YOKOGAWA ZR402G, ZR22A, ZR202G, ZR202A, ZR22G User Manual

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User ’s Manual

Model ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

IM 11M12A01-04E

11th Edition

u Introduction

Thank you for purchasing the ZR202G Integrated type Oxygen/Humidity Analyzer.

Please read the following respective documents before installing and using the ZR202G Integrated type Oxygen/Humidity Analyzer.

The related documents are as follows.

General Specications

Contents Document number Note

Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers

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

User’s Manual

Contents Document number Note

Model ZR202G Integrated type Oxygen/Humidity Analyzer

Model ZR22A, ZR202A Heater Assembly

Model EXAxt ZR Series HART Protocol

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

GS 11M12A01-01E

IM 11M12A01-04E (This manual)

IM 11M12A01-21E

IM 11M12A01-51E

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

manual.

The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer is usually the Oxygen Analyzer, but it is to the High Temperature Humidity Analyzer when the option code “/HS (Set for Humidity Analyzer)” is selected.

In this manual, the Oxygen Analyzer is mainly listed. When there are not mentions such as “in the case of Humidity Analyzer”, it becomes same as the Oxygen Analyzer.

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

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

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

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

IM 11M12A01-51E has been published as ‘’Model EXAxt ZR series HART protocol’’.

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Models and descriptions in this manual are listed below.

Models and descriptions in this manual

Model Product Name

ZR202G Integrated type Oxygen

ZO21R Probe protector ○ ○

ZH21B

ZA8F

ZR20H Automatic Calibration unit ○ ○ ○ ○

ZO21S Standard gas unit ○ ○ ○ ○

CMPL: Customer Maintenance Parts List

Analyzer

Dust protector (only for Humidity analyzer)

Flow setting unit (for manual calibration use)

Case Assembly for calibration

gas cylinder (Part No. E7044KF)

Check valve (Part No.

K9292DN, K9292DS)

Dust lter for the detector (Part

No. K9471UA)

Dust guard protector (Part No.

K9471UC)

Specication

○ ○ ○ ○ ○

○ ○

○ ○ ○

○ ○

Description in this manual

Installation Operation

Maintenance

CMPL

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

Table of Contents

Chapter Outline

1. Overview

2. Specications

3. Installation Installation method for each equipment A C

4. Piping

5. Wiring

6. Components

7. Startup

8. Detailed Data Setting Details of key operations and displays B C

9. Calibration

10. Other Functions Other functions described B C

11. Inspection and Maintenance

12. Troubleshooting

CMPL (parts list) User replaceable parts list C B

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

Equipment models and system

conguration examples Standard specication, model code (or

part number), dimension drawing for each equipment

Examples of piping in three standard system

congurations

Wiring procedures such as “Power supply wiring”, “output signal wiring” or others

Major parts and function are described in this manual

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

Describes the calibration procedure required in the course of operation.

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

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

Installation Operation

B C B

A B B

A C

C B B

Relates to

Maintenance

A C

B C

B A

C A

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

n For the safe use of this equipment

WARNING

Be sure not to accidentally drop it. Handle safely to avoid injury.

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

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

CAUTION

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

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

analyzer.

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

• Check the calibration gas piping before introducing the calibration gas to ensure that there

is no leakage of the gas. If there is any leakage of the gas, the moisture drawn from the sample gas may damage the sensor.

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

iii

n NOTICE

l Specication check

When the instrument arrives, unpack the package with care and check that the instrument

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

of model codes.

l Details on operation parameters

When the EXAxt ZR Separate type Oxygen Analyzer arrives at the user site, it will operate

based on the operation parameters (initial data) set before shipping from the factory. Ensure that the initial data is suitable for the operation conditions before conducting analysis. Where necessary, set the instrument parameters for appropriate operation. For details of setting data, refer to chapters 7 to 10. When user changes the operation parameter, it is recommended to note down the changed setting data.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

u Safety Precautions

n Safety, Protection, and Modication of the Product

• In order to protect the system controlled by the product and the product itself and ensure

safe operation, observe the safety precautions described in this user’s manual. We assume no liability for safety if users fail to observe these instructions when operating the product.

• If this instrument is used in a manner not specied in this user’s manual, the protection

provided by this instrument may be impaired.

• If any protection or safety circuit is required for the system controlled by the product or for

the product itself, prepare it separately.

• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter

simply referred to as YOKOGAWA) when replacing parts or consumables.

• Modication of the product is strictly prohibited.

• The following safety symbols are used on the product as well as in this manual.

WARNING

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

CAUTION

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

CAUTION

This symbol gives information essential for understanding the operations and functions.

NOTE

This symbol indicates information that complements the present topic.

This symbol indicates Protective Ground Terminal.

This symbol indicates Function Ground Terminal. Do not use this terminal as the protective ground terminal.

n Warning and Disclaimer

The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

n Notes on Handling User’s Manuals

• Please hand over the user’s manuals to your end users so that they can keep the user’s

manuals on hand for convenient reference.

• Please read the information thoroughly before using the product.

• The purpose of these user’s manuals is not to warrant that the product is well suited to any

particular purpose but rather to describe the functional details of the product.

• No part of the user’s manuals may be transferred or reproduced without prior written

consent from YOKOGAWA.

• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at

any time, without notice or obligation.

• If you have any questions, or you nd mistakes or omissions in the user’s manuals, please

contact our sales representative or your local distributor.

n Drawing Conventions

Some drawings may be partially emphasized, simplied, or omitted, for the convenience of

description.

Some screen images depicted in the user’s manual may have different display positions or character types (e.g., the upper / lower case). Also note that some of the images contained in this user’s manual are display examples.

In the gure listed in this manual, the example of the oxygen analyzer is shown mainly. In the case of the humidity analyzer, unit indication may be different. Please read it appropriately.

n Product Disposal

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

n Trademark Acknowledgments

• All other company and product names mentioned in this user’s manual are trademarks or

registered trademarks of their respective companies.

• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this

user’s manual.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

n Special descriptions in this manual

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

l Operation keys, displays on the panel

Enclosed in [ ]. (Ex. “MODE” key)

(Ex. message display → “BASE”)

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

l Drawing for ashing

Indicated by gray characters (Flashing) (lit)

l Displays on the LCD display panel

Alphanumerics Alphanumerics AlphanumericsLED Display LED Display LED Display

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

u CE marking products

n Authorised Representative in EEA

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

n Identication Tag

This manual and the identication tag attached on packing box are essential parts of the product.

Keep them together in a safe place for future reference.

n Users

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

n How to dispose the batteries:

This is an explanation about the EU Battery Directive. This directive is only valid in the EU.

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

vii

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

dispose them as domestic household waste.

Battery type: Manganese dioxide lithium battery

Notice:

The symbol (see above) means they shall be sorted out and collected as ordained in the EU Battery Directive.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

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Model ZR202G Integrated type Oxygen/Humidity Analyzer

IM 11M12A01-04E 11th Edition

CONTENTS

u Introduction ....................................................................................................i

u Safety Precautions ......................................................................................iv

u CE marking products .................................................................................vii

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

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

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

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

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

1.2 < EXAxt ZR > System Components ................................................................1-4

1.2.1 System Components ......................................................................... 1-4

1.2.2 Oxygen/Humidity Analyzer and Accessories ..................................... 1-4

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

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

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

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer ..........................2-2

2.1.3 ZO21R Probe Protector ..................................................................... 2-9

2.1.4 ZH21B Dust Protector ...................................................................... 2-10

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit ................ 2-11

2.2.1 ZA8F Flow Setting Unit .................................................................... 2-11

2.2.2 ZR20H Automatic Calibration Unit ................................................... 2-14

2.3 ZO21S Standard Gas Unit .............................................................................. 2-16

2.4 Other Equipment ............................................................................................. 2-17

2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA) ....................... 2-17

2.4.2 Dust Guard Protector (K9471UC) .................................................... 2-17

2.4.3 Stop Valve (part no. L9852CB or G7016XH) ................................... 2-18

2.4.4 Check Valve (part no. K9292DN or K9292DS) ................................ 2-18

2.4.5 Air Set ............................................................................................... 2-19

2.4.6 Zero Gas Cylinder (part no. G7001ZC) ........................................... 2-20

2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder ....... 2-21

2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder ................. 2-21

2.4.9 ZR202A Heater Assembly ............................................................... 2-22

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

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

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3.1.1 Probe Insertion Hole .......................................................................... 3-1

3.1.2 Installation of the Probe ..................................................................... 3-2

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

(K9471UC) Probe Protector (ZO21R) ............................................... 3-2

3.1.4 Installation of ZH21B Dust Protector ................................................. 3-4

3.2 Installation of ZA8F Flow Setting Unit ............................................................ 3-5

3.3 Installation of ZR20H Automatic Calibration Unit ......................................... 3-6

3.4 Installation of the Case Assembly (E7044KF) for Calibration Gas Cylinder 3-7

3.5 Insulation Resistance Test ............................................................................... 3-8

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

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

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

4.1.2 Piping for the Calibration Gas ............................................................ 4-2

4.1.3 Piping for the Reference Gas............................................................. 4-2

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

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

4.2.2 Piping for the Calibration Gas ............................................................ 4-3

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

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

4.4 Piping for the Oxygen Analyzer with Pressure Compensation ................... 4-6

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation ...... 4-8

4.4.2 Piping for the Calibration Gas ............................................................ 4-8

4.4.3 Piping for the Reference Gas............................................................. 4-8

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

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

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

5.1.2 Wiring ................................................................................................. 5-2

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

5.2 Wiring for Analog Output ................................................................................. 5-3

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

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

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

5.3.1 Wiring for Power Line ......................................................................... 5-4

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

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

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

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

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

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

5.5.2 Wiring Procedure ............................................................................... 5-6

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

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

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6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit ........................ 6-2

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

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

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

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

7.4 Operation of Infrared Switch ........................................................................... 7-2

7.4.1 Display and Switches ......................................................................... 7-2

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

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

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

7.4.5 Changing Set Values ......................................................................... 7-6

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

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

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

7.7.1 Oxygen Analyzer -Minimum Current (4 mA) and Maximum Current (20

mA) Settings....................................................................................... 7-9

7.7.2 Output Range Setting ...................................................................... 7-11

7.7.3 Humidity Analyzer -Minimum Current (4 mA) and Maximum Current (20

mA) Settings..................................................................................... 7-11

7.8 Setting Display Item ........................................................................................ 7-12

7.8.1 Oxygen Analyzer - Setting Display Item ..........................................7-12

7.8.2 Humidity Analyzer - Setting Display Item ......................................... 7-13

7.9 Checking Current Loop .................................................................................. 7-13

7.10 Checking Contact I/O ......................................................................................7-14

7.10.1 Contact Output Check ..................................................................... 7-14

7.10.2 Checking Calibration Contact Output .............................................. 7-15

7.10.3 Checking Input Contacts .................................................................. 7-16

7.11 Calibration .......................................................................................................7-16

7.11.1 Calibration Setup .............................................................................7-16

7.11.2 Manual Calibration ........................................................................... 7-19

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

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

8.1.1 Oxygen Analyzer_Current Output Setting ......................................... 8-1

8.1.2 Oxygen Analyzer_Analog Output Setting .......................................... 8-1

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

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

8.1.4 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA 8-2

8.1.5 Input Ranges ...................................................................................... 8-2

8.1.6 Entering Output Damping Constants ................................................. 8-5

8.1.7 Selection of Output Mode .................................................................. 8-5

8.1.8 Default Values .................................................................................... 8-5

8.2 Output Hold Setting .......................................................................................... 8-5

8.2.1 Denition of Equipment Status .......................................................... 8-6

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

8.2.3 Output Hold Setting ............................................................................ 8-7

8.2.4 Default Values .................................................................................... 8-7

8.3 Setting Alarms ................................................................................................... 8-8

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

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

8.3.3 Alarm Setting...................................................................................... 8-9

8.3.4 Default Values .................................................................................. 8-10

8.4 Output Contact Setup ..................................................................................... 8-10

8.4.1 Output Contact ................................................................................. 8-10

8.4.2 Setting Output Contact .................................................................... 8-11

8.4.3 Default Values .................................................................................. 8-12

8.5 Input Contact Settings .................................................................................... 8-12

8.5.1 Input Contact Functions ................................................................... 8-12

8.5.2 Setting Input Contact ....................................................................... 8-13

8.5.3 Default Values .................................................................................. 8-13

8.6 Other Settings .................................................................................................8-13

8.6.1 Setting the Date-and-Time ............................................................... 8-13

8.6.2 Setting Periods over which Average Values are Calculated and Periods

over which Maximum and Minimum Values Are Monitored.............8-14

8.6.3 Setting Fuels .................................................................................... 8-15

8.6.4 Setting Measurement Gas Temperature and Pressure ................... 8-19

8.6.5 Setting Purging ................................................................................ 8-20

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

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

9.1.1 Principle of Measurement with a zirconia oxygen analyzer .............. 9-1

9.1.2 Measurement Principle of Zirconia Humidity Analyzer ...................... 9-2

9.1.3 Calibration Gas .................................................................................. 9-4

9.1.4 Compensation .................................................................................... 9-4

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

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

9.2.1 Mode .................................................................................................. 9-6

9.2.2 Calibration Procedure ........................................................................ 9-6

9.2.3 Zero gas Concentration ..................................................................... 9-7

9.2.4 Span gas Concentration .................................................................... 9-7

9.2.5 Calibration Time ................................................................................. 9-7

9.3 Calibration ......................................................................................................... 9-9

9.3.1 Manual Calibration ............................................................................. 9-9

9.3.2 Semi-automatic Calibration ............................................................... 9-9

9.3.3 Automatic Calibration ....................................................................... 9-10

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

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

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10.1.1 Oxygen Concentration ..................................................................... 10-2

10.1.2 Humidity ........................................................................................... 10-2

10.1.3 Mixing Ratio ..................................................................................... 10-2

10.1.4 Relative Humidity ............................................................................. 10-2

10.1.5 Dew Point ......................................................................................... 10-2

10.1.6 Air Ratio............................................................................................10-3

10.1.7 Cell Temperature .............................................................................. 10-3

10.1.8 Process Gas Temperature ............................................................... 10-3

10.1.9 C. J. Temperature............................................................................. 10-3

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

10.1.11 Cell Voltage ...................................................................................... 10-4

10.1.12 Thermocouple Voltage ..................................................................... 10-4

10.1.13 Cold Junction Voltage ...................................................................... 10-4

10.1.14 Current Output .................................................................................10-4

10.1.15 Response Time ................................................................................ 10-4

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

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

10.1.18 Heater On-Time Ratio ...................................................................... 10-5

10.1.19

10.1.20 Maximum Oxygen Concentration, Humidity, and Mixing Ratio ...... 10-6

10.1.21 Minimum Oxygen Concentration, Humidity, and Mixing Ratio ........ 10-6

10.1.22 Average Oxygen Concentration, Humidity, and Mixing Ratio ......... 10-6

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

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

10.1.25 Time .................................................................................................10-7

10.1.26 Software Revision ............................................................................ 10-7

10.2 Operational Data Initialization ...................................................................... 10-7

10.3 Initialization Procedure .................................................................................. 10-8

10.4 Reset ................................................................................................................. 10-8

10.5 Handling of the ZO21S Standard Gas Unit .................................................10-21

10.5.1 Standard Gas Unit Component Identication ................................ 10-21

10.5.2 Installing Gas Cylinders ................................................................. 10-21

10.5.3 Calibration Gas Flow ......................................................................10-22

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

10.6.1 Preparation Before Calibration ......................................................10-24

10.6.2 Operating the Span Gas Flow Setting Valve .................................10-24

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

10.6.4 Treatment After Calibration ............................................................ 10-24

Oxygen Concentration (with time constant), Humidity (with time constant), and

Mixing Ratio (with time constant) ............................................................. 10-6

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

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

11.1.1 Cleaning the Calibration Gas Tube .................................................. 11-1

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

11.1.3 Replacement of the Heater Assembly ............................................. 11-4

11.1.4 Replacement of Dust Filter .............................................................. 11-6

11.1.5 Replacement of O-ring ..................................................................... 11-6

11.1.6 Stopping and Re-starting Operation ................................................ 11-7

11.2 Inspection and Maintenance of the Converter ............................................ 11-7

11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit .......... 11-9

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 ................... 12-4

12.2.1 What is an Alarm? ............................................................................ 12-4

12.2.2 Measures Taken When Alarms are Generated ...............................12-4

12.3 Measures When Measured Value Shows an Error ...................................... 12-8

12.3.1

12.3.2

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

Measured Value Higher (Lower for Humidity Analyzer) Than True Value

Measured Value Lower (Higher for Humidity Analyzer) Than True Value

.. 12-8

.. 12-9

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

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

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

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<1. Overview>

1. Overview

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

The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer integrates both probe and converter. The analyzers need not use a sampling device, and allow direct installation of the

probe in the wall of a ue or furnace to measure the concentration of oxygen in the stack gas of

the temperature up to 700°C.

The EXAxt ZR Integrated-type Zirconia High-temperature Humidity Analyzer integrates the detector and the converter in one unit. This analyzer can measure humidity of hot air continuously, so can be used to measure humidity of air in driers which are heated by steam or

electricity. It can also be used in a variety of manufacturing applications with humidiers, as well

as with driers, for humidity measurement and control. It can help improve productivity in these

application elds.

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

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

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

, SOx and NOx.

1-1

1.1 < EXAxt ZR > System Conguration

The system conguration should be determined by the conditions; e.g. whether the calibration is to be automated, and whether ammable gas is present and requires safety precautions. The system conguration can be classied into three basic patterns as follows:

1.1.1 System 1

This is the simplest system consisting of an integrated type analyzer. This system can be implemented for monitoring oxygen concentration in the combustion gases boiler, and 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 ZO21S standard gas unit is used for calibration.

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

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<1. Overview>

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

1-2

Stop valve

Calibration gas

Figure1.1 Example of System 1

NOTE

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

by the installation location.

• A stop valve should be connected to the calibration gas inlet of the equipment. The valve

should be fully closed unless calibration is in progress.

1.1.2 System 2

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

In case of humidity analyzer, 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.

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

100 to 240 V AC

Contact input Analog output, contact output

Digital output (HART)

ZO21S Standard gas unit

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

F1.1E.ai

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

Stop valve

Check valve

Reference gas

Calibration gas

Figure1.2 Example of System 2

100 to 240 V AC

Contact input

Analog output, contact output Digital output (HART)

Flowmeter

ZA8F flow setting unit

Needle

valve

Air Set

Instrument air

Span gas(Same as Zero gas calibration)

Calibration

gas pressure

regulator

Calibration gas unit case

Zero gas cylinder

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<1. Overview>

1.1.3 System 3

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

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

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

1-3

Automatic calibration unit

ZR20H

Reference gas

Span gas

Calibration gas (Zero)

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

*1 Shield cable:

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

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

*3 When a zirconia oxygen analyzer is used, 100% N2 gas cannot be used as the zero gas.

Use approx. 1 vol% O

gas (N2-based).

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

with automatic calibration unit (ZR202G-

100 to 240 V AC

Calibration

gas pressure

regulator

Calibration gas unit case

Contact input Analog output, contact output

Digital output (HART)

Air Set

Instrument air

Zero gas cylinder

Figure1.3 Example of System 3

□-□-□-A-□-□-□-□-A)

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1.2 < EXAxt ZR > System Components

1.2.1 System Components

1-4

System Components

Separate type

System cong.

Ex.1 Ex.2 Ex.3

Oxygen Analyzer

Model ZR202G Integrated type Zirconia Oxygen Analyzers A A A A A Model ZO21R Probe Protector for Zirconia Oxygen Analyzers B B B B K9471UA Dust Filter for Oxygen Analyzer B B B B K9471UC Dust Guard Protector B B B B B ZH21B Dust protector (only for Humidity Analyzer) B B B B Model ZO21S Standard Gas Unit A B B Model ZA8F Flow Setting Unit for manual calibration A B B Model ZR20H Automatic Calibration Unit for Integrated type Analyzer A B B L9852CB, G7016XH Stop Valve for Calibration gas line A (A) B B K9292DN,K9292DS Check Valve for Calibration gas line (A) B B G7003XF/K9473XK, G7004XF/K9473XG Air Set A A B B G7001ZC Zero gas Cylinder A A B B G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder A A B B E7044KF Case Assembly for Calibration gas Cylinder A A B B Model ZR202A Heater Assembly (Spare Parts for ZR202G) B B B B B

A: Items required for the above system example B: To be selected depending on each application. For details, refer to corresponding chapter. (A): Select either

1.2.2 Oxygen/Humidity Analyzer and Accessories

Sample gas temperature 0 to 700°C

Mounting Insertion length

Horizontal

vertical

Vertical

Horizontal

vertical

Horizontal

vertical

Vertical

0.4 to

2 m

2.5 m

or more

3 m

or less

0.4

2 m

2.5 m

or more

General-use Probe

Dust protector

(ZH21B)

Humidity analyzer use

Probe Protector

(ZO21R)

Gas Flow

Sample inlet

Dust Filter

(K9471UA)

Dust Guard

Protector

(K9471UC)

ZR202G

Only

ZR22G-040

Detector (ZR202G)

Detector(ZR202G)

Application

• Boiler

• Heating furnace

• For pulverized coal boiler with gas flow velocity

10 m/sec or more

• Cement Kiln

• Black liquid recovery boiler

• Cement Kiln

Humidity Analyzer

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2. Specications

This chapter describes the specications for the following:

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

ZO21R-L Probe protector (See Section 2.1.3)

ZH21B Dust protector (See Section 2.1.4)

ZA8F Flow setting unit (See Section 2.2.1)

ZR20H Automatic calibration unit (See Section 2.2.2)

ZO21S Standard gas unit (See Section 2.3)

K9471UA Dust Filter for Oxygen Analyzer (See Section 2.4)

2.1 General Specications

2.1.1 Standard Specications

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

(excluding inammable gases). May not be applicable corrosive gas

such as ammonia, chlorine is present-check with YOKOGAWA.) (In case of Humidity Analyzer, Water vapor (in vol%) in mixed gases (air and water vapor))

Measured System: Zirconia system

Measurement Range: 0.01 to 100 vol%O (In case of Humidity Analyzer, 0 to 100 vol% H

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

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

or partial range In case of Humidity Analyzer, Moisture quantity: 0 to 25 through 0 to 100 vol% H

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

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

to the loop (multi-drop mode).

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

partial range.

O or 0 to 1.000 kg/kg)

O (in 1 vol% H2O), or

2-1

(in 1 vol%O2),

Display Range: Oxygen concentration; 0 to 100 vol%O2

In case of Humidity Analyzer,

Moisture quantity; 0 to 100 vol% H

O, Mixture ratio; 0 to 1 kg/kg, Relative

humidity; 0 to 100% RH (Note), Dew point; -40 to 370°C (Note)

Note: These values are affected by temperature and absolute pressure, So accurate temperature

and pressure values must be inputted to the converter.

Warm-up Time: Approx. 20 min.

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

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

±0.5% Maximum value of set range; less than 0 to 25 vol%O ±1% Maximum value of set range; 0 to 25 vol%O

or more and up

to 0 to 100 vol%O

range

In case of Humidity Analyzer, ± 1 vol% H2O; (Sample gas pressure 2

kPa or less)

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Linearity: (Excluding standard gas tolerance)

(Excluding the case where the reference gas is by natural convection) (Use oxygen of known concentration (within the measuring range) as the zero and span calibration gases.)

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

range

(Sample gas pressure: within ±4.9 kPa)

±3% Maximum value of set range; 0 to 25 vol%O

or more and less than 0 to 50 vol%O2 range

(Sample gas pressure: within ±0.49 kPa)

±5% Maximum value of set range; 0 to 50 vol%O

or more and up to 0 to 100 vol%O2 range

(Sample gas pressure: within ±0.49 kPa)

In case of Humidity Analyzer,

± 2 vol% H ± 3 vol% H

O; (Sample gas pressure: within ± 0.49 kPa)

O; (Sample gas pressure: 2 kPa or less)

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

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

In case of Humidity Analyzer,

Both zero and span ± 3 vol% H

O/month

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

from calibration gas inlet and analog output start changing.)

2-2

Installation Altitude: 2000 m or less

Category based on IEC 61010: II (Note)

Pollution degree based on IEC 61010: 2 (Note)

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

Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric strength.

Degree 2 is the normal indoor environment.

Safety, EMC and RoHS conforming standards the ZR202G

Safety: EN 61010-1, EN 61010-2-030, CAN/CSA-C22.2 No. 61010-1,

UL Std. No. 61010-1

EMC: EN 61326-1 Class A*, Table 2, EN 61326-2-3, EN 61000-3-2

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

EMC Regulatory Arrangement in Australia and New Zealand (RCM)

EN61326-1 Class A

Korea Electromagnetic Conformity Standard

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

instrument in the industrial environment only.

RoHS: EN 50581

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer

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

Display: 6-digit LCD

Switch: Three optical switches

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

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

to the loop (multi-drop mode).

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

Contact Input Signal: Two points

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Sample Gas Temperature: 0 to 700°C

It is necessary to mount the cell using inconel cell-bolts when the temperature is greater than 600°C.

High temperature service ― greater than 700°C ― is not

available.

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

recommended to use pressure compensated type. When the pressure in the furnace exceeds 5 kPa, pressure compensated type is required.)

No pressure uctuation in the furnace should be allowed.

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

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

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

Probe Material: SUS 316 (JIS)

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

Storage Temperature: -30 to +70°C

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

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.

Reference Gas System: Natural Convection, Instrument Air, or Pressure Compensated

Instrument Air System (excluding Natural Convection): Pressure; 200 kPa + the pressure inside the furnace (It is recommended to use air

which is dehumidied by cooling to dew point -20°C or less, and dust or

oil mist are removed.)

Consumption; Approx. 1Nl/min

Wetted Material: SUS 316 (JIS), Zirconia, SUS304 (JIS) or ASTM grade 304 (ange),

Hastelloy B, (Inconel 600, 601)

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

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

Gas Connection: Rc1/4 or 1/4NPT(F)

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

Installation: Flange mounting

Probe Mounting Angle: Horizontal to vertically downward.

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

Case: Aluminum alloy

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

Finish: Polyurethane corrosion-resistance coating

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

Insertion length of 1.0m: approx. 10 kg (JIS 5K 65) / approx. 15 kg (ANSI 150 4) Insertion length of 1.5m: approx. 12 kg (JIS 5K 65) / approx. 17 kg (ANSI 150 4) Insertion length of 2.0m: approx. 14 kg (JIS 5K 65) / approx. 19 kg (ANSI 150 4) Insertion length of 3.0m: approx. 17 kg (JIS 5K 65) / approx. 22 kg (ANSI 150 4)

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Functions (inclused Humidity Analyzer)

Display Function: Displays values of the measured oxygen concentration, moisture

quantity, mixture ratio, etc.

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

such status occurs.

Calibration Functions:

Automatic calibration; Requires the Automatic Calibration Unit. It calibrates

automatically at specied intervals.

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

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

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

operation interactively with the optical switch.

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

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

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

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

Display and setting content:

Display Related Items: Oxygen concentration (vol% O

moisture quantity (in hot gases) (vol% H

), output current value (mA), air ratio,

O), mixture ratio(kg/kg), relative

humidity(%RH), dew point (°C), Cell temperature (°C ), thermocouple reference junction temperature (°C ), maximum/minimum/average oxygen concentration (vol% O quantity (vol% H

O), maximum/minimum/average mixture ratio (kg/

), maximum/ minimum/average moisture

kg), cell e.m.f. (mV), cell internal resistance (Ω), cell condition (in four

grades), heater on-time rate (%), calibration record (ten times), time (year/month/day/hour/minute), output 1, 2 current (mA), cell response time (seconds),

Calibration Setting Items:

Span gas concentration (vol% O2), zero gas concentration (vol%O2),

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

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

up/maintenance/calibrating/abnormal, 4 mA/20 mA point oxygen concentration (vol% O

), time constant, preset values when warming-up/

maintenance/calibrating/abnormal, output preset values on abnormal

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

oxygen concentration low alarm/low-low alarm limit values (vol% O oxygen concentration alarm hysteresis (vol% O alarm/ high-high alarm limit values (vol% H alarm/ low-low alarm limit values (vol% H

), moisture quantity high

O), moisture quantity low

O), mixture ratio high alarm/ high-high alarm limit values (kg/kg), mixture ratio low alarm/ low-low alarm limit values (kg/kg), moisture quantity alarm hysteresis (vol% H

O), 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 and

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

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

input)

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

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

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

1 vol% O

, and partial range is available (Maximum range value/

minimum range value 1.3 or more)

For the log output, the minimum range value is xed at 0.1 vol%

4 to 20 mA DC linear or log can be selected. Input/output isolation.

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

1 vol% O

, and partial range is available (Maximum range value/

minimum range value 1.3 or more)

For the log output, the minimum range value is xed at 0.1 vol%

4 to 20 mA DC linear or log can be selected. Input/output isolation.

Output damping; 0 to 255 seconds.

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

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

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

) can be added to high/low alarms.

The following functions are programmable for contact outputs. (1) Abnormal, (2) High-high alarm, (3) High alarm, (4) Low-low alarm, (5) Low alarm, (6) Maintenance, (7) Calibration, (8) Range switching answer-back, (9) Warm-up, (10) Calibration gas pressure decrease (answer-back of contact input), (11) Flameout gas detection (answerback of contact input).

Contact Input: Two points, voltage-free contacts

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

(switched range is xed), (3) External calibration start, (4) Process alarm

(if this signal is received, the heater power turns off)

Contact capacity: Off-state leakage current: 3 mA or less

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

calibration, A/D converter abnormal, digital circuit abnormal

Calibration:

Method; zero/span calibration Calibration mode; Auto, semi-auto and manual (All are operated using optical switches).

Either zero or span can be skipped.

Zero calibration gas concentration setting range;

0.3 to 100 vol% O

(minimum setting: 0.01 vol% O2).

Span calibration gas concentration setting range;

4.5 to 100 vol% O

(minimum setting: 0.01 vol% O2).

Use nitrogen-balanced mixed gas containing 0 to 10 vol% O

oxygen for standard zero gas and 80 to 100 vol% O

scale of oxygen for

standard span gas.

Calibration interval; date/time setting: maximum 255 days

scale of

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l Model and Codes

Model Sufx code

ZR202G - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Length -040

Wetted material

Flange (*2)

Auto Calibration -N

Reference gas -C

Gas Thread -R

Connection box thread -P

Instruction manual -J

— -A - - - - - - - - - - Always -A Options

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

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

*3 Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to 700°C). *4 For humidity measurements, be sure to specify /HS options. Pressure compensation of reference gas can not be selected. *5 Specify either /CV or /SV option code. *6 Not used with the high temperature humidity analyzer. *7 Specify either /SCT or /PT option code. *8 No need to specify the option codes, /CV and /SV, since the check valves are provided with the Automatic Calibration Unit. Automatic calibration cannot be used when natural convection is selected as reference air. *9 Sun shield hood is still effective even if scratched. Hood is necessary for outdoor installation out of sun shield roof. *10 Recommended if sample gas contains corrosive gas like chlorine.

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

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

-070

-100

-150

-200

-250

-300

-S

-C

ZO21R-L-200-

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-R

-S

-W

-A

-B

-E

-P

-T

-G

-M

-T

Tag plates

NAMUR NE43 compliant

□. Specify the ange sufx code either -C or -K.

-E

-C

Valves

Filter

Option code

- - - - - - - - - -

/C /HS /CV /SV /H /F1 /F2 /SCT /PT /C2

/C3

Description

Integrated type Zirconia Oxygen/ Humidity Analyzer

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m

2.5 m (*1)

3.0 m (*1) Stainless steel (SUS316)

Stainless steel with Inconel calibration gas tube (*10) ANSI Class 150 2 RF

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

Not required Horizontal mounting (*8) Vertical mounting (*8)

Natural convection External connection (Instrument air) (*11) Pressure compensated (*11)

Rc1/4 1/4NPT (Female)

G1/2 Pg13.5 M20 x1.5 mm 1/2NPT

Japanese English Chinese

Inconel bolt (*3) Set for Humidity Analyzer (*4) Check valve (*5) Stop valve (*5) Hood (*9) Dust Filter (*6) Dust Guard Protector (*6) Stainless steel tag plate (*7) Printed tag plate (*7) Failure alarm down-scale: Output status at CPU failure and hardware error is 3.6 mA or less (*12) Failure alarm up-scale: Output status at CPU failure and hardware error is 21.0 mA or more (*12)

2-6

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338 to 351

l EXTERNAL DIMENSIONS

Model ZR202G Integrated type Zirconia Oxygen/Humidity Analyzers

2-7

Unit: mm

L= 0.4, 0.7,

1.0, 1.5, 2.0,

2.5, 3.0 (m)

Ø50.8

Rc1/4 or 1/4NPT Reference gas inlet

153 to 164

252 to 265

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

Rc1/4 or 1/4NPT Calibration gas inlet

Ø123

Display side

122

48.5

125

Terminal side

170

ØA

ØB

Flange

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

A B C

152.4

190.5

228.6 165 200 220 155 175 185 210 229 190 155

l Standard Accessories

Item Parts. No. Q'ty Description

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

120.6

152.4

190.5 125 160 180 130 140 150 175

190.5

152.4 127

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

4 - Ø11.5

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

Flange

ØA

ØB

Flange

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  <2.Specications>

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

L= 0.4, 0.7,

1.0, 1.5, 2.0,

2.5, 3.0 (m)

342 ± 4

Rc1/4 or 1/4NPT Reference gas inlet

2-8

Unit: mm

Ø123

Display side

122

Ø50.8

Reference gas outlet

Flange

PIPING

PIPING:A

156 ± 3

256 ± 4

Flange

A B 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

Stop

valve

Rc1/4 or 1/4NPT Calibration gas inlet

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

4 - Ø11.5

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

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

48.5

ØA

ØB

ØA

ØB

Terminal side

170

Flange

125

F11_02.EPS

l Standard Accessories

Item Parts. No. Q'ty Description

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

274

l Hood (Option code /H)

± 4

± 3

150

± 3

2-9

Unit: mm

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

2.1.3 ZO21R Probe Protector

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

detector from wearing by dust particles.

When probe insertion length is 2.5 m or more and horizontal installation, specify the ZO21R-L-

200-□*B to reinforce the probe.

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

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

equivalent . However, ange thickness is different.

Material: SUS316 (JIS), SUS304 (JIS) or ASTM grade 304 (Flange)

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

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

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

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

process-side ange.

l Model and Codes

Model Sufx code

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

Insertion length

Flange ( *1) -J

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

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

-100

-150

-200

-A

Option

code

- - - - - -

1.05 m

1.55 m

2.05 m JIS 5K 65 FF

ANSI Class 150 4 FF

F13.ai

Description

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

l EXTERNAL DIMENSIONS

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

Washer (12)

Gas flow

JIS 5K 65 FF 155 130 4 - Ø15 5 40

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

Mounting nut (M12)

SUS316

Ø60.5

l (Insert length)

l=1050,1550,2050

Flange<1> A B C t D

gasket (t3.0)

ØA

Dimensions of holes on opposing surface

F2-3E.ai

2-10

Unit: mm

2.1.4 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.

Insertion length: 0.428m

Flange: JIS 5K 80 FF or ANSI Class 150 4 FF (However, ange thickness is

different)

Material: SUS 316(JIS), SUS304 (JIS) or ASTM grade 304 (ange)

Weight: Approximately 6kg (JIS), approximately 8.5kg (ANSI)

Mounting: Mounted on the probe or process ange with bolts and associated nuts

and washers.

l Model and Codes

Model Sufx code

ZH21B - - - - - - - - - - - - - - - - - - - Dust Protector (0 to 600 °C)

Insertion length -40 - - - - - - 0.428 m

Flange ( *1) -J

-A

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

Note: The ange thickness varies.

(*1) Specify the probe ZR22G-040-h-K (*2) Specify the probe ZR22G-040-h-C

Option

code

- - - - - -

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

Description

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Unit: mm

428 (Insertion length)

øA

ø72

JIS flange

Install facing upwards

ø76.3

ANSI flange

øB

2-11

øB

Flange A B C t D

JIS 5K 80 FF 180 145 4 - Ø19 12 40

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

øB

ZH21B.ai

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit

2.2.1 ZA8F Flow Setting Unit

This ow setting unit is applied to the reference gas and the calibration gas in a system conguration (System 2). Used when instrument air is provided.

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

reference gas.

Standard Specications

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

Construction: Dust-proof and rainproof construction

Case Material: SPCC (Cold rolled steel sheet)

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

Tube Connections: Rc1/4 or 1/4NPT (Female)

Reference Gas Pressure:

Air Consumption: Approx. 1.5 l/min

Weight: Approx. 2.3 kg

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

Clean air supply of sample gas pressure plus approx. 50 kPa G (or

sample gas pressure plus approx.150 kPa when a check valve is used.)

Pressure at inlet of the  ow setting unit. (Max. 300 kPa G)

NOTE

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

l Model and Codes

Model Sufx code Option code Description

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

Joint -J

-A

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

- - - - - - - - -

Rc 1/4 With 1/4 NPT adapter

2-12

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

l External Dimensions

2-13

ø6 Hole

235.8

222.8

Calibration gas outlet

Reference gas outlet

REFERENCE CHECK

Span gas inlet

CHECK

REF

OUT

180

140

REFERENCE

Unit : mm (inch)

SPAN

ZERO

Zero gas inlet

Piping connection port A

AIR

SPAN

ZERO

Piping connection port A

Model

2035

ZA8F-J*C

2B mounting pipe

5 - Rc1/4

PIPNG INSIDE THE FLOW SETTING UNIT

CHECK OUT

Flowmeter Flowmeter

ZERO

GAS IN

SPAN

GAS IN

REF OUT

Air Set

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

Instrument air inlet

AIR IN

Instrument air Approx. 1.5 l/min.

ZA8F-A*C

5 - 1/4NPT

Weight : Approx. 2.3 kg

F2.6E.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

2.2.2 ZR20H Automatic Calibration Unit

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

l Specications

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

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

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

Mounting: Mounted on ZR202G, no vibration

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

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

Finish: Polyurethane corrosion-resistance coating

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

Piping Connection: Rc1/4 or 1/4NPT (Female)

Power Supply: 24V DC (from ZR202G), Power consumption: Approx.1.3 W

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

(Pressure at inlet of automatic calibration unit)

Air Consumption: Approx. 1.5 l/min

Weight: Approx. 2 kg

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

Ambient Humidity: 0 to 95% RH

Storage Temperature: -30 to +65°C

2-14

l Model and Codes

Model Sufx code

ZR20H - - - - - - - - - - - - - - - - - - - - - Automatic calibration unit for ZR202G *1

Gas piping connection

Reference air *2 -E

Mounting -A

— -A - - - - - - - - Always -A

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

-R

-T

-P

-B

Option

code

- - - - - - - -

Description

Rc1/4 1/4NPT (F)

Instrument air Pressure compensated

Horizontal mounting Vertical mounting

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Unit: mm

l External Dimensions

(1) Horizontal Mounting (-A)

Ø84

258

243

2-15

SPAN IN REF IN ZERO IN

166.5

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

(2) Vertical Mounting (-B)

SPAN IN REF IN ZERO IN

166.5

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

Ø80

66.540 40

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

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

49111

Ø80

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

MAX

MODEL ZR20H

SUFFIX

STYLE

AMB.TEMP

USED WITH

NO.

AUTO CAL. UNIT

ZR20HMODEL

SUFFIX

STYLE

SUPPLY 690kPa MAX.

-20 TO 558C

AMB.TEMP

USED WITHZR202G

NO.

AUTO CAL. UNIT

690kPa MAX.SUPPLY

-20 TO 558C

ZR202G

[ 84

180MAX444040 66.5

PIPNG INSIDE THE AUTOMATIC CALIBRATION UNIT

Calibration gas

Check valve

Reference gas

Automatic calibration unit

ZR202G body

Span gas solenoid valve

Zero gas solenoid valve

Span gas flowmeter

Reference gas flowmeter

Needle valve

Zero gas flowmeter

SPAN IN

REF. IN

ZERO IN

To Air set

To Zero gas cylinder

F4.11E.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

2.3 ZO21S Standard Gas Unit

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

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

The ZO21S does not conform to CE marking.

l Standard Specications

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

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

Sealed Zero Gas Cylinders (6 provide): E7050BA

Capacity: 1 l

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

Composition: 0.95 to 1.0 vol% O

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

Power Consumption: Max. 5 VA

Case material: SPCC (Cold rolled steel sheet)

Paint: Epoxy resin, baked

Paint Color: Mainframe; Munsell 2.0 GY3.1/0.5 equivalent Cover; Munsell 2.8 GY6.4/0.9 equivalent

Piping: Ø6 x Ø4mm exible tube connection

Weight: Approx. 3 kg

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

(N2 balanced)

2-16

l Model and Codes

Model Sufx code Option code Description

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

Power supply

Panel -J

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

-2

-3

-4

-5

-7

-8

-E

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

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

Japanese version English version

l External Dimensions

253

228

1600

354

Flow checker Span gas valve

Zero gas valve Gas outlet

Zero gas cylinder (6 cylinder): E7050BA

F24.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Carborundum filter (SiC)

2.4 Other Equipment

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

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

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

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

sensor.

l Standard specication

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

approximately perpendicular to the probe.)

Mesh: 30 microns

Material: SiC (Filter), SUS316 (JIS)

Weight: Approx. 0.2 kg

Part No. Description

K9471UA Filter

K9471UX Tool

2-17

Detector

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

Ø51

Screw

Increasing of insertion length

2.4.2 Dust Guard Protector (K9471UC)

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

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

Material: SUS316

Weight: Approx. 0.3 kg

Unit: mm

F31.EPS

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Ø50.8

Increasing of insertion length

100

4-Ø6

2-18

Unit: mm

122

F11-1.ai

2.4.3 Stop Valve (part no. L9852CB or G7016XH)

This valve is mounted on the calibration gas line in the system to allow for manual calibration.

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

Standard Specications

Connection: Rc1/4 or 1/4NPT (Female)

Material: SUS 316 (JIS)

Weight: Approx. 150 g

Part No. Description

L9852CB Joint: Rc1/4, Material: SUS316 (JIS)

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

Ø48

Rc1/4 or 1/4NPT

(Full open length)

F15.ai

2.4.4 Check Valve (part no. K9292DN or K9292DS)

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

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

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

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

l Standard Specications

Connection: Rc1/4 or 1/4NPT (Female)

Material: SUS304 (JIS)

Pressure: Between 70 kPa G or more 350 kPa G or less

Weight: Approx. 90 g

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Unit: mm

Part No. Description

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

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

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

2-19

Approx. 19 Approx. 54

2.4.5 Air Set

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

l Standard Specications

Part no. G7003XF or K9473XK

Primary Pressure: Max. 1 MPa G

Secondary Pressure: 0.02 to 0.2 MPa G

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

Weight: Approx.1 kg

F30.EPS

Part No. Description

G7003XF Joint: Rc1/4, Material: Zinc alloy

K9473XK Joint: 1/4 NPT (F), Material: Zinc alloy with adapter

Part. no. G7004XF or K9473XG

Primary Pressure: Max. 1 MPa G

Secondary Pressure: 0.02 to 0.5 MPa G

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

Weight: Approx. 1 kg

Part No. Description

G7004XF Joint: Rc1/4, Material: Zinc alloy

K9473XG Joint: 1/4 NPT (F), Material: Zinc alloy with adapter

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Unit : mm

l External Dimensions

Unit : mm

Panel cut dimensions

Horizontal mounting

ø15

Vertical mounting

View A

2-20

Primary

+0.5

-0

2-ø2.2

Ø74

Secondary

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

2-ø6.5

max. 55

Max. 210

Secondary pressure gauge

2-M6 screw depth 8

Panel (Horizontal mounting)

Panel (Vertical mounting)

Approx. 122

F22_1.ai

2.4.6 Zero Gas Cylinder (part no. G7001ZC)

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

l Standard Specications

Capacity: 3.4 l

Filled pressure: 9.8 to 12 MPa G

Composition: 0.95 to 1.0 vol%O

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

485

325

Weight : Approx. 6 kg

ø140

(N2-balanced)

F32.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Approx.112

Unit : mm

2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas

Cylinder

This regulator valve is used with the zero gas cylinders.

l Standard Specications

Primary Pressure: Max. 14.8 MPa G

Secondary Pressure: 0 to 0.4 MPa G

Connection: Inlet; W22 14 threads, right hand screw

Outlet; Rc1/4 or 1/4NPT (Female)

Material: Brass body

Secondary pressure gauge

Primary pressure gauge

2-21

Approx. 59

Regulator handle

Approx. 163 Approx. 174

Stop valve

* Outlet

Part No.

G7013XF

G7014XF

Primary safety valve

* Outlet

Rc1/4

1/4 NPT female screw

Secondary safety valve

Approx. 82

W22 (Righthanded screw)

2.4.8 Case Assembly (E7044KF) for Calibration gas

Cylinder

This case is used to store the zero gas cylinders.

l Standard Specications

Installation: 2B pipe mounting

Material: SPCC (Cold rolled steel sheet)

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

Weight: Approx. 10 kg with gas cylinder

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Unit : mm

Ø 45

2-22

324

Pressure regulator

G7013XF/ G7014XF

200 180

Zero gas cylinder

(G7001ZC)

496

(158.3)

(160)

2B mounting pipe

( Ø60.5 )

F23.ai

The oblique line is an opening portion.

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

2.4.9 ZR202A Heater Assembly

l Model and Codes

Model Sufx code Option code Description

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

Length (*1) -040

-070

-100

-150

-200

-250

-300

Jig for change -A

-N

― -A - - - - - - - - - - - Always -A

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

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

- - - - - - - - - - -

0.4 m

0.7 m 1 m

1.5 m 2 m

2.5 m 3 m

with Jig None

l External Dimensions

Jig for change

(K9470BX)

Ø 21.7

K9470BX

L±12

F2.16.EPS

L: length

Model & Code

ZR202A-040

ZR202A-070

ZR202A-100

ZR202A-150

ZR202A-200

ZR202A-250

ZR202A-300

Weight (kg)

552

Approx. 0.8

852

Approx. 1.2

1152

1652

2152

2652

3152

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Approx. 1.6

Approx. 2.2

Approx. 2.8

Approx. 3.4

Approx. 4.0

<3. Installation>

3. Installation

This chapter describes installation of the following equipment:

Section 3.1 Model ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

Section 3.2 Model ZA8F Flow Setting Unit

Section 3.3 Model ZR20H Automatic Calibration Unit

Section 3.4 Case Assembly (E7044KF) for Calibration gas Cylinder

3.1 Installation of ZR202G Zirconia Oxygen/

Humidity Analyzer

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

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

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

radiant heat.

(3) A clean environment without any corrosive gases.

NOTE

3-1

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

(4) No vibration.

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

(6) No sample gas pressure uctuations.

CAUTION

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

3.1.1 Probe Insertion Hole

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.

• If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet

should face downwards.

• When using the detector with pressure compensation, ensure that the ange gasket does not block the reference gas outlet on the detector ange. If the ange gasket blocks the

outlet, the detector cannot conduct pressure compensation. Where necessary, make a

notch on the ange gasket.

• The sensor (zirconia cell) at the probe tip may deteriorate due to thermal shock if water

drops are allowed to fall on it, as it is always at high temperature.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<3. Installation>

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

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

a 5° tilt).

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

tip should point downstream.

3-2

(vertical)

100 mm

(Note) When using the detector with pressure compensation, ensure that the ange gasket does not block the reference gas outlet on

the detector ange. If the ange gasket blocks the outlet, the detector cannot perform pressure compensation.

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

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

Figure 3.1 Illustrates an example of the probe insertion hole

Bounds of the probe insertion hole location

Flange matches the detector size

Note

100 mm

(horizontal)

3.1.2 Installation of the Probe

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 anges to prevent gas leakage. The gasket material

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

Type

Standard 50.8 mm in diameter (Note) With dust filter 51 mm in diameter (Note) With probe protector With dust protector

Four-hole flange Eight-hole flange

Outside diameter of detector

60.5 mm in diameter (Note)

80 mm in diameter or longer (Note)

JIS flange

(the detector with

F3-1E.ai

dust protector)

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

<General-use detector>

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

If a dust lter (see Section 2.4.1) is used, make sure it is properly attached to the detector. Refer to Section 3.1.3 for installation of the dust lter.

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

inlet should face downward.

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

CAUTION

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

combustion systems other than these, it may have adverse effects such as response delay.

The combustion conditions should be examined carefully before using a lter.

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<3. Installation>

F31.EPS

Ø50.8

Increasing of insertion length

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

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

construction, especially the sensor assembly.

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

clockwise. Put a hook pin wrench (K9471UX), Ø52 to 55 in diameter, into the hole on the dust lter to fasten or remove it. Apply a heat-resistant coating (see Note 1) to the threads on the detector.

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

resistant coating.

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

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

Carborundum filter (SiC)

Detector

Ø51

3-3

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

Figure 3.2 Installation of the dust lter

Increasing of insertion length

Screw

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

case of ordering the detector. The protector should be used when preventing dusts and water drops from lowering the detector performance is desired. Screw the protector on the top of the detector so as to cover the top. When attaching or detaching the protector, perform by hooking holes of its side with a hook pin wrench for Ø52-55 hole( Pin diameter 4.5 mm: P/N K9471UX or the like) or by pass a screwdriver through the holes. When re-attaching the protector after detaching it, apply the “Never-Seez Nickel Special” to it.

100

4-Ø6

Figure 3.3 Installation of the dust guard protector

The detector is used with a probe protector to support the probe (ZR202G) when the probe length is 2.5m or more and mounted horizontally.

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

122

F11-1.ai

the probe insertion hole.

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<3. Installation>

Unit: mm

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

loose.

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

3-4

Direction of the sample gas flow

Detector top

Figure 3.4 Probe protector (supporting the mounting strength)

Notch

2050

Ø60.5

Gasket (t1.5)

Calibration gas inlet

Reference gas inlet

F3103E.ai

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

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

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

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

to the downstream of the sample gas ow.

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

loose.

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

downward.

1050,1550, 2050

Direction of the sample gas flow

Detector top

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

Figure 3.5 Mounting of detector with a probe protector (Dust wear protect)

Gasket (t1.5)

CAUTION

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

3.1.4 Installation of ZH21B Dust Protector

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

protector in the probe insertion hole.

Calibration gas inlet

Reference gas inlet

F3104E.ai

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<3. Installation>

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

downward.

Unit : mm

Reference gas inlet Calibration gas inlet

F3-2E.ai

Figure 3.6 Installation of the dust lter

3.2 Installation of ZA8F Flow Setting Unit

The following should be taken into consideration:

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

(2) Near to the detector and the converter

(3) No corrosive gas.

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

(5) No vibration.

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

3-5

n Mounting of ZA8F Flow Setting Unit

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

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

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

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

tting is rmly attached to the pipe.

F3401E.ai

Figure 3.7 Pipe Mounting

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<3. Installation>

Unit: mm

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

223

3-6

140

F3.13E.ai

Figure 3.8 Mounting holes

4 - Ø6 hole, or M5 screw

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

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

F3.14E.ai

Figure 3.9 Wall mounting

3.3 Installation of ZR20H Automatic Calibration

Unit

The following should be taken into consideration:

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

(2) Near to the detector and the converter

(3) No corrosive gas.

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

(5) No vibration.

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

n Mounting of ZR20H Automatic Calibration Unit

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

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

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

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

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<3. Installation>

F3.15E.ai

3-7

Horizontal mounting on the ZR202G (-A)

214 MAX44 66.540 40

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

Vertical mounting on the ZR202G (-B)

258

243

Display side

166.5

Terminal box side

Unit: mm

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

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

166.5

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

45 160

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

66.540 40180 MAX44

Figure 3.10 Automatic Calibration Unit Mounting

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

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

The following should be taken into consideration:

(1) Easy access for cylinder replacement

(2) Easy access for checking

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

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

heat.

(5) No vibration

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<3. Installation>

n Mounting

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

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

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

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

tting is rmly attached to the pipe.

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

F3-16E.ai

Figure 3.11 Pipe Mounting

3-8

3.5 Insulation Resistance Test

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

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

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

Remove wiring from the converter and the detector.

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

2. Connect crossover wiring between L and N.

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

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

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

wiring and ground, to discharge.

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

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

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<3. Installation>

Contact input 1

3-9

DI-1

Figure 3.12

Contact input 2

DI-2

(+)

Insulation

resistance

tester

Crossover wiring

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

(-)

Remove

Crossover wiring

jumper plate

Insulation resistance

tester

F3.17E.ai

Insulation

resistance

tester

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Blank Page

<4. Piping>

4. Piping

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

Integrated type Zirconia Oxygen/Humidity Analyzer.

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

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

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

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

• When the instrument applies natural convection for reference gas (Model ZR202G----C), ambient air near the probe is used for reference gas; therefore the accuracy of

analysis will be affected by ambient humidity changes or the like. If more accurate analysis

is necessary, use instrument air (dehumidied to the dew point -20°C or lower, removed any

dust, oil mist and the like) for reference gas. Stable analyzing can be conducted when using instrument air.

4.1 Piping for System 1

The piping in System 1 is illustrated in Figure 4.1

4-1

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

Stop valve

Calibration gas

100 to 240 V AC

Contact input Analog output, contact output

Digital output (HART)

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

ZO21S Standard gas unit

Figure 4.1 Piping for System 1

Piping in System 1 is as follows:

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

F1.1E.ai

CAUTION

• The stop valve should be connected directly to the equipment. If any piping is present

between the analyzer and the stop valve, condensed water may be produced in the pipe, which may cause damage to the sensor by rapid cooling when the calibration gas is introduced.

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<4. Piping>

4.1.1 Piping Parts for System 1

Check that the parts listed in Table 4.1 are provided.

Table 4.1 Piping Parts

Equipment Piping location Parts Name Description

Oxygen/ Humidity Analyzer

Note: Parts with marking * are used when required.

General parts can be found on the local market.

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

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

Joint for tube connection

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

YOKOGAWA

Rc1/4 (1/4NPT) for a 6x4mm soft tube

General parts

4.1.2 Piping for the Calibration Gas

When carrying out calibration, connect the piping (6(O.D) x 4(I.D.) mm tube) from the standard gas unit to the calibration gas inlet of the oxygen analyzer. Mount the stop valve (of a quality

specied by YOKOGAWA) through a nipple (found on the local market) as illustrated in Figure

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

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

4-2

Stop valve

Tube connection joint

Figure 4.2 Piping for the Calibration Gas Inlet

Nipple

F4.2E.ai

4.1.3 Piping for the Reference Gas

• Normally, no piping is required for the reference gas inlet when the equipment applies

natural convection for reference gas (models ZR202G-----C). Leave the plug as it is. If the air around the probe is polluted and the necessary oxygen concentration (21 vol%O cannot be obtained, make instrument air piping as in Section 4.2, System 2.

• When the equipment uses instrument air for the reference gas, piping is required as

described in Section 4.2, System 2 (models ZR202G-----E or P).

4.2 Piping for System 2

Piping in System 2 is illustrated in Figure 4.3.

)

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<4. Piping>

F1.2E.ai

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

4-3

Stop valve

Check valve

Reference gas

Calibration gas

100 to 240 V AC

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

Flowmeter

ZA8F flow setting unit

Needle

valve

Air Set

Pressure

regulator

Calibration gas unit case

Figure 4.3 Piping for System 2

System 2 illustrated in Figure 4.3 requires piping as follows:

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

equipment.

4.2.1 Piping Parts for System 2

Check that the parts listed in Table 4.2 are provided.

Table 4.2 Piping Parts

Instrument air

Span gas(Same as Zero gas calibration)

Zero gas cylinder

Equipment Piping location Parts Name Description

Oxygen/ Humidity

Calibration gas inlet Stop valve or check

valve

Analyzer

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

Zero gas cylinder User' s scope

Pressure Regulator (G7013XF or G7014XF) recommended by

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

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

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

Note: Parts with marking * are used when required.

General parts can be found on the local market.

4.2.2 Piping for the Calibration Gas

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

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

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

Mount the stop valve or the check valve (recommended by YOKOGAWA) through the nipple (found on the local market) at the calibration gas inlet of the equipment as illustrated in Figure

4.4. (The stop valve or the check valve may have been mounted on the equipment when

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

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

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

YOKOGAWA

K9473XG) recommended by YOKOGAWA

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<4. Piping>

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

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

Stop valve or check valve

F4.8E.ai

Figure 4.4 Piping for the Calibration Gas Inlet

4.2.3 Piping for the Reference Gas

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

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

setting unit.

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

setting unit and the analyzer.

4-4

4.3 Piping for System 3

Piping in System 3 is illustrated in Figure 4.5. In System 3, calibration is automated; however, the

piping is basically the same as that of System 2. Refer to Section 4.2.

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

pressures are approximately the same. The ow rate of zero and span gases (normally

instrument air) are set by a individual needle valve. After installation and wiring, check zero gas calibration contact output (see Sec. 7.10.2), and adjust zero gas regulator and calibration gas

needle valve so that zero gas ow is within the permitted range. Next check span gas calibration contact output and adjust air set so that span gas ow is within the permitted range.

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer with automatic calibration

Automatic Calibration Unit

ZR20H

Reference gas

Span gas

Calibration gas (Zero)

100 to 240 V AC

Air Set

Pressure

regulator

Contact input Analog output, contact output

Digital output (HART)

Instrument air

Zero gas cylinder

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

Figure 4.5 Piping for System 3

Calibration gas unit case

F1.3E.ai

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<4. Piping>

F3.15E.ai

Piping Diagram

Installation of ZR20H Automatic Calibration Unit

Horizontal mounting on the ZR202G (-A)

214 MAX44 66.540 40

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

Vertical mounting on the ZR202G (-B)

258

Display side

243

166.5

Terminal box side

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

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

166.5

4-5

Unit: mm

Calibration gas

Reference gas

Check

valve

ZR202G body

Span gas solenoid valve

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

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

Span gas flowmeter

Reference gas flowmeter

45 160

SPAN IN

REF. IN

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

66.540 40180 MAX44

To Air set

Zero gas solenoid valve

Automatic Calibration Unit

Zero gas flowmeter

Needle valve

To Zero gas cylinder

ZERO IN

F4.11E.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<4. Piping>

4.4 Piping for the Oxygen Analyzer with Pressure Compensation

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

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

NOTE

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

The detector with pressure compensation is illustrated in Figure 4.6.

342±4

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

4-6

Unit: mm

Reference gas outlet

PIPING

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

Figure 4.6 Oxygen Analyzer with Pressure Compensation

PIPING

Stop valve

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

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

ØA

ØB

Flange

F4.12E.ai

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

Valve operation

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

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

gas outlet.

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

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

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

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

necessary.

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

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<4. Piping>

CAUTION

• Use suitable cable glands to completely seal the detector. As far as possible do not stop the instrument air ow, to prevent the sample gas from entering the detector and damaging the

zirconia cell.

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

Figure 4.7 illustrates an example of System 2 using the analyzer with pressure compensation.

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

ZR202G Integrated type Zirconia Oxygen Analyzer with pressure compensation

4-7

Stop valve

Check valve

Reference gas

Calibration gas

Figure 4.7 Illustrates an example of System 2 using the analyzer with pressure compensation.

100 to 240 V AC

Contact input

Analog output, contact output Digital output (HART)

Flowmeter

ZA8F flow setting unit

Needle

valve

Air Set

Instrument air

Span gas(Same as Zero gas calibration)

Pressure

regulator

Calibration gas unit case

Zero gas cylinder

F1.2E.ai

NOTE

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

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<4. Piping>

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation

Check that the parts listed in Table 4.3 are provided.

Table 4.3 Piping Parts

Equipment Piping location Parts Name Description

Oxygen Analyzer with pressure compensation

Note: Use parts with marking * as required.

General parts can be found on the local market.

Calibration gas inlet Check valve or stop

valve

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

Zero gas cylinder User's scope

Pressure regulator (G7013XF or G7014XF) recommended by

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

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

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

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

YOKOGAWA

K9473XG) recommended by YOKOGAWA

4-8

4.4.2 Piping for the Calibration Gas

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

4.4.3 Piping for the Reference Gas

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

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<5. Wiring>

5. Wiring

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

5.1 General

WARNING

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

CAUTION

This product complies with CE marking. Where compliance with CE marking is necessary, the following wiring procedure is necessary.

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

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

947-3.

• It is recommended that the external switch or circuit breaker be mounted in the same room

as the equipment.

• The external switch or circuit breaker should be installed within the reach of the operator,

and marked as the power supply switch of this equipment.

5-1

Wiring procedure

Wiring should be made according to the following procedure:

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

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

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

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

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

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

Table 5.1 Cable Specications

Terminal name of converter Name Need for shields Number of wires

L, N,

AO+, AO- Analog output Ο 2

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

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

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

Power supply 2 or 3 *

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<5. Wiring>

WARNING

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

CAUTION

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

• Protective grounding should be connected in ways equivalent to JIS D style (Class 3) grounding (the grounding resistance is 100 Ω or less).

• Special consideration of cable length should be taken for the HART communication, For the

detail, refer to Section 1.1.2 of the IM 11M12A01-51E “Communication Line Requirements”.

5.1.1 Terminals for the External Wiring

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

5-2

DIDI

1 2 C DO DO

Figure 5.1 Terminals for External Wiring

1 2

L NFG

–

5.1.2 Wiring

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

(1) Analog output signal

(2) Power and ground

(3) Contact output

(4) Contact input

G FG

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<5. Wiring>

F28.EPS

Model ZR202G Integrated type Zirconia Oxygen Analyzer

Analyzer

5-3

(-)

Contact output 1

100 to 240 V AC, 50 or 60 Hz

Contact input 1

Contact input 2

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

FG9AO

(+)

Analog output 4-20 mA DC Digital output

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

in the equipment or the ground terminal on the case.

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

Contact output 2

Figure 5.2 Wiring Connection

5.1.3 Mounting of Cable Gland

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

Figure 5.3 Cable Gland Mounting

5.2 Wiring for Analog Output

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

load resistance including the wiring resistance of 550Ω or less.

AO(+)

AO(

Rc1/4 or 1/4NPT Reference gas inlet

Rc1/4 or 1/4NPT Calibration gas inlet

Shielded cables

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

Cable gland

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Receiver

Figure 5.4 Wiring for Analog Output

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<5. Wiring>

Ground

5.2.1 Cable Specications

Use a 2-core shielded cable for wiring.

5.2.2 Wiring Procedure

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

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

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

CAUTION

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

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

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

5-4

5.3 Wiring Power and Ground Terminals

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

DIDI

Grounding to the earth terminal on the equipment case

Equipment case

Crimp contact of the grounding line

Grounding terminal

Lock washer

100~240VAC 50/60Hz

Figure 5.5 Power and Grounding Wiring

5.3.1 Wiring for Power Line

1 2 C DO DO

+ -

1 2

FGG

L NFG

Jumper plate

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

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

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

screws for cable connections.

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<5. Wiring>

Analyzer

5.3.2 Wiring for Ground Terminals

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

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

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

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

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

the equipment.

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

corresponding crimp-on terminals.

5.4 Wiring for Contact Output

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

Do the contact output wiring according to the following requirements.

5-5

Terminal box

DO-1

DO-2

Figure 5.6 Contact Output Wiring

5.4.1 Cable Specications

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

5.4.2 Wiring Procedure

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

screws for cable connections.

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

lamp and annunciator) within these limits.

5.5 Wiring for Contact Input

Annunciator or the like

#1 Output

#2 Output

F5.6E.ai

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

To use these contact signals, proceed wiring as follows:

Converter Terminal box

DI-1

DI-2

DI-C

Figure 5.7 Contact Input Wiring

Contact input 1

Contact input 2

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<5. Wiring>

5.5.1 Cable Specications

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

5.5.2 Wiring Procedure

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

the corresponding crimp contact.

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

input that satises the descriptions in Table 5.2.

Table 5.2 Identication of Contact Input ON/OFF

Closed Open

Resistance 200 Ω or less 100 kΩ or more

5-6

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6-1

6. Components

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

6.1 ZR202G Zirconia Oxygen/Humisity Analyzer

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

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

1.0, 1.5, 2.0, 2.5 or 3.0m.

Calibration gas pipe opening

Screw

Bolt

Pipe support

Contact

Metal O-ring

U-shaped pipe

Sensor (cell)

Filter

Washer

Figure 6.1 Integrated type Zirconia Oxygen/Humidity Analyzer

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

Dust filter mounting screw

Probe

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<6. Components>

Reference gas

Horizontal mounting Vertical mounting

6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit

flow setting valve

Span gas flow setting valve

Zero gas flow setting valve

Flowmeter for reference gas

6-2

Flowmeter for calibration gas

Figure 6.2 ZA8F Flow Setting Unit

Flowmeter for Span gas

Flowmeter for Reference gas

Flowmeter for Zero gas

Span gas

ZERO INREF INSPAN IN ZERO INREF INSPAN IN

flow setting valve

Span gas flow setting valve

Flowmeter for Span gas

F6-4E.ai

Flowmeter for Reference gas

Flowmeter for Zero gas

Zero gas flow setting valve

Span gas flow setting valve

Reference gas flow setting valve

Figure 6.3 ZR20H Automatic Calibration Unit

Reference gas flow setting valve

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<7. Startup>

7. Startup

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

converter to analog output conrmation to manual calibration.

In the gure listed in this manual, the example of the oxygen analyzer is shown mainly.

In the case of the humidity analyzer, unit indication may be different. Please read it appropriately.

7-1

Check piping and wiring connections

Set up valves

Supply power

Confirm converter type setting

Select gas to be measured

Set output ranges

Check current loop

Check contact action

Calibrate analyzer

Set detailed data

Place in normal operation

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Figure 7.1 Startup Procedure

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

7.1 Checking Piping and Wiring Connections

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

7.2 Valve Setup

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

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

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<7. Startup>

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

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

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

completing the valve setup, be sure to tighten the lock nut.

NOTE

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

setting unit.

7.3 Supplying Power to Converter

CAUTION

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

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

7-2

Supply power to the converter. A display as in Figure 7.2, which indicates the detector’s sensor temperature, then appears. As the heat in the sensor increases, the temperature gradually rises to 750°C. This takes about 20 minutes after the power is turned on, depending somewhat on the ambient temperature and the sample gas temperature. After the sensor temperature has stabilized at 750°C, the converter is in the measurement mode. The display panel then displays the oxygen concentration as in Figure 7.3. This is called the basic panel display.

Figure 7.2 Display of Sensor Temperature Figure 7.3 Measurement Mode Display

While Warming Up

7.4 Operation of Infrared Switch

7.4.1 Display and Switches

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

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<7. Startup>

4: Decimal point

7-3

µMmNkgalbbl % scftm3 /d /s /h /m

3: Engineering-unit display area

Figure 7.4 Infrared switch and the display

ENT

1: Data display area

2: Infrared switch

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

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

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

humidity is displayed.

4. Decimal point: A decimal point is displayed.

Table 7.1 Switch and Function

Switch Function

Moves the position of the digit to the right. If you continuously touch the key, the position

of the digit will move continuously to the right, nally returning to the leftmost position

after reaching the rightmost position of the digit.

2. Selects Yes or No.

When you touch this key together with the [ENT] key, the previous display then appears,

3. or the operation will be cancelled.

^ Used to change values. If you continuously touch this key, the value of the digit will increase

continuously, e.g., from 1 to 2 to 3 (for numeric data), or from A to B to C (for alphabetic

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

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

2. Used to enter data.

3. Advances the operation.

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

To touch any of the keys continuously, rst touch the surface and then completely remove your nger from the surface. Then touch it again.

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

acceptance element. Infrared light-waves from the element bounces on the operator’s nger and are reected back to the acceptance element, thereby causing the infrared switch to turn on and off, depending on the strength of the reected light-waves. From this operating principles,

carefully observe the following:

CAUTION

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

not reect the infrared light-waves, and a “dSPErr” error will be issued.

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

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

touching the glass surface of the switch.

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

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<7. Startup>

Basic panel display

7.4.2 Display Conguration

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

set operation parameters. Figure 7.5 shows the conguration of display items. The parameter codes are listed in groups of seven; which are briey described in Table 7.2.

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

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

Password entry display

Group A setup display

7-4

Group B setup display

Group C setup display

Group D setup display

Group E setup display

Group F setup display

Group G setup display

Figure 7.5 Display Conguration

Table 7.2 Display Functions

Display Function and item to be set

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

heater temperature while warming up. In case of humidity analyzer, displays the oxygen con. or moisture quantity, or mixture ratio in normal operation. If an

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

Parameter code selection display

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<7. Startup>

7.4.3 Entering Parameter Code Selection Display

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

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

Switch operation Display Description

> ∧ > ∧

ENT

21.0%

PASSno

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

Continuously touch the [ENT] key for at least three seconds to display "PASSno."

7-5

> ∧

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

ENT

0000

1000

1100

1102

A01

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

digit that is ashing.

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

ashing will be 1.

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

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

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

ashing to the right one more digit. Continuously touch the [>] key, and the position of the digit that is ashing will move continuously

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

touch [∧] key, and the numeric value increases continuously.

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

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

CAUTION

• If no key is touched for at least 20 seconds during password entry, the current display will

automatically switch to the basic panel display.

• If no key is touched for at least 10 minutes during parameter code selection, the current

display will automatically switch to the basic panel display.

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7.4.4 Selecting Parameter Codes

Switch operation Display Description

> ∧

ENT

A01

Password has been entered and the parameter code selection display has appeared.

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

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

move to the right. This allows you to change 0.

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

the right one more digit. This enables you to change numeric character 1.

7-6

> ∧

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

ENT

ENT Set

A01

b01

C01

d01

Value

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

to A. Continuously touch the [>] key, and the position of the digit that is

ashing will move continuously to the right.

If you touch the [∧] key once, character A will change to B.

Touch the [∧] key once to change to C.

Continuously touch the [∧] key, and the value of the digit that is ashing will increase continuously, from D to E to F to G to A. Numeric values will change from 0 to 1 to 2 to 3 … to 8 to 9 and back to 0. However, numbers that are not present in the parameter codes will be skipped. Each digit is changed independently. Even though a low-order digit changes from 9 to 0, a high-order digit will not be carried.

After you select the desired character, touch the [ENT] key. The set data will be displayed.

7.4.5 Changing Set Values

(1) Selecting numeric values from among preset values

Switch operation Display Description

> ∧

ENT

The set value is displayed after the parameter code selection. An

example of how to select either 0, 1, or 2 as the set value is given below. (The currently set value is 0.)

Touch the [∧] key once to change the current value from 0 to 1.

> ∧

ENT

C01

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

If you touch the [∧] key again, the numeric value will return to 0. Continuously touch the [∧] key, and the numeric values will change continuously.

Display the desired numeric value and touch the [ENT] key. The display will then return to the parameter code selection

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<7. Startup>

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

Switch operation Display Description

> ∧

ENT

00.0

09.0

The set value is displayed after the parameter code selection. An example of entering "9.8" is given below. (The currently set value is

0.0)

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

digit to be changed.

Continuously touch the [>] key, and the position of the digit that is ashing

will move continuously to the right.

Touch the [∧] key to set the numeric value 9. Continuously touch the [∧] key, and the numeric value will change in sequence from 0 to 1 to 2 to 3 … to 8 to 9 and back to 0.

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

right.

7-7

> ∧

(3) If invalid numeric values are entered.

Switch operation Display Description

> ∧

ENT

09.8

C11

98.0

Err

00.0

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

Where the correct numeric value is displayed, touch the [ENT] key.

If you touch the [ENT] key again, the ashing stops and the current set

value will be in effect.

Touch the [ENT] key once again to return to the parameter code selection display.

If an invalid numeric value (beyond the input range specied) is entered,

"Err" will appear for two seconds after touching the [ENT] key.

"Err" appears for two seconds, and the display returns to the rst set

value. Re-enter the numeric value.

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<7. Startup>

7.5 Conrmation of Equipment Type Setting

This equipment can be used for both the Oxygen Analyzer and the Humidity Analyzer. If you

choose optional specication /HS at the time of purchase, the equipment is set for the Humidity

Analyzer.

Before setting the operating data, be sure to check that the desired model has been set. Note that if the equipment type setting is changed after operating data are set, the operating data that have been set are then initialized and the default settings remain. Set the equipment type with parameter code 「F01」. See Table 10.7 or Table 10.8, later in this manual.

CAUTION

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

Table 7.3 Converter Type Setting Procedure

Switch operation Display Description

> ∧

ENT

A01 F01

Display after the password has been entered.

Touch the [∧] key to switch to Group F. If an unwanted alphabetic character after F has been entered, continuously touch the [∧] key to return to the original.

Touch the [ENT] key for conrmation. If 0 (zero) is entered, the oxygen

analyzer is already set. If 1 (one) is entered, the humidity analyzer has been set. Change the setting following the steps below.

Continuously touch the [∧] key, and the position of the digit will change from 1 to 0 to 1 to 0. Release the [ENT] key when 0 is displayed.

7-8

> ∧

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

ENT

ENT Basic

F01

panel

display

Touch the [ENT] key. The numeric value will ash.

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

Touch the [ENT] key once again, and the display will change to the parameter code.

Touch the [>] key together with the [ENT] key to return to the basic panel display. (This is not required if you proceed to make another setting.) (The displayed numeric characters indicate the measurement gas concentration.)

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<7. Startup>

7.6 Selection of Measurement Gas

Combustion gases contain moisture created by burning hydrogen in the fuel. If this moisture is removed, the oxygen concentration might be higher than before. You can select whether the oxygen concentration in a wet gas is to be measured directly, or compensated for its dry-gas value before use. Use the parameter code “F02” to set the measurement gas. For details on the parameter code, see Table 10.7 or Table 10.8, later in this manual.

Table 7.4 Setting Measurement Gas

Switch operation Display Description

> ∧

ENT

A01 F01

F01

Display after the password has been entered.

Touch the [∧] key to switch to Group F. If an unwanted alphabetic character after F has been entered, continuously touch the [∧] key to return to the original.

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

right.

7-9

> ∧

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

ENT

ENT Basic

F02

F03

panel

display

Touch the [∧] key to change the numeric value to 2. If an unwanted numeric value has been entered, continuously touch the [∧] key to return to the original.

Touch the [ENT] key for conrmation. If 0 (zero) is entered, the oxygen

concentration in a wet gas is already set. If the oxygen concentration in a dry gas is to be entered, follow the steps below to set 1 (one).

Continuously touch the [∧] key, and the position of the digit will change from 1 to 0 to 1 to 0. Release the [ENT] key when 1 (one) is displayed.

Touch the [ENT] key. The numeric value will ash.

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

Touch the [ENT] key once again, and the display will change to the parameter code selection panel.

7.7 Output Range Setting

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

7.7.1 Oxygen Analyzer -Minimum Current (4 mA) and Maximum Current (20 mA) Settings

Use the parameter codes “C11” to set the oxygen concentration at 4 mA and “C12” to set the oxygen concentration at 20 mA. The following shows where 10% O at 20 mA.

is set at 4 mA and 20% O2

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<7. Startup>

Table 7.5 Minimum and Maximum Value Setting Procedure

Switch operation Display Description

> ∧

ENT

A01 C01

Display after the password has been entered.

Set the oxygen concentration at 4 mA. Change the parameter code to C11. Touch the [∧] key to switch to Group C.

7-10

> ∧

ENT

C01

C11

000

010

C11

C12

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

right.

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

Touch the [ENT] key to display the current set value (0% O2 has been set).

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

right.

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

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

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

Touch the [ENT] key once again, and the display will switch to the parameter code selection display.

Set the oxygen concentration at 20 mA. Touch the [>] key to move the

position of the digit that is ashing to the right.

Touch the [∧] key to enter the numeric value 2.

> ∧

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

ENT

ENT Basic

025

020

C12

panel

display

Touch the [ENT] key to display the current set value.

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

right.

Touch the [∧] key to change the numeric value to 0. The numeric value will change from 5 to 6 ... to 9 and back to 0.

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

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

Touch the [ENT] key once again to switch to the parameter code selection display.

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7.7.2 Output Range Setting

Select any one of the analog output settings — oxygen, humidity, and mixing ratio. If the /HS

option was specied at the time of purchase, the equipment is a humidity analyzer. For other than

this setting, the analyzer is an oxygen analyzer. If mixed measurement is required, change the existing output setting as follows. Use parameter code C01 for the setting. When the humidity

analyzer is specied in the above setting for the type of detector, the analog output will be set to

“humidity” if data initialization is performed.

7.7.3 Humidity Analyzer -Minimum Current (4 mA) and Maximum Current (20 mA) Settings

This section describes how to set the humidity readings corresponding to 4 mA and 20 mA to 30% H

Table 7.6 Minimum and Maximum Value Setting Procedure

O and 80% H2O respectively.

Switch operation Display Description

> ∧

ENT

A01 C01

Display after the password has been entered.

Set the humidity reading at 4 mA. Change the parameter code to C13. Touch the [∧] key to switch to Group C.

7-11

> ∧

ENT

C01

C11

C13

000

030

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

right.

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

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

right.

Touch the [∧] key to enter the numeric value 13.

Touch the [ENT] key to display the current set value. The humidity 0% H

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

right.

Touch the [∧] key to change the numeric value to 3.

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

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

0 is now being displayed.

> ∧

ENT

C13

C14

025

Touch the [ENT] key once again, and the display will switch to the parameter code selection display.

Set the humidity reading at 20 mA. Touch the [>] key to move the position

of the digit that is ashing to the right.

Touch the [∧] key to change the number 3 in C13 to “4.”

Touch the [ENT] key to display the current set value.

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Switch operation Display Description

> ∧

ENT

025

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

right.

7-12

> ∧

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

ENT

ENT Basic

085

080

C14

panel

display

Touch the [∧] key to change the number 2 in C25 to “8.”

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

right.

Touch the [∧] key to change the number 5 in C85 to “0.” The number changes from 5 to 6 . to 9 to 0.

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

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

Touch the [ENT] key once again to switch to the parameter code selection display.

7.8 Setting Display Item

7.8.1 Oxygen Analyzer - Setting Display Item

Display items are dened as items displayed on the basic panel display.

Parameter code “A00” or “F08” is used to set the display items as shown in Table 7.7. The oxygen concentration is set at the factory before shipment. In addition, if the data initialization is performed, the oxygen concentration will be set.

Table 7.7 Display Item

Values set with A00 or F08 Items displayed on the basic panel display

0 Indicates the oxygen concentration.

1 or 2 For humidity analyzers only. (if 1 or 2 is set for the oxygen analyzer,

3 Displays an item for the current output.

CAUTION

If you set “3” in the parameter code “A00” or “F08”, be sure to select “Oxygen Concentration” in the following mA output setting (see Section 8.1, “Current Output Setting”).

"0.0" is only displayed on the basic panel display.)

If the output damping has been set for the current output, values involving the output damping are displayed.

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7.8.2 Humidity Analyzer - Setting Display Item

Display items are those items that are displayed on the basic panel display. Parameter code A00 or F08 is used to set the display items as shown in the table below. If the humidity analyzer /HS

option was specied at the time of purchase, the equipment is a humidity analyzer. For other than

the above, the equipment is set to oxygen concentration at the factory before shipment. If mix ratio is to be measured, change the existing setting as follows.

Additionally, when humidity analyzer is selected in the Detector Type Setting in the previous section, the display item will be humidity if data initialization is performed.

Table 7.8 Display Item

Values set with A00 or F08 Items displayed on the basic panel display

0 Indicates the oxygen concentration.

1 Indicates the humidity.

2 Indicates the mix ratio.

3 Displays an item for the current output.

If the output damping has been set for the current output, values involving the output damping are displayed.

7.9 Checking Current Loop

7-13

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

Table 7.9 Checking Current Loop

Switch operation Display Description

> ∧

ENT

ENT Basic

A01

G01

00.0

10.0

G01

panel

display

Display after the password has been entered.

Touch the [∧] key to switch to Group G.

Touch the [ENT] key. The output current remains preset with the outputhold feature (Section 2.3).

Touch the [∧] key to set the numeric value 1 (to set a 10-mA output).

Touch the [ENT] key to have all the digits ash.

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

A 10-mA output is then issued.

Touch the [ENT] key once again to switch to the parameter code selection display. At that point, the output current returns to the normal value.

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

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

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7.10 Checking Contact I/O

Conduct a contact input and output check as well as an operation check of the solenoid valves for the optional automatic calibration unit.

Table 7.10 Parameter Codes for Checking Contact I/O

Check item Parameter code Set value and contact action

Contact output 1 G11 0 Open

1 Closed

Contact output 2 G12 0 Open

1 Closed

Automatic calibration solenoid valve (zero gas)

Automatic calibration solenoid valve (span gas)

Contact input 1 G21 0 Open

Contact input 2 G22 0 Open

G15 0 Off

1 On

G16 0 Off

1 On

1 Closed

7-14

7.10.1 Contact Output Check

Follow Table 7.11 to check the contact output. The table uses an example with contact output 1.

Table 7.11 Checking Contact Output

Switch operation Display Description

> ∧

ENT

A01

G01

G11

Display after the password has been entered.

Touch the [∧] key to switch to Group G.

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

right one digit.

Touch the [∧] key to enter 1.

Touch the [ENT] key to have 0 (zero) ash. The contact is then open.

Touch the [∧] key to set 1 (one).

Touch the [ENT] key. The ashing continues.

Touch the [ENT] key again to stop the ashing, and the contact will be

closed.

> ∧

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

ENT

ENT Basic

G11

panel

display

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

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CAUTION

If you conduct an open-close check for the contact output 2, Error 1 (cell voltage failure) or Error 2 (heater temperature abnormal) will occur. This is because the built-in heater power of the detector, which is connected to contact output 2, is turned off during the above check. So, if the above error occurs, reset the equipment or turn the power off and then back on to restart (refer to Section 10.4, “Reset,” later in this manual).

7.10.2 Checking Calibration Contact Output

The calibration contacts are used for the solenoid valve drive signals for the Automatic Calibration Unit. This output signal enables you to check the equipment operation. Check the

owmeter gas ow for that operation.

Follow the steps in Table 7.12. The table uses an example with a zero gas solenoid valve.

Table 7.12 Checking Calibration Contact Output

Switch operation Display Description

> ∧

ENT

A01

G01

Display after the password has been entered.

Touch the [∧] key to switch to Group G.

7-15

> ∧

ENT

ENT Basic

G01

G11

G15

panel

display

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

right one digit.

Touch the [∧] key to enter 1.

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

right one digit.

Touch the [∧] key to enter 5.

Touch the [ENT] key to have 0 ash.

The solenoid valve remains closed.

Touch the [∧] key to enter 1.

Touch the [ENT] key. The ashing continues.

Touch the [ENT] key again to stop the ashing, and the solenoid valve will be open to let the calibration gas ow.

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

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

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7.10.3 Checking Input Contacts

Follow Table 7.13 to check the input contacts. The table uses an example with input contact 1.

Table 7.13 Checking Input Contacts

Switch operation Display Description

> ∧

ENT

A01

G01

Display after the password has been entered.

Touch the [∧] key to switch to Group G.

7-16

> ∧

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

ENT

ENT Basic

G01

G21

panel

display

7.11 Calibration

The converter is calibrated in such a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases.

There are three types of calibration procedures available:

(1) Manual calibration conducting zero and span calibrations, or either of these calibrations in

turn.

(2) Semi-automatic calibration which uses the infrared switches or a contact input signal and

conducts calibration operations based on a preset calibration time and stable time.

(3) Automatic calibration conducted at preset intervals.

Manual calibration needs the ZA8F Flow Setting Unit to allow manual supply of the calibration gases. Semi-automatic and automatic calibrations need ZR20H Automatic Calibration Unit to allow automatic supply of the calibration gases. The following sections set forth the manual calibration procedures. For details on semi-automatic and automatic calibrations, consult Chapter 9, “Calibration,” later in this manual

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

right one digit.

Touch the [∧] key to enter 2.

Touch the [ENT] key. 0 is displayed with the contact open. If the contact is closed, the display will be 1 (one). This enables you to check whether or not the wiring connections have been properly made or not.

Touch the [ENT] key once again to switch to the parameter code selection display.

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

7.11.1 Calibration Setup

Set the following three items before carrying out a calibration. Parameter codes for these set items are listed in Table 7.14.

(1) Mode setting

There are three calibration modes: manual, semi-automatic, and automatic.

Select the desired mode. This section uses manual mode for calibration.

(2) Oxygen concentration in zero gas

Enter the zero gas oxygen concentration for calibration.

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(3) Oxygen concentration in span gas

Enter the span gas oxygen concentration for calibration. If instrument air is used, enter 21

vol % O

. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a

span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.

CAUTION

If instrument air is used for the span gas, dehumidify the air to a dew point of -20°C and remove any oil mist or dust.

Incomplete dehumidifying or unclean air will have an adverse effect on the measurement accuracy.

Table 7.14 Calibration Parameter Codes

Set item Parameter code Set value

Calibration mode B03 0 Manual calibration

1 Semi-automatic calibration

2 Automatic calibration

Zero gas oxygen concentration B01 Enter oxygen concentration.

Span gas oxygen concentration B02 Enter oxygen concentration.

7-17

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Table 7.15 Calibration Setup Procedure

Switch operation Display Description

> ∧

ENT

A01

b01

001.00

Display after the password has been entered.

Set the zero gas concentration. Switch the parameter code to B01. Here, set 0.98%.

Touch the [ENT] key to display the currently set value.

7-18

> ∧

ENT

001.00

000.00

000.90

000.98

b01

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

to 1.

Touch the [∧] key to change to 0.

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

to the right one digit.

Touch the [∧] key to change the numeric value to 9.

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

to the right one digit.

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

Touch the [ENT] key to have all the digits ash.

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

Touch the [ENT] key once again to switch to the parameter code selection display.

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

> ∧

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

ENT b03

ENT

ENT Basic panel

b03

display

Next, set the calibration mode. Switch the parameter code to B03.

Touch the [ENT] key to display the currently set value. If it is 0, you can leave it as is. If it is other than 0, change it to 0 (zero).

Touch the [ENT] key. The numeric value will ash.

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

Touch the [ENT] key once again to switch to the parameter code selection display.

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7.11.2 Manual Calibration

The following describes how to conduct a calibration.

n Preliminary

Before conducting a manual calibration, be sure that the ZA8F Flow Setting Unit zero gas

ow valve is fully closed. Open the zero gas cylinder pressure regulator so that the secondary

pressure will be a sample gas plus approx. 50 kPa (or sample gas pressure plus approx. 150 kPa when a check valve is used, maximum pressure rating is 300 kPa).

n Calibration Implementation

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

Table 7.16 Conducting Calibration

Switch operation Display Description

> ∧

ENT

A01

b10

Display after the password has been entered.

Switch the parameter code to B10. (The key operations for this procedure are omitted.)

7-19

> ∧

ENT

CAL

SPAn Y

21.00

OPEn

/20.84

20.84

Touch the [ENT] key, and "CAL" will be displayed. To cancel the above, touch the [>] key and [ENT] key together to return to the B10 display.

If you touch the [ENT] key again, "CAL" then ashes.

To cancel the above, touch the [>] key and [ENT] key together, the display will return to the B10 display.

If you touch the [ENT] key again, "SPAn Y" appears (Y is ashing).

If you omit the span calibration, touch the [>] key, and change "Y" to "N". If you touch the [ENT] key, the display then jumps to "ZEro Y."

Touch the [ENT] key to display the calibration gas value, in other words, the span gas concentration set in Section 7.10.1, "Calibration Setup." To cancel the above, touch the [>] key and [ENT] key together, then the display returns to "SPAn Y."

If you touch the [ENT] key, "OPEn" and the currently measured value are displayed alternately. Open the Flow Setting Unit span

gas ow valve and adjust the span gas ow to 600 ± 60 ml/min. To

do this, loosen the valve lock nut and gently turn the valve control (shaft) counterclockwise.

Check the calibration gas owmeter for conrmation.

If the automatic calibration unit is connected, open the span gas solenoid valve, and the measured value changes to the span gas value. When the display becomes stable, proceed to the next step. To cancel the above, touch the [>] key and [ENT] key together, then the display returns to "SPAn Y."

If you touch the [ENT] key, all the digits ash. At that point, no

calibration is conducted yet.

> ∧

ENT

ZEro Y

If you touch the [ENT] key again, the ashing stops and "ZEro Y"

appears.

Close the span gas ow valve. Secure the span gas lock nut for

leakage. If the automatic calibration unit is connected, close the span gas solenoid valve. If zero gas calibration is omitted, touch the [>] key to change "Y" to "N". Next, if you touch the [ENT] key, the display jumps to "CALEnd."

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Switch operation Display Description

> ∧

ENT

0.98

OPEn

/0.89

0.89

Touch the [ENT] key to display the calibration gas value.

This value must be the zero gas concentration set in Section

7.10.1, "Calibration Setup," earlier in this manual. To cancel the above, touch the [>] key and [ENT] key together, then the display returns to "ZEro Y."

If you touch the [ENT] key, "OPEn" and the currently measured value are displayed alternately. Open the Flow Setting Unit zero

gas ow valve and adjust the zero gas ow to 600 ± 60 ml/min. To

do this, loosen the valve lock nut and gently turn the valve control (shaft) counterclockwise.

Check the calibration gas owmeter for conrmation. If the

automatic calibration unit is connected, open the zero gas solenoid valve, and then the measured value changes to the zero gas value. When the display becomes stable, proceed to the next step. To cancel the above, touch the [>] key and [ENT] key together, then the display returns to "ZEro Y."

If you touch the [ENT] key, all the digits ash. At that point, no

calibration is conducted yet.

7-20

> ∧

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

The symbol [

“/” indicates that the characters are displayed alternately.

ENT

CALEnd

ENT

ENT Basic panel

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

b10

display

Touch the [ENT] key again to get the measured value to agree

with the zero gas concentration. Close the zero gas ow valve.

Secure the valve lock nut for leakage during measurement. If the automatic calibration unit is connected, close the span gas

solenoid valve. "CALEnd" ashes during the output hold time. If "output hold" is specied in the Output Hold setting," it remains as

an analog output (see Section 8.2). When the preset output hold time is up, the calibration is complete.

The output hold time is set to 10 minutes at the factory. If you touch both the [>] key and [ENT] key at the same time during the preset Output Hold Time, the calibration is aborted and the parameter code selection display appears.

If you touch the [>] key and [ENT] key together, then the basic panel display appears.

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8. Detailed Data Setting

8.1 Current Output Setting

8.1.1 Oxygen Analyzer_Current Output Setting

This section describes setting of the analog output range. Table 8.1 shows parameter codes for the set items.

Table 8.1 Current Output Parameter Codes

Set item Parameter code Set value

Analog output C01 0 Oxygen concentration

1 4 mA (xed *1)

2 4 mA (xed *1)

Output mode C03 0 Linear

1 Logarithm

Min. oxygen concentration C11 Oxygen concentration at 4 mA

Max. oxygen concentration C12 Oxygen concentration at 20 mA

Output damping constant C30 0 to 255 seconds

*1: For the oxygen analyzer, set 0 (zero) only for parameter code C01. When it is set, the current output is 4-mA xed regardless of

the oxygen concentration.

8-1

8.1.2 Oxygen Analyzer_Analog Output Setting

This section describes how to set the analog output range.

(1) To provide an oxygen concentration, use parameter code C11 to set the minimum

oxygen concentration at 4 mA, and use parameter code C12 to set the maximum oxygen concentration at 20 mA.

(2) To provide a humidity output, use parameter code C13 to set the minimum humidity at 4 mA,

and use parameter code C14 to set the maximum humidity at 20 mA.

(3) To provide a mix ratio, use parameter code C15 to set the minimum mix ratio at 4 mA, and

use parameter code C14 to set the maximum mixing ratio at 20 mA.

Refer to Table 8.2 for the parameter codes.

Table 8.2 Current Output Parameter Codes

Set item Parameter code Set value

Analog output C01 0 Oxygen concentration

1 Humidity

2 Mixing ratio

Output mode C03 0 Linear

1 Logarithm

Min. oxygen concentration C11 Oxygen concentration reading corresponding to 4 mA

Max. oxygen concentration C12 Oxygen concentration reading corresponding to 20 mA

Min. humidity C13 Humidity reading corresponding to 4 mA

Max. humidity C14 Humidity reading corresponding to 20 mA

Min. mixing ratio C15 Mixing ratio at 4 mA

Max. mixing ratio C16 Mixing ratio at 20 mA

Output damping constant C30 0 to 255 seconds

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<8. Detailed Data Setting>

8-2

NOTE

When you select logarithmic mode in Section 8.1.3, “Output Mode,” later in this manual, the oxygen concentration, humidity reading, and mixing ratio remain constant at 0.1% O and 0.01 kg/kg respectively.

, 0.1% H2O

8.1.3 Setting Minimum Oxygen Concentration (at 4 mA) and Maximum Oxygen Concentration (at 20 mA)

Set the oxygen concentration values at 4 mA and 20 mA.

The minimum concentration of oxygen for the minimum current (4 mA) is 0% O O

The maximum concentration of oxygen for the maximum current (20 mA) ranges from 5% to 100% O If it does not fall within this input range setting, the setting will be invalid, and the previous set values will remain.

Setting example 1

If the setting (for a 4 mA current) is 10% O maximum (20 mA) point at 13% O

, and must be greater than 1.3 times the concentration of oxygen set for the minimum.

, you must set the oxygen concentration for the

or 6% to 76%

Setting example 2

If the setting (for a 4 mA current) is 75% O maximum (20 mA) point at 98% O

(Numbers after the decimal point are rounded up.)

(75 × 1.3).

, you must set the oxygen concentration for the

CAUTION

When you select logarithmic mode, the minimum output remains constant at 0.1% O2, and the parameter “C11” display remains unchanged.

8.1.4 Minimum and Maximum Settings Corresponding to 4

mA and 20 mA

Set the output items for oxygen concentration reading, humidity reading and mixing ratio corresponding to 4 mA and 20 mA. When the oxygen concentration was selected with parameter

code C01, use parameter codes C11 and C12 for the minimum and maximum settings; when

the humidity setting was selected with parameter code C01, use parameter codes C13 and C14

for those settings; and when the mix ratio setting was selected with parameter code C01, use

parameter codes C15 and C16 for those settings.

8.1.5 Input Ranges

The range low and high values are restricted as follows:

l Oxygen Concentration setting range

The range min. O2 concentration value (corresponding to 4 mA output) can be set to either 0 vol%O

The range max. O in the range of 5 to 100 vol%O range min. setting.

or in the range of 6 to 76 vol%O2.

concentration value (corresponding to 20 mA output) can be set to any value

, however the range max. setting must be at least 1.3 times the

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<8. Detailed Data Setting>

If you do not observe this restriction, the measurement will be invalid, and any previous valid

value will be used. The gray area in gure represents the valid setting range.

Setting example 1

If the range minimum (corresponding to 4 mA output) is set to 10 vol%O (corresponding to 20 mA output) must be at least 13 vol%O

then range maximum

Setting example 2

If the range minimum (corresponding to 4 mA output) is set to 75 vol%O (corresponding to 20 mA output) must be at least 75x1.3=98 vol%O

then range maximum

(rounding decimal part up).

8-3

(for a maximum current of 20 mA)

Maximum oxygen concentration, vol%O

5 15 25 35 45 55 65 75

Ranges over which oxygen concentrations can be set

Outside ranges

Minimum oxygen concentration, vol%O2 (for a minimum current of 4 mA)

Minimum-Maximum setting range of oxygen concentration

Figure A

l Humidity (amount-of-moisture-content) setting range

The minimum humidity is set to 0% H2O or ranges from 26 to 100% H2O. The maximum humidity ranges from 25% to 100% H the minimum.

O, and must be greater than 0.8 times plus 23 the humidity set for

F8.0E.ai

Setting example 1

If the setting (for a 4 mA current) is 0% H than 25% H

Setting example 2

If the setting (for a 4 mA current) is 26% H than 44% H

O, (263 0.8 + 23% H2O). (Numbers after the decimal point are rounded up.)

O, you must set the maximum (20 mA) point at more

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<8. Detailed Data Setting>

100

Ranges over which oxygen

concentrations can be set

8-4

Maximum humidity (for a 20-mA current), % H

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Minimum humidity (for a 4-mA current), % H2O

Outside ranges

Figure B Max. and Min. Humidity Set Ranges

l “Mixing ratio” setting range

The minimum mixing ratio is set to 0 kg/kg or ranges from 0.201 to 0.625 kg/kg. The maximum “mixing ratio” setting ranges from 0.2 to 1.0 kg/kg, and must be greater than 1.3 times plus 0.187 the mixing ratio set for the minimum.

Setting example 1

If the setting (for a 4 mA current) is 0 kg/kg, you must set the maximum (20 mA) point at more than 0.2 kg/kg.

Setting example 2

If the setting (for a 4 mA current) is 0.201 kg/kg, you must set the maximum (20 mA) point at more than 0.449 kg/kg, (0.201 3 1.3 + 0.187 kg/kg). (Numbers after the decimal point are rounded up.)

F8-2E.ai

0.95

0.9

0.85

0.8

0.75

0.7

0.65

0.6

Maximum mixing ratio, kg/kg at 20 mA

0.55

0.5

0.45

0.4

0.201

Ranges over which oxygen concentrations can be set

0.25

0.3

0.35

Minimum mixing ratio, kg/kg at 4 mA

0.4 0.45 0.5

Figure C Max. and Min. Mixing Ratio Set Ranges

Outside ranges

0.55

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0.6 0.65

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<8. Detailed Data Setting>

8.1.6 Entering Output Damping Constants

If a measured value adversely affected by a rapid change in the sample gas oxygen concentration is used for the control means, frequent on-off actions of the output will result. To avoid this, the converter allows the setting of output damping constants ranging from 0 to 255 seconds.

8.1.7 Selection of Output Mode

You can select a linear or logarithmic output mode. The former provides linear characteristics between the analog output signal and measured value.

NOTE

When you select logarithmic mode, the minimum output remains constant at 0.1% O2, and the humidity remains set to 0.1% H values. Set value of C11 to C16 remains unchanged.

O and mixing ratio is set to 0.01 kg/kg, regardless of the set

8.1.8 Default Values

When the analyzer is delivered or data are initialized, the output current settings are by default as shown in Table 8.3.

8-5

Table 8.3 Output Current Default Values

Item Default setting

Min. oxygen concentration

Max. oxygen concentration

Minimum humidity

Maximum humidity

Minimum ratio setting 0 kg/kg

Maximum ratio setting 0.2 kg/kg

Output damping constant 0 (seconds)

Output mode Linear

25%

H2O

8.2 Output Hold Setting

The “output hold” functions retain an analog output signal at a preset value during the equipment’s warm-up time or calibration or if an error arises.

Table 8.4 shows the analog outputs that can be retained and the individual states.

Table 8.4 Analog Output Hold Setting

Equipment status

Output hold values available

4 mA O

20 mA O

Without hold feature O O O

Retains output from just before occurrence

Set value (2.4 to 21.6 mA) O O O O

O: The output hold functions are available. *1: The output hold functions on error occurrence are unavailable when option code “/C2” or “/C3” (NAMER NE 43 compliant) is

specied.

During

warm-up

During

maintenance

O O O

During

calibration

Error

occurrence

(*1)

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<8. Detailed Data Setting>

Output hold time during calibration

8.2.1 Denition of Equipment Status

(1) During warm-up

“During warm-up” is the time required after applying power until the sensor temperature stabilizes at 750°C, and the equipment is in the measurement mode. This status is that the sensor temperature is displayed on the basic panel.

(2) During maintenance

“During maintenance” is the time from when a valid password is entered in the basic panel display to enable the parameter code selection display until the display goes back to the basic panel display

(3) During calibration (see Chapter 9, Calibration)

In the manual calibration, proceed with the calibration operation with the parameter code

「B10」 to display the span gas conrmation display for the rst span calibration, thus

starting the calibration time when the [ENT] key is touched. After a series of calibrations is complete and the preset output stabilization time has elapsed, the calibration time will be up.

Figure 8.1 shows the denition of “during calibration” in the manual calibration.

Switch operation Display

> ∧

ENT

b10

8-6

> ∧

ENT

CAL

SPAn Y

21.00

OPEn/20.84

20.84

ZEro Y

0.98

OPEn/0.89

0.89

> ∧

Figure 8.1 Denition of During Calibration

ENT

CALEnd

b10

Measured-value

display

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<8. Detailed Data Setting>

During error occurrence

Preference order (high)

8.3.2E.siki

In a semi-automatic calibration, “during calibration” is the time, starting when a calibration

instruction is executed with an infrared switch or a contact input, to make a series of calibrations, until the preset output stabilization time elapses.

In an automatic calibration, “during calibration” is the time, starting when automatic

calibration is carried out at the calibration start time, until the preset output stabilization time elapses.

(4) “Error” appears when Error 1 to Error 4 are being issued

8.2.2 Preference Order of Output Hold Value

The output hold value takes the following preference order:

During calibration

During maintenance

During warm-up

For example, if the output current is set to “4 mA” during maintenance, and “without hold” output during calibration is preset, the output is held at 4 mA in the maintenance display. However, the output hold is released at the time of starting the calibration, and the output will be held again at 4 mA after completing the calibration and when the output stabilization time elapses.

8-7

8.2.3 Output Hold Setting

Table 8.5 lists parameter codes with set values for individual set items.

Table 8.5 Parameter Codes for Output Holding

Set items Parameter code Set value

During warm-up C04 0 4 mA

During maintenance C05 0 Without hold feature

During calibration C06 0 Without hold feature

During error occurrence C07 0 Without hold feature

Note: “C07” is not displayed when option code “/C2” or “/C3” (NAMUR NE 43 compliant) is specied.

8.2.4 Default Values

When the analyzer is delivered, or if data are initialized, output holding is by default as shown in Table 8.6.

1 20 mA

2 Holds Set value

1 Last measured value.

2 Holds set values.

1 Last measured value.

2 Holds set values.

1 Last measured value.

2 Holds set values.

Table 8.6 Output Hold Default Values

Status Output hold (min. and max. values) Preset value

During warm-up 4 mA 4 mA

Under maintenance Holds output at value just before maintenance started. 4 mA

Under calibration or blow-back Holds output at value just before starting calibration 4 mA

On Error occurrence Holds output at a preset value. 3.4 mA

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<8. Detailed Data Setting>

Alarm output

Hysteresis

8.3 Setting Alarms

The analyzer enables the setting of four alarms high-high, high, low, and low-low alarms depending upon the oxygen concentration. The following section sets forth the alarm operations and setting procedures.

8.3.1 Alarm Values

(1) High-high and high alarm values

High-high alarms and high alarms are issued when they are set to be detected with parameter codes “D41” and “D42”, and if the measured values exceed the preset oxygen

concentration values specied with “D01” and “D02”.

(2) Low and low-low alarm values

Low alarms and low-low alarms are issued when they are set to be detected with parameter codes “D43” and “D44”, and if the measured values are lower than the preset oxygen

concentration values specied with “D03” and “D04”.

8.3.2 Alarm Output Actions

If the measured values of the oxygen concentration uctuate between normal (steady-state)

values and alarm setting, there may be a lot of alarm-output issuing and canceling. To avoid this, set the delay time and allow for hysteresis for alarm canceling under the alarm output conditions, as Figure 8.2 shows. When the delay time is set, an alarm will not be issued so quickly even if the measured value differs from the steady-state and enters the alarm setpoint range. If the measured value remains within the alarm setpoint range for a certain period of time (for the preset delay time), an alarm will result. On the other hand, there will be a similar delay each time the measured value returns to the steady state from the alarm setpoint range (canceling the alarm status). If hysteresis is set, alarms will be canceled when the measured value is less than or more than the preset hysteresis values. If both the delay time and hysteresis are set, an alarm will be issued if the measured value is in the alarm setpoint range and the delay time has elapsed. When the alarm is reset (canceled), it is required that the measured value be beyond the preset hysteresis value and that the preset delay time. Refer to Figure 8.2 for any further alarm output actions. The delay time and hysteresis settings are common to all alarm points.

8-8

Alarm range

7.5%

High alarm setpoint

5.5%

Oxygen concentration

Delayed time: 5 seconds

ON OFF

Figure 8.2 Alarm Output Action

Delayed time: 5 seconds

2.0%

F8.2E.ai

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

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

(1) Although oxygen concentration measurement “A” has exceeded the high alarm setpoint,

“A” falls lower than the high alarm setpoint before the preset delayed time of ve seconds

elapses. So, no alarm is issued.

(2) Oxygen concentration measurement “B” exceeds the high alarm setpoint and the delayed

time has elapsed during that measurement. So, an alarm results.

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<8. Detailed Data Setting>

(3) Although oxygen concentration measurement “C” has fallen lower than the hysteresis set

value, that measurement exceeds the hysteresis set value before the preset delayed time has elapsed. So, the alarm is not canceled.

(4) Oxygen concentration measurement “D” has fallen below the hysteresis set value and the

preset delayed time during measurement has elapsed, so the alarm is canceled.

8.3.3 Alarm Setting

Set the alarm setpoints following Table 8.7 listing parameter codes.

Table 8.7 Parameter Codes for Alarms

Set item Parameter code Set value

Oxygen concentration high-high alarm setpoint D01 0-100% O Oxygen concentration high alarm setpoint D02 0-100% O Oxygen concentration low alarm setpoint D03 0-100% O Oxygen concentration low-low alarm setpoint D04 0-100% O Humidity high-high alarm setpoint D05 0-100% H2O Humidity high alarm setpoint D06 0-100% H Humidity low alarm setpoint D07 0-100% H Humidity low-low alarm setpoint D08 0-100% H Mixing ratio high-high alarm setpoint D11 0-1 kg/kg Mixing ratio high alarm setpoint D12 0-1 kg/kg Mixing ratio low alarm setpoint D3 0-1 kg/kg Mixing ratio low-low alarm setpoint D14 0-1 kg/kg Oxygen concentration alarm hysteresis D30 0-9.9% O Humidity alarm hysteresis D31 0-9.9% H2O Mixing ratio alarm hysteresis D32 0-0.1 kg/kg Delayed alarm action D33 0-255 seconds Oxygen concentration high-high alarm detection D41 0 Not detected

1 Detected

Oxygen concentration high alarm detection D42 0 Not detected

1 Detected

Oxygen concentration low alarm detection D43 0 Not detected

1 Detected

Oxygen concentration low-low alarm detection D44 0 Not detected

1 Detected

Humidity high-high alarm detection D45 0 Not detected

1 Detected

Humidity high alarm detection D46 0 Not detected

1 Detected

Humidity low alarm detection D47 0 Not detected

1 Detected

Humidity low-low alarm detection D48 0 Not detected

1 Detected

Mixing ratio high-high alarm detection D51 0 Not detected

1 Detected

Mixing ratio high alarm detection D52 0 Not detected

1 Detected

Mixing ratio low alarm detection D53 0 Not detected

1 Detected

Mixing ratio low-low alarm detection D54 0 Not detected

1 Detected

8-9

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<8. Detailed Data Setting>

CAUTION

Even with alarms set, if “Not detected” has been set in the above alarm detection, no alarm is issued. Be sure to set “Detected” in the above alarm detection if you use alarm features.

8.3.4 Default Values

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

Table 8.8 Alarm Setting Default Values

Set item Set value

Oxygen concentration high-high alarm setpoint 100% O

Oxygen concentration high alarm setpoint 100% O

Oxygen concentration low alarm setpoint 0% O

Oxygen concentration low-low alarm setpoint 0% O

Humidity high-high alarm setpoint 100% H2O

Humidity high alarm setpoint 100% H

Humidity low alarm setpoint 0% H

Humidity low-low alarm setpoint 0% H

Mixing ratio high-high alarm setpoint 1 kg/kg

Mixing ratio high alarm setpoint 1 kg/kg

Mixing ratio low alarm setpoint 0 kg/kg

Mixing ratio low-low alarm setpoint 0 kg/kg

Oxygen concentration alarm hysteresis 0.1% O

Humidity alarm hysteresis 0.1% H2O

Mixing ratio alarm hysteresis 0.001 kg/kg

Delayed alarm action 3 seconds

High-high alarm detection Not detected

High alarm detection Not detected

Low alarm detection Not detected

Low-low alarm detection Not detected

8-10

8.4 Output Contact Setup

8.4.1 Output Contact

Mechanical relays provide contact outputs. Be sure to observe relay contact ratings. (For details,

see Section 2.1, “General Specications.”) The following sets forth the operation mode of each

contact output. Output contact 1 you can select open or closed contact when the contact is “operated”. For output contact 2, contact is closed. The relay for output contact 1 is energized when its contacts are closed and vice versa. Accordingly, when no power is supplied to the equipment, those contacts remain open. In addition, the relay for output contact 2 is energized when the corresponding contact is open and de-energized when that contact is closed.

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<8. Detailed Data Setting>

Table 8.9 Setting Output Contacts

Operating state When no power is applied to this equipment

Output contact 1 Open (de-energized) or closed

Open

(energized) selectable.

Output contact 2 Closed (de-energized) only. Closed

8.4.2 Setting Output Contact

Set the output contacts following Table 8.10.

Table 8.10 Parameter Codes for Output Contact Setting

Set item Parameter

code

Output contact 1

Operation E10 0 Operated in closed status. (Normally de-energized)

1 Operated when open. (Normally energized)

Error E20 0 Not operated if an error occurs.

1 Operated if an error occurs.

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

1 Operated if a high-high alarm occurs.

High alarm E22 0 Not operated if a high alarm occurs.

1 Operated if a high alarm occurs.

Low alarm E23 0 Not operated if a low alarm occurs.

1 Operated if a low alarm occurs.

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

1 Operated if a low-low alarm occurs.

Maintenance E25 0 Not operated during maintenance.

1 Operated during maintenance (see Section 8.3.1).

Calibration E26 0 Not operated during calibration.

1 Operated during calibration (see Section 8.3.1).

Measurement range change

E27 0 Not operated when changing ranges.

1 Operated when changing ranges.

Warm-up E28 0 Not operated during warming up.

1 Operated during warming up.

Calibration gas pressure

decrease

Unburnt gas

E29 0

E32 0 Not operated while a unburnt gas detection contact is being closed.

detection

Note 1: Output contact 2 remains closed. Note 2: The oxygen concentration alarm must be preset (see Section 8.4). Note 3: Range change answer-back signal. For this action, the range change must be preset during the setting of input contacts

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

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

(see Section 8.6).

during the setting of input contacts.

input contacts.

Not operated while a calibration gas pressure decrease contact is being closed.

Operated while a calibration gas pressure closed.

(Note 4)

1 Operated while a unburnt gas detection contact is being closed.

Set value

(Note 2)

(Note 3)

(Note 2)

decrease

(Note 1)

contact is being

8-11

(Note 5)

WARNING

Output contact 2 is linked to the detector’s heater power safety switch. As such, if output contact 2 is on, the heater power stops and an Error 1 (cell voltage abnormal) or Error 2 (heater temperature abnormal) occurs.

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<8. Detailed Data Setting>

8.4.3 Default Values

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

Table 8.11 Output Contact Default Settings

Item Output contact 1 Output contact 2

High-high alarm

High alarm

Low alarm

Low-low alarm

Error O

Warm-up O

Output range change

Calibration

Maintenance O

High limit temperature alarm

Calibration gas pressure

Unburnt gas detection

Operating contact status Open Closed (xed)

O: Present

decrease

8-12

NOTE

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

8.5 Input Contact Settings

8.5.1 Input Contact Functions

The converter input contacts execute set functions by accepting a remote (contact) signal. Table

8.12 shows the functions executed by a remote contact signal.

Table 8.12 Input Contact Functions

Set item Function

Calibration gas pressure decrease

Measuring range change While contact input is on, the analog output range is switched to 0-25% O

Calibration start If a contact signal is applied, semi-automatic calibration starts (only if the semi-

Unburnt gas detection If a contact signal is on, the heater power will be switched off. (An one-to

While a contact signal is on, neither semi-automatic nor automatic calibrations can be made.

automatic or automatic mode has been setup). Contact signal must be applied for at least one second. Even though a continuous contact signal is applied, a second calibration cannot be made. If you want to make a second calibration, turn the contact signal off and then back on.

11-second time interval single-output signal is available as a contact signal.) If this operation starts, the sensor temperature decreases and an error occurs. To restore it to normal, turn the power off and then back on, or reset the analyzer.

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<8. Detailed Data Setting>

CAUTION

• Measurement range switching function by an external contact input is available for analog output 1 only and the range is xed to 0-25%O

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

automatic” or “Automatic”.

8.5.2 Setting Input Contact

To set the input contacts, follow the parameter codes given in Table 8.13.

Table 8.13 Parameter Codes for Input Contact Settings

Set item Parameter code Set value

Input contact 1 (function) E01 0 Invalid

1 Calibration gas pressure decrease

2 Measuring range change

3 Calibration

4 Unburnt gas detection

Input contact 2 (function) E02 0 Invalid

1 Calibration gas pressure decrease

2 Measuring range change

3 Calibration

4 Unburnt gas detection

Input contact 1 (action) E03 0 Operated when closed

1 Operated when open

Input contact 2 (action) E04 0 Operated when closed

1 Operated when open

8-13

8.5.3 Default Values

When the analyzer is delivered, or if data are initialized, the input contacts are all open.

8.6 Other Settings

8.6.1 Setting the Date-and-Time

The following describe how to set the date-and-time. Automatic calibration works following this setting.

Use parameter code “F10” to set the date-and-time.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

YOKOGAWA ZR402G, ZR22A, ZR202G, ZR202A, ZR22G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

u Introduction

u Safety Precautions

u CE marking products

1. Overview

1.1.1 System 1

1.1.2 System 2

1.1.3 System 3

1.2 < EXAxt ZR > System Components

1.2.1 System Components

1.2.2 Oxygen/Humidity Analyzer and Accessories

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer

2.1.3 ZO21R Probe Protector

2.1.4 ZH21B Dust Protector

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit

2.2.1 ZA8F Flow Setting Unit

2.2.2 ZR20H Automatic Calibration Unit

2.3 ZO21S Standard Gas Unit

2.4 Other Equipment

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

2.4.2 Dust Guard Protector (K9471UC)

2.4.3 Stop Valve (part no. L9852CB or G7016XH)

2.4.4 Check Valve (part no. K9292DN or K9292DS)

2.4.5 Air Set

2.4.6 Zero Gas Cylinder (part no. G7001ZC)

2.4.9 ZR202A Heater Assembly

3. Installation

3.1.1 Probe Insertion Hole

3.1.2 Installation of the Probe

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

3.1.4 Installation of ZH21B Dust Protector

3.2 Installation of ZA8F Flow Setting Unit

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

3.5 Insulation Resistance Test

4. Piping

4.1 Piping for System 1

4.1.1 Piping Parts for System 1

4.1.2 Piping for the Calibration Gas

4.1.3 Piping for the Reference Gas

4.2 Piping for System 2

4.2.1 Piping Parts for System 2

4.2.2 Piping for the Calibration Gas

4.2.3 Piping for the Reference Gas

4.3 Piping for System 3

4.4 Piping for the Oxygen Analyzer with Pressure Compensation

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation

4.4.2 Piping for the Calibration Gas

4.4.3 Piping for the Reference Gas

5. Wiring

5.1 General

5.1.1 Terminals for the External Wiring

5.1.2 Wiring

5.1.3 Mounting of Cable Gland

5.2 Wiring for Analog Output

5.2.2 Wiring Procedure

5.3 Wiring Power and Ground Terminals

5.3.1 Wiring for Power Line

5.3.2 Wiring for Ground Terminals

5.4 Wiring for Contact Output

5.4.2 Wiring Procedure

5.5 Wiring for Contact Input

5.5.2 Wiring Procedure

6. Components

6.1 ZR202G Zirconia Oxygen/Humisity Analyzer

6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit

7. Startup

7.1 Checking Piping and Wiring Connections

7.2 Valve Setup

7.3 Supplying Power to Converter

7.4 Operation of Infrared Switch

7.4.1 Display and Switches

7.4.3 Entering Parameter Code Selection Display

7.4.4 Selecting Parameter Codes

7.4.5 Changing Set Values

7.6 Selection of Measurement Gas

7.7 Output Range Setting

7.7.1 Oxygen Analyzer -Minimum Current (4 mA) and Maximum Current (20 mA) Settings