Separate-type Detector and Related Equipment ........................ 2-3

2.2.1 ZR22G General-use Separate-type Detector ........................................... 2-3

2.2.2 ZH21B Dust Protector ............................................................................. 2-8

2.3 ZR402G Separate-type Converter ................................................................... 2-9

2.3.1 Standard Specifications ........................................................................... 2-9

2.3.2 Function ................................................................................................. 2-10

2.4 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit ............. 2-16

2.4.1 ZA8F Flow Setting Unit........................................................................ 2-16

2.4.2 ZR40H Automatic Calibration Unit ...................................................... 2-18

2.5 ZO21S Standard Gas Unit ............................................................................ 2-21

2.6 Other Equipment ........................................................................................... 2-22

2.6.1 Stop Valve (Part Number: L9852CB or G7016XH) ............................ 2-22

2.6.2 Check Valve (Part Number: K9292DN or K9292DS) ......................... 2-23

2.6.3 Air Set................................................................................................... 2-24

2.6.4 Zero-gas Cylinder (Part Number: G7001ZC) ....................................... 2-26

2.6.5 Pressure Regulator for Gas Cylinder

(Part Number: G7013XF or G7014XF) .............................................. 2-26

2.6.6 Case Assembly for Calibration-gas Cylinder

(Part Number: E7044KF)..................................................................... 2-27

2.6.7 Model ZR22A Heater Assembly ........................................................... 2-28

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

3.1 Installation of the Detector ............................................................................. 3-1

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

3.1.2 Probe Insertion Hole ................................................................................ 3-2

3.1.3 Installation of the Detector ...................................................................... 3-3

3.1.4 Installation of ZH21B Dust Protector ..................................................... 3-3

viii

IM 1M12A01-03E

3.2 Installation of the Converter ........................................................................... 3-4

3.2.1 Location .................................................................................................. 3-4

3.2.2 Mounting of the Converter ...................................................................... 3-4

3.3 Installation of ZA8F Flow Setting Unit ......................................................... 3-7

3.3.1 Location ................................................................................................... 3-7

3.3.2 Mounting of ZA8F Flow Setting Unit .................................................... 3-7

3.4 Installation of ZR40H Automatic Calibration Unit........................................ 3-9

3.4.1 Location ................................................................................................... 3-9

3.4.2 Mounting of ZR40H Automatic Calibration Unit .................................. 3-9

3.5 Installation of E7044KF Case Assembly for

the Calibration-gas Cylinder ......................................................................... 3-11

3.5.1 Location ................................................................................................. 3-11

3.5.2 Mounting................................................................................................ 3-11

3.6 Insulation Resistance Test ............................................................................. 3-12

3.7 External Dimensions of Detectors with Pressure Compensation................. 3-13

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

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

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

4.1.2 Connection to the Calibration Gas Inlet ................................................. 4-2

4.1.3 Connection to the Reference Gas Inlet ................................................... 4-2

4.2 Piping for System 2 ........................................................................................ 4-3

4.2.1 Piping Parts for System 2........................................................................ 4-3

4.2.2 Piping for the Calibration Gas ................................................................ 4-4

4.2.3 Piping for the Reference Gas .................................................................. 4-4

4.3 Piping for System 3 ........................................................................................ 4-5

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

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

5.1.1 Terminals for the External Wiring in the Converter .............................. 5-3

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

5.1.3 Mounting of Cable Gland........................................................................ 5-4

5.2 Wiring for Detector Output ............................................................................. 5-5

5.2.1 Cable Specifications ................................................................................ 5-5

5.2.2 Connection to the Detector...................................................................... 5-6

5.2.3 Connection to the Converter ................................................................... 5-7

5.3 Wiring for Power to Detector Heater ............................................................. 5-8

5.3.1 Cable Specifications ................................................................................ 5-8

5.3.2 Connection to Detector............................................................................ 5-8

5.3.3 Connection to Converter ......................................................................... 5-9

5.4 Wiring for Analog Output ............................................................................. 5-10

5.4.1 Cable Specifications .............................................................................. 5-10

5.4.2 Wiring Procedure................................................................................... 5-10

5.5 Power and Grounding Wiring....................................................................... 5-11

5.5.1 Power Wiring......................................................................................... 5-11

5.5.2 Grounding Wiring ................................................................................. 5-11

5.6 Wiring for Contact Output............................................................................ 5-12

5.6.1 Cable Specifications .............................................................................. 5-12

5.6.2 Wiring Procedure................................................................................... 5-12

5.7 Wiring for ZR40H Automatic Calibration Unit ........................................... 5-13

5.7.1 Cable Specifications .................................................................................. 5-14

5.7.2 Wiring Procedure ...................................................................................... 5-14

IM 11M12A01-03E

5.8 Wiring for Contact Input ............................................................................... 5-15

5.8.1 Cable Specifications .............................................................................. 5-15

5.8.2 Wiring Procedure................................................................................... 5-15

5.9 Temperature Input Wiring ............................................................................ 5-16

5.9.1 Applicable Temperature Transmitter .................................................... 5-16

5.9.2 Cable Specifications .............................................................................. 5-16

5.9.3 Wiring Procedure................................................................................... 5-16

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

6.1 ZR22G Detector .............................................................................................. 6-1

6.1.1 General-purpose Detector ........................................................................ 6-1

6.2 ZR402G Converter.......................................................................................... 6-2

6.3 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit ..................... 6-3

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

7.1 Checking Piping and Wiring Connections ..................................................... 7-1

7.2 Checking Valve Setup ..................................................................................... 7-1

7.3 Supplying Power to the Converter .................................................................. 7-2

7.4 Touchpanel Switch Operations ....................................................................... 7-3

7.4.1 Basic Panel and Switch ........................................................................... 7-3

7.4.2 Display Configuration (for High-temperature Humidity Analyzer) ....... 7-4

7.4.3 Display Functions .................................................................................... 7-5

7.4.4 Entering Numeric and Text Data ............................................................ 7-5

7.5 Confirmation of Converter Type Setting........................................................ 7-7

7.6 Confirmation of Detector Type Setting .......................................................... 7-8

7.7 Current Output Setting.................................................................................... 7-8

7.7.1 Analog Output Setting ............................................................................. 7-8

7.7.2 Minimum Current (4 mA) and Maximum Current (20 mA) Settings ... 7-9

7.8 Setting Display Item ..................................................................................... 7-10

7.9 Checking Current Loop ................................................................................. 7-12

7.10 Checking Contact I/O ................................................................................... 7-13

7.10.1 Checking Contact Output ...................................................................... 7-13

7.10.2 Checking Calibration Contact Output................................................... 7-14

7.10.3 Checking Input Contacts ....................................................................... 7-14

7.11 Calibration ..................................................................................................... 7-15

7.11.1 Calibration Setup................................................................................... 7-15

7.11.2 Manual Calibration................................................................................ 7-16

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

8.1 Current Output Setting.................................................................................... 8-1

8.1.1 About Input Ranges ................................................................................. 8-1

8.1.2 Setting Minimum Current (4 mA) and Maximum Current (20 mA) ..... 8-4

8.1.3 Entering Output Damping Constants ...................................................... 8-4

8.1.4 Selection of Output Mode ....................................................................... 8-4

8.1.5 Default Values ......................................................................................... 8-5

8.2 Output Hold Setting ........................................................................................ 8-6

8.2.1 Definition of Equipment Status ............................................................... 8-6

8.2.2 Preference Order of Output Hold Value ................................................. 8-7

8.2.3 Output Hold Setting................................................................................. 8-8

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

IM 1M12A01-03E

8.3 Alarm Setting .................................................................................................. 8-9

8.3.1 Alarm Values ........................................................................................... 8-9

8.3.2 Alarm Output Actions ............................................................................. 8-9

8.3.3 Alarm Setting Procedure ....................................................................... 8-10

8.3.4 Default Values ....................................................................................... 8-11

8.4 Output Contact Setup .................................................................................... 8-12

8.4.1 Output Contact....................................................................................... 8-12

8.4.2 Setting Procedure................................................................................... 8-12

8.4.3 Default Values ....................................................................................... 8-15

8.5 Input Contact Settings................................................................................... 8-16

8.5.1 Input Contact Functions ........................................................................ 8-16

8.5.2 Setting Procedure................................................................................... 8-17

8.5.3 Default Values ....................................................................................... 8-17

8.6 Other Settings................................................................................................ 8-18

8.6.1 Setting the Date-and-Time .................................................................... 8-18

8.6.2 Setting Periods over which Average Values Are Calculated and Periods over

which Maximum and Minimum Values Are Monitored ...................... 8-19

8.6.3 Setting Measurement Gas Temperature and Pressure .......................... 8-20

8.6.4 Setting Purging ...................................................................................... 8-22

8.6.5 Setting Passwords .................................................................................. 8-23

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

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

9.1.1 Measurement Principle of Zirconia Humidity Analyzer ........................ 9-1

9.1.2 Calibration Gas ........................................................................................ 9-3

9.1.3 Compensation .......................................................................................... 9-4

9.1.4 Characteristic Data from a Sensor Measured During Calibration .......... 9-5

9.2 Calibration Procedures .................................................................................... 9-6

9.2.1 Calibration Setting ................................................................................... 9-6

9.2.2 Default Values ......................................................................................... 9-9

9.2.3 Calibration ............................................................................................. 9-10

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

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

10.1.1 Detailed Display .................................................................................... 10-1

10.1.2 Trend Graph ........................................................................................... 10-5

10.1.3 Auto(matic) Display-Revert Time......................................................... 10-7

10.1.4 Entering Tag Name ............................................................................... 10-8

10.1.5 Language Selection ............................................................................... 10-8

10.2 Blowback....................................................................................................... 10-9

10.2.1 Blowback Setup..................................................................................... 10-9

10.3 Operational Data Initialization.................................................................... 10-13

10.4 Reset ............................................................................................................ 10-17

10.5 Handling of the ZO21S Standard Gas Unit................................................ 10-18

10.5.1 Standard Gas Unit Component Identification ..................................... 10-18

10.5.2 Installing Gas Cylinders ...................................................................... 10-19

10.5.3 Calibration Gas Flow........................................................................... 10-20

10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit .................. 10-23

10.6.1 Preparation Before Calibration ............................................................ 10-23

10.6.2 Operating the Span Gas Flow Setting Valve...................................... 10-23

10.6.3 Operating the Zero Gas Flow Setting Valve ...................................... 10-24

10.6.4 Operation After Calibration................................................................. 10-24

IM 11M12A01-03E

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 ............................................................ 11-3

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

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

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

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

11.2.1 Replacing Fuses..................................................................................... 11-9

11.2.2 Cleaning............................................................................................... 11-10

11.2.3 Adjust LCD screen contrast ................................................................ 11-10

11.3 Replacing Flowmeter in ZR40H Autocalibration Unit .............................. 11-11

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

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

12.1.1 What is an Error? .................................................................................. 12-1

12.1.2 Measures to Take When an Error Occurs ............................................. 12-2

12.2 Displays and Measures to Take When Alarms are Generated ..................... 12-5

12.2.1 What is an Alarm? ................................................................................. 12-5

12.2.2 Measures Taken When Alarms are Generated.................................. 12-7

12.3 Countermeasures When Measured Value Shows Error ............................. 12-13

12.3.1 Measured Value Higher Than True Value.......................................... 12-13

12.3.2 Measured Value Lower Than True Value .......................................... 12-14

12.3.3 Measurements Sometimes Show Abnormal Values........................... 12-14

Customer Maintenance Parts List ................................................ CMPL 11M12A01-03E

Customer Maintenance Parts List ................................................ CMPL 11M12C01-01E

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

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

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

xii

IM 1M12A01-03E

1. Overview

The EXAxt ZR Separate-type Zirconia High-temperature Humidity Analyzer is used to measure the humidity of hot gases continuously in driers which use hot gas or electricity as the heat source. It can also be used in a variety of manufacturing applications in humidifiers, as well as in driers, for humidity measurement and control. It can help improve productivity in these application fields.

The ZR402G Separate-type converter is equipped with an LCD touchpanel which has various setting displays, a calibration display, humidity trend display, with easier operation and improvement of display functions. The converter is equipped with various standard functions such as measurement and calculation as well as maintenance functions including a self-test. Analyzer calibration can also be fully automated and ZR40H, the automatic calibration unit, is provided. Choose the detector which best suits your needs so that an optimal humidity control system can be obtained.

Some examples of typical system configuration are illustrated following pages :

1. Overview

IM 11M12A01-03E

1-1

1.1 < EXAxt ZR > System Configuration

The system configuration should be determined by the conditions; e.g. whether the calibration gas flow should be automated. The system configuration can be classified into three basic patterns as follows:

1.1.1 System 1

This is the simplest system consisting of a detector and a converter. This system can be implemented for monitoring humidity in a production process such as food production. No piping is required for the reference gas (air) which is fed in at the installation site. The handy ZO21S standard gas unit is used for calibration.

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

CAUTION

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

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

Separate type Zirconia High Temperature Humidity Analyzer, Model ZR22G Detector

Stop valve

Signal (6-core shield cable)

Heater (2-core)

Calibration gas

Figure 1.1

Model ZR402G Converter

EXA

ZR402G

100 to 240 V AC

Contact input Analog outout, contact output

Digital output (HART)

Model ZO21S Standard gas unit

F1.1E.EPS

1-2

IM 11M12A01-03E

1.1.2 System 2

1. Overview

This system is for accurate monitoring and controlling humidity when the installation environment is polluted with gases other than the air. Instrument air (clean and dry air of oxygen concentration 21%) is used for the reference gas and the span gas for calibration. Zero gas is fed in from a cylinder during calibration. The gas flow is controlled by the ZA8F flow setting unit (for manual valve operation).

Separate type Zirconia High Temperature Humidity Analyzer, Model ZR22G Detector

Check valve or Stop valve

Calibration gas

Signal (6-core shield cable)

Heater (2-core)

Reference gas

Model ZA8F flow setting unit

Figure1.2

Model ZR402G Converter

Flowmeter

Needle

EXA

ZR402G

valve

100 to 240 V AC

Contact input Analog outout, contact output

Digital output (HART)

Air Set

Instrument air Span gas (Same as Zero gas calibration unit)

Calibration gas pressure regulator

Calibration gas unit case

Zero gas cylinder

F1.2E.EPS

IM 11M12A01-03E

1-3

1.1.3 System 3

This system is for accurate monitoring and controlling of humidity. Instrument air (clean and dry air) is used for the reference gas and the span gas for calibration. Zero gas is fed in from a cylinder during calibration. The calibration gas flow is controlled automatically by the ZR40H automatic calibration unit.

This system is similar to system 2, except that the calibration gas flow is automated using the ZR40H automatic calibration unit.

Separate type Zirconia High Temperature Humidity Analyzer, Model ZR22G Detector

Check valve

Reference gas

Calibration gas

Signal (6-core shield cable)

Heater (2-core shield cable)

Model ZR40H Auto-Calibration unit

Flowmeter

Model ZR402G Converter

EXA

ZR402G

Needle

vaive

Air Set

100 to 240 V AC

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

lnstrument air

Calibration gas pressure regulator

Calibration gas unit case

Zero gas cylinder

F1.3E.EPS

Figure1.3

*1 Shield cable : Use shielded signal cables, and connect the shield to the FG terminal of the converter. *2 Select the desired probe from the Probe Configuration table on page 1-5

1-4

*3 100% N2 gas cannot be used as the zero gas. Use approximately 1% of O2 gas (N2 based).

IM 11M12A01-03E

1.2 < EXAxtZR > System Components

1.2.1 System Components

Model or Part No. Product Name System 1 System 2 System 3

ZR22G Detector, Separate-type High-temperature

Humidity Analyzer, Detector

ZR402G Converter, Separate-type High-temperature

Humidity Analyzer, Converter ZH21B Dust protector ZO21S Standard gas unit ZA8F Flow setting unit (for manual calibration) ZR40H Automatic calibration unit (for separate type) L9852CB/G7016XH Stop valve K9292DN/K9292DS Check valve K9473XH/K9473XJ, Air set G7004XF/K9473XG G7001ZC Zero gas cylinder G7013XF/G7014XF Pressure regulator for gas cylinder E7044KF Case assembly for calibration-gas cylinder

ZR22A Heater Assembly

(Spare parts for Model ZR22G)

d : The essential products for the system s : Selected depending on your applications

(d) : Select either

1. Overview

Separate type

d d d

s s s d

d (d)

(d) d

d d

d d d d d d

s s s

T1.1E.EPS

1.2.2 Detectors and Accessories

dGeneral-use Detector (sample gas temperature: 0 to 7008C)

Standard detector Model

ZR22G

Mounting angle

The probe insertion length: 0.4 to 2m

Vertical to horizontal

The probe insertion length: 2.5 to 3m

Vertical

Detector with dust protector

Model

ZR22G-040

and

ZH21B

Mounting angle

Vertical to horizontal

(The probe insertion length: 0.4m)

F1.4E.EPS

IM 11M12A01-03E

1-5

2. Specifications

This chapter describes the specifications for the following: ZR22G General-use separate-type detector (See Section 2.2.1) ZH21B Dust protector (See Section 2.2.2) ZR402G Separate-type converter (See Section 2.3) ZA8F Flow setting unit (See Section 2.4.1) ZR40H Automatic calibration unit(See Section 2.4.2) ZO21S Standard gas unit(See Section 2.5)

2.1 General Specifications

2.1.1 Standard Specifications

High Temperature Humidity Analyzer

Oxygen concentration in mixed gas which consists of water vapor and air is proportional to the volume rate of air, so the volume rate of water vapor can be calculated by the oxygen concentration.

2. Specifications

Measured Object:Water vapor (in vol%) in mixed gases (air and water vapor) Measured System: Zirconia system Measured Range: 0.01 to 100 vol% O2, 0 to 100 vol% H2O or 0 to 1.000 kg/kg Output Signal: 4 to 20 mA DC (maximum load resistance 550V) Oxygen concentration;

Any setting in the range of 0 to 5 through 0 to 100 vol%O2 (in 1 vol% O2), or partial range.

Moisture quantity: 0 to 25 through 0 to 100 vol% H2O (in 1 vol% H2O), or partial

range. Mixture ratio 0 to 0.2 through 0 to 1.000 kg/kg (in 0.001 kg/kg), or

partial range.

Digital Communication (HART): 250 to 550V, depending on quantity of field devices

connected to the loop (multi-drop mode). (Note) HART is a registered trademark of the HART Communication

Foundation.

Display Range: Oxygen concentration; 0 to100 vol% O2 , Moisture quantity; 0 to 100

vol% H2O Mixture ratio; 0 to 1 kg/kg Relative humidity; 0 to 100 %RH Dew point; -40 to 3708 C (Note) Those values are calculated by temperature and absolute

pressure. Then accurate temperature and pressure value must be input to the converter.

Warm-up Time: Approx. 20 min.

(Note) These characteristics are calculated by oxygen concentration measured in air which include water vapor.

IM 11M12A01-03E

2-1

Repeatability: (Note1)

61 vol% H2O (sample gas pressure 2 kPa or less)

Linearity: (Excluding standard gas tolerance)

(Note1) (Use oxygen of known concentration (in the measuring range) as the

zero and span calibration gas.)

62 vol% H2O; (Sample gas pressure: within 60.49 kPa) 63 vol% H2O; (Sample gas pressure: 2 kPa or less)

Drift: (Excluding the first two weeks in use)

(Note1) both zero and span 63 vol% H2O/month

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

from calibration-gas inlet and analog output starts changing.) (Note1) These tolerances do not apply to the pressure compensated

version, or where natural convection is used for the reference air.

2-2

IM 11M12A01-03E

2.2 General-use Separate-type Detector and Related Equipment

The “Detector with dust protector” consists of ZR22G general-use separate-type detector and ZH21B dust protector (refer to Section 2.2.2).

2.2.1 ZR22G General-use Separate-type Detector

Sample Gas Temperature: 0 to 7008 C (Probe only)

It is necessary to mount the cell using Inconel cell-bolts when the temperature is 6008 C or greater.

Sample Gas Pressure: -5 to +20 kPa (When the pressure in the process exceeds 3kPa,

it is recommended that you compensate the pressure. When the pressure in the process exceeds 5kPa, you must perform pressure compensation.)

No pressure fluctuation in the process should be allowed. Probe Length: 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m Probe Material: SUS 316 (JIS) Ambient Temperature: -20 to +1508 C Reference Air System: Natural Convection, Instrument Air Instrument Air System (excluding Natural Convection):

Pressure; 200 kPa + the pressure inside the dryer, (It is recommended to

use air which has been dehumidified by cooling to dewpoint -208 C or

less, and with dust or oil mist removed.)

Consumption; Approx. 1Nl/min

Note: When the detector is used in conjunction with a check valve and a

ZA8F Flow Setting Unit, the maximum pressure of sample gas is 150

kPa. When with a check valve and a ZR40H Auto Calibration Unit, it is

200 kPa. If the pressure of your sample gas exceeds these limits, consult

with Yokogawa. Material in Contact with Gas: SUS 316 (JIS), Zirconia, SUS 304 (JIS) (flange),

Hastelloy B, (Inconel 600, 601) Construction: Heater and thermocouple replaceable construction. Non explosion-proof

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

2. Specifications

IM 11M12A01-03E

Terminal Box Case: Material; Aluminium alloy Terminal Box Paint Color:

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

Finish: Polyurethane corrosion-resistant coating Gas Connection: Rc 1/4 or 1/4 FNPT

Wiring Connection: G1/2, Pg13.5, M20 by 1.5mm, 1/2 NPT Installation: Flange mounting

2-3

Probe Mounting Angle: Horizontal to vertically downward.

When the probe insertion length is 2 m or less, installing at angles from

horizontal to vertically downward is available.

When the probe insertion length exceeds 2.5 m, mount vertically down-

ward (within 658 ) and use a probe protector. Weight:

Insertion length of 0.4 m: approx. 6 kg (JIS 5K 65) / approx. 11 kg (ANSI 150 4) Insertion length of 1.0 m: approx. 8 kg (JIS 5K 65) / approx. 13 kg (ANSI 150 4) Insertion length of 1.5 m: approx. 10 kg (JIS 5K 65) / approx. 15 kg (ANSI 150 4) Insertion length of 2.0 m: approx. 12 kg (JIS 5K 65) / approx. 17 kg (ANSI 150 4) Insertion length of 3.0 m: approx. 15 kg (JIS 5K 65) / approx. 20 kg (ANSI 150 4)

2-4

IM 11M12A01-03E

2. Specifications

Model and Codes

Model ZR22G

Suffix code

Option

code

Description

Separate type Detector of Zirconia High Temperature Humidity

[ Style : S2 ]

Analyzer

Length

-040

-070

-100

-150

-200

-250

-300

Wetted material

-S

-C

Flange (*2)

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-R

-S

-W

Reference air

-C

-E

-P

Gas Thread

-T

Connection box thred

-P

-G

-M

-T

-Q

Instruction manual

-J

-E

-A

Options

/D /C /CV /SV

/PT

-R

/SCT

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m

2.5 m (*1)

3.0 m (*1) SUS316 Stainless steel with lnconel calibration gas tube ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 SUS304 DIN PN10 DN80 SUS304 DIN PN10 DN100 SUS304 JIS 5K 65 FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Westinghouse

Natural convection External connection (Instrument air) (*8) Pressure Compensation (*8) Rc 1/4 1/4 NPT(F) G1/2 Pg13.5 M20 x1.5 mm 1/2NPT Quick connect (*6) Japanese English Always-A DERAKANE coating (*7) Inconel bolt (*3) Check valve (*4) Stop valve (*4) Stainless steel tag plate (*5) Printed tag plate (*5)

*1 When installing horizontally the probe whose insertion length is 2.5 meters or more, use the Probe Protector. Be sure to specify ZO21R-L-hhh-h. Specify the flange suffix code either -C or -K. *2 The thickness of the flange depends on its dimensions. *3 Inconel probe bolts and U shape pipe for calibration are used. Use this option for high temperature use (ranging from 600 to 700 8C). *4 Specify either /CV or /SV option code. *5 Specify either /SCT or /PT option code. *6 Not waterproof, protect from rain.Operating maximum temperature is 80 8C. Available only in the U.S. *7 Available only in the U.S. DERAKANE is a registered trademark of the Dow Chemical Company. *8 Piping for reference air must be installed to supply reference air constantly at a specified flow rate.

T2.1E.EPS

IM 11M12A01-03E

2-5

EXTERNAL DIMENSIONS Model ZR22G Detectors Separate type Zirconia High Temperature Humidity Analyzer

[50.8

L=0.15, 0.4, 0.7, 1.0,

1.5, 2.0, 2.5, 3.0 (m)

Flange

283 to 292

155 to 163 69

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

[124

Flange

ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 SUS304 DIN PN10 DN80 SUS304 DIN PN10 DN100 SUS304 JIS 5K 65 FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JIS 5K 32 FF SUS304 JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Westinghouse

AB C

152.4

190.5

228.6 165 200 220 155 175 185 210 115 229 190 155

120.6

152.4

190.5 125 160 180 130 140 150 175

190.5

152.4 127

4 - [19 4 - [19 8 - [19 4 - [18 8 - [18 8 - [18 4 - [15 4 - [19 8 - [19 8 - [19 4 - [15 8 - [19 4 - [19

4 - [11.5

19 24 24 18 20 20 14 18 18 18

24 24 14

Flange

F07_01.EPS

2-6

IM 11M12A01-03E

2. Specifications

Model ZR22G...-P Detectors(with pressure compensation), Separate type Zirconia High Temperature Humidity Analyzer, Detectors

f50.8

L=0.15, 0.4, 0.7, 1.0,

1.5, 2.0, 2.5, 3.0 (m)

Reference gas outlet

Flange

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

Flange

303

156

PIPING

PIPING : A

AB C

152.4

190.5

228.6 165 200 220 155 175 185 210 229 190 155

120.6

152.4

190.5

152.4

125 160 180 130 140 150 175

127

4 - [19 4 - [19 8 - [19 4 - [18 8 - [18 8 - [18 4 - [15 4 - [19 8 - [19 8 - [19 8 - [19 4 - [19

4 - [11.5

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

PIPING

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

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

f124

Flange

F07_02.EPS

IM 11M12A01-03E

2-7

2.2.2 ZH21B Dust Protector

This protector is designed to protect the probe output from dust agitation (i.e., to prevent combustible materials from entering the probe cell where humidity measurements are made) in a dusty environment.

d Standard Specification

Insertion length: 0.428m Flange: JIS 5K 80 FF SUS304 or ANSI Class 150 4 FF SUS304 (However,

Material: SUS 316(JIS), SUS 304(JIS) (flange) Weight: Approximately 6kg (JIS), approximately 8.5kg (ANSI) Mounting: Mounted on the probe or process flange with bolts and associated

flange thickness is different)

nuts and washers.

Model Suffix code

ZH21B

Insertion length

Flange ( *1)

Style code

* The flange thickness varies.

Specify the probe ZR22G-040-h-K in code of (1)

-040 0.428 m

-A

Option

code

Dust Protector (0 to 6008C)

-J

ZR22G-040-h-C in code of (2)

JIS 5K 80 FF SUS304 (1) ANSI Class 150 4B FF SUS304 (2)

Style B

Dust protector

[

Install facing upwards

Description

428

T2.2E.EPS

76.3

[

Unit ; mm

[

2-8

Insertion hole;minimum[80

ANSI flange

Size of each part of flange

Flange

JIS 5K 80 FF SUS304

ANSI Class 150 4B FF SUS304

180

228.6

145

190.5

four holes of

diameter 19

eight holes of diameter 19

2.3E-1.EPS

JIS flange

Insertion hole;minimum[80

F2.3E.EPS

IM 11M12A01-03E

2.3 ZR402G Separate-type Converter

2.3.1 Standard Specifications

Operated using an LCD touchscreen on the converter. Display: LCD display of size 320 by 240 dot with touchscreen. Output Signal: 4 to 20 mA DC, two points (maximum load resistance 550 V) Contact Output Signal: four points (one is fail-safe, normally open) Contact Input: two points Analog Input: one point (thermal input 4-20 mA) Auto-calibration Output: Two points (for dedicated auto-calibration unit) Ambient Temperature: -20 to +558C Storage Temperature: -30 to +708C Humidity Ambient: 0 to 95%RH (Non-condensing) Installation Altitude: 2000 m or less Category based on IEC 1010: II (Note)

2. Specifications

Pollution degree based on IEC 1010: 2 (Note)

Note: Installation category, called over-voltage category, specifies impulse withstanding voltage. Category II is for electrical equipment. Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce breakdown voltage. Degree 2 is the normal indoor environment.

Power Supply Voltage: Ratings; 100 to 240 V AC Acceptable range; 85 to 264 V AC Power Supply Frequency: Ratings; 50/60 Hz Acceptable range; 45 to 66 Hz Power Consumption: Max. 300 W, approx. 100 W for ordinary use. Safety and EMC conforming standards Safety: EN61010-1

CSA C22.2 No.61010-1 UL61010-1

EMC: EN 61326 Class A

EN 55011 Class A Group 1 EN 61000-3-2 AS/NZS CISPR 11

Maximum Distance between Probe and Converter: Conductor two-way resistance must be 10 V or less (when a 1.25 mm2 cable or equivalent is used, 300 m or less.)

Construction: Outdoor installation, equivalent to NEMA 4 (with conduit holes completely sealed with a plastic cable gland optional)

Wiring Connection: G1/2, Pg13.5, M20 by 1.5 mm, 1/2 NPT, eight holes Installation: Panel, wall or 2B pipe mounting Case: Aluminum alloy Paint Color: Door: Sliver gray (Munsell 3.2PB7.4/1.2)

Case: Sliver gray (Munsell 3.2PB7.4/1.2)

Finish: Polyurethane corrosion-resistant coating Weight: Approx. 6 kg

IM 11M12A01-03E

2-9

2.3.2 Function

Display Functions:

Value Display; Displays values of the measured Oxygen concentration,

moisture quantity, mixture ratio etc.

Graph Display; Displays trends of measured oxygen concentration moisture

quantity, mixture ratio etc.

Data Display; Displays various useful data for maintenance, such as cell

temperature, reference junction temperature, maximum/

minimum moisture quantity and the like.

Status Messages; Indicates an alarm or error occurrence with flashing of the corre-

sponding icon. Indicates status such as warming-up, calibrating, or the like by symbols.

Alarm, Error Display: Displays alarms such as “Abnormal moisture quantity” or

errors such as “Abnormal cell e.m.f.” when any such status occurs.

Calibration Functions:

Auto-Calibration; Requires the Auto-calibration Unit. It calibrates automatically at

specified intervals.

Semi-auto Calibration; Requires the Auto-calibration Unit. Input calibration direction

on the touchpanel or contact, then it calibrates automatically afterwards.

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

operation interactively with an LCD panel.

Blowback Function:

Output through the contact at a set period and time. Auto/semi-auto selectable.

Maintenance Functions:

Can update data settings during daily operation and checking. Display data settings, calibration data settings, blowback data settings,

current output loop check, input/output contact check.

Setup Functions:

Initial settings suit for the plant conditions when installing the con verter. Equipment settings, current output data settings, alarm data settings, contact data settings, other settings.

Self-diagnosis:

This function diagnoses conditions of the converter or the probe and indicates when any abnormal condition occurs.

Password Functions:

Enter your password to operate the analyzer excepting data display. Individual passwords can be set for maintenance and setup.

2-10

IM 11M12A01-03E

Display and setting content:

Measuring-related items: Oxygen concentration (vol% O2), moisture quantity(vol% H2O),

Display Related Items: Oxygen concentration (vol% O2), Moisture quantity (vol% H2O),

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

Output Related Items: Analog output/output mode selection, value conditions when

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

2. Specifications

mixture ratio (kg/kg), relative humidity (%RH) and dew point (8 C)

mixture ratio (kg/kg), relative humidity (%RH), dew point (8 C), cell temperature (8 C), thermocouple reference junction temperature (8 C), maximum/ minimum/average oxygen concentration (vol% O2), maxi-mum/minimum/ average moisture quantity (vol% H2O), maximum/minimum/average mixture ratio (kg/kg), cell e.m.f. (mV), output 1, 2 current (mA), cell response time (seconds), cell internal resistance (V), cell condition (in four grades), heater ontime ratio (%), calibration history (ten times), time (year/month/day/hour/ minute)

(vol% O2), calibration mode (auto, semi-auto, manual), calibration type and method (zero-span calibration, zero calibration only, span calibration only), stabilization time (min.sec), calibration time (min.sec), calibration period (day/ hour), starting time (year/month/day/hour/minute)

warming-up/maintenance/calibrating(or blowback)/abnormal, oxygen concentration at 4mA/20mA (vol% O2), moisture quantity at 4mA/20mA (vol% H2O), mixture ratio at 4mA/20mA (kg/kg), time constant.

(vol% O2), Oxygen concentration low-alarm/low-low alarm limit values (vol% O2), moisture quantity high-alarm/high-high alarm limit values (vol% H2O), moisture quantity low-alarm/low-low alarm limit values (vol% H2O), mixture ratio high-alarm/high-high alarm limit value (kg/kg), mixture ratio low-alarm/ low-low alarm limit values (kg/kg), oxygen concentration alarm hysteresis (vol% O2), moisture quantity alarm hysteresis (vol% H2O), mixture ratio alarm hysteresis (kg/kg), oxygen concentration/moisture quantity/mixture ratio alarm detection, alarm delay (seconds).

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

to 3 (abnormal, high-high alarm, high-alarm, low-alarm, low-low alarm, maintenance, calibrating, range switching, warming-up, calibration-gas pressure-decrease, temperature high-alarm, blow back, unburnt gas detected)

Converter Output: Two points mA analog output (4 to 20 mA DC (maximum load

resistance of 550V) and one of two mA digital output points (HART) (minimum load resistance of 250V).

Range: any setting between 0 to 5 through 0 to 100 vol% O2, 0 to 25 through 0 to 100

vol% H2O, 0 to 0.200 through 0 to 1.000 kg/kg or partial range is available. For the log output, the minimum range values are fixed at 0.1 vol% O2 for the

oxygen concentration, 0.1 vol% H2O for the moisture quantity, and 0.01 kg/kg for the mixture ratio.

4 to 20 mA DC linear or log can be selected. Input/output isolation provided. Output damping 0-255 (sec.) Can select hold or non-hold, and set preset value for hold.

IM 11M12A01-03E

2-11

Contact Output: Four points, contact capacity 30V DC 3A, 250V AC 3A

(resistive load). Three 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 (answerback of contact input), (11) Temperature high-alarm, (12) Blowback start, (13) Flameout gas detection (answerback of contact input), (14) Calibration coefficient alarm, (15) Startup power stabilization timeout alarm

Contact output 4 is set to normally operated, and fixed error status. Converter Input: Thermal input one point (4 to 20 mA DC) Contact Input: Two points, voltage-free contact inputs

The following functions are programmable for contact inputs:

(1) Calibration-gas pressure decrease alarm, (2) Range switching (switched

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

received, the heater power turns off), (5) Blowback start Contact capacity: Off-state leakage current: 3 mA or less Self-diagnosis: cell abnormal , cell temperature abnormal (low/high), calibration

abnormal, A/D converter defective, digital circuit defective

Calibration:Method; zero/span calibration

Calibration mode; automatic, semi-automatic and manual (All are operated

interactively with an LCD touchpanel). Either zero or span can be skipped.

Zero calibration-gas concentration setting range: 0.3 to 100 vol% O2 (minimum

in 0.01 vol%).

Span calibration-gas concentration setting range: 4.5 to 100 vol% O2 (minimum

in 0.01 vol%).

Use nitrogen-based mixed gas containing about 10% of oxygen for standard

zero-gas, and 80 to 100 % of oxygen for standard span-gas.

Calibration period; date/time setting: maximum 255 days

2-12

IM 11M12A01-03E

d Model and Suffix Codes

Model

Suffix code

ZR402G

Converter thread

-P

-G

-M

-T

Display

-J

-E

-G

-F

Instruction manual

Options

Tag plates

*1 Specify either /SCT or /PT option code. *2 Sun shield hood is still effective even if scratched. *3 Be sure to use the equipment with the option code /HS.

Option

code

Description

Separate type Zirconia High Temperature Humidity Analyzer, Converter

G1/2 Pg13.5 M20x1.5 mm 1/2NPT Japanese English German French

-J

-E

-A /HS

/H /SCT /PT

Japanese English

Always -A

Set for Humidity Analyzer (*3)

Hood (*2) Stainless steel tag plate (*1)

Printed tag plate (*1)

2. Specifications

T2.4E.EPS

IM 11M12A01-03E

2-13

280

d External Dimensions

Unit ;mm

1 to 6 (Panel Thickness)

2-inch mounting pipe

EXA

ZR402G

4 - f 6 holes for Wall mounting

126.5

100

120.2

228

57.3

136.3

54.7

(1/2NPT)

111

40 40

8-G1/2, 8-1/2NPT etc (Wiring connection)

2346

38 2414 38

( for wall mounting)

190

Wall mounting

d Accessories

Item Fuse Bracket for mounting

Screw for Bracket

126.5

Part. No. A1113EF F9554AL

F9123GF

4 - f 6 holes

Qty

1 1

4-R8 to R10 or 4-C5 to C8

183

Panel Cut-out

Description

3.15A for pipe mounting, panel mounting or wall mounting

274

F2.5E.EPS

2-14

IM 11M12A01-03E

2. Specifications

d Hood (Option / H)

243

6362

12355

ZR402G

251.5

6263

3994.5

205.5

155.5

Unit ;mm

Hood material : Aluminum

IM 11M12A01-03E

2-15

2.4 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit

2.4.1 ZA8F Flow Setting Unit

This flow setting unit is applied to the reference gas and the calibration gas in a system configuration (System 2).

This unit consists of a flow meter and flow control valves to control the flow of calibration gas and reference air.

• Standard Specifications

FIowmeter: Calibration gas; 0.1 to 1.0 l/min. Reference air; 0.1 to 1.0 l/min. Construction: Dust-proof and rainproof construction Case Material: SPCC (Cold rolled steel sheet) Painting: Baked epoxy resin, Dark-green (Munsell 2.0 GY 3.1/0.5 or equivalent) Pipe Connections: Rc1/4 or 1/4FNPT Reference Air pressure: Clean air supply of measured gas pressure plus approx. 50 kPa G

(or measured gas pressure plus approx. 150kPa G when a check valve is used) pressure at inlet of the auto-calibration unit (Maximum 300 kPaG). Air Consumption: Approx. 1.5 l/min Weight: Approx. 2kg Calibration gas (zero gas,span gas) flow : 0.7 l/min (at calibration time only)

d Model and Codes

Model Suffix code Option code Description

ZA8F

Joint

Style code

-J

-A

Flow setting unit

Rc 1/4

With 1/4" NPT adapter Style A

T2.5E.EPS

2-16

IM 11M12A01-03E

d External Dimensions

2. Specifications

Reference air outlet

f6 hole

235.8

222.8

Zero gas outlet

REFERENCE CHECK

Span gas inlet

180

140

REFERENCE

SRAN

Unit: mm

ZERO

Zero gas inlet

268

ZERO

GAS IN

20 2035 35

CHECK OUT

Flow meter

SPAN

GAS IN

4-Rc1/4

Piping connection

port

Instrument air inlet

REF OUT

Flow meter

AIR IN

IM 11M12A01-03E

Airset

Instrument air Approx 1.5 l/min.

Air pressure: without check valve ; measured gas pressure 1 approx.50 kPaG with check valve ; measured gas pressure 1 approx.150 kPaG

F2.6E.EPS

2-17

2.4.2 ZR40H Automatic Calibration Unit

This automatic calibration unit is applied to supply specified flow of reference gas and calibration gas during automatic calibration to the detector in a system configuration (System 3).

• Specifications

Used when auto calibration is required for the separate type and instrument air is provided. The solenoid valves are provided as standard.

Construction: Dust-proof and rainproof construction:

NEMA4X/IP67 solenoid valve only (excluding flowmeter) Mounting: 2-inch pipe or wall mounting, no vibration Materials: Body; Aluminum alloy, Piping; SUS316 (JIS), SUS304 (JIS), Flowmeter; MA

Finish: Polyurethane corrosion-resistance coating, mint green (Munse11 5.6BG3.3/2.9) Piping Connection: Refer to Model and Suffix Codes Power Supply: 24V DC (from ZR402G), Power consumption; Approx. 1.3W Reference Air Pressure: Sample gas pressure plus Approx. 150 kPa (690 kPa max.),

(Pressure at inlet of auto-calibration unit)

(acrylic resin), Bracket ; sus304 (JIS)

Air Consumption: Approx. 1.5 l/min Weight: Approx. 3.5 kg Ambient Temperature: -20 to +558 C, no condensation or freezing Ambient Humidity: 0 to 95% RH Storage Temperature: -30 to +658 C

d Model and Codes

Model Suffix code Option code Description

ZR40H

Gas piping connection

Wiring connection

-R

-T

-P

-G

-M

-T

-A

Automatic calibration unit for ZR402G

Rc 1/4

1/4" NPT

Pipe connection (G1/2) Pg 13.5 20 mm (M20 x 1.5) 1/2 NPT

Always -A

T2.5-1E.EPS

2-18

IM 11M12A01-03E

d External Dimensions

2B pipe mounting example

*1 with four M6 screws can wall-mount

54 71.526

41.2 41.2

Flowmeter

Setting Valve for reference air

wiring inlet ; 2-G1/2,Pg13.5,M2031.5 or 1/2NPT(Female)

(wiring inlet is at same position on rear)

90 116.5

6.5

12223

250

140

2. Specifications

Unit : mm

49.5

OCK

Setting Valve for calibration gas

calibration gas outlet Rc1/4 or 1/4 NPT(Female)

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

102 MAX58

3040 47.5 25

46 16

IM 11M12A01-03E

reference air outlet Rc1/4 or 1/4 NPT(Female)

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

F2.6-2E.EPS

2-19

Piping

CHECK

OUT

flow meter

REF OUT

flow meter

*2 *2

EV1 EV2

ZERO GAS IN

AIR IN

Instrument air Approx.

1.5 l/min.

*2 Needle valve is supplied as accessory with flow meter.

F2.6-3E.EPS

2-20

IM 11M12A01-03E

2.5 ZO21S Standard Gas Unit

This is a handy unit to supply zero gas and span gas to the detector in a system configuration based on System 1. It is used in combination with the detector only during calibration.

d Standard Specifications

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

gas cylinder with sealed inlet, flow rate checker and flow rate needle valve. Sealed Zero Gas Cylinders (6 provided): E7050BA Capacity: 1 l Filled pressure: Approx. 686 kPa G (at 35 8 C) Composition: 0.95 to 1.0 vo1% O2+N2 based Power Supply: l00, 110, 115, 200, 220, 240 V AC6 10%, 50/60 Hz Power Consumption: Max. 5 VA Case Material: SPCC (Cold rolled steel sheet)

2. Specifications

Point: Epoxy resin, baked Paint Color:

Mainframe; Munsell 2.0 GY3.1/0.5 equivalent

Cover; Munsell 2.8 GY6.4/0.9 equivalent Piping: f 63f 4mm flexible tube connection Span Gas: Internal pump draws in air from atmosphere, and feeds to detector. Weight: Approx. 3 kg

p Non CE Mark.

d Model and Codes

Model

ZO21S

Power supply

Panel

Style code

Suffix code Option code

-2

-3

-4

-5

-7

-8

-J

-E

Description

Standard gas unit

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 Style A

T2.6E.EPS

IM 11M12A01-03E

2-21

d External Dimensions

1600

Zero gas cyilnder (6 cyilnder): E7050BA

354

Unit : mm

228

253

Flow checker

Span gas valve

Zero gas valve

Gas outlet

F2.7E.EPS

2.6 Other Equipment

2.6.1 Stop Valve (Part Number: L9852CB or G7016XH)

This valve is mounted on the calibration gas line in the system to allow for one-touch calibration. This applies to the system configuration shown for system 1 in section 1.

Standard Specifications

Connection: Rc 1/4 or 1/4 FNPT Material: SUS 316 (JIS) Weight: Approx. 80 g

Part No.

L9852CB G7016XH

Joint: RC 1/4, Material: SUS 316 (JIS) Joint:

Description

1/4 NPT,

Material:

SUS 316 (JIS)

Unit: mm

T2.9E.EPS

2-22

Rc1/4 or 1/4NPT

(Full open length)

F15.EPS

IM 11M12A01-03E

2.6.2 Check Valve (Part Number: K9292DN or K9292DS)

This valve is mounted on the calibration gas line (directly connected to the detector). This is applied to a system based on the (System 2 and 3) system configuration.

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

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

Standard Specifications

Connection: Rc1/4 or 1/4FNPT Material: SUS304 (JIS) Pressure: 70 kPa G or more,and 350 kPa G or less Weight: Approx. 40 g

2. Specifications

1/4 NPT

Description

, Material:

SUS304

Part No.

K9292DN K9292DS

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

Approx.19

Joint: RC 1/4, Material: SUS304 (JIS) Joint:

(JIS)

T2.10E.EPS

Unit : mm

Approx.54

F2.11E.EPS

IM 11M12A01-03E

2-23

2.6.3 Air Set

Part Number: K9473XH or K9473XJ

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

Standard Specifications

Primary Pressure: Max. 2 MPa G Secondary Pressure: 0 to 0.25 MPa G Connection: Rc1/4 or 1/4FNPT (includes joint adapter) Weight: Approx.1 kg

Part No.

K9473XH

K9473XJ

(53.5)

(63)

Description

Joint: Rc 1/4, Material: Aluminum Joint:

1/4

NPT (F) , Material: Body; Aluminum,

Dimensions in parentheses are approximate.

(116)

[54

Adapter; Zinc alloy

T2.11E.EPS

69.5

Unit: mm

(43.5)

OUT

(135.5)

[48

2-24

18.5

Bracket Mounting Dimensions

K9473XH: Piping connection (IN: Primary side, OUT: Secondary side), Rc1/4

K9473XJ: Piping connection (IN: Primary side, OUT: Secondary side), 1/4NPT

IM 11M12A01-03E

Part Number; G7004XF or K9473XG

Primary Pressure: Max. 1 MPa G Secondary Pressure: 0.02 to 0.5 MPa G Connection: Rc1/4 or 1/4 FNPT with joint adapter

2. Specifications

Part No.

G7004XF

K9473XG

Joint: Rc 1/4, Material: Zinc Alloy Joint:

d External Dimensions

Panel cut dimensions

Horizontal mounting

[15

+0.5

-0

2-2.2

Description

1/4

NPT (F) , Material: Body; Zinc Alloy,

Vertical mounting

2-[6.5

max. 55

Adapter; SUS316

T2.13E.EPS

Unit : mm

View A

2-[6 screw depth 10

Panel (Horizontal mounting)

Primary

[74

Secondary

Max. 210

Secondary pressure gauge

G7004XF: Rc 1/4 K9473XG: 1/4NPT connector

Approx. 122

Panel (Vertical mounting)

IM 11M12A01-03E

2-25

2.6.4 Zero-gas Cylinder (Part Number: G7001ZC)

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

Standard Specifications

Capacity: 3.4 l Filled pressure: 9.8 to 12 MPa G Composition: 0.95 to 1.0 vol% O2 in N

(Note) Export of such high pressure filled gas cylinders to most countries is prohibited or restricted.

Unit : mm

485

325

[

140

Weight : Approx. 6 kg

F2213.EPS

2.6.5 Pressure Regulator for Gas Cylinder (Part Number: G7013XF or G7014XF)

This regulator valve is used with the zero gas cylinders.

Standard Specifications

Primary Pressure: Max. 14.8 MPa G Secondary Pressure: 0 to 0.4 MPa G Connection: Inlet W22 14 threads, right hand screw

Outlet Rc1/4 or 1/4FNPT

Material: Brass body

Regulator handle

Approx.112

Outlet

Approx. 59

Approx. 163

Part No. G7013XF G7014XF

Stop valve

Secondary pressure gauge

Primary safety valve

Approx. 174

p Outlet Rc1/4 1/4 NPT female screw

Primary pressure gauge

Secondary safety valve

Approx. 82

Unit : mm

W22 (Righthanded screw)

2-26

IM 11M12A01-03E

2.6.6 Case Assembly for Calibration-gas Cylinder (Part Number: E7044KF)

This case is used to store the zero gas cylinders.

Standard Specifications

Case Paint: Baked epoxy resin, Jade green (Munsell 7.5 BG 4/1.5) Installation: 2B pipe mounting Material: SPCC (Cold rolled steel sheet) Weight: Approx. 3.6kg, 10 kg with gas cylinder (Note) Export of such high pressure filled gas cylinders to most countries is prohibited

or restricted.

Unit : mm

2. Specifications

324

496

(Note) E7044KF (case assembly) has no zero gas cylinder

and pressure regulator.

Pressure regulator

G7013XF/ G7014XF

Zero gas cylinder

(G7001ZC)

200

180

2B pipe (f60.5)

F2.15E.EPS

IM 11M12A01-03E

2-27

2.6.7 Model ZR22A Heater Assembly

Table 2.1 ZR22A

Option code

-N

-A

-B

-C

d External Dimensions

Model Suffix code Description

ZR22A

Length (p1)

Jig for change -A

Reference air (*3)

p1 Suffix code of length should be selected as same as ZR22G installed. p2 Jig part no. is K9470BX to order as a parts after purchase. p3 Select appropriately among "-A", "-B", "-C" according to the reference air supply method and style.

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

-015

-040

-070

-100

-150

-200

-250

-300

Style: S2

Heater Assembly for ZR22G

0.15 m

0.4 m

0.7 m 1 m

1.5 m 2 m

2.5 m 3 m

with Jig (*2) None

Reference air Natural convention External connection (Instrument air) Pressure compensated (for ZR22G S2) Pressure compensated (for ZR22G S1)

T23.EPS

[ 45

Jig for change

(K9470BX)

[ 21.7

K9470BX

L612

F2.16E.EPS

L length

Model & Code

ZR22A-040 ZR22A-070 ZR22A-100 ZR22A-150 ZR22A-200 ZR22A-250 ZR22A-300

Unit : mm

L 552 852

1152 1652 2152 2652 3152

Weight (kg) Approx. 0.8 Approx. 1.2 Approx. 1.6 Approx. 2.2 Approx. 2.8 Approx. 3.4 Approx. 4.0

2-28

IM 11M12A01-03E

3. Installation

This chapter describes installation of the following equipment:

3.1 Detector

3.2 Converter

3.3 ZA8F Flow Setting Unit

3.4 ZR40H Automatic Calibration Unit

3.5 E7044KF Case Assembly for Calibration-gas Cylinder

3.1 Installation of the Detector

3.1.1 Location

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

(1) Easy and safe access to the detector for checking and maintenance work. (2) Ambient temperature of not more than 150°C, and the terminal box should not

affected by radiant heat.

(3) A clean environment without any corrosive gases.

3. Installation

CAUTION

• A natural convection type detector (model ZR22G-h-h-h-C), which uses ambient air as reference gas, requires that the ambient oxygen concentration be constant.

(4) No vibration. (5) The measurement gas satisfies the specifications described in Chapter 2. (6) No measurement gas-pressure fluctuations.

IM 11M12A01-03E

3-1

3.1.2 Probe Insertion Hole

Includes those analyzers equipped with a dust protector. When preparing the probe insertion hole, the following should be taken into consider-

ation:

CAUTION

• The outside dimension of detector may vary depending on its options. Use a pipe that is large enough for the detector. Refer to Figure 3.1 for the dimensions.

• If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards. When using the detector with pressure compensation, ensure that the flange gasket does not block the reference air outlet on the detector flange. If the flange gasket blocks the outlet, the detector cannot conduct pressure compensation. Where necessary, make a notch in the flange gasket. Confirm the external dimensions of the detector in Section 3.7 before installation.

• The sensor (zirconia cell) at the probe tip may deteriorate due to condensation as it is always at high temperature.

(1) Do not mount the probe with the tip higher than the probe base. (2) If the probe length is 2.5 meters or more, the detector should be mounted vertically

(nomore than a 5° tilt).

(3) The detector probe should be mounted at right angles to the measurement gas

flow or the probe tip should point downstream. Figure 3.1 illustrates an example of the probe insertion hole.

(vertical)

100mm

(Note) When using the detector with ZH21B dust protector the diameter of the hole should be 80mm or larger.

Bounds of the probe insertion hole location

Flange matches to the detector size

*1 *Note

100mm

Type Outside diameter of detector

Standard 50.8 mm in diameter (Note) With dust protector 80 mm in diameter or longer(Note)

(horizontal)

Four-hole flange Eight-hole flange

When using the detector with pressure compensation, ensure that the flange gasket does not block the reference air outlet on the detector flange. If the flange gasket blocks the outlet, the detector cannot conduct pressure compensation. Where necessary, make a notch in the flange gasket. Confirm the outside dimensions of the detector in Section 3.7 before installation.

Figure 3.1 Example of forming probe insertion hole

JIS flange(the detector with dust protector)

F3.1E.EPS

3-2

IM 11M12A01-03E

3.1.3 Installation of the Detector

CAUTION

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

• A gasket should be used between the flanges to prevent gas leakage. The gasket material should be heatproof and corrosion-proof, suited to the characteristics of the measured gas

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

<General-use detector>

(1) Make sure that the cell mounting screws (four) at the probe tip are not loose. (2) Where the detector is mounted horizontally, the calibration gas inlet and the refer-

ence gas inlet should face downward.

3. Installation

3.1.4 Installation of ZH21B Dust Protector

(1) Put the gasket that is provided by the user between the flanges and mount the dust

protector in the probe insertion hole.

(2) Make sure that the cell assembly mounting screws (four) at the probe tip are not

loose.

(3) Mount the detector so that the calibration gas inlet and the reference gas inlet face

downward

Unit;

Calibration gas inlet Reference gas inlet

IM 11M12A01-03E

F3.2E.EPS

Figure 3.2 Installation of the dust filter

3-3

3.2 Installation of the Converter

3.2.1 Location

The following should be taken into consideration when installing the converter: (1) Readability of the indicated values of moisture concentration or messages on the

converter display.

Easy and safe access to the converter for operating keys on the panel. (2) Easy and safe access to the converter for checking and maintenance work. (3) An ambient temperature of not more than 558C and little change in temperature

(recommended within 158C in a day). (4) The normal ambient humidity (recommended between 40 to 75 %RH) and without

any corrosive gases. (5) No vibration. (6) Near to the detector. (7) Not in direct rays of the sun. If the sun shines on the converter, prepare the hood (/

H) or other appropriate sunshade.

3.2.2 Mounting of the Converter

The converter can be mounted on a pipe (nominal JIS 50A: O.D. 60.5 mm), a wall or a panel. The converter can be mounted at an angle to the vertical, however, it is recommended to mount it vertically plane.

Mount the converter as follows.

<Pipe Mounting> (1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for

mounting the converter. (Converter weighs approximately 6 kg.) (2) Mount the converter on the pipe. Fix it firmly on the pipe in the procedure described

in Figure 3.3.

dMounting procedure

1. Put four bolts in the holes on the fitting.

2. Clamp the pipe with the fitting and a bracket, with the four bolts passing through the bracket holes.

3. Secure the fitting and the bracket tightly to the pipe with four washers and nuts.

A pipe to be mounted (nominal JIS 50A)

Bracket

*Fitting

*Washer

*Screw

Nut

3-4

Bolt

* Note: These fittings are attached to the equipment when it is delivered.

Figure 3.3 Pipe Mounting

Washer

F3.7E.EPS

IM 11M12A01-03E

(1) Drill mounting holes through the wall as shown in Figure 3.4.

Unit: mm

Four holes 6 mm in diameter or M5 screw

126.5

3. Installation

190

F3.8E.EPS

Figure 3.4 Mounting holes

(2) Mount the converter. Secure the converter on the wall using four screws. Note: For wall mounting, the bracket and bolts are not used.

F3.5E.EPS

Figure 3.5 Wall Mounting

IM 11M12A01-03E

3-5

(1) Cut out the panel according to Figure 3.6.

Unit: mm

274

183

F3.6E.EPS

Figure 3.6 Panel cutout sizes

(2) Remove the fitting from the converter by loosening the four screws. (3) Insert the converter case into the cutout hole of the panel. (4) Attach the mounting fitting which is once removed in step (2) again to the converter. (5) Firmly fix the converter to the panel. Fully tighten the two clamp screws to hold the

panel with the fitting.

Clamp screw

Figure 3.7 Panel mounting

Washer

Nut

Fitting

F3.7E.EPS

3-6

IM 11M12A01-03E

3.3 Installation of ZA8F Flow Setting Unit

3.3.1 Location

The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work.

(2) Near to the detector and the converter for operating keys on the panel. (3) No corrosive gas. (4) An ambient temperature of not more than 558C and little changes of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain.

3.3.2 Mounting of ZA8F Flow Setting Unit

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

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

mounting the flow setting unit. (The unit weighs approximately 2 to 3.5 kg.) (2) Mount the flow setting unit on the pipe by tightening the nuts with the U-bolt so that

the metal fitting is firmly attached to the pipe.

3. Installation

IM 11M12A01-03E

F3.8E.EPS

Figure 3.8 Pipe Mounting

3-7

(1) Make a hole in the wall as illustrated in Figure 3.9.

Unit : mm

223

140

F3.9E.EPS

4 - f6 hole, or M5 screw

Figure 3.9 Mounting holes

(2) Mount the flow setting unit. Remove the pipe mounting parts from the mount fittings

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

F3.10E.EPS

Figure 3.10 Wall mounting

3-8

IM 11M12A01-03E

3.4 Installation of ZR40H Automatic Calibration Unit

3.4.1 Location

The following should be taken into consideration:

(1) Easy access to the unit for checking and maintenance work. (2) Near to the detector and the converter (3) No corrosive gas. (4) An ambient temperature of not more than 558C and little change of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain.

3.4.2 Mounting of ZR40H Automatic Calibration Unit

The Automatic Calibration Unit can be mounted either on a pipe (nominal JIS 50A ) or on a wall. It should be positioned vertically so that the flowmeter works correctly.

(1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting of Automatic Calibration Unit. (The unit weights approximately 3.5 kg.) (2) Mount the Automatic Calibration Unit on the pipe by tightening the nuts with the U-bolt so that the metal fitting is firmly attached to the pipe.

3. Installation

IM 11M12A01-03E

F3.11E.EPS

Figure 3.11 Pipe Mounting

3-9

(1) Make a hole in the wall as illustrated in Figure 3.12.

Unit : mm

223

140

F3.12E.EPS

4 - f6.5 hole, or M6 screw

Figure 3.12 Mounting holes

(2) Mount the Automatic Calibration Unit. Remove the pipe mounting parts from the

mount fittings of the flow setting unit and attach the unit on the wall with four screws. When setting it with M5 bolts, use washers.

[6.5

3-10

F3.13E.EPS

Figure 3.13 Wall Mounting

IM 11M12A01-03E

3.5 Installation of E7044KF Case Assembly for the Calibration-gas Cylinder

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

3.5.1 Location

The following should be taken into consideration: (1) Easy access for cylinder replacement

(2) Easy access for checking (3) Near to the detector and converter as well as the flow setting unit. (4) The temperature of the case should not exceed 408C due to rays of the sun or

radiated heat.

(5) No vibration

3.5.2 Mounting

Mount the calibration gas unit case on a pipe (nominal JIS 50A) as follows: (1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for

mounting the flow setting unit. (The sum of the calibration gas unit case and the calibration gas cylinder weighs approximately 4.2 kg.)

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

metal fitting is firmly attached to the pipe.

3. Installation

IM 11M12A01-03E

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

F3.14E.EPS

Figure 3.14 Pipe Mounting

3-11

3.6 Insulation Resistance Test

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

The applied voltage for this test shall be 500 V DC or less. The voltage shall be applied for as short a time as practicable to confirm that insulation resistance is 20 MV or more.

Remove wiring from the converter and the detector.

1. 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 kV 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 ground can be conducted in the same manner.

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

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

Insulation resistance tester

crossover wiring

1FG2

AO1

(+)

12FG13

DI-114DI-215DI-C16AI

Contact input 1

Temperature transmitter input 4 to 20mA

DO-124DO-125DO-226DO-227DO-328DO-329DO-430DO-431HTR32HTR33L34N35G

Remove wiring to connect external circuits and connect crossover wiring

Separate-type Zirconia High Temperature Humidity Analyzer, ZR402G Converter

AO1

(-)

AO2

(+)

Contact input 2

AO2

(-)

(+)

17 AI (-)

ZERO

(-)

AC-

SPAN

Automatic Calibration Unit

(+)

(-)

AC-

COM

Solenoid valve

Span gas

for automatic calibration

Solenoid valve for automatic calibration

Zero gas

CELL

(+)

21FG22

CELL

(-)

crossover wiring

Separate-type Zirconia High Temperature Humidity Analyzer, ZR22G Detector

CELL

(+)

(-)TC(+)TC(-)CJ(+)CJ(-)

Remove jumper plate

HTR HTR

3-12

Insulation resistance tester

F3.17E.EPS

IM 11M12A01-03E

3. Installation

3.7 External Dimensions of Detectors with Pressure Compensation

dZR22G-hhh-h-A-P Flange ; ANSI Class 150 2 RF SUS304

Reference gas outlet

Model, Code

ZR22G-040-h-A ZR22G-070-h-A ZR22G-100-h-A ZR22G-150-h-A ZR22G-200-h-A ZR22G-250-h-A ZR22G-300-h-A

Flange

400

700 1000 1500 2000 2500 3000

ANSI Class 150 2 RF SUS304

156

PIPING : A

Specification

PIPING

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

152.4 120.6

Rc1/4 or 1/4NPT Reference air inlet

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

Flange

4-f19

Flange

PIPING

Unit : mm

Weight

skgd Approx. 6 Approx. 7

Approx. 8

Approx. 10 Approx. 12 Approx. 14 Approx. 15

F3.8.1E.EPS

IM 11M12A01-03E

3-13

dZR22G-hhh-h-B-P Flange ; ANSI Class 150 3 RF

Reference gas outlet

Flange

156

PIPING

PIPING : A

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Unit : mm

Flange

Model, Code

ZR22G-040-h-B ZR22G-070-h-B ZR22G-100-h-B ZR22G-150-h-B ZR22G-200-h-B ZR22G-250-h-B ZR22G-300-h-B

400

700 1000 1500 2000 2500 3000

Specification

ANSI Class 150 3 RF SUS304

dZR22G-hhh-h-C-P Flange ; ANSI Class 150 4 RF

Reference gas outlet

Model, Code

ZR22G-040-h-C ZR22G-070-h-C ZR22G-100-h-C ZR22G-150-h-C ZR22G-200-h-C ZR22G-250-h-C ZR22G-300-h-C

Flange

400

700 1000 1500 2000 2500 3000

Specification

ANSI Class 150 4 RF SUS304

156

PIPING

: B

PIPING : A

Flange

190.5 152.4

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Flange

228.6 190.5

4-f19

8-f19

Flange

PIPING

Weight

skgd Approx. 9 Approx. 10

Approx. 11

Approx. 13 Approx. 14 Approx. 16 Approx. 18

F3.8.2E.EPS

Unit : mm

Weight

skgd

Approx. 11 Approx. 12

Approx. 13

Approx. 15 Approx. 17 Approx. 18 Approx. 20

F3.8.3E.EPS

3-14

IM 11M12A01-03E

dZR22G-hhh-h-E-P Flange ; DIN PN10 DN50

3. Installation

Rc1/4 or 1/4NPT Reference air inlet

156

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

Reference gas outlet

Flange

Model, Code

ZR22G-040-h-E ZR22G-070-h-E ZR22G-100-h-E ZR22G-150-h-E ZR22G-200-h-E ZR22G-250-h-E ZR22G-300-h-E

400

700 1000 1500 2000 2500 3000

dZR22G-hhh-h-F-P Flange ; DIN PN10 DN80

PIPING

: B

PIPING : A

Specification

DIN PN10 DN50

SUS304

156

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

165 125

Flange

4-f18

Rc1/4 or 1/4NPT Reference air inlet

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

Flange

PIPING

Weight

skgd Approx. 7 Approx. 8

Approx. 9

Approx. 10 Approx. 12 Approx. 14 Approx. 16

F3.8.4E.EPS

Unit : mm

IM 11M12A01-03E

Reference gas outlet

Model, Code

ZR22G-040-h-F ZR22G-070-h-F ZR22G-100-h-F ZR22G-150-h-F ZR22G-200-h-F ZR22G-250-h-F ZR22G-300-h-F

Flange

400

700 1000 1500 2000 2500 3000

PIPING : A

Specification

DIN PN10 DN80

SUS304

PIPING

: B

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Flange

200 160

8-f18

Flange

PIPING

Weight

skgd

Approx. 8

Approx. 10

Approx. 11

Approx. 12 Approx. 14 Approx. 16 Approx. 18

F3.8.5E.EPS

3-15

dZR22G-hhh-h-G-P Flange ; Equivalent to DIN PN10 DN100

Reference gas outlet

Flange

156

PIPING

PIPING : A

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Unit : mm

Flange

Model, Code

ZR22G-040-h-G ZR22G-070-h-G ZR22G-100-h-G ZR22G-150-h-G ZR22G-200-h-G ZR22G-250-h-G ZR22G-300-h-G

400

700

1000 1500 2000 2500 3000

Specification

DIN PN10 DN100

SUS304

dZR22G-hhh-h-K-P Flange ; Eguivalent to JIS 5K 65 FF

Reference gas outlet

Flange

156

PIPING

: B

PIPING : A

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Flange

220 180

Rc1/4 or 1/4NPT Reference air inlet

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

8-f18

Flange

PIPING

Weight

skgd Approx. 9 Approx. 11

Approx. 12

Approx. 13 Approx. 15 Approx. 17 Approx. 19

F3.8.6E.EPS

Unit : mm

3-16

Model, Code

ZR22G-040-h-K ZR22G-070-h-K ZR22G-100-h-K ZR22G-150-h-K ZR22G-200-h-K ZR22G-250-h-K ZR22G-300-h-K

400

700 1000 1500 2000 2500 3000

Specification

JIS 5K 65 FF

SUS304

Flange

155 130

4-f15

PIPING

IM 11M12A01-03E

Weight

skgd Approx. 6 Approx. 7

Approx. 8

Approx. 10 Approx. 12 Approx. 14 Approx. 15

F3.8.7E.EPS

3. Installation

dZR22G-hhh-h-L-P Flange ; JIS 10K 65 FF

Reference gas outlet

Model, Code

ZR22G-040-h-L ZR22G-070-h-L ZR22G-100-h-L ZR22G-150-h-L ZR22G-200-h-L ZR22G-250-h-L ZR22G-300-h-L

Flange

400

700 1000 1500 2000 2500 3000

156

PIPING

PIPING : A

Specification

JIS 10K 65 FF

SUS304

: B

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Flange

175 140

4-f19

Flange

PIPING

Unit : mm

Weight

skgd Approx. 7 Approx. 8

Approx. 9

Approx. 11 Approx. 13 Approx. 14 Approx. 16

F3.8.8E.EPS

dZR22G-hhh-h-M-P Flange ; JIS 10K 80 FF

Reference gas outlet

Model, Code ZR22G-040-h-M

ZR22G-070-h-M ZR22G-100-h-M ZR22G-150-h-M ZR22G-200-h-M ZR22G-250-h-M ZR22G-300-h-M

Flange

400

700 1000 1500 2000 2500 3000

156

PIPING

PIPING : A

Specification

JIS 10K 80 FF

SUS304

: B

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Flange

185 150

8-f19

Flange

PIPING

Unit : mm

Weight

skgd Approx. 7 Approx. 8

Approx. 9

Approx. 11 Approx. 13 Approx. 15 Approx. 16

F3.8.9E.EPS

IM 11M12A01-03E

3-17

dZR22G-hhh-h-P-P Flange ; JIS 10K 100 FF

Reference gas outlet

Flange

156

PIPING

: B

PIPING : A

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

Unit : mm

Flange

Model, Code

ZR22G-040-h-P ZR22G-070-h-P ZR22G-100-h-P ZR22G-150-h-P ZR22G-200-h-P ZR22G-250-h-P ZR22G-300-h-P

400

700 1000 1500 2000 2500 3000

JIS 10K 100 FF

dZR22G-hhh-h-R-P Flange ; JPI Class 150 4 RF

Reference gas outlet

Flange

Specification

SUS304

156

PIPING

: B

PIPING : A

Flange

210 175

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

8-f19

Flange

PIPING

Weight

skgd Approx. 8 Approx. 10

Approx. 11

Approx. 12 Approx. 14 Approx. 16 Approx. 18

F3.8.10.EPS

Unit : mm

3-18

Model, Code

ZR22G-040-h-R ZR22G-070-h-R ZR22G-100-h-R ZR22G-150-h-R ZR22G-200-h-R ZR22G-250-h-R ZR22G-300-h-R

400

700 1000 1500 2000 2500 3000

Specification

JPI Class 150 4 RF SUS304

Flange

229 190.5

8-f19

PIPING

IM 11M12A01-03E

Weight

skgd Approx. 11 Approx. 12

Approx. 13

Approx. 15 Approx. 17 Approx. 19 Approx. 20

F3.8.11.EPS

dZR22G-hhh-h-S-P Flange ; JPI Class 150 3 RF

Reference gas outlet

Flange

156

PIPING

: B

PIPING : A

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

3. Installation

Unit: mm

Flange

Model, Code

ZR22G-040-h-S ZR22G-070-h-S ZR22G-100-h-S ZR22G-150-h-S ZR22G-200-h-S ZR22G-250-h-S ZR22G-300-h-S

400

700 1000 1500 2000 2500 3000

dZR22G-hhh-h-W-P Flange ; Westinghouse

Reference gas outlet

Flange

Specification

JPI Class 150 3 RF SUS304

156

PIPING

PIPING : A

: B

Flange

190 152.4

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valve

4-f19

Flange

PIPING

Weight

skgd Approx. 9 Approx. 10

Approx. 11

Approx. 13 Approx. 14 Approx. 16 Approx. 18

F3.8.12E.EPS

Unit: mm

IM 11M12A01-03E

Model, Code ZR22G-040-h-W

ZR22G-070-h-W ZR22G-100-h-W ZR22G-150-h-W ZR22G-200-h-W ZR22G-250-h-W ZR22G-300-h-W

400

700 1000 1500 2000 2500 3000

Specification

Westinghouse

Flange

155 127

4-f11.5

PIPING

Weight

skgd Approx. 6 Approx. 7

Approx. 8

Approx. 10 Approx. 12 Approx. 14 Approx. 15

F3.8.13E.EPS

3-19

4. Piping

This chapter describes piping procedures based on three typical system configurations for EXAxt ZR Separate-type Zirconia High-temperature Humidity Analyzer.

• Ensure that each check valve, stop valve and joint used for piping do not allow

• Be sure to conduct leakage test after pipes piping.

• Basically, apply instrument air (dehumidified by cooling to the dew point –20°C or

• When the instrument uses natural convection for reference gas, ambient air near the

4. Piping

leakage. Especially, if there is any leakage of from the calibration gas pipes and joints, it may cause clogging of the piping or incorrect calibration.

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

detector is used for reference gas; therefore the accuracy of analysis will be affected by ambient temperature changes or the like. If more accurate analysis is necessary, use instrument air (dehumidified by cooling to the dew point –20°C or lower, and removing any dust, oil mist and the like) for reference gas. Stable analyzing can be conducted when using instrument air.

4.1 Piping for System 1

The piping in System 1 is illustrated in Figure 4.1.

Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Detector

Stop valve

Calibration gas

Figure 4.1 Piping in System 1

Piping in System 1 is as follows:

• Place a stop valve through the nipple at the calibration gas inlet of the detector. Then mount a joint for a 6 mm (O.D.)34 mm (I.D.) soft tube at the stop valve connection hole of the inlet side (see Section 4.1.2). The tube is to be connected to this joint only during calibration.

Model ZR402G Converter

EXA

ZR402G

Signal (6-core shield cable)

Heater (2-core)

Model ZO21S Standard gas unit

100 to 240 V AC

Contact input Analog output, contact output

Digital output (HART)

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

F4.1E.EPS

IM 11M12A01-03E

CAUTION

• The stop valve should be connected directly to the detector. If any piping is present between the detector and the stop valve, water may condense in the pipe, which may cause damage to the sensor by rapid cooling when the calibration gas is introduced. The stop valve should be closed except while the calibration gas is being introduced. Piping is required if the air around the detector is not clean.

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

4-1

• It is recommended to use ZH21B dust protector to protect the probe output from dust agitation (i.e., to prevent combustible materials from entering the probe cell) where humidity measurements are made under dusty or combustible, such as paper dust, environment.

4.1.1 Parts Required for Piping in System 1

Check that the parts listed in Table 4.1 are ready.

Table 4.1

Detector Piping location Parts Note General-use Calibration gas inlet Stop valve Recommended by YOKOGAWA detector (L9852CB or G7016XH)

nipple * Rc1/4 or 1/4 NPT generic parts joint for tube connection Rc1/4 (1/4NPT) for f63f4mm generic parts

Reference gas inlet (sealed up) (when piping is required, refer to section 4.1.3)

Note : Parts with marking * are used when required.

4.1.2 Connection to the Calibration Gas Inlet

When carrying out calibration, connect the piping (6(O.D)34(I.D.) mm tube) from the standard gas unit to the calibration gas inlet of the detector. First, mount a stop valve (of a quality specified by YOKOGAWA) or a nipple (found on the open market) as illustrated in Figure 4.2, and mount a joint (also found on the open market) at the stop valve tip. (The stop valve may be mounted on the detector prior to shipping the detector is shipped.)

soft tube

T4.1E.EPS

Note : Mount the stop valve close to the detector.

Tube connection joint

Figure 4.2 Connection to the calibration gas inlet

4.1.3 Connection to the Reference Gas Inlet

• Normally, no piping is required for the reference gas inlet when the equipment uses natural convection for reference gas (models ZR22G-h-h-h-C). Leave the plug as it is. If the air around the detector is polluted and the necessary oxygen concentration (21 vol%O2) cannot be obtained, prepare piping the same as which described in Section 4.2, System 2.

• When the equipment uses instrument air for the reference gas, piping is required as described in Section 4.2, System 2 (models ZR22G-h-h-h-E).

NippleStop valve

F4.2E.EPS

4-2

IM 11M12A01-03E

4.2 Piping for System 2

Piping in System 2 is illustrated in Figure 4.7.

Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Detector

Model ZR402G Converter

EXA

ZR402G

4. Piping

Stop valve or Check valve

Calibration gas

Reference gas

Signal (6-core shield cable)

Heater (2-core)

Model ZA8F flow setting unit

Flowmeter

Needle

valve

Calibration gas pressure regulator

Calibration gas unit case

100 to 240 V AC

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

Air Set

Instrument air

Span gas (Same as Zero gas

Calibration unit)

Zero gas

cylinder

F4.7E.EPS

Figure 4.7 Piping for System 2

Piping in System 2 is as follows:

• Place a stop valve or check valve through the nipple at the calibration gas inlet of the detector.

4.2.1 Piping Parts for System 2

Check that the parts listed in Table 4.2 are ready.

Table 4.2

Detector Piping location Parts Note General-use Calibration gas inlet Stop valve or check valve Recommended by YOKOGAWA detector (L9852CB or G7016XH)

Reference gas inlet Air set Recommended by YOKOGAWA

Note : Parts with marking * are used when required.

Provided by YOKOGAWA

(K9292DN or K9292DS) Nipple * Rc1/4 or 1/4 NPT generic parts Zero gas cylinder User's scope

Gas pressure regulator Recommended by YOKOGAWA

(G7013XF or G7014XF) Joint for tube connection Rc1/4 or 1/4 NPT generic parts

(K9473XH/K9473XJ or

G7004XF/ K9473XG) Joint for tube connection Rc1/4 or 1/4 NPT generic parts

T4.2E.EPS

IM 11M12A01-03E

4-3

4.2.2 Piping for the Calibration Gas

This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit, and between the ZA8F flow setting unit and the ZR22G detector.

The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 408 C. Mount a regulator valve (specified by YOKOGAWA) on the cylinder.

Mount a check valve or the stop valve (specified by YOKOGAWA) or the nipple (found on the open market) at the calibration gas inlet of the detector as illustrated in Figure

4.8. (The check valve or the stop valve may have been mounted on the detector when shipped.) Connect the flow setting unit and the detector to a stainless steel pipe 6 mm (O.D.) 34 mm or larger (I.D.) (or nominal size 1/4 inch).

Stop valve or Check valve

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

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

Figure 4.8 Piping for the Calibration Gas Inlet

4.2.3 Piping for the Reference Gas

Reference gas piping is required between the air source (instrument air) and the flow setting unit, and between the flow setting unit and the detector.

Insert the air set next to the flow setting unit in the piping between the air source and the flow setting unit.

Use a 6 mm (O.D.) 3 4 mm or larger (I.D.) (or nominal size 1/4 inch) stainless steel pipe between the flow setting unit and the detector.

F4.8E.EPS

4-4

IM 11M12A01-03E

4.3 Piping for System 3

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

Adjust secondary pressure of both the air set and the zero gas reducing valve so that these two pressures are approximately the same. The flow rate of zero and span gases (normally instrument air) are set by a single needle valve.

After installation and wiring, check the calibration contact output (see Sec. 7.10.2), and adjust zero gas reducing valve and calibration gas needle valve so that zero gas flow is within the permitted range. Next check span gas calibration contact output and adjust air set so that span gas flow is within the permitted range.

4. Piping

CHECK OUT

flow meter

REF OUT

flow meter

*2 *2

EV1 EV2

ZERO GAS IN

AIR IN

Instrument air Approx.

1.5 l/min.

*2: Needle valve comes with flowmeter

F2.6-3E.EPS

It is recommended to use ZH21B dust protector to protect the probe output from dust agitation (i.e., to prevent combustible materials from entering the probe cell) where humidity measurements are made under dusty or combustible environment.

Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Detecor

Model ZR402G Converter

EXA

ZR402G

IM 11M12A01-03E

Conduit

Signal

Check valve

Reference gas

Calibration gas

(6-core shield cable)

Heater (2-core shield cable)

Model ZR40H Auto Calibration unit

Figure 4.9 Piping for System 3

Flowmeter

Needle

valve

100 to 240 V AC

Air Set

Contact input Analog output, contact output

Digital output (HART)

Instrument air

Calibration gas pressure regulator

Calibration gas unit case

Zero gas cylinder

F4.9E.EPS

4-5

5. Wiring

In this Chapter, the wiring necessary for connection to the EXAxtZR Separate-type Zirconia High-temperature Humidity Analyzer is described.

5.1 General

CAUTION

• NEVER supply current to the converter or any other device constituting a power

• This product complies with CE marking.

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

2. Use an external switch or circuit breaker rated 5A and conforming with IEC 947-1 or

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

4. The external switch or circuit breaker should be installed within the reach of the

5. Wiring

circuit in combination with the converter, until all wiring is completed.

Where compliance with CE marking is necessary, the following piping procedure is necessary.

IEC947-3.

room as the converter.

operator, and marked as the power supply switch of this equipment.

IM 11M12A01-03E

5-1

Wiring procedure

Wiring should be preformed according to the following procedure:

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

2. The outer sheath of the signal line should be stripped to a length of 50 mm or less. The outer sheath of the power cable should be stripped to a length of 20 mm or less.

3. Signals may be affected by noise emission when the signal lines, power cable and heater cable are located in the same conduit. When using conduit, signal lines should be installed in a separate conduit from power and heater cables.

4. Install metal blind plug(s) in unused cable connection gland(s) of the converter.

5. Metal conduit should be grounded.

6. The following cables are used for wiring:

Table 5.1 Cable specifications

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

CELL+, CELLHTR TC+, HTR TCCJ+, CJHEATER L, N, AO-1+, AO-1-, AO-2+, AO-2DO-1, DO-2, DO-3, DO-4 AC-Z, AC-S, AC-C

DI-1, DI-2, DI-C

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

Converter signal

Converter heater Power supply Analog output Contact output Automatic Calibration unit Contact input

CVVS

CVV CVV

CVVS

CVV CVV

CVV

2 or 3 *

2 or 4 2 to 8

T5.1E.EPS

CAUTION

• Select suitable cable O.D. to match the cable gland size.

• Protective grounding should be connected (Class 3) grounding (the grounding resistance is 100V or less).

• Special cable length should be taken consideration. For detail of the HART communication, refer to IM11M12A01-51E HART Protocol Section 1.1.2 Communication Line Requirement..

5-2

IM 11M12A01-03E

5.1.1 Terminals for the External Wiring in the Converter

Open the front door and remove the terminal cover to gain access to the converter external wiring terminals (see Figure 5.2).

CAUTION

After wiring necessary cable to the converter terminals, be sure to fix the terminal covering plate with two screws again.

5. Wiring

Front door

5.1.2 Wiring

Terminals are visible when the terminal cover is removed.

Cable inlet

F5.2E.EPS

Figure 5.2 Terminals for external wiring in the converter

Connect the following wiring to the converter. It requires a maximum of eight wiring connections as shown below.

(1) Detector output (connects the converter with the detector.) (2) Detector heater power (connects the converter with the detector.) (3) Analog output signal (4) Power and ground (5) Contact output (6) Operation of the solenoid valve of automatic calibration unit (7) Contact input (8) Temperature input

IM 11M12A01-03E

5-3

Model ZR402G Separate type Zirconia High Temperature Humidity Analyzer, Converter

Analog

output 1 4-20 mA DC Digital output

Analog output 2

4-20 mA DC

Model ZR22G Separate type Zirconia High Temperature Humidity Analyzer, Detector

1FG2

12FG13

DI-114DI-215DI-C16AI

Temperature transmitter input 4 to 20mA

DO-124DO-125DO-226DO-227DO-328DO-329DO-430DO-431HTR32HTR33L34N35G36FG HTR HTR

Contact output 1

AO1

(+)

(-)

Contact input 2

Contact input 1

Contact output 2

AO2

(+)

AO2

(-)

(+)

Contact output 3

(+)

(-)

AC-

(-)

AC-

ZERO

SPAN

Solenoid valve for span gas for automatic calibration

Contact output 4

(+)

Flow setting unit

(-)

AC-

COM

Solenoid valve for zero gas for automatic calibration

CELL

(+)

21FG22

CELL

(-)

100-240V AC 50/60 Hz

CELL

(+)

(-)TC(+)TC(-)CJ(+)CJ(-)

*1 The protective grounding for the converter should be connected either the protective ground terminal in the equipment or

the ground terminal on the case. Standard regarding grounding: Ground to earth (Class 3 grounding), ground resistance: 100 V or less.

Figure 5.3 Wiring connection to the converter

5.1.3 Mounting of Cable Gland

F5.3E.EPS

For each cable connection opening of the converter, mount a conduit that matches the thread size or a cable gland.

EXA

ZR402G

8-G1/2, 8-1/2NPT or the like (Wiring connection)

Ground terminal (M4)

Adaptor for 1/2 NPT thread

F5.4E.EPS

Figure 5.4 Cable gland mounting

5-4

IM 11M12A01-03E

5.2 Wiring for Detector Output

This wiring enables the converter to receive cell output from the detector, output from a thermocouple and a reference junction compensation signal. Install wires that allow for 10 V of loop resistance or less. Keep detector signal wiring away from power wiring.

Separate the signal and the power wiring.

(1) Ambient temperature of the detector: 808C or less

Detector Converter

5. Wiring

CELL(+)

CELL(-)

TC(+)

TC(-)

CJ(+)

CJ(-)

Shielded cables

(2) Ambient temperature of the detector: exceeding 808C

Detector Converter

CELL(+)

CELL(-)

TC(+)

TC(-)

CJ(+)

CJ(-)

Heat-resistant wiring

Terminal box

Shielded cables

Figure 5.5 Wiring for detector output

CELL(+) CELL(-) TC(+) TC(-) CJ(+) CJ(-) FG

F5.5E.EPS

CAUTION

If shielded cables cannot be used between the detector and the terminal box, for example, when heat-resistant wiring is used, locate the detector and the terminal box as close together as possible.

5.2.1 Cable Specifications

Basically, PVC sheathed PVC insulated cable (six core) is used for this wiring. When the ambient temperature of the detector exceeds 80°C, install a terminal box, and connect with the detector using six-piece 600-V silicon rubber insulated glass braided wire.

IM 11M12A01-03E

5-5

5.2.2 Connection to the Detector

To connect cables to the detector, proceed as follows: (1) Mount conduits of the specified thread size or cable glands to the wiring connections

of the detector. The detector may need to be removed in future for maintenance, so be sure to allow a sufficient cable length.

(2) If the ambient temperature at the location of wire installation is 80 to 1508 C, be sure

to use a flexible metallic wire conduit. If a non-shielded “ 600V silicon rubber insulated glass braided wire “ is used, keep the wire away from noise sources to avoid noise interference.

(3) Figure 5.6 shows the layout of the detector terminals.

TC 1(with Si TUBE)

CELL 1

TC 2

CELL

(+)

(-)TC(+)TC(-)CJ(+)CJ(-)

To the ground

HTR HTR

To the converter or the terminal box

123456

TCCELL CJ

To the converter or the terminal box

Figure 5.6 Detector terminals

The sizes of the terminal screw threads are M3.5 except for the M4 on grounding terminal. Each wire in the cable should be terminated in the corresponding size of crimp-on terminal(*1).

F5.6E.EPS

5-6

*1 If the ambient temperature at the detector installation site exceeds 608 C, use a “ bare

crimp-on terminal”.

(4) Except when a “600V silicon rubber insulated glass braided wire” is used, connect

the cable shield to the FG terminal of the converter.

IM 11M12A01-03E

5.2.3 Connection to the Converter

To connect the wiring to the converter, proceed as follows: (1) M4 screws are used for the terminals of the converter. Each wire in the cable should

be terminated in the corresponding sige crimp-on terminal.

(2) When a rubber insulated glass braided wire is used for wiring to the detector, use a

terminal box. For wiring between the terminal box and the converter, use basically a cable, e.g. PVC sheathed PVC insulated cable, rather than individual wires.

Note

The above is to prevent moisture or corrosive gas from entering the converter and to ground the detector without fail.

5. Wiring

IM 11M12A01-03E

5-7

5.3 Wiring for Power to Detector Heater

This wiring provides electric power from the converter to the heater for heating the sensor in the detector.

(1) Ambient temperature of the detector: 808C or less

Detector Converter

HTR 7 HTR 8

(2) Ambient temperature of the detector: exceeding 808C

Detector Converter

HTR 7 HTR 8

Figure 5.7 Wiring for power to the detector heater

5.3.1 Cable Specifications

HEATER

Terminal box

HEATER

Heat-resistant wiring

F5.7E.EPS

Basically, PVC insulated PVC sheathed control cables (2 cores) are used for this wiring. When the ambient temperature of the detector exceeds 808 C, install a terminal box, and connect to the detector using six 600V silicon rubber insulated glass braided wires.

5.3.2 Connection to Detector

When connecting the cable to the detector, proceed as follows: (1) Mount cable glands or conduits of the specified thread size to the wiring connections

of the detector. The detector may need to be removed in future for maintenance, so be sure to allow sufficient cable length.

(2) If the ambient temperature at the location of wire installation is 80 to 1508 C, be sure

to use a flexible metallic conduit for the wire. If a non-shielded 0 600V silicon rubber insulated glass braided wire 0 is used, keep the wire away from noise sources, to avoid noise interference.

(3) The size of the terminal screw threads is M3.5. Each cable should be terminated in

the corresponding size crimp-on terminals (*1) respectively.

*1 If the ambient temperature at the detector installation site exceeds 608 C, use a 0 bare

crimp-on terminal0 .

5-8

IM 11M12A01-03E

CAUTION

•Before opening the detector cover, loosen the lock screw. If the screw is not loosened first, the screw will damage the cover, and the terminal box will require replacement. When opening and closing the cover, remove any sand particles or dust to avoid gouging the thread.

• Notice when closing the cover of the detector After screwing the cover in the detector body, secure it with the lock screw.

Lock screw

5. Wiring

Figure 5.8

5.3.3 Connection to Converter

To connect the wiring to the converter, proceed as follows: (1) M4 screws are used for the terminal of the converter. Each cable should be termi-

nated in the corresponding size crimp-on terminals.

(2) When a rubber insulated glass braided wire is used for wiring to the detector, use a

terminal box. For wiring between the terminal box and the converter, use basically a cable, e.g., PVC sheathed PVC insulated cable rather than wire.

Note

The above is to prevent moisture or corrosive gas from entering the converter. Where the ambient environment of the detector and the converter is well-maintained, it is permissible allowed to connect the wiring from the detector directly to the converter with protection by conduits.

WARNING

Detector cover

F5.8E.EPS

IM 11M12A01-03E

This wiring is to carry power for the heater. Be careful to wire the correct terminals, and be careful not to ground or short circuit terminals when wiring, as otherwise the instrument may be damaged.

5-9

5.4 Wiring for Analog Output

This wiring is for transmitting 4 to 20 mA DC output signals to a device, e.g. recorder. Maintain the load resistance including the wiring resistance at 550V or less.

Converter

AO1(+) AO1(-) AO2(+) AO2(-)

Figure 5.9 Wiring for analog output

5.4.1 Cable Specifications

For this wiring, use a 2-core or a 4-core shielded cable.

5.4.2 Wiring Procedure

(1) M4 screws are used for the terminals of the converter. Each wire of the cable should

be terminated in corresponding crimp-on terminals. Ensure that the cable shield is connected to the FG terminal of the converter.

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

Shielded cable

Receiver 1

Receiver 2

F5.9E.EPS

5-10

IM 11M12A01-03E

5.5 Power and Grounding Wiring

This wiring supplies power to the converter and grounds the converter/detector.

5. Wiring

Grounding to the ground terminal

on the converter case

FG terminal

Figure 5.10 Power and Grounding wiring

5.5.1 Power Wiring

Connect the power wiring to the L and N terminals of the converter. Proceed as follows: (1) Use a 2-core or a 3-core shielded cable.

(2) The size of converter terminal screw threads is M4. Each cable should be terminated

corresponding crimp-on terminals.

5.5.2 Grounding Wiring

Converter case

Lock washer

Crimp-on terminal

the ground wire

Converter

LNG

100 - 240VAC

50/60Hz

Detector

Earth

Jumper plate

F5.10E.EPS

The ground wiring of the detector should be connected to the ground terminal of the detector case. The ground wiring of the converter should be connected to either the ground terminal of the converter case or the protective ground terminal in the equipment. The ground terminals of the detector and the converter are of size M4. Proceed as follows:

(1) Keep ground resistance to 100V or less (JIS Class 3 ground). (2) When the ambient temperature of the wiring installation is 80 to 1508 C for the wiring

of the detector, use wiring material with sufficient heat resistance.

(3) When connecting the ground wiring to the ground terminal of the converter case, be

sure that the lock washer is in contact with the case surface (see Figure 5.10.).

(4) Ensure that the jumper plate is connected between the G terminal and the protective

ground terminal of the converter.

IM 11M12A01-03E

5-11

5.6 Wiring for Contact Output

Contact outputs 1 to 3 can be freely assigned to "low limit alarm", "high limit alarm", etc. user selectable, but the assignment of contact output 4 is fixed ("error output"). And the action (contact closed on error output) also cannot be changed.

When using these contact outputs, install the wiring as follows:

Converter

DO-1 DO-1

DO-2 DO-2

DO-3 DO-3

DO-4 DO-4

Figure 5.11 Contact output wiring

5.6.1 Cable Specifications

Number of wires in cable varies depending on the number of contact used.

5.6.2 Wiring Procedure

Terminal box Annunciator or the like

#1 Output

#2 Output

#3 Output

#4 Output

F5.11E.EPS

(1) M4 screws are used for the terminals of the converter. Each wire in the cable should

be terminated in the corresponding crimp-on terminal.

(2) The capacities of the contact output relay are 30 V DC 3 A, 250V AC 3 A. Connect

a load (e.g. pilot lamp and annunciator) within these limits.

5-12

IM 11M12A01-03E

5.7 Wiring for ZR40H Automatic Calibration Unit

This wiring is for operating the solenoid valve for the zero gas and the span gas in the ZR40H Automatic Calibration Unit, in a system where the calibration gas flow rate is automatically controlled (e.g. System configuration 3). When installing this wiring, proceed as follows:

Wiring inlet

Span gas solenoid valve

Zero gas solenoid valve

2-G1/2, Pg13.5, M20 or 1/2NPT

COMMON

SPAN

ZERO

5. Wiring

COMMON SPAN ZERO

to ZR402G terminal "AC-COM"

to ZR402G terminal "AC-SPAN"

to ZR402G terminal "AC-ZERO"

Terminal screw : M4

Wire or equivalent

Figure 5.12 Automatic Calibration Unit

F5.12E.EPS

IM 11M12A01-03E

5-13

5.7.1 Cable Specifications

Use a three-core cable for this wiring.

5.7.2 Wiring Procedure

M4 screws are used for the terminals of the converter. Each cable should be terminated in the corresponding crimp-on terminals. M4 screws are used for the terminals of the solenoid valve as well.

Converter

AC-Z AC-S

ZR40H Automatic

Calibration unit

Zero

AC-C

Span

F5.13.EPS

Figure 5.13 Wiring for Automatic Calibration Unit

5-14

IM 11M12A01-03E

5.8 Wiring for Contact Input

The converter can execute specified function when receiving contact signals. To use these contact signals, wire as follows:

Converter Terminal box

DI-1 DI-2

DI-C

Figure 5.14 Contact Input Wiring

5.8.1 Cable Specifications

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

5. Wiring

Contact input 1

Contact input 2

F5.14E.EPS

5.8.2 Wiring Procedure

(1) M4 screws are used for the terminals of the converter. Each cable should be termi-

nated in the corresponding crimp-on terminals.

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

contact input that satisfies the specifications in Table 5.2.

Table 5.2 Identification of Contact Input ON/OFF

Resistance

Closed Open

200V or less 100 kV or more

T5.2E.EPS

IM 11M12A01-03E

5-15

5.9 Temperature Input Wiring

When inputting the measurement gas temperature from external of the equipment, connect a two-wire temperature transmitter. The relative humidity and dew point are acquired based on the temperature signal from the connected transmitter, in the case where the setting is “Temperature input selected” and “external input”. As for the wiring of the temperature transmitter and thermocouples, refer to appropriate temperature transmitter instruction manual.

Converter

Temperature transmitter

AI1 AI2

Shielded cables

5.9.1 Applicable Temperature Transmitter

Apply a temperature transmitter that is suit for the following interfaces:

Output signal: 4 to 20 mA DC, two-wire system Maximum supply voltage from the analyzer: 24 V DC Input resistance of the analyzer: Maximum 250 V (The load resistance of the

Temperature Transmitter Burnout

When outputting a burnout signal of the temperature transmitter with a contact output of the analyzer, use “high-limit temperature alarm”. (Refer to Section 8.4, “Contact Output Setting.”) In this case, set the burnout signal of the temperature transmitter to exceed the high limit (20 mA or more).

F5.15E.EPS

transmitter is the total of wiring resistance and input resistance.)

5.9.2 Cable Specifications

Use a two-core shielded cable for wiring.

5.9.3 Wiring Procedure

(1) M4 screws are used for the converter terminals. Cables should be equipped with

appropriate crimp contacts. Ensure that the cable shield be connected to the FG terminal of the converter.

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

5-16

IM 11M12A01-03E

6. Components

In this chapter, the names and functions of components are described for the major equipment of the EXAxt ZR Separate-type Zirconia High-temperature Humidity Analyzer.

6.1 ZR22G Detector

6.1.1 General-purpose Detector

6. Components

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

Bolt

Probe this part is inserted in the process. Select length from 0.4,

0.7, 1.0, 1.5, 2.0, 2.5 or 3.0 m.

Metal O-ring

Pipe support

U-shaped pipe

Filter

Washer (or plain washer)

Figure 6.1 General-use Detector

Calibration gas

Contact

Sensor (cell)

pipe opening

Flange used to mount the detector. Select from JIS or ANSI standard models.

Dust filter mounting screw

Probe

Screw

F6.1E.EPS

IM 11M12A01-03E

6-1

6.2 ZR402G Converter

Complete Operation Display

d Interactive operations along with operation display d A variety of display modes2enabling you to select the operation mode freely d Back-lit LCD display allows viewing even in areas of low lighting d Error codes and details of errors are displayed, no need to refer to the appropriate instruction manual d Password for security

Typical Converter Displays

d Example of basic display

Tag:

0.0

%H2O

21.0%H2O -Output1

21.0%H

This deta provides for interective operation.

d Example of trend display changes

2O -Output2

2displays data

Self-testing suggests countermeasures for problems

If a problem occurs, the liquid-crystal display will provides an error code and description of the problem. This enables prompt and appropriate corrective action to be taken.

Error code Reason for error E--1 Cell failure E--2 Abnormal heater temperature E--3 Defective A/D converter E--4 Faulty EEPROM ALARM1 Abnormal oxygen concentration ALARM2 Abnormal moisture ALARM3 Abnormal mixing ratio ALARM6 Abnormal zero calibration factor ALARM7 Abnormal span calibration factor ALARM8 Stabilization time over

Figure 6.3 Converter

During automatic calibration,you can check has stabilized of display data while viewing oxygen trend data,thus providing highly reliable calibration.

d Example of setting data display - displays data changes

Commissioning

Basic setup

r mA-output setup r Alarms setup r Contact setup r Others

Enter

d One-touch interactive display operation d User-friendly design providing easy operation

without need to use the instruction manual

F7.6E.EPS

F6.3E.EPS

6-2

IM 11M12A01-03E

6. Components

6.3 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit

Reference gas flow setting valve

Span gas flow setting valve

Zero gas flow setting valve

Flowmeter for reference gas

Flowmeter for Calibration gas

Figure 6.4 ZA8F Flow Setting Unit

Flowmeter for Calibration gas

Flowmeter for Reference gas

Reference gas flow setting valve

CAL.OUTREF.OUT

Made in Japan

F6.4E.EPS

Terminal Box

ZERO INSPAN IN

IM 11M12A01-03E

Calibration gas flow setting valve

F6.5E.EPS

Figure 6.5 ZR40H Automatic Calibration Unit

6-3

7. Startup

The following describes the minimum operating requirements — from supplying power to the converter to analog output confirmation to manual calibration.

System tuning by the HART communicator, refer to IM11M12A01-51E “HART Communication Protocol”

7.1 Checking Piping and Wiring Connections

Check that the piping and wiring connections have been properly completed in accordance with Chapter 4, “Piping,” and Chapter 5, “Wiring.”

7.2 Checking Valve Setup

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

7. Startup

(1) If a stop valve is used in the detector’s calibration-gas inlet, fully close this valve. (2) If instrument air is used as the reference gas, adjust the air-set secondary pressure so

that an air pressure equals measured gas pressure plus approx.50 kPa (or measured gas pressure plus approx. 150 kPa when a check valve is used, maximum pressure rating is 300 kPa) is obtained. Turn the reference-gas flow setting valve in the flow setting unit to obtain a flow of 800 to 1000 ml/min. (Turning the valve shaft counterclockwise increases the rate of flow. Before turning the valve shaft, if the valve has a lock nut, first loosen the lock nut.) After completing the valve setup, be sure to tighten the lock nut.

Note

The calibration-gas flow setting is described later. Fully close the needle valve in the flow setting unit.

IM 11M12A01-03E

7-1

7.3 Supplying Power to the Converter

CAUTION

To avoid temperature changes around the sensor, it is recommended that rather than

tuning it on and off power be continuously supplied to the High-temperature Humidity

Analyzer if it is used in an application where it is used periodically.

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

Supply power to the converter. A display as in Figure 7.1, which indicates the detector’s sensor temperature, then appears. As the heat in the sensor increases, the temperature gradually rises to 7508 C. This takes about 20 minutes after the power is turned on, depending somewhat on the ambient temperature and the measured gas temperature. After the sensor temperature has stabilized at 7508 C, the converter is in measurement mode. The display panel then displays the oxygen concentration as in Figure 7.2. This is called the basic panel display.

Tag:

319

4.00mA -Output1

4.00mA -Output2

Warmup

Figure 7.1 Display of Sensor Figure 7.2 Measurement Mode Display Temperature During Warmup

Hold

Tag:

0.0

%H2O

4.00mA -Output1

4.00mA -Output2

F7.02E.EPS

7-2

IM 11M12A01-03E

7.4 Touchpanel Switch Operations

7.4.1 Basic Panel and Switch

The converter uses a touchpanel switch which can be operated by just touching the panel display. Figure 7.3 shows the basic panel display. The switches that appear in the switch display area vary depending on the panel display, allowing all switch operations. Table

7.1 shows the switch functions.

7. Startup

Tag name display area

Primary value

Secondary value

Tertiary value

Figure 7.3 Basic Panel Display

Tag name display area: Displays the set tag name (Refer to Section 10.1.4, “Entering Tag Name”).

Primary to tertiary display items: Displays the selected item. (Refer to Section 7.8, “Setting Display Item”.)

Switch display area: Displays switches and functions selected according to the panel display.

Alarm and error display area: Displays an error if an alarm or error occurs. If you touch this area, the details of the error or alarm are then displayed.

Tag:

0.0

4.00mA -Output1

4.00mA -Output2

%H2O

Switch display area

Alarm and error display area

F7.3E.EPS

IM 11M12A01-03E

Table 7.1 Switches and Their Functions

Home key: Returns to the Execution/Setup display.

Reject key: Moves back to the previous display.

Cursor key: Moves the cursor down.

Graph display key: Displays a trend graph.

Alarm: Displayed if an alarm arises.

Enter

Enter key: Enters the input value and sets up the selected item.

Setup key: Used to enter the Execution/Setup display.

Detailed-data key: Displays the analog input value.

Cursor: Points the cursor at the currently selected item.

Error: Displayed if an error occurs.

T7.1E.EPS

7-3

7.4.2 Display Configuration (for High-temperature Humidity Analyzer)

Figure 7.3.1 shows the display configuration. A password positioned below the displays enables Execution/Setup to be protected. If a password has not been set, press the [Enter] key to proceed to the next panel display. The Home key enables you to return to Execution/Setup from any panel display.

[Basic panel display]

[Detailed-data display]

Calibration execution

Returns to the Execution/Setup display.

[Execution/Setup display]

[Password Entry display]

Blow back execution Reset panel display

Returns to the Execution/Setup display.

[Trend Graph display]

Maintenance panel display

Display setup

Display item Trend graph Auto return time Language Calibration setup Mode Points Zero- and Span-gas conc. Timing Blow back setup mA-output loop check Contact check

Commissioning (Setup) display mA-output setup mA-output1 mA-output2 Set presets Alarms setup Hysteresis Contact delay Setpoints Contact setup Input contacts Output contacts Others Clock Averaging Input temp Passwords Defaults

7-4

Figure 7.3.1 Display Configuration

Returns to the Execution/Setup display.

F7.3.1E.EPS

IM 11M12A01-03E

7.4.3 Display Functions

Individual panel displays in the display configuration provide the following functions:

(1) Basic panel display: Displays the values measured in three selected items (see

Section 7.9, “Setting Display Items”). (2) Execution/Setup display: Selects the calibration, maintenance and setup items. (3) Detailed-data display: This allows you to view such detailed data as the cell electro-

motive force and cell temperature (see Section 10.1.1, “Detailed-data Display,” later

in this manual). (4) Trend Graph display: Displays a trend graph (see Section 10.1.2, “Trend Graphs,”

later in this manual). (5) Calibration execution: Makes zero and span calibrations (see Chapter 9, “Calibra-

tion,” and the associated sections later in this manual). (6) Blow-back execution: Executes a “blow back” (see Section 10.2, “Blow Back,” later

in this manual). (7) Reset panel display: If an error arises, you can restart the equipment from this

display (for more details, see Section 10.4, “Reset,” later in this manual). (8) Maintenance panel display: Sets the data for equipment maintenance or makes a loop

check. (9) Commissioning (Setup) display: Sets up the operation data. (For details, see Chapter

8, “Detailed-data Settings,” and the associated sections later in this manual.)

7. Startup

7.4.4 Entering Numeric and Text Data

This section sets out how to enter numeric and text data. If only numeric values are entered, a numeric-data entry display as in Figure 7.4 then appears. Press the numeral keys to enter numeric values. If those values include a decimal point as in Figure 7.4, the decimal point need not be entered because the decimal point position is already fixed, so just enter 00098.

New value: 000.98 % O2

Figure 7.4 Numeric-data Entry Display

To enter a password (in combination with text data, numeric values and codes), the alphabetic character entry panel display first appears. If you press any numeral key (0 to

9), the current display then changes to the numeric-value entry panel display, enabling you to enter numeric values. If you press the “other” key, the current display then changes to the code-entry display, enabling you to enter codes. These displays alternate between the three. Figure 7.5 shows the relationship between these three displays. Three alphabetic characters and three codes are assigned for each individual switch. If the alphabetic character key is pressed and held, three characters appear in turn. Move the cursor to the desired character and release the key to enter it. If an incorrect character is entered, move the cursor to re-enter the characters. The following shows an example of entering “abc%123.

Enter

F7.4E.EPS

IM 11M12A01-03E

7-5

Operation Display Press the [ABC] key once. A

Press and hold the [ABC] key. A A B C Release the [ABC] key when the character B AB

appears in the cursor position. Enter the character C in the same manner ABC

as above. Press the [other] key.

Press and hold the [$%&] key and enter “%.” ABC%

Then press the [0-9] key. Enter the numeric characters 1, 2 and 3 in turn. ABC%123

Press the [Enter] key to complete the entry.

Enter your password

E F

N O

W X

Enter your password

0-9

other

Space

- $

B C

K L

T U

H I

Q R

Z @

Enter

Siki7.4E

A-Z

other

9 56 2

Figure 7.5 Text Entry Display

Enter

A-Z

0-9

{ [ }

0 #

+ ,

? @

% &

—

. /

[

\ ]

( )

; <

_ ‘

’

Enter

F7.5E.EPS

7-6

IM 11M12A01-03E

7.5 Confirmation of Converter Type Setting

This converter can be used for both the Oxygen Analyzer and the Humidity Analyzer. Before setting the operating data, be sure to check that the desired converter model has been set.

Note that if the converter type setting is changed, the operating data that have been set are then initialized and the default settings remain. To set the desired operating data, follow these steps:

(1) Press the setup key. (2) Use the .key to select Setup and press the [Enter] key. (3) In the password display, enter the [Enter] key. If the password is to be set again,

enter the new password (for details, see Section 8.6.5, “Passwords,” later in this manual).

(4) The Setup display shown in Figure 7.6 appears. Select “Basic setup” and press the

[Enter] key.

(5) The Basic setup display shown in Figure 7.7 then appears. Confirm the currently set

converter type. If the Humidity Analyzer option /HS was selected at the time of purchase, the converter was set for high-temperature humidity use before shipment.

(6) If the converter type is to be changed, press the [Enter] key. The display shown in

Figure 7.8 then appears.

(7) Use the .key to select the type of equipment. Then press the [Enter] key to com-

plete the converter selection.

(8) If the type of converter is changed after setting the operating data, those data are then

initialized and the default settings remain. Reset the operating data to meet the new type of equipment.

7. Startup

Commissioning

Basic setup

r mA-output setup r Alarms setup r Contact setup r Others

Enter

F7.6E.EPS

Basic setup

This instrument is for Humidity Please note:changing this Basic setting will return ALL other setting to Default!!

r Detector is ZR22

Figure 7.6 Commissioning (“Setup”) Figure 7.7 Basic Setup Display Display

Basic setup

This instrument is for

Please note:changing this Basic setting will return ALL other setting to Default!!

r Detector is ZR22

Figure 7.8 Basic Setup

Oxygen

Humidity

Enter

F7.8E.EPS

Enter

F7.7E.EPS

IM 11M12A01-03E

7-7

7.6 Confirmation of Detector Type Setting

Check that the detector in Figure 7.7 is the one for this equipment.

DANGER

• If this converter is to be used in conjunction with the ZO21D, the power requirements are limited to 150 V AC or less, 50 Hz or 60 Hz (it cannot be used with a 150V or greater, or in the EEC). If detector settings are to be changed, first disconnect the wiring connections between the detector and the converter. Then change detector settings appropriately.

7.7 Current Output Setting

This section sets forth analog output settings. For details, consult Section 8.1,“Current Output Settings,” later in this manual.

7.7.1 Analog Output Setting

Select any one of the analog output settings — Oxygen, Humidity, and Mixing from the mA-output range display. If the /HS option is specified at the time of purchase, the equipment is a humidity analyzer. For other than this setting, the analyzer is an oxygen analyzer. If a mixed measurement is required, change the current output setting as given below. If the humidity analyzer is specified in the above detector type setting, the analog output is set to “humidity” when the data initialization is attempted.

(1) Select the Setup from the Execution/Setup display. (2) From the Commissioning (Setup) display, select “mA-output setup”; the display

shown in Figure 7.9 then appears.

(3) Select “mA-output1” from the “mA-outputs” display. The “mA-output1 range”

display shown in Figure 7.10 then appears.

(4) Select the Parameter, then the Oxygen, Humidity, and Mixing appear in the mA-

output1 range display (Figure 7.10.1). Select “Mixing” and press the [Enter] key. (5) The “Mixing” in Figure 7.10.2 appears. (6) Perform the same setting in mA-outpout2 if necessary.

mA-outputs

Both outputs are 4-20mA mA-output1

r mA-output2 r Set presets

Enter

F7.9E.EPS

mA-output1 range

Parameter: Humidity Set range r Min. humidity conc: 0 %H r Max. humidity conc: 25 %H

r Output damping: 0 s r Output mode: Linear

Enter

F7.10E.EPS

Figure 7.9 mA-outputs Setting Figure 7.10 mA-output1 Range Display Display

7-8

IM 11M12A01-03E

Yokogawa ZR22, ZR402 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

r For the safe use of this equipment

1. Overview

1.1 < EXAxt ZR > System Configuration

1.1.1 System 1

1.1.2 System 2

1.1.3 System 3

1.2 < EXAxtZR > System Components

1.2.1 System Components

1.2.2 Detectors and Accessories

2.1 General Specifications

2.1.1 Standard Specifications

2. Specifications

2.2 General-use Separate-type Detector and Related Equipment

2.2.1 ZR22G General-use Separate-type Detector

2.2.2 ZH21B Dust Protector

2.3 ZR402G Separate-type Converter

2.3.1 Standard Specifications

2.3.2 Function

2.4.1 ZA8F Flow Setting Unit

2.4.2 ZR40H Automatic Calibration Unit

2.5 ZO21S Standard Gas Unit

2.6 Other Equipment

2.6.1 Stop Valve (Part Number: L9852CB or G7016XH)

2.6.2 Check Valve (Part Number: K9292DN or K9292DS)

2.6.3 Air Set

2.6.4 Zero-gas Cylinder (Part Number: G7001ZC)

2.6.7 Model ZR22A Heater Assembly

3.1 Installation of the Detector

3.1.1 Location

3. Installation

3.1.2 Probe Insertion Hole

3.1.3 Installation of the Detector

3.1.4 Installation of ZH21B Dust Protector

3.2 Installation of the Converter

3.2.1 Location

3.2.2 Mounting of the Converter

3.3 Installation of ZA8F Flow Setting Unit

3.3.1 Location

3.3.2 Mounting of ZA8F Flow Setting Unit

3.4 Installation of ZR40H Automatic Calibration Unit

3.4.1 Location

3.4.2 Mounting of ZR40H Automatic Calibration Unit

3.5 Installation of E7044KF Case Assembly for the Calibration-gas Cylinder

3.5.1 Location

3.5.2 Mounting

3.6 Insulation Resistance Test

4. Piping

4.1 Piping for System 1

4.1.1 Parts Required for Piping in System 1

4.1.2 Connection to the Calibration Gas Inlet

4.1.3 Connection to the Reference Gas Inlet

4.2 Piping for System 2

4.2.1 Piping Parts for System 2

4.2.2 Piping for the Calibration Gas

4.2.3 Piping for the Reference Gas

4.3 Piping for System 3

5.1 General

5. Wiring

5.1.1 Terminals for the External Wiring in the Converter

5.1.2 Wiring

5.1.3 Mounting of Cable Gland

5.2 Wiring for Detector Output

5.2.1 Cable Specifications

5.2.2 Connection to the Detector

5.2.3 Connection to the Converter

5.3 Wiring for Power to Detector Heater

5.3.1 Cable Specifications

5.3.2 Connection to Detector

5.3.3 Connection to Converter

5.4 Wiring for Analog Output

5.4.1 Cable Specifications

5.4.2 Wiring Procedure

5.5 Power and Grounding Wiring

5.5.1 Power Wiring

5.5.2 Grounding Wiring