Yokogawa ZR22-AV550G User Manual

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User's Manual

Model AV550G Zirconia Oxygen Analyzer Averaging Converter

IM 11M12D01-01E

3rd Edition

Introduction

The EXAxt Series AV550G Zirconia Oxygen Analyzer Averaging Converter is designed for oxygen measurement at multiple points in flue ducts of industrial furnaces and can be used to optimize the combustion process. For the AV550G system, various types of EXAxt ZR Series detectors as well as optional accessories are available. The best measurement can be achieved by selecting instruments appropriate to your application.

This manual provides information, such as installation, operation, inspection and maintenance procedures, about the instruments used in the AV550G averaging converter measurement system. Any sections concerning instruments not included in your system may be skipped.

Before using the instruments, read any descriptions related to your instruments and system to ensure the best performance.

Regarding the HART communication, refer to IM 11M12D01-51E. IM 11M12D01-51E has been published as "Model EXAxt AV550G HART protocol."

Regarding the FOUNDATION Fieldbus communication, refer to IM 11M12D01-61E. IM 11M12D01-61E has been published as "Model EXAxt AV550G Fieldbus communication."

The models and description items in this manual are as follows:

Models and descriptions in this manual

Description in this manual

Model Product Name Specification Installation Operation Maintenance CMPL

ZR22G General-use detector s s s s s ZR22G High-temperature detector (0.15m) s s s s AV550G Averaging Converter s s s s s ZO21R-L Probe protector s s ZO21P-H High-temperature probe adapter s s s ZA8F Flow setting unit (for manual calibration use) s s s

- Auxiliary ejector for high-temperature use (Part No. E7046EC, EN) s s s

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

- Check valve (Part No. K9292DN, K9292DS) s s

- Dust filter for the detector (Part No. K9471UA) s s

- Dust guard protector (Part No. K9471UC) s s

CMPL : Customer Maintenance Parts List

T.Int.1E

User's manuals of instruments related to the AV550G Averaging Converter are as follows:

Model ZR22G ZO21DW

Title Separate Type Zirconia Oxygen Analyzer In-Site Type Zirconia Oxygen Analyzer

Manual No. IM 11M12A01-02E IM 11M03A02-E

Tbl-01.eps

IM 11M12D01-01E

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

Table of Contents

Relates to

Chapter Outline Installation Operation Maintenance

1. Overview Equipment models and system configuration examples

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

3. Installation Installation method for each equipment

4. Piping Examples of piping in three standard system configurations

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

6. Components Major parts and function are described in this manual

7. Startup Basic procedure to start operation of AV550G. Chapter 7 enables you to operate the equipment immediately.

8. Detailed Data Setting Details of key operations and displays

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

10. Other Functions Other functions described

11. Inspection and How to conduct maintenance of AV550G and procedures

Maintenance for replacement of deteriorated parts

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

CMPL (parts list) User replaceable parts list

: Read and completely understand before operating the equipment.

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

: Recommended to read it at least once.

T.Int.2E

IM 11M12D01-01E

r For the safe use of this equipment

CAUTION

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

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

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

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

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

DANGER

AV550G is very heavy. Handle it with care. Be sure not to accidentally drop it. Handle safely to avoid injury.

Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment. In addition, confirm that the power is switched off when connecting power supply.

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

When carrying the AV550G Averaging Converter, mark sure this is done by two or more people.

(1) About This Manual

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

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

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

• This manual explains the functions contained in this product, but does not warrant that those will suit the particular purpose of the user.

• Every effort has been made to ensure accuracy in the preparation of this manual. However, should any errors or omissions come to the attention of the user, please contact the nearest Yokogawa Electric representative or sales office.

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

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

IM 11M12D01-01E

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(2) Safety and Modification Precautions

• Follow the safety precautions in this manual when using the product to ensure protection and safety of personnel, product and system containing the product.

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

DANGER

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

WARNING

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

CAUTION

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

Tip

This symbol gives information that complements the present topic.

SEE ALSO

This symbol identifies a source to which to refer.

Protective Conductor Terminal

Function Earth Terminal (Do not use this terminal as the protective conductor

terminal.)

Alternating current

IM 11M12D01-01E

• Special descriptions in this manual

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

• Displays on the panel 0 0.

(Ex. message display 0 BASE 0)

(Ex. data display 0 1020 )

IM 11M12D01-01E

r NOTICE

• Specification check When the instrument arrives, unpack the package with care and check that the instrument has not been damaged during transportation. In addition, please check that the specification matches the order, and required accessories are not missing. Specifications can be checked by the model codes on the nameplate. Refer to Chapter 2 Specifications for the list of model codes.

• Details on operation parameters When the AV550G Averaging Converter 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.

r After -Sales Warranty

d Do not modify the product.

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

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

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

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

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

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

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

period.

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

manual.

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

Yokogawa Electric did not supply.

• Failure due to improper or insufficient maintenance by user.

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

Yokogawa does not authorize.

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

abnormal.

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

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

warfare, radiation and other natural changes.

IM 11M12D01-01E

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

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

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

into systems or resells the product.

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

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

IM 11M12D01-01E

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IM 11M12D01-01E

Contents

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

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

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

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

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

1.1 System Configuration...................................................................................... 1-1

1.1.1 System Configuration Using Flow Setting Units for Manual Calibration1-1

1.1.2 System Configuration to Perform Automatic Calibration ...................... 1-2

1.2 System Components........................................................................................ 1-3

1.2.1 System Components and Their Applicability ......................................... 1-3

1.2.2 Detectors and Accessories....................................................................... 1-3

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

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

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

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

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

2.2.2 ZO21R-L Probe Protector ....................................................................... 2-8

2.3 High-Temperature Separate-type Detector and Related Equipment.............. 2-9

2.3.1 ZR22G (0.15m) High-Temperature Separate-type Detector .................. 2-9

2.3.2 ZO21P-H Adapter for High-Temperature Probe .................................. 2-10

2.4 AV550G Averaging Converter ..................................................................... 2-12

2.4.1 Standard Specification ........................................................................... 2-12

2.4.2 Functions................................................................................................ 2-13

2.5 ZA8F Flow Setting Unit ............................................................................... 2-19

2.5.1 ZA8F Flow Setting Unit ........................................................................ 2-19

2.6 Other Equipment ........................................................................................... 2-21

2.6.1 Dust Filter for the Detector (Part No.: K9471UA)............................... 2-21

2.6.2 Dust Guard Protector (Part No.: K9471UC)......................................... 2-21

2.6.3 Auxiliary Ejector for High Temperature

(Part No. E7046EC or E7046EN)........................................................ 2-22

2.6.4 Stop Valve (Part No. L9852CB or G7016XH) .................................... 2-24

2.6.5 Check Valve (Part No. K9292DN or K9292DS) ................................. 2-25

2.6.6 Air Set.................................................................................................... 2-26

2.6.7 Zero Gas Cylinder (Part No. G7001ZC)............................................... 2-28

2.6.8 Cylinder Regulator Valve (Part No. G7013XF or G7014XF) ............. 2-28

2.6.9 Calibration Gas Unit Case (Part No. E7044KF) .................................. 2-29

2.6.10 Model ZR22A Heater Assembly........................................................... 2-30

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

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

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

3.1.2 Probe Insertion Hole................................................................................ 3-1

3.1.3 Installation of the Detector...................................................................... 3-2

3.1.4 Installation of the Dust Filter( Part No K9471UA), etc ......................... 3-3

3.1.5 Procedures for installing the dust guard protector (K9471UC).............. 3-4

3.1.6 Detector with a probe protector

(Model ZO21R-L-hhh-h *B for enhance forth ................................ 3-4

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3.1.7 Detector with a probe protector

(Model ZO21R-L-hhh-h *B for dust wear protect............................ 3-5

3.2 Installation of the Detector (Model ZR22G-015) ........................................... 3-6

3.2.1 Installation Location ................................................................................ 3-6

3.2.2 Usage of the High-temperature Probe Adapter (Model ZO21P-H) ....... 3-6

3.2.3 Probe Insertion Hole................................................................................ 3-7

3.2.4 Mounting of the High-Temperature Detector ......................................... 3-8

3.3 Installation of the Averaging Converter ......................................................... 3-9

3.3.1 Installation Location .............................................................................. 3-10

3.3.2 Installation in an Instrument Panel ....................................................... 3-10

3.3.3 Outdoor Installation............................................................................. 3-12

3.4 Installation of ZA8F Flow Setting Unit ....................................................... 3-13

3.4.1 Location ................................................................................................. 3-13

3.4.2 Mounting of ZA8F Flow Setting Unit .................................................. 3-13

3.5 Installation of the Calibration Gas Unit Case .............................................. 3-15

3.5.1 Location ................................................................................................. 3-15

3.5.2 Mounting................................................................................................ 3-15

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

4.1 Piping for a System Using Flow Setting Units for Manual Calibration ........ 4-1

4.1.1 Parts Required for Piping in a System Using Flow Setting Units

for Manual Calibration ............................................................................ 4-3

4.1.2 Piping for the Calibration Gases ............................................................. 4-3

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

4.1.4 Piping to the High Temperature Probe Adapter ..................................... 4-4

4.1.5 Piping for Blowback................................................................................ 4-6

4.1.6 Piping for Indication check ..................................................................... 4-7

4.1.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs...... 4-8

4.2 Piping for a System to Perform Automatic Calibration................................. 4-9

4.2.1 Parts Required for Piping in a System to Perform Automatic

Calibration ............................................................................................. 4-10

4.2.2 Piping for the Calibration Gases ........................................................... 4-11

4.2.3 Piping for the Reference Gas ................................................................ 4-12

4.2.4 Piping to the High Temperature Probe Adapter ................................... 4-12

4.2.5 Piping for Blowback............................................................................. 4-12

4.2.6 Piping for Indication Check ................................................................. 4-12

4.2.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs.... 4-13

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

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

5.1.1 Wiring Precautions .................................................................................. 5-2

5.1.2 Wiring Holes ........................................................................................... 5-4

5.1.3 External Wiring Connection Terminals of the Averaging Converter .... 5-4

5.1.4 Types of Wiring and Cables ................................................................... 5-5

5.2 Wiring for the Averaging Converter and Peripheral Devices........................ 5-6

5.2.1 Preparation for Wiring to the Averaging Converter ............................... 5-6

5.2.2 Preparation for Wiring to Detectors........................................................ 5-6

5.2.3 Power and Ground Wiring ...................................................................... 5-8

5.2.4 Power Wiring to Detector Heaters .......................................................... 5-8

5.2.5 Signal Wiring to Detectors.................................................................... 5-10

5.2.6 Ground Wiring of Detectors .................................................................. 5-11

5.2.7 Wiring for Individual and Average Concentration Analog Outputs .... 5-12

IM 11M12D01-01E

5.2.8 Wiring for Solenoid Valve for Automatic Calibration ......................... 5-12

5.2.9 Wiring for Individual/Common Error Contact Outputs

and Common Contact Outputs .............................................................. 5-13

5.2.10 Wiring for Contact Inputs ..................................................................... 5-15

5.3 Wiring and Piping Examples ........................................................................ 5-16

5.3.1 Wiring and Piping for Automatic Calibration ...................................... 5-16

5.3.2 Wiring and Piping for Automatic Calibration and 3rd Gas Indication

Check ..................................................................................................... 5-16

5.3.3 Wiring and Piping for Blowback .......................................................... 5-17

5.3.4 Wiring and Piping for Automatic Calibration and Blowback .............. 5-17

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

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

6.1.1 General-purpose Detector (except for Model ZR22G-015) ................... 6-1

6.1.2 High-Temperature Detector (Model ZR22G-015).................................. 6-2

6.2 AV550G Averaging Converter ....................................................................... 6-3

6.2.1 Components and Function....................................................................... 6-3

6.2.2 Touchpanel Switch Operations ............................................................... 6-3

6.2.2.1 Panels and Switches ................................................................................ 6-3

6.2.2.2 Switches and Their Functions ................................................................. 6-5

6.2.2.3 Display Configuration ............................................................................. 6-6

6.2.2.4 Display Functions .................................................................................... 6-7

6.2.2.5 Entering Numeric and Text Data .......................................................... 6-10

6.3 ZA8F Flow Setting Unit ............................................................................... 6-12

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

7.1 Startup procedure ............................................................................................ 7-1

7.2 Check Piping and Wiring................................................................................ 7-2

7.3 Set Valve type ................................................................................................. 7-2

7.4 Setting Detector model ................................................................................... 7-3

7.5 Supply Power to Averaging Converter........................................................... 7-5

7.6 Selection of Gas to be Measured .................................................................... 7-6

7.7 Current Output Range Setting ......................................................................... 7-7

7.8 Averaging Group Setting ................................................................................ 7-8

7.9 Calibration ....................................................................................................... 7-9

7.9.1 Setting Calibration Gas Concentration.................................................... 7-9

7.9.2 Performing Manual Calibration............................................................. 7-10

7.10 Analog Output Current Loop Check............................................................ 7-13

7.11 Checking Operation of Contact Input, Contact Output ............................... 7-14

7.11.1 Contact Output Operation Check........................................................... 7-14

7.11.2 Checking contacts used to operate solenoid valves during autocalibration7-15

7.11.3 Checking Contact Inputs........................................................................ 7-15

8. Setting Operating Parameters - Detail, and Examples ............................................ 8-1

8.1 Setting Analog Outputs................................................................................... 8-1

8.1.1 Analog Output Range (Per-Channel) ...................................................... 8-1

8.1.2 Output Hold Setting (Applies to All Outputs) ........................................ 8-3

8.1.3 Setting Output Smoothing Coefficient

(Applies to All Analog Outputs) ............................................................. 8-8

8.1.4 Setting Output Mode (Applies to All Analog Outputs).......................... 8-8

8.2 Oxygen Concentration Alarm Setting ............................................................. 8-9

8.2.1 Setting the Alarm Values (Individual Settings) ...................................... 8-9

IM 11M12D01-01E

8.2.2 Alarm Delay Time and Hysteresis (Applies to All Alarm Settings)...... 8-9

8.3 Assigning Contact Outputs ........................................................................... 8-13

8.4 Assigning Contact Inputs .............................................................................. 8-15

8.5 Other Settings................................................................................................ 8-17

8.5.1 Date and Time ....................................................................................... 8-17

8.5.2 Average Value / Max. and Min. Monitoring Time .............................. 8-18

8.5.3 "Fuel" Setup: Humid Exhaust Gas or "Dry" Equivalent Oxygen

Content .................................................................................................. 8-19

8.5.4 Setting Password.................................................................................... 8-24

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

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

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

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

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

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

9.2 Calibration Setup............................................................................................. 9-5

9.2.1 Mode ........................................................................................................ 9-5

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

9.2.3 Zero Gas Concentration........................................................................... 9-6

9.2.4 Span Gas Concentration .......................................................................... 9-6

9.3 Performing Calibration .................................................................................. 9-10

9.3.1 Performing Manual Calibration............................................................. 9-10

9.3.2 Semi-Automatic Calibration .................................................................. 9-10

9.3.3 Starting AutoCalibration........................................................................ 9-12

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

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

10.1.1 Cell Voltage .......................................................................................... 10-1

10.1.2 Thermocouple Voltage .......................................................................... 10-2

10.1.3 Cold Junction Resistance (C.J. Voltage) .............................................. 10-2

10.1.4 Cell temperature.................................................................................... 10-2

10.1.5 C. J. Temperature.................................................................................. 10-2

10.1.6 Span-gas and Zero-gas Correction Ratios ............................................ 10-2

10.1.7 Cell Response Time ............................................................................. 10-3

10.1.8 Robustness of a Cell ............................................................................. 10-3

10.1.9 Cell’s Internal Resistance..................................................................... 10-3

10.1.10 Recommended Next Calibration Date ................................................. 10-4

10.1.11 Heater On-Time Ratio .......................................................................... 10-4

10.1.12 Time ..................................................................................................... 10-4

10.1.13 Ch. card Rev., Ctrl. card Rev. ............................................................. 10-5

10.1.14 Maximum Oxygen Concentration ........................................................ 10-5

10.1.15 Minimum Oxygen Concentration ........................................................ 10-5

10.1.16 Average Oxygen Concentration........................................................... 10-5

10.1.17 History of Calibration Time................................................................. 10-5

10.1.18 Internal Temperature Alarm Logging.................................................. 10-5

10.2 Trend Graphs............................................................................................... 10-6

10.2.1 Trend Graph Screen .............................................................................. 10-6

10.2.2 Time Axis of Trend Graph ................................................................... 10-7

10.2.3 Trend Graph Display Settings .............................................................. 10-8

10.3 Other Display-related Functions ................................................................. 10-9

10.3.1 Auto-return Time.................................................................................. 10-9

IM 11M12D01-01E

10.3.2 Selecting Language ............................................................................... 10-9

10.3.3 LCD Auto Off..................................................................................... 10-10

10.3.4 Display Contrast Adjustment.............................................................. 10-10

10.3.5 Tag Name Entry.................................................................................. 10-10

10.4 Indication Check......................................................................................... 10-11

10.4.1 Mode .................................................................................................. 10-11

10.4.2 Procedure for Performing an Indication Check ................................ 10-12

10.4.3 Setting Contacts for Operating Third Check Gas Solenoid Valve ... 10-12

10.4.4 Setting Indication Check Timing ...................................................... 10-13

10.4.5 Running an Indication Check ............................................................ 10-15

10.4.6 Starting Auto Indication Check ......................................................... 10-18

10.5 Blowback .................................................................................................... 10-19

10.5.1 Mode .................................................................................................. 10-19

10.5.2 Setting Contacts for Operating Solenoid Valves .............................. 10-20

10.5.3 Setting Blowback Start Time ............................................................ 10-21

10.5.4 Operation of Blowback .................................................................... 10-23

10.5.5 Performing Blowback ........................................................................ 10-24

10.6 Purging ...................................................................................................... 10-25

10.7 Parameter Initialization ............................................................................. 10-27

10.8 Methods of Operating Valves in the ZA8F Flow Setting Unit ................ 10-31

10.8.1 Preparation Before Calibration .......................................................... 10-31

10.8.2 Operating the Span Gas Flow Setting Valve .................................... 10-31

10.8.3 Operating the Zero Gas Flow Setting Valve..................................... 10-32

10.8.4 Operation After Calibration............................................................... 10-32

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

11.1 Removing and Attaching the Front Cover................................................... 11-2

11.1.1 Removing the Front Cover .................................................................. 11-2

11.1.2 Attaching the Front Cover ................................................................... 11-2

11.2 Hot Swap Function ..................................................................................... 11-2

11.3 Inspection and Maintenance of the Detector .............................................. 11-4

11.3.1 Cleaning the Filter in Sensor Assembly .............................................. 11-4

11.3.2 Cleaning the Calibration Gas Tube ..................................................... 11-4

11.3.3 Replacing the Sensor Assembly .......................................................... 11-5

11.3.4 Replacement of the Heater Unit .......................................................... 11-7

11.3.5 Replacement of filter assembly ......................................................... 11-10

11.3.6 Replacement of O-ring ...................................................................... 11-10

11.3.7 Cleaning the High-temperature Probe Adapter................................. 11-10

11.3.8 Stopping and Re-starting Operation .................................................. 11-11

11.4 Inspection and Maintenance of the Averaging Converter ....................... 11-12

11.4.1 Fuse Replacement .............................................................................. 11-12

11.4.2 Cleaning ............................................................................................. 11-13

11.5 Adding Channel Cards .............................................................................. 11-14

11.6 Adding the Expansion Power Supply Unit .............................................. 11-15

11.7 Replacing Limited Life Components ....................................................... 11-16

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

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

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

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

12.1.3 Error Displays ......................................................................................... 12-3

12.1.4 Remedies When an Error Occurs ........................................................... 12-4

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12.2 Displays and Remedies When Alarms are Generated ............................... 12-7

12.2.1 Alarm Types ....................................................................................... 12-7

12.2.2 Alarm Displays ................................................................................... 12-8

12.2.3 Remedies when Alarms are Generated .............................................. 12-9

12.3 Countermeasures When Measured Value Shows Error ........................... 12-16

12.3.1 Measured Value Higher Than True Value....................................... 12-16

12.3.2 Measured Value Lower Than True Value ....................................... 12-17

12.3.3 Measurements Sometimes Show Abnormal Values ........................ 12-17

Customer Maintenance Parts List ................................................CMPL 11M12D01-01E

Customer Maintenance Parts List ................................................CMPL 11M12A01-02E

Customer Maintenance Parts List ................................................CMPL 11M06B02-01E

Customer Maintenance Parts List ................................................CMPL 11M03B01-10E

Customer Maintenance Parts List ................................................CMPL 11M03B01-05E

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

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1. Overview

Zirconia oxygen analyzers are used in combustion facilities to measure the flue gas oxygen concentration. Boiler operators use the oxygen measurement to optimize fuel usage, minimize atmospheric emissions and reduce energy consumption.

A multiple point oxygen measurement system may be required for situations when gas stratification in the flue duct affects combustion control. The AV550G Averaging Converter can accept inputs from up to eight zirconia oxygen detectors. It sends output signals for the individual as well as averages of multiple oxygen concentrations. A robust multipoint converter reduces installation and maintenance costs.

A large 5.7-inch color LCD display shows various measurement, setup, calibration, and trend screens. Its intuitive touch screen is easy to read and makes set up and maintenance simple. Other standard features include new self-diagnostics and a hot swap function that allows a desired probe to be disconnected/reconnected for inspection or maintenance just by turning off the power of the relevant channel.

The ZR22G separate-type detector uses a highly reliable zirconia sensor and its heater assembly can be replaced in the field. The in situ probe is mounted on the duct wall and directly measures the oxygen concentration of a sample gas at a temperature of up to 7008C. For higher temperature applications up to 14008C, the ZO21P-H High Temperature Probe Protector is available for use in conjunction with a 0.15-m ZR22G general-purpose detector.

1. Overview

The averaging converter system is ideal for combustion control in large utility boilers or various industrial furnaces.

This chapter explains system configurations with some typical examples.

1.1 System Configuration

The AV550G Zirconia Oxygen Analyzer Averaging Converter system can be configured by selecting detectors and an averaging converter that meet the individual requirements and flow setting units for calibration.

Subsection 1.1.1 presents a typical system configuration using flow setting units for manual calibration. A typical system configuration to perform automatic calibration is provided in Subsection 1.1.2.

1.1.1 System Configuration Using Flow Setting Units for Manual Calibration

This system consists of detectors, an averaging converter, and flow setting units (Model ZA8F), as shown in Figure 1.1. Note that the ZA8F Flow Setting Units are required as many as the detectors connected to the averaging converter.

A reference gas needs to be supplied at a constant flow rate to the detectors. This reference gas must be clean, dry air having a constant percentage of oxygen. Typically, instrument air that has been dehumidified down to a dew point of approximately -208C and is free from oil mist or dust, is used as the air source. This air is also used as a span gas for the detectors during calibration. A zero gas for calibration is supplied from a cylinder to the detectors.

IM 11M12D01-01E

1-1

Stop

Valve L9852CB G7016XH

ZR22G Detector (max. 8 detectors)

Check

Valve

K9292DN

K9292DS

Reference gas Calibration gas

Flowmeter

Model ZA8F flow setting unit

Cell output, thermocouple output, cold contact compensation

(0.75mm Heater

(1.25mm

, 6-core)

, 2-core)

Model AV550G Averaging Converter

Analog outputs : Averaged and individual outputs 4 to 20 mA DC

Contact output Contact input

Needle

Valve

Airset

Calibration gas pressure regulator

Zero gas cylinder

Instrument air Span gas (Calibration gas unit same as for zero gas)

Calibration gas unit case

Power supply : 100 / 115 V AC, 230V AC 50 / 60 Hz65%

F01.EPS

Figure 1.1 Typical System Configuration Using Flow Setting Units for Manual

Calibration

1.1.2 System Configuration to Perform Automatic Calibration

A typical system configuration to perform automatic calibration is illustrated in Figure

1.2. The system consists of detectors, an averaging converter, solenoid valves, needle valves for flow control, and a float-type flowmeter.

Detector

Reference gas line

Solenoid valve

Flowmeter

Signal Heater

Calibration gas line

Needle valve

Instrument air

Air set

Averaging Converter (AV550G)

Calibration contact outputs

Solenoid valve

Flowmeter

Stop valve

Pressure regulator

Analog outputs:

Averaged and individual outputs

Contact output Contact input

Power supply

Span gas cylinder (Instrument air)

Zero gas cylinder

1-2

Figure 1.2 Typical System Configuration to Perform Automatic Calibration

IM 11M12D01-01E

1.2 System Components

1.2.1 System Components and Their Applicability

1. Overview

Item

Averaging Converter

Detector

Flow setting unit

Needle valve

Flowmeter

Solenoid valve

Solenoid valve for

zero/span switching

Stop valve

Air set

Pressure regulator for

zero gas cylinder

Zero gas cylinder

AV550GSee §1.2.2 ZA8F For flow control 0 to 1 L/min G700

Solenoid valve for switching two streams

L9852CB, G7016XH K9473XH, K9473XJ, G7004XF, K9473XG

G7013XF, G7014XF

G7001ZC

1.2.2 Detectors and Accessories

Process gas temperature 0 to 7008C Process gas temperature 0 to 14008C

Mounting Horizontal

vertical

Vertical

Horizontal

vertical

Horizontal

vertical

Vertical

Insertion length

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 High temperature detector

Probe Protector

(ZO21R)

Gas Flow

Sample inlet

Filter

(K9471UA)

Dust Guard

Protector

(K9471UC)

Model / Part Number/

Specifications Manual Calibration

(A or B)

XP, E7057G

Detector

(ZO21DW-L)

Detector (ZR22G)

Application

Boiler Heating furnace

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

Black liquid recovery boiler

Cement Kiln

Sample outlet

Probe protector for high temperature use ZO21P-H

Temperature: Probe material SUS310S 8008C Probe material SiC 14008C Mounting: V ertical downwards Insertion length: 1.0m, 1.5m When duct pressure is atmospheric or negative, attach air ejector.

High temperature auxiliary ejector (E7046EC, E7046EN)

Needle valve

Inlet

System 1

ssd

Absorption

structure

Sample inlet

Automatic Calibration

High temperature detector

Pressure gauge

Ejector

assy.

Blow

System 2

ssd

Tbl 1-2.eps

Application Heating

furnace

F1.4E.EPS

IM 11M12D01-01E

1-3

1-4

IM 11M12D01-01E

2. Specifications

This chapter describes the specifications for the following: ZR22G General-use separate-type detector (See Section 2.2.1) ZO21R-L Probe protector (See Section 2.2.2) ZR22G (0.15 m) High-temperature separate-type detector (See Section 2.3.1) ZO21P-H Adapter for High temperature probe (See Section 2.3.2) AV550G Averaging converter (See Section 2.4) ZA8F Flow setting unit (See Section 2.5.1)

Other equipment (See Section 2.6)

2.1 General Specifications

2.1.1 Standard Specifications

2. Specifications

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

(excluding inflammable gases)

To check if sampled gases containing a corrosive gas such as ammonia or

chlorine may be applicable to our oxygen gas analyzer, contact with

YOKOGAWA or its agent. Measurement System: Zirconia system Oxygen concentration: 0.01 to 100 vol% O Output Signal: 4 to 20 mA DC (maximum load resistance 550V) Measurement Range: Any setting in the range of 0 to 5 through 0 to 100 vol% O2 (in

1 vol% O2), or partial range

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

connected to the loop (multi-drop mode). Note: HART is a registered trademark of the HART Communication Foundation. Display Range: 0 to 100 vol% O Warm-up Time: Approx. 20 min.

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

60.5% Maximum value of range setting. (range up to 0 to 25 vol% O2)

IM 11M12D01-01E

61% Maximum value of range setting. (range from 0 to 25 vol% O2 up to 0 to 100 vol% O2)

Linearity: (Excluding standard gas tolerance)

2-1

(Excluding the case where the reference air flow is natural convection) (Use oxygen of known concentration (in the measuring range) as the zero and

span calibration gas.)

61% Maximum value of range setting ; from 0 to 5 vol% O2 to 0 to 25

vol% O2 range

(Sample gas pressure: within 64.9 kPa) 63% Maximum value of range setting ; from 0 to 25 vol%O2 to 0 to 50 vol%

O2 range

(Sample gas pressure: within 60.49 kPa) 65% Maximum value of range setting ; from 0 to 50 vol% O2 to 0 to 100 vol%

O2 range (Sample gas pressure: within 60.49 kPa)

Drift: (Excluding the first two weeks in use)

(Excluding the case where the reference air flow is natural convection.) Both zero and span 62% Maximum value of range setting/month

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

introduced from calibration gas inlet and analog output start changing.)

2-2

IM 11M12D01-01E

2.2 General-use Separate-type Detector and Related Equipment

General-use separate-type detector ZR22G can be used in combination with the probe protector ZO21R-L (see Section 2.2.2).

2.2.1 ZR22G General-use Separate-type Detector

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

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

700 to 14008C (with High Temperature Probe Adapter) For high-temperature sample gas, apply 0.15 m length probe and High tempera

ture Probe Adapter ZO21P-H.

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

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

For 0.15m probe, 0.5 to 5 kPa.

2. Specifications

No pressure fluctuation in the furnace should be allowed. Note: When the detector is used in conjunction with a check valve and a ZA8F

Flow Setting Unit, the maximum pressure of sample gas is 150 kPa. When with a check valve and a ZR40H Auto Calibration Unit, it is 200 kPa. If the pressure

of your sample gas exceeds these limits, consult with Yokogawa. Probe Length: 0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.6, 4.2, 4.8, 5.4 m Probe Material: SUS 316 (JIS) Ambient Temperature: -20 to +1508C Reference Air System: Natural Convection, Instrument Air, Pressure Compensation

(other than for probe length 0.15 m) Instrument Air System (excluding Natural Convection) :

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

air which has been dehumidified by cooling to dew point -208C or less, and had

dust or oil mist removed.)

Consumption; Approx. 1 Nl/min Material in Contact with Gas: SUS 316 (JIS), Zirconia, SUS 304 (JIS) (flange),

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

Non explosion-proof JIS C0920 / equivalent to IP44D.

Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely

sealed with a cable gland in the recirculation pressure compensated version.)

IM 11M12D01-01E

2-3

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

Case; Off-white (Munsell 0.6GY3.1/2.0)

Cover; Moss green (Munsell 2.5Y8.4/1.2) Finish: Polyurethane corrosion-resistant coating Gas Connection: Rc1/4 or 1/4FNPT Wiring Connection: G1/2, Pg13.5, M20 by 1.5 mm, 1/2 NPT Installation: Flange mounting Probe Mounting Angle: Horizontal to vertically downward.

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

horizontal to vertically downward.

When the probe insertion length is 2.5 or more, mount vertically downward

(within 658), and if using a probe protector install at angles between horizontal

and vertically downward (within 658).

Weight: Insertion length of 0.4 m: approx. 6 kg (JIS 5K 65) / approx. 11 kg (ANSI 150 4)

Insertion length of 1.0 m: approx. 8 kg (JIS 5K 65)) / approx. 13 kg (ANSI 150 4) Insertion length of 1.5 m: approx. 10 kg (JIS 5K 65)) / approx. 15 kg (ANSI 150 4) Insertion length of 2.0 m: approx. 12 kg (JIS 5K 65)) / approx. 17 kg (ANSI 150 4) Insertion length of 3.0 m: approx. 15 kg (JIS 5K 65)) / approx. 20 kg (ANSI 150 4) Insertion length of 3.6 m: approx. 17 kg (JIS 5K 65)) / approx. 22 kg (ANSI 150 4) Insertion length of 4.2 m: approx. 19 kg (JIS 5K 65)) / approx. 24 kg (ANSI 150 4) Insertion length of 4.8 m: approx. 21 kg (JIS 5K 65)) / approx. 26 kg (ANSI 150 4) Insertion length of 5.4 m: approx. 23 kg (JIS 5K 65)) / approx. 28 kg (ANSI 150 4)

2-4

IM 11M12D01-01E

d Model and Codes

Model ZR22G Length

-015

-040

-070

-100

-150

-200

-250

-300

-360

-420

-480

-540

Wetted material

-S

-C

Flange (*3)

Reference air -C

Gas Thread -R

Connection box thread

Instruction manual

Options

Suffix code

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-Q

-R

-S

-W

-E

-P

Valves

Filter

Tag plates

2. Specifications

Style: S2

Option

code

Separate type Zirconia Oxygen/ High Temperature Humidity Analyzer, Detector

0.15 m (for high temperature use) (*1)

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m

2.5 m (*2)

3.0 m (*2)

3.6 m (*2)

4.2 m (*2)

4.8 m (*2)

5.4 m (*2) SUS316 Stainless steel with Inconel calibration gas tube (*11)

ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 A SUS304 DIN PN10 DN80 A SUS304 DIN PN10 DN100 A SUS304 JIS 5K 65 FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JIS 5K 32 FF SUS304 (for high temperature use) (*4) JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Westinghouse Natural convection External connection (Instrument air) (*12) Pressure compensated (*12)

Rc 1/4

-T

-P

-G

-M

-T

-Q

-J

-E

-A

1/4 FNPT G1/2

Pg13.5 M20 x1.5 mm 1/2NPT Quick connect (*9)

Japanese English

Always -A DERAKANE coating (*10)/D Inconel bolt (*5)/C

/CV /SV

/F1 /F2

/SCT /PT

Check valve (*6) Stop valve (*6)

Dust Filter (*7) Dust Guard Protector (*7)

Stainless steel tag plate (*8) Printed tag plate (*8)

Description

*1 Used with the ZO21P High Temperature Probe Adapter. Select flange (-Q). *2 When installing horizontally the probe whose insertion length is 2.5 meters or more, use the Probe Protector. Be sure to specify ZO21R-L-200-h. Specify the flange suffix code either -C or -K. *3 The thickness of the flange depends on its dimensions. *4 Not used in conjunction with —P (pressure compensation) for reference air. The flange thickness does not conform to JIS specificatio *5 Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to 700 8C). *6 Specify either /CV or /SV option code. *7 Not used with the high temperature humidity analyzer.

*8 Specify either /SCT or /PT option code. *9 Not waterproof, avoid rain. Operating maximum temperature is 808C. Available only in the U.S. *10 Available only in the U.S. DERAKANE is a registered trademark of the Dow Chemical Company. *11 Recommended if measured gas contains corrosive gas like chlorine. *12 Piping for reference air must be installed to supply reference air constantly at a specified flow rate.

IM 11M12D01-01E

T2.1.EPS

2-5

EXTERNAL DIMENSIONS

1. Model ZR22G Separate type Zirconia Oxygen Analyzer, Detectors

[50.8

L=0.15, 0.4, 0.7, 1.0,

1.5, 2.0, 2.5, 3.0

3.6, 4.2, 4.8, 5.4 (m)

Flange

283 to 292

155 to 163 69

Rc1/4 or 1/4NPT Calibration gas inlet

[124

Rc1/4 or 1/4NPT Reference air inlet

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

Flange

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

AB C

152.4

190.5

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

120.6

152.4

190.5 125 160 180 130 140 150 175

190.5

152.4 127

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

4 - [11.5

19 24 24 18 20 20 14 18 18 18

24 24 14

Flange

F2.1E.EPS

2-6

IM 11M12D01-01E

2. Specifications

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

[50.8

L=0.4, 0.7, 1.0, 1.5,

2.0, 2.5, 3.0, 3.6,

4.2, 4.8, 5.4 (m)

Reference gas outlet

Flange

303

156

PIPING

PIPING : A

AB C

152.4

190.5

228.6 165 200 220 155 175 185 210 229 190 155

120.6

152.4

190.5

152.4

125 160 180 130 140 150 175

127

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

4 - [11.5

Rc1/4 or 1/4NPT Reference air inlet

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

Rc1/4 or 1/4NPT Calibration gas inlet

Stop Valv e

PIPING

[124

Flange

F2.2E.EPS

IM 11M12D01-01E

2-7

2.2.2 ZO21R-L Probe Protector

This probe protector is required for the general-use detector when it is used for oxygen concentration measurements in powdered coal boilers or in fluidized furnaces to prevent abrasion due to dust particles when gas flow exceeds 10 m/s.

When using a ZR22G general-use separate-type detector in the horizontal position, be sure to select a probe protector ZO21R-L-hhh-h*B to support the probe.

Insertion Length: 1.05 m, 1.55 m, 2.05 m. Flange: JIS 5K 65A FF SUS304. ANSI Class 150 4 FF (without serration). However,

flange thickness is different. Material: SUS316 (JIS), SUS304 (JIS) (Flange) Weight: 1.05 m; Approx. 6/10 kg (JIS/ANSI), 1.55 m; Approx. 9/13 kg (JIS/ANSI),

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

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

process-side flange.

Model Suffix code

ZO21R

Insertion length

Flange ( *1)

*1 Thickness of flange depends on dimensions of flange.

Gas flow

-L

-100

-150

-200

-J

-A

Style code

[60.5

l (Insertion length)

l=1050,1550,2050

Option

code

Washer (12)

Mounting nut (M12)

SUS316

Probe Protector (0 to 700 8C)

1.05 m (3.5 ft)

1.55 m (5.1 ft)

2.05 m (6.8 ft) JIS 5K 65 FF SUS304

ANSI Class 150 4 FF SUS304

Style B

Description

T2.2E.EPS

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

gasket (t1.5)

Unit ; mm

2-8

Flange<1>

JIS 5K 65 FF SUS304

ANSI Class 150 4 FF SUS304

155

228.6

Dimensions of holes on opposing surface

130

190.5

4 -[15

8 -[19

F2.3E.EPS

IM 11M12D01-01E

2. Specifications

2.3 High-Temperature Separate-type Detector and Related Equipment

2.3.1 ZR22G (0.15m) High-Temperature Separate-type Detector

Standard Specifications Construction: Water-resistant, non-explosionproof Probe length: 0.15 m Terminal box: Aluminium alloy Probe material: Probe material in contact with gas: SUS 316 (JIS) (Probe), SUS 304

(JIS) (Flange), Zirconia (Sensor), Hastelloy B, (Inconel 600, 601) Weight: Approx. 3 kg Installation: Flange mounting (The use of high-temperature detector probe adapter

ZO21P-H is necessary.) Flange standard: JIS 5 K 32 FF equivalent (thickness varies) Mounting angle: Any angle between horizontal and vertical (high-temperature probe is

fitted with an adapter) Reference gas and calibration gas piping

connection:Rc 1/4 or 1/4 NPT female Cable inlet: G 1/2, Pg 13.5, M20 3 15, 1/2 NPT Ambient temperature: -20 to 1508C Sample gas temperature: 0 to 7008C (temperature at the measuring point of the sam-

pling gas. 0 to 7508C or 0 to 14008C when the probe adapter for high

temperature is used.

Temperature of the probe adapter shall not exceed 3008C to protect the

gasket and avoid the bolts seizing together. Sample gas pressure: -0.5 to +5 kPa: when used at the range of more than 0 to

25 vol% O2, -0.5 to +0.5 kPa. (An auxiliary ejector is required for

negative pressure application.) Model and Code Refer to “Model and Code” in page 2-5. External Dimensions Refer to the Figure in page 2-6.

IM 11M12D01-01E

2-9

2.3.2 ZO21P-H Adapter for High-Temperature Probe

The probe adapter is used to lower the sample gas to a temperature below 7008C (below 3008C at probe adapter surface) before it is fed to the detector.

Insertion length: 1 m, 1.5 m Material in Contact with Gas:

SUS 316 (JIS), Zirconia, SiC or SUS 310S, SUS 304(JIS) (flange) Probe Material: SiC, SUS 310S (JIS) Installation: Flange mounting (FF type or RF type) Probe Mounting Angle: Vertically downward within 658

Where the probe material is SUS 310S, horizontal mounting is available. Construction: Non explosion-proof. Rainproof construction Weight:Insertion length of 1.0 m: approx. 6.5 kg (JIS) / approx. 8.5 kg (ANSI) Insertion length of 1.5 m: approx. 7.5 kg (JIS) / approx. 9.5 kg (ANSI) Sample gas temperature: 0 to 14008C (when using SiC probe) 0 to 8008C (when

using SUS 310S probe adapter) Sample gas pressure: -0.5 to + 5 kPa. When using in the range of 0 to 25 vol% O2 or

more, the sample gas pressure should be in the range of -0.5 to +0.5 kPa. (Where the sample gas pressure for the high-temperature probe is negative, an auxiliary ejector is necessary.)

d Model and Codes

Model Suffix code

ZO21P

Material

Insertion length

Flange

Style code

.......................................

-H

.....................................

-A

.....................................

-B

...............................

-100

...............................

-150

-J

-N

-M

-L

-A

-R

-Q

-T

-S

-E

Option

code

.............................

............................

......................

Description

High Temperature Probe Adapter SiC

SUS 310S

1.0 m

1.5 m JIS 5K 50 FF SUS304

JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 ANSI Class 150 4 RF SUS304 ANSI Class 150 2 1/2 RF SUS304 ANSI Class 150 3 RF SUS304 JPI Class 150 3 RF SUS304 JPI Class 150 4 RF SUS304 DIN PN10 DN50 A SUS304

Style A

T2.3E.EPS

2-10

IM 11M12D01-01E

External Dimensions

Measured gas outlet

R1/2 (Note2)

Approx. 351

180

f60.5

2. Specifications

Unit: mm

Flange (Thickness)

JIS 5K 32 FF

Gasket (Thickness 3)

f60.5

170

Approx, 215

Approx. 48

Approx, 100

(Insertion length) (Note1)

f30

f52 over

f115

Flange <1>

Flange provided by customer

High temperature

Probe SiC pipe

110

f124

Detector (ZR22G)

Reference air inlet <2>

Pipe hole (2-G1/2,2-1/2NPT.etc)

Calibration gas inlet <3>

(Note 1) 1=1000 or 1500 (mm) (Note 2) Sample gas outlet

(if the sample gas pressure is negative, connect the auxiliary ejector.)

IM 11M12D01-01E

<1> Flange

JIS 5K 50 FF SUS304 130

ANSI Class 150 4 RF SUS304

<2>,<3> joint

Rc 1/4

1/4 FNPT

228.6

105

190.5

4-[15 8-[19

F2.4E.EPS

2-11

2.4 AV550G Averaging Converter

2.4.1 Standard Specification

Compatibility of Detectors : ZR22G, ZO21D, ZO21DW Number of Detectors : 1 to 8

Expandable up to 8 Bases, these for 4CH and 8CH are available Averaging interval : 0.2 seconds

Display: 5.7 inches color LCD display of size 320 by 240 dot with touch screen Output Signal: 4 to 20 mA DC (maximum load resistance 550V)

Average-value Output; 3 points Independent Output; Output to each channel

Common isolation / Individual isolation selectable (Note) Number of averaging output is 2 when suffix code “ -F”

(FOUNDATION Fieldbus communication) is selected.

Independent Output; Output to each channel

Common isolation / Individual isolation selectable. Used exclusively for communication when suffix code “ -F”

(FOUNDATION Fieldbus communication) is selected.

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

Normally open / normally closed selectable

Common Contact Output; 5 points, Four of the output points can be selected to either

normally energized or normally deenergized status. Contact output 5 is normally energized.

Contact Output for Individual Channel Fail; Output to each channel

Solenoid Valve Contact Output: Contact capacity 30V DC 1A, 250V AC 1A,

24V DC (option code "/24" ) maximum output current 50 mA Contact Input: 2 points, voltage free contacts Ambient Temperature: -5 to +508C Storage Temperature: -20 to +708C Humidity Range: 10 to 85%RH (non-condensing) Installation Altitude: 2000 m or less Category based on IEC 1010: II (Note) Pollution degree based on IEC 1010:2 (Note)

Note: Installation category, called over-voltage category, specifies impulse withstand

voltage. Category II is for electrical equipment. Pollution degree indicates the degree of existence of solid, liquid, gas or other

inclusions which may reduce dielectric strength. Degree 2 is the normal indoor environment.

Power Supply Voltage: Ratings; 100 / 115 V AC, 230 V AC

Acceptable range; 85 to 126.5 V AC, 195.5 to 253 V AC

Power Supply Frequency: Rating; 50/60 Hz

Acceptable range; 50Hz±5%, 60Hz±5%

Power Consumption:

Max 1 kw for steady operation Max 1.8 kw for warm-up

Normally energized.

2-12

IM 11M12D01-01E

2. Specifications

Safety and EMC conforming standards

Safety: Conforms to EN 61010-1: 2001

CSA C22.2 No.1010.1 certified

UL 61010B-1 certified

EMC: Conforms to EN 61326: 2002

AS/NZS CISPR II Maximum Distance between Probe and Converter: Conductor two-way resistance must be 10V or less (when a 1.25mm2 cable or equivalent

is used, 300 m or less) Construction: Indoor installation Wiring Connection: Number of wire holes 30 pieces

Wire hole size: [17 mm for grommet

[6 to [12 mm for cable gland (option). Installation: Wall mounting Case: Aluminum alloy (100 V type) Paint Color: Silver Gray (Munsell 3.2PB7.4/1.2)

2.4.2 Functions

Finish: Polyurethane corrosion-resistance coating Weight: Approx. 13kg (100 V type)

Display Functions:

Value Display; Displays values of the measured oxygen concentration, etc Graph Display; Displays trends of measured oxygen concentration Data Display; Displays various useful data for maintenance, such as cell

temperature, reference junction temperature, maximum/minimum

oxygen concentration, or the like.

Status Message; Indicates an alarm or error occurrence with flashing of the

corresponding icon. Indicates status such as warming-up,

calibrating, or the like by icon.

Alarm, Error Display; Displays alarms such as “Abnormal cell e.m.f.” when any

such status occurs. Calibration functions:

Auto-Calibration; It calibrates automatically at specified intervals. Semi-auto Calibration; Input calibration direction on the touch screen or contact,

then it calibrates automatically afterwards.

IM 11M12D01-01E

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

gas in operation interactively with an LCD touch screen. Validation Function: Permits control room activation of zero, span or midpoint gas

concentrations without running an actual calibration.

Blowback Function:

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

2-13

Maintenance Functions:

Setup Functions:

Self-diagnosis:

Password Functions:

Display and Setting Content:

Measuring Related Items:

Display Items:

Can operate updated data settings in daily operation and checking. Display data settings, calibration data settings, blowback data settings, current output loop check, input/output contact check.

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

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

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

Oxygen concentration (vol% O2)

Cell e.m.f(mV), thermocouple e.m.f(mV), cold junction resistance(V), cell temperature(8C), cold junction temperature(8C), span correction factor(%), zero correction factor(%), cell response time(second), cell condition(in four grades), cell internal resistance(V), next calibration estimate(year/month/day), heater ontime rate(%), time(year/month/day, hour/minute), software revision, maximum/ minimum/average oxygen concentration(vol%O2), calibration record(ten times), internal temperature rise alarm record.

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 calibra tion, zero calibration only, span calibration only), stabilization time(minute/ second), calibration time(minute/second), calibration period(day/hour), starting time(year/month/day, hour/minute)

Equipment Related Items:

Measuring gas selection; wet/dry Detector selection; ZR22/ZO21

Output Related Items:

Analog output/output mode selection, output conditions when warming- up/ maintenance/calibrating (during blowback)/abnormal, 4 mA/20 mA point oxygen concentration (vol%O2), time constant, preset values when warming-up/ maintenance/calibrating during blowback abnormal, output preset values on abnormal.

Alarm Related Items:

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

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

550V)).

2-14

Average-value output; 3 points (average value a, average value b, average

a + b

c =

)

IM 11M12D01-01E

2. Specifications

Independent Output; Output to each channel

Range; any setting between 0 to 5 through 0 to 100 vol% O2 in 1 vol% O2, or

partial range is available (Maximum range value/minimum range value

1.3 or more) For the log output, the minimum range value is fixed at 0.1 vol% O2. 4 to 20 mA DC linear or log can be selected.

Input/output isolation. Output damping: 0 to 255 seconds.

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

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

load) Four of the output points can be selected to either normally energized or

normally deenergized status. Delayed functions (0 to 255 seconds) and hysteresis function (0 to 9.9 vol%O2

can be added to high/low alarms. The following functions are programmable for contact outputs. (1) Abnormal, (2) High-high alarm, (3) High alarm, (4) Low-low alarm, (5)

Low-alarm, (6) Maintenance, (7) Calibration, (8) Range switching answerback, (9) Warm-up, (10) Calibration-gas pressure decrease (answerback of contact input), (11) Blowback start, (12) Process alarm (answerback of contact input), (13) Calibration coefficient alarm, (14) Internal temperature rise alarm.

Contact output 5 is set to normally operated, fixed error status.

Contact Output for Individual Channel Fail: Output to each channel

Normally energized.

Each channel cards provides a failure contact output.

(1)Abnormal cell, (2)abnormal cell temperature(high/low), (3)abnormal channel card, (4)abnormal control card, (5)abnormal card commu nication

Contact Input: Two points, contact input

The following functions are programmable for contact inputs: (1) Calibration-gas pressure decrease alarm, (2) Range switching, (3) External

calibration start, (4) Process alarm (if this signal is received, the heater power turns off), (5) Validation start, (6) Blow-back start

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

card, abnormal control card, abnormal card communication

Calibration: Method; zero/span calibration

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

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

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

in smallest units). Span calibration-gas concentration setting range: 4.5 to 100 vol% O2 (0.01 vol% O2 in smallest units). Use nitrogen-balanced mixed gas containing 0 to 10 % scale of oxygen, and 80 to 100 % scale of oxygen for standard zero gas and standard span-gas respectively.

IM 11M12D01-01E

Calibration period; date/time setting; maximum 255 days/23hours.

2-15

FOUNDATION Fieldbus communication function

The bi-directional digital communication as standard for FOUNDATION Fieldbus that is established by Fieldbus foundation.

Interface : FOUNDATION Fieldbus H1 (communication speed : 31.25 kb/s) Physical layer type :

113 (standard-power signaling, bus powered, non I.S.)

Communication line condition:

power supply----9 to 32 VDC, current supply----15 mA (Max)

Signal insulation :

communication terminal to grand terminal, dielectric strength 500 Vrms

(50/60 Hz, 1 min). Device : Link master Function block : AI block : 3 blocks (1 block for each channels)

Transfer the data of averaging oxygen concentration to other instruments. DI block : 2 blocks

Transfer the status of error and alarm to other instruments. MAI block 1 block (8 channels)

Transfer the data of oxygen concentration to other instruments. MAO block 1 block (8 channels)

Import the data of other instruments.

2-16

IM 11M12D01-01E

d Model and Suffix Code

2. Specifications

1. Detector Refer to GS 11M12A01-01E for a detailed explanation of the detector specifications

and available accessories.

2. Averaging Converter

Model

Suffix Code

AV550G

Base

Number of Channel Card (*2)

Display

Power supply

-B

-A1

-A2

-A3

-A4

-A5

-A6

-A7

-A8

-B1

-B2

-B3

-B4

-B5

-B6

-B7

-B8

-J

-E

-F

-G

-1

-2

-A

(*1)

Communication

Options

Select code "-B" (8 Channel Base) when future expansion exceeding 4 channels is expected.

(*1)

By so doing, the expansion can be made economically.

(*2)

Common isolation is recommended, when the same instrument receives the analog outputs from each channel card. Individual isolation is recommended to prevent the trouble by mutual interference, when different instrument receives the analog outputs from each channel card.

(*3)

When suffix code "-2" (230 V AC) is selected, select code "-A" (4 Channel Base).

(*4)

When suffix code "-F" (FOUNDATION Fieldbus communication) is selected, used exclusively

for communication.

(*5)

Input 01 to 30 in h h.

Option

Code

Specification

Averaging Converter 4 Channel Base

8 Channel Base

Oxygen Channel Card, Common Isolation

1 2

Oxygen Channel Cards, Common Isolation

Oxygen Channel Card, Individual Isolation

Oxygen Channel Cards, Individual Isolation

Japanese English French German

100 / 115 V AC 230 V AC

-E

-F /SCT

/24 /G

HART communication FOUNDATION Fieldbus communication

Stainless steel tag plate

24 Voltage output for Solenoid valve Cable gland (Numbers in )

(*3)

(*5)

(*4)

T02.EPS

IM 11M12D01-01E

3. Channel Code

Model

Suffix Code

AV55CM

-A1

-A2

-A3

-A4

-A5

-A6

-A7

Number of Channels (*1)

-A8

-B1

-B2

-B3

-B4

-B5

-B6

-B7

-B8

-A

Option

(*1) -A h are common Isolation types -B h are Individual Isolation types Up to 4 channel cards can be added in the 230 VAC version. (*2) Expansion power supply unit is required, when using the 4 channel base and extending the number of channel cards to five or more. The expansion power supply unit cannot be added in the 230 VAC version.

(*3) Expansion power supply unit is required, when using the 4 channel base and extending the number of channel cards to five or more. Available only in U.S.

Option

/K1

/K2

Code

Specification

Channel Card

Oxygen Channel Card, Common Isolation

1 2

Oxygen Channel Cards, Common Isolation

Oxygen Channel Card, Individual Isolation

Oxygen Channel Cards, Individual Isolation

Always -A Expansion power supply unit for dry contact

output of solenoid valve output. Expansion power supply unit for 24 volt

output of solenoid valve output.

(*2)

(*3)

T03.EPS

2-17

• External Dimensions

165.1 266.735.5

Extension view

150 30017.3

480 465

3.5

R3.5

457

Distance between mounting hole

465

(without cable gland and grommet)

480

4-knobs

Unit: mm

166.5

10-M5 holes

165.1 266.7 150 300

Maintenance space

200

• AV550G Standard Accessories

Name

Fuse 2 2.5A

Hexagonal Allen Wrench

Part No

A1112EF

L9827AS 1 For lock screw.

200

300

200

RemarksQuantity

T01.EPS

800

2-18

IM 11M12D01-01E

2.5 ZA8F Flow Setting Unit

2.5.1 ZA8F Flow Setting Unit

This flow setting unit is applied to the reference gas and the calibration gas in a system configuration (System 1).

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

Standard Specifications FIowmeter: Calibration gas; 0.1 to 1.0 l/min. Reference air; 0.1 to 1.0 l/min. Construction: Dust-proof and rainproof construction Case Material: SPCC (Cold rolled steel sheet) Painting: Baked epoxy resin, Dark-green (Munsell 2.0 GY 3.1/0.5 or equivalent) Pipe Connections: Rc1/4 or 1/4FNPT Reference Air pressure: Clean air supply of measured gas pressure approx. 50 kPa G (or measured gas pressure plus approx. 150 kPa G when a check valve is used)

2. Specifications

pressure at inlet of the auto-calibration unit.(Maximum 300 kPaG) Air Consumption: Approx. 1.5 l/min Weight: Approx. 2.3kg Calibration gas (zero gas, span gas) flow 0.7 l/m (at calibration time only)

Note

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

Model Suffix code Option code Description

ZA8F

Joint Style code *B

-J

-A

Flow setting unit

Rc 1/4

With 1/4" NPT adapter

Style B

T2.5E.EPS

IM 11M12D01-01E

2-19

• External Dimensions

f6 hole

Unit: mm

180 140

REFERENCE CHECK

Reference air outlet

235.8

222.8

Zero gas outlet

268

REFERENCE

SRAN

Span gas inlet

20 2035 35

CHECK OUT

REF OUT

ZERO

Zero gas inlet

Instrument air inlet

4-Rc1/4

Piping connection

port

2-20

ZERO GAS IN

Flow meter

SPAN GAS IN

Flow meter

AIR IN

Instrument air Approx 1.5 l/min.

Air pressure ;

Airset

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

F2.6E.EPS

IM 11M12D01-01E

2.6 Other Equipment

f51

SiC Caborundum filter

Increasing of insertion length

F2.8E.EPS

Unit : mm

2.6.1 Dust Filter for the Detector (Part No.: K9471UA)

This filter is used to protect the detector sensor from a corrosive dust component or from a high concentration of dust when the oxygen concentration in utility boilers or concrete kilns are to be measured. This filter requires a measurement gas flow of 1m/sec or faster, for circulation of the gas in the sensing part.

• Standard specification

Applicable detector: Standard-type detector for general-use (the measurement gas

flow should be approximately perpendicular to the probe.) Mesh: 30 microns Material: Sic (Filter), SUS316 (JIS) Weight: Approx. 0.2 kg

2. Specifications

Part No.

K9471UA K9471UX

Description

Filter Tool

2.6.2 Dust Guard Protector (Part No.: K9471UC)

Recommended to be used when sample gas is likely to flow directly into the cell due to its flow direction in the stack or the like, flammable 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

T2.7E.EPS

IM 11M12D01-01E

Increasing of insertion length

100

50.8

[

4-[6

122

F11-1.eps

2-21

2.6.3 Auxiliary Ejector for High Temperature (Part No. E7046EC or E7046EN)

This ejector is used where pressure of measured gas for high temperature detector is negative. This ejector consists of an ejector assembly, a pressure gauge and a needle valve.

Standard Specifications Ejector Assembly Ejector Inlet Air Pressure: 29 to 68 kPa G Air Consumption: Approx. 30 to 40 l/min Suction gas flow rate: 3 to 7 l/min Connection to high-temperature probe adapter: R 1/2 Connection: Rc1/4 or 1/4 FNPT, SUS304 (JIS) Tube Connection: ([6/[4 mm or 1/4 inch copper tube or stainless tube) Pressure Gauge Assembly

Type: JIS B7505, A1.5U3/8 x75

Material in Contact with Gas: SUS316 (JIS)

Case Material: Aluminum alloy (Paint color; black)

Scale: 0 to 100 kPa G

Bushing (G3/8 x Rc1/4 or 1/4NPT, SUS304 (JIS)) Needle Valve

Connection: Rc1/4 or 1/4FNPT

Material: SUS316 (JIS)

Part No.

E7046EC

E7046EN

Description

RC 1/4 [6 / [4 TUBE joint: SUS304 (JIS) 1/4 NPT, 1/4 TUBE joint: SUS304 (JIS)

T2.8E.EPS

2-22

IM 11M12D01-01E

E7046EC ; Piping connections, Rc1/4( p part) or Rc1/4( pp part ), E7046EN ; Piping connections,1/4NPT female ( p part) or 1/4NTP male( pp part )

Pressure gauge

f63f4 or 1/4 inch, conduit (stainless)

2. Specifications

Needle valve

lnstrument air inlet

Po (kPa)

200

100

f43

Height when fully open Approx.67

Not included in high temperature use auxiliary ejector.

P= 0.5

Approx.88

Qa (l/min)

Needle

valve

Air

source

Ejector assembly

Approx.

Auxiliary ejector for high-temperature mounting place use.

PT 1/2 male

Pressure gauge

Detector

Ejector

L (m)

Pg (kPa)

-1.0

-0.5

P (kPa)

Suction pressure characteristics

IM 11M12D01-01E

P (kPa)

Air consumption characteristicsPressure setting characteristics

Qg (l/min)

Gas Pressure:

0 kPa

Gas pressure : -15 Pa

P (kPa)

Suction flow characteristics

(Note) Pipes and connectors are not provided.

Gas

Po (kPa) : Pressure setting P (kPa) : Drive pressure (at the ejector entrance) Pg (kPa) : Suction pressure Qa (l/min) : Air consumption Qg (l/min) : Suction flow L (m) : Distance between the ejector and the pressure gauge

F2.9E.EPS

2-23

< Pressure setting for the auxiliary ejector for high-temperature use > Pressure supply for the auxiliary ejector should be set so that the suction flow of the measured gas becomes approximately 5 l/min.

To set this, proceed as follows: (1) In Graph 4, draw a horizontal line from the 5 l/min point. on the vertical axis

(Suction flow: Qg) toward the gas pressure line to be used, to find the point of intersection. Draw a line vertically down from the point of intersection to the axis to find the drive pressure, P (at the ejector entrance).

(2) In Graph 1, determine Po (pressure setting) from L (the distance between the ejector

and the pressure gauge).

(3) Open the needle valve to supply air for the ejector to the pressure gauge until it

indicates the pressure setting, Po.

Note

Qg (the suction flow) may require change according to the conditions of use. Refer to Section 3.2.2 and Section 4.1.4 for details.

Graph explanation

1) Graph 1 is to compensate for pressure loss in piping between the ejector and the

pressure gauge, and find Po (pressure setting).

2) Graph 2 shows correlation between P (drive pressure) and Qa (air consumption).

3) Graph 3 shows correlation between P (drive pressure) and Pg (suction pressure; when

the measured gas inlet of the ejector is closed).

4) Graph 4 shows correlation between P (drive pressure) and Qg (suction flow) for each

gas pressure.

2.6.4 Stop Valve (Part No. L9852CB or G7016XH)

This valve is mounted on the calibration gas line in the system using flow setting unit for manual calibration.

Standard Specifications Connection: Rc 1/4 or 1/4 FNPT

Material: SUS 316 (JIS) Weight: Approx. 80 g

Part No.

L9852CB G7016XH

Rc1/4 or 1/4NPT

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

Description

1/4 NPT,

Material:

(Full open length)

F15.EPS

SUS316

(JIS)

T2.9E.EPS

2-24

IM 11M12D01-01E

2.6.5 Check Valve (Part No. K9292DN or K9292DS)

This valve is mounted on the calibration gas line in the system such as the one using flow setting units for manual calibration or the one performing when unburnt gas is generated.

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

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

Standard Specifications Connection: Rc1/4 or 1/4FNPT

Material: SUS304 (JIS) Pressure: 70 kPa G or more and 350 kPa G or less Weight: Approx. 40 g

2. Specifications

1/4 NPT

Description

, Material:

SUS304

Part No.

K9292DN

K9292DS

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

Approx.19

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

(JIS)

T2.10E.EPS

Unit : mm

Approx.54

F2.11E.EPS

IM 11M12D01-01E

2-25

2.6.6 Air Set

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

• Part No.K9473XH or K9473XJ

Standard Specifications Primary Pressure: Max. 2 MPa G

Secondary Pressure: 9.8 to 196 kPa G Connection: Rc1/4 or 1/4NPT(F) (includes joint adapter) Weight: Approx.1 kg

Part No.

K9473XH

K9473XJ

(53.5)

(63)

Description

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

1/4

NPT (F) , Material: Body; Aluminum,

Dimensions in parentheses are approximate.

(116)

[54

Adapter; SUS316

(97)

T2.11E.EPS

Unit: mm

(43.5)

OUT

(135.5)

69.5 42

2-26

18.5

Bracket Mounting Dimensions

K9473XH: Piping connection (IN: Primary side, OUT: Secondary side), Rc1/4 K9473XJ: Piping connection (IN: Primary side, OUT: Secondary side), 1/4NPT(F)

IM 11M12D01-01E

• Part No. G7004XF or K9473XG

Standard Specifications Primary Pressure: Max. 1 MPa G

Secondary Pressure: 20 to 500 kPa G Connection: Rc1/4 or 1/4 FNPT with joint adapter

2. Specifications

Part No.

G7004XF

K9473XG

d External Dimensions

Panel cut dimensions

Horizontal mounting

[15

+0.5

-0

2-2.2

Description

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

1/4

with adapter

FNPT , Material: Zinc Alloy

Vertical mounting

2-[6.5

max. 55

T2.13E.EPS

Unit : mm

View A

2-[6 screw depth 10

Panel (Horizontal mounting)

Primary

[74

Secondary

Max. 210

Secondary pressure gauge

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

Approx. 122

Panel (Vertical mounting)

IM 11M12D01-01E

2-27

2.6.7 Zero Gas Cylinder (Part No. G7001ZC)

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

Standard Specifications Capacity: 3.4 l

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

(Note) Export of such high pressure filled gas cylinder to most countries is prohibited

or restricted.

Unit : mm

485

325

[140

Weight : Approx. 6 kg

F213E.EPS

2.6.8 Cylinder Regulator Valve (Part No. G7013XF or G7014XF)

This regulator valve is used with the zero gas cylinders. Standard Specifications Pressure gauge: Primary 0 to 25 àa G, Secondary 0 to 0.5 MPa G Connection: Inlet W22 14 threads, right hand screw Outlet Rc1/4 or 1/4NPT(F) Material: Brass body

Secondary pressure gauge

0.5 MPaG

Primary pressure gauge

25 MPaG

Approx.112

2-28

Approx. 59

Approx. 163

Regulator handle

Stop valve

Outlet

Part No. G7013XF G7014XF

Primary safety valve

Approx. 174

p Outlet Rc1/4 1/4 NPT female screw

Secondary safety valve

Approx. 82

W22 (Righthanded screw)

IM 11M12D01-01E

2.6.9 Calibration Gas Unit Case (Part No. E7044KF)

This case is used to store the zero gas cylinders.

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

Installation: 2B pipe mounting Material: SPCC (Cold rolled steel sheet) Weight: 3.6 kg, Approx. 10 kg with gas cylinder (Note) Export of such high pressure filled gas cylinder to most countries prohibited or

restricted.

324

Pressure regulator

G7013XF/ G7014XF

Zero gas cylinder

(G7001ZC)

2. Specifications

Unit: mm

200

180

496

(Note) E7044KF (case assembly) has no zero gas cylinder and pressure regulator.

2B pipe ( f60.5)

F2.15E.EPS

IM 11M12D01-01E

2-29

2.6.10 Model ZR22A Heater Assembly

Option code

-N

-A

-B

-C

d External Dimensions

Model Suffix code Description

ZR22A

Length (p1)

Jig for change -A

Reference air (*3)

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

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

-015

-040

-070

-100

-150

-200

-250

-300

Style: S2

Heater Assembly for ZR22G

0.15 m

0.4 m

0.7 m 1 m

1.5 m 2 m

2.5 m 3 m

with Jig (*2) None

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

T23.EPS

[ 45

Jig for change

(K9470BX)

[ 21.7

K9470BX

L612

F2.16E.EPS

L length

Model & Code

ZR22A-015 ZR22A-040 ZR22A-070 ZR22A-100 ZR22A-150 ZR22A-200 ZR22A-250 ZR22A-300

Unit : mm

L 302 552 852

1152 1652 2152 2652 3152

Weight (kg) Approx. 0.5 Approx. 0.8 Approx. 1.2 Approx. 1.6 Approx. 2.2 Approx. 2.8 Approx. 3.4 Approx. 4.0

2-30

IM 11M12D01-01E

2. Specifications

IM 11M12D01-01E

2-31

3. Installation

This chapter describes installation of the following equipment: Section 3.1 Detector (except model ZR22G-015) Section 3.2 Detector (model ZR22G-015) Section 3.3 Averaging Converter Section 3.4 ZA8F Flow Setting Unit Section 3.5 Calibration Gas Unit Case (E7044KF)

3.1 Installation of the Detector

3.1.1 Location

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

(2) Ambient temperature of not more than 1508C, and the terminal box should not

affected by radiant heat.

(3) A clean environment without any corrosive gases.

3. Installation

CAUTION

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

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

3.1.2 Probe Insertion Hole

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

ation:

CAUTION

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

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

• When using the detector with pressure compensation, ensure that the flange gasket does not block the reference air outlet on the detector flange. If the flange gasket blocks the outlet, the detector cannot conduct pressure compensation. Where necessary, make a notch in the flange gasket. Confirm the outside dimensions of the detector in Chapter 3.8 of IM 11M12A01-02E before installation.

• 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 11M12D01-01E

3-1

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

(no more than a 58 tilt).

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

the probe tip should point downstream.

Figure 3.1 illustrates an example of the probe insertion hole.

(vertical)

100 mm

Note

(Note) When using the detector with pressure compensation, ensure that the flange gasket does not block the reference air outlet on the detector flange. If the flange gasket blocks the outlet, the detector cannot perform pressure compensation. Where necessary, make a notch in the flange gasket.

Figure 3.1 Example of forming probe insertion hole

3.1.3 Installation of the Detector

Bounds of the probe insertion hole location

Flange matches the detector size

(horizontal)

100 mm

Type Outside diameter of detector

Standard 50.8 mm in diameter (Note) With dust filter 51 mm in diameter (Note) With probe protector 60.5 mm in diameter (Note)

Four-hole flange Eight-hole flange

F3.1E.EPS

CAUTION

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

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

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

<General-use detector>

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

If a dust filter (see Section 2.6.1) is used, make sure it is properly attached to the detector. Refer to Section 3.1.4 for installation of the dust filter.

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

ence gas inlet should face downward.

3-2

IM 11M12D01-01E

3.1.4 Installation of the Dust Filter( Part No K9471UA), etc

CAUTION

• The dust filter 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 filter is used in combustion systems other than these, it may have adverse effects such as response delay. These combustion conditions should be examined carefully before using a filter.

• The dust filter requires gas flow of 1 m/sec. or faster at the front surface of the filter (K9471UA).

When you specify option code /F1, the detector is shipped with the dust filter mounted. Follow this procedure replace the filter on the detector. It is recommended that you read Chapter 11 prior to filter mounting, for it is necessary to be familiar with the detector’s construction, especially the sensor assembly.

(1) Mount the dust filter assembly by putting it on the end of the detector and screw the

assembly clockwise. Put a hook pin wrench (K9471UX), [52 to 55 in diameter, into the hole on the assembly to fasten or remove it. Apply a heat-resistant coating (see Note 1) to the threads on the detector. When remounting Filter assembly after having once removed it from the detector, reapply the heat-resistant coating.

3. Installation

Note 1: As the detector is heated to 7008C, it is recommended to use heat-resistant

coating on the threads to prevent seizing up. Name of the heat-resistant coating material: NEVER SEIZE NICKEL SPECIAL”.

SiC Carborundum filter

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

f 51

Additional length

Unit : mm

Detector

Screw

F3.2E.EPS

Figure 3.2 Installation of the dust filter

IM 11M12D01-01E

3-3

3.1.5 Procedures for installing the dust guard protector (K9471UC)

The ZR22G detector is shipped with the dust guard protector when the option code “/ F2” is specified 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 [52-55 hole( Pin diameter 4.5 mm: P/N K9741UX or the like) or by pass a screwdriver through the holes. When re-attaching the protector after detaching it, apply the “Never Seize Nickel Special” to it.

Increasing of insertion length

100

50.8

[

4-[6

122

F11-1.eps

3.1.6 Detector with a probe protector (Model ZO21R-L-hhh-h *B for enhance forth

The detector is used with a probe protector to support the probe (ZR22G) when the probe length is 2.5m or more and it is mounted horizontally.

(1) Put a gasket (provided by the user) between the flanges, and mount the probe

protector in the probe insertion hole.

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

loose.

(3) Mount the detector so that the reference gas and calibration gas inlet faces down-

ward.

Flow direction of the measurement gas

1050,1550,2050

[60.5

Notch

Probe top

Figure 3.3 Probe protector (supporting the mounting strength)

Gasket (t1.5)

Unit: mm

Reference gas inlet Calibration gas inlet

F3.3E.EPS

3-4

IM 11M12D01-01E

3. Installation

3.1.7 Detector with a probe protector (Model ZO21R-L-hhh-h *B for dust wear protect

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 flow exceeds 10m/s (fine-carbon boiler or fluid-bed furnace).

(1) Put a gasket (provided by the user) between the flanges, and mount the probe

protector in the probe insertion hole. The probe protector should be installed so that the notch is downstream of the measurement gas flow.

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

loose.

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

inlet should face downward.

CAUTION

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

1050,1550,2050

Direction of the measurement gas flow

Probe top

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

Figure 3.4 Mounting of detector with a probe protector

Gasket (t1.5)

F3.4E.EPS

Unit: mm

Reference gas inlet Calibration gas inlet

IM 11M12D01-01E

3-5

3.2 Installation of the Detector (Model ZR22G-015)

3.2.1 Installation Location

This model detector is used with the High-temperature Probe Adapter (Model ZO21P-H) when the temperature of sample gas exceeds 7008C, or when it is required due to maintenance spaces.

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

(2) Ambient temperature of not more than 1508C and the terminal box should not be

exposed to radiant heat. (3) A clean environment without any corrosive gases. (4) No vibration. (5) The measured gas should satisfy the specifications described in Chapter 2.

3.2.2 Usage of the High-temperature Probe Adapter (Model ZO21P-H)

During analysis, the surface temperature of the probe adapter should be within the range from the dew point of the measured gas and 3008C to prevent ejector clogging, gasket deterioration or bolt scoring.

Where the dew point of the measured gas is not known, keep within the range 2008C to 3008C.

The temperature shall be measured at the probe in the probe adapter and the surface of the blind flange at the opposite side.

When the surface temperature is not within the above range, the following measures can be taken to change the temperature.

(1) When the furnace pressure is negative, lower the pressure setting to reduce induction

flow of the measurement gas.

Refer to Section 2.6.3, Auxiliary Ejector for High Temperature, for the setting of

induction flow.

When you reduce induction flow, ensure that the ejector inducts air when the furnace

pressure fluctuates. (2) When the furnace pressure is positive, close the needle valve for the sample gas

outlet to reduce the exhaust gas flow. Refer to Section 4.1.4, Piping to the High-

temperature Probe Adapter. (3) When the probe adapter is surrounded by a heat insulator, remove the heat insulator.

Ensure that the temperature of the probe adapter does not fall below the dew point of

the gas in winter. (4) To prevent temperature rises due to radiant heat, insert heat insulator between the

wall of the furnace and the probe adapter. (5) To prevent temperature rises from thermal conduction, place the mounting flange as

far from the wall of the furnace as possible.

3-6

IM 11M12D01-01E

<When the surface temperature is less than 2008C or the dew point of the measure-

ment gas>

(1) When the furnace pressure is negative, raise the analyzer pressure to increase

induction flow of the measurement gas.

Refer to Section 2.6.3, Auxiliary Ejector for High-temperature Use, for the setting of

induction flow.

If there is much dust in the gas, the ejector may become clogg is induction flow

increases. (2) When the furnace pressure is positive, open the needle valve for the sample gas

outlet to increase the gas flow.

Refer to Section 4.1.4, Piping to the High-temperature Probe Adapter. (3) Warm the probe adapter. Refer to Section 4.2.4, Piping to the High-temperature

Probe Adapter. Ensure that its temperature does not drop below freezing point in

winter. (4) When the surface temperature is still less than 2008C or the dew point of the mea-

surement gas, even if the above measures have been taken, warm the probe adapter

using a heat source such as steam.

3.2.3 Probe Insertion Hole

A high-temperature detector consists of a ZR22G-015 Detector and ZO21P Hightemperature Probe Adapter. When forming the probe insertion hole, the following should be taken into consideration:

3. Installation

100mm

(1) If the probe is made of silicon carbide (SiC), the probe hole should be formed so that

the probe is mounted vertically (no more than a 58 tilt). (2) In the case where the probe is made of stainless steel and the probe adapter is to be

mounted horizontally, the probe hole should be formed so that the probe tip is not

higher than the probe base. Figure 3.5 illustrates examples of the probe insertion hole.

JIS 5K 50 FF (equivalent) or ANSI Class 150 4 RF (equivalent) flange

A space of 52 mm or more in diameter, and

for

the length of the probe

The allowable margin for probe tilt is within658.

An SiC probe shall be mounted vertically.

long enough

Figure 3.5 Examples of the probe insertion hole

A space of 52 mm or more in diameter, and long enough the length of the probe

Never mount the probe with its tip higher than the base

Horizontal mounting is used with a SUS probe.

100mm

JIS 5K 50 FF (equivalent) or ANSI Class 150 4 RF (equivalent) flange

F3.5E.EPS

IM 11M12D01-01E

3-7

3.2.4 Mounting of the High-Temperature Detector

Note

Ceramic (zirconia) is used in the sensor (cell) portion on the detector probe tip. Care should be taken not to drop the detector during installation. The same applies to a probe made of silicon carbide (SiC). A gasket should be used on the flange surface to prevent gas leakage. The gasket material should be selected depending on the characteristics of the measurement gas. It should be heatproof and corrosion-proof. The parts, which should be supplied by the user, are listed in Table 3.2.

Table 3.2 Accessories for mounting high-temperature probe adapter

Mounting flange specification Accessory name Number Note

JIS 5K 50 FF (equivalent) Gasket 1 Heatproof and corrosionproof

Bolt (M12 by 50) 4 Nut (M12) 4 Washer (for M12) 8

ANSI Class 150 RF (equivalent) Gasket 1 Heatproof and corrosionproof

Bolt (M16 by 60) 8 Nut (M16) 8 Washer (for M16) 16

A high-temperature detector should be mounted as follows:

T3.2E.EPS

(1) It is recommended to mount the detector vertically. When it is impossible due to the

physical arrangements and the detector is mounted horizontally, ensure that the probe

tip be placed no higher than the probe base. (2) When mounting a high-temperature probe adapter, be sure to insert a gasket between

the flanges to prevent gas leakage. When the furnace pressure is negative, ensure that

there is no leakage of air into the furnace. (3) When mounting the detector in a position other than vertical, the cable inlet should

face downward. (4) When installing the detector in a low-temperature location such as in the open air,

cover the probe adapter including the ejector with a heat insulator (e.g. ceramic

wool) to keep it warm and to prevent condensation of drain on the ejector.

Wiring connection

Mount the probe so that the probe tip is not higher than the probe base.

Wiring connection

3-8

When using an SiC probe, mount the probe vertically with an allowable tilt of ±5°.

F3.6E.EPS

Figure 3.6 Mounting of the High-temperature Detector

IM 11M12D01-01E

3.3 Installation of the Averaging Converter

The averaging converter is designed for indoor installation and should be installed in the instrument panel in a control room. For outdoor installation, the averaging converter should be installed in an outdoor instrument panel protected from direct sunlight and the weather.

DANGER

High voltages are present inside the averaging converter. To prevent unintentional

opening of the front cover, it is securely attached by a lock screw on the right side of the case. Loosen the lock screw to remove the front cover, and securely tighten the lock screw after the front cover has been attached.

How to remove the front cover

• Loosen the 4 knob bolts by hand, and then loosen the lock screw with the Allen wrench supplied.

• Remove the front cover by lifting up slightly then pulling away from the case.

3. Installation

How to attach the front cover

• Attach the front cover, aligning the slots on the sides of the cover with the knob bolts on the case, and then pull the cover down until it is seated firmly.

• Hand tighten the knob bolts, and then securely tighten the lock screw with the Allen wrench supplied.

Knob Bolt

Lock Screw

IM 11M12D01-01E

Figure 3.7 How to Remove/Attach the front Cover

3-9

3.3.1 Installation Location

Follow the guidelines below when selecting a location for the averaging converter. (1) The touch screen display should be clearly visible and easily accessible for key

operation: the display at eye level is recommended.

(2) A wall or construction should be strong enough to support the weight of the

converter. (3) The converter should be easily accessible for inspections and maintenance. (4) The ambient temperature should be in the range of -5 to 508C and the temperature

variation should be small: the daily temperature range within 158C is recommended. (5) The humidity should be in the range of 10 to 85%RH and no condensation may

occur. (6) No corrosive gases are present. (7) No dust exists. (8) There is minimal vibration. (9) The converter should be near the detectors: the two-way resistance between detector

and converter should not exceed 10V.

DANGER

• The averaging converter is heavy. Take extra care not to accidentally drop it. Installation work should be done by an adequate number of people.

CAUTION

The averaging converter is heavy (100/115 VAC version: approx. 13 kg, 230 VAC

version: approx. 25 kg) so needs to be installed on a wall or construction strong enough to support.

3.3.2 Installation in an Instrument Panel

When installing the averaging converter in an instrument panel, operability, maintainability, and environmental resistance should be considered.

(1)Installation Space and Relationship to Peripheral Devices

Follow the instructions below to determine the positions of the averaging converter and peripheral devices.

• Do not place heat-generating devices in close proximity of the averaging converter: specially, avoid a place under the averaging converter.

• Do not place power related devices such as transformers or electromagnetic switches in close proximity of the averaging converter.

• Segregate wiring ducts for signal lines and those for power lines and do not place in close proximity.

Figure 3.8 shows the requirements for the mounting holes for the averaging converter. See Section 2.4 for the dimensions of the averaging converter and maintenance clearance.

3-10

IM 11M12D01-01E

6-M5 screws

300 [267]

150 [165]

3. Installation

Unit: mm

465

Note: Dimensions in inches are given in parentheses.

F3302.EPS

Figure 3.8 Mounting holes

(2)Preventing Excessive Temperature Rise in an Instrument Panel

Use a cooling method such as one of those shown in Figure 3.9 if there is a danger of the temperature inside an instrument panel exceeding the temperature range limits.

AV550G

Fan

AV550G

Air Filter

IM 11M12D01-01E

Forced air circulationForced air ventilationNatural air cooling

Figure 3.9 Preventing Excessive Temperature Rise in Panel

CAUTION

If an internal temperature rise alarm occurs, use a more effective method to cool the

inside of an instrument panel down to within the converter operating temperature range.

3-11

3.3.3 Outdoor Installation

The averaging converter is designed for indoor installation. For outdoor installation, the averaging converter should be housed in an outdoor case protected from direct sunlight and the weather. The outdoor case should be equipped with a cooling system for controlling the internal temperature, if necessary. Also, the outdoor case should be installed in a location that keeps the case free from corrosive gases or dust.

CAUTION

If an internal temperature rise alarm occurs, use a more effective method to cool the

inside of an outdoor case down to within the converter operating temperature range.

3-12

IM 11M12D01-01E

3.4 Installation of ZA8F Flow Setting Unit

3.4.1 Location

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

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

3.4.2 Mounting of ZA8F Flow Setting Unit

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

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

mounting the flow setting unit. (The unit weighs approximately 2 to 3.5 kg.)

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

the metal fitting is firmly attached to the pipe.

3. Installation

IM 11M12D01-01E

F3.12E.EPS

Figure 3.10 Pipe Mounting

3-13

(1) Make a hole in the wall as illustrated in Figure 3.11.

Unit : mm

223

140

F3.13E.EPS

4 - f6.5 hole, or M6 screw

Figure 3.11 Mounting holes

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

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

F3.14E.EPS

Figure 3.12 Wall mounting

3-14

IM 11M12D01-01E

3.5 Installation of the Calibration Gas Unit Case

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

3.5.1 Location

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

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

radiated heat.

(5) No vibration

3.5.2 Mounting

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

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

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

metal fitting is firmly attached to the pipe.

3. Installation

IM 11M12D01-01E

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

F3.16E.EPS

Figure 3.13 Pipe Mounting

3-15

3-16

IM 11M12D01-01E

4. Piping

This chapter describes piping procedures for the AV550G Zirconia Oxygen Analyzer Averaging Converter system based on two typical system configurations.

4.1 Piping for a System Using Flow Setting Units for Manual Calibration

The piping for a system using flow setting units for manual calibration is shown in Figure 4.1.

ZR22G Detector (max. 8 detectors)

Cell output, thermocouple output, cold contact compensation

, 6-core)

(0.75mm Heater

, 2-core)

(1.25mm Model AV550G Averaging Converter

Analog outputs : Averaged and individual outputs 4 to 20 mA DC

4. Piping

Contact output

Check

Valve K9292DN K9292DS

Reference gas Calibration gas

Flowmeter

Model ZA8F flow setting unit

Needle

Valve

Airset

Calibration gas pressure regulator

Zero gas cylinder

Instrument air Span gas (Calibration gas unit same as for zero gas)

Calibration gas unit case

Contact input

Power supply : 100 / 115 V AC, 50 / 60 Hz65%

Figure 4.1 Typical Piping for System Using Flow Setting Units for Manual

Calibration

F01.EPS

IM 11M12D01-01E

4-1

The following outlines some points to note regarding the piping for this system.

• Install a stop valve through a nipple on the calibration gas inlet of the detector. Note: The stop valve should be connected directly to the detector. If any piping is

present between the detector and the stop valve, condensation may develop in the pipe, causing damage to the detector by rapid cooling when the calibration gas is introduced.

• When a high temperature detector is used and the pressure of a sample gas is negative, connect an auxiliary ejector on the sample gas outlet of the high temperature probe adapter. (See Figure 4.3 in Subsection 4.1.4.)

• When a high temperature detector is used and the pressure of a sample gas is 0.49 Pa or higher, it is recommended that a throttle (e.g., needle valve) be installed on the sample gas outlet of the high temperature probe adapter. (See Figure 4.4 in Subsection

4.1.4.)

Note: This is to lower the temperature of a sample gas below 7008C. When both the

temperature and the pressure of a sample gas are high, the temperature of the sample gas may not fall below 7008C before the gas reaches the detector. On the other hand, the temperature of a sample gas may drop too much and thus condensation develops in the high temperature probe ejector. During wintertime, it is recommended that the probe adapter be protected with an insulating material to prevent condensation.

• When a high temperature detector is used and blowback is required to eliminate dust accumulating in the probe of the high temperature probe adapter, air supply piping for purging should be installed.

Note: If a sample gas contains much dust (e.g., in recovery boilers or cement kilns),

the probe is more likely to become clogged. To eliminate this dust accumulation using air pressure, piping is generally installed from an air source only when cleaning is performed. Some cases, however, may need a permanent installation of the blowback piping. See Subsection 4.1.5 for the installation of blowback piping.

4-2

IM 11M12D01-01E

4.1.1 Parts Required for Piping in a System Using Flow Setting Units for Manual Calibration

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

Table 4.1

Detector Piping Location Part Description

General-purpose Calibration gas inlet Stop valve Yokogawa recommended: detector L9852CB or G7016XH

* Nipple Rc1/4 or 1/4 NPT General Tube fitting Rc1/4 (1/4NPT) for a f6 3f4mm General

soft tube

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

High-temperature Calibration gas inlet Stop valve Yokogawa recommended: detector L9852CB or G7016XH

* Nipple Rc1/4 or 1/4 NPT General

Tube fitting Rc1/4 (1/4 NPT) for a f6 3f4mm soft tube Reference gas inlet (sealed up) (when piping is required, refer to § 4.1.3) Sample gas outlet * Auxiliary ejector Yokogawa recommended,

E7046EC or E7046EN

* Equal tee, connection R1/4 or 1/4 NPT General

fitting

* Needle valve Rc1/4 or 1/4 NPT General

* Reducing nipple R1/2 to R1/4 or R1/2 to 1/4 NPT General

4. Piping

Note: Parts marked with an asterisk (*) are used when required.

General parts are commercially available.

4.1.2 Piping for the Calibration Gases

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

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

Mount a check valve or stop valve (specified by YOKOGAWA) on the nipple (found on the open market) at the calibration gas inlet of the detector as illustrated in Figure 4.8. (The check valve or the stop valve may have been mounted on the detector when shipped.) Connect the flow setting unit and the detector to a stainless steel pipe 6 mm (O.D.) ~ 4 mm or larger (I.D.) (or nominal size 1/4 inch).

Tube connection joint

T4.1E.EPS

NippleStop valve

IM 11M12D01-01E

F4.2E.EPS

Figure 4.2 Connection to the calibration gas inlet

4-3

4.1.3 Piping for the Reference Gas

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

4.1.4 Piping to the High Temperature Probe Adapter

A sample gas should be at a temperature below 7008C before it reaches the detector. Also, a sample gas needs to be sucked if its pressure is negative. The piping for these purposes should be connected to the high temperature probe adapter. For the use of the probe adapter when the high temperature detector is used, refer to Subsection 3.2.2.

• If the pressure of a sample gas is negative, connect an auxiliary ejector (E7046EC/ E7046EN) as shown in Figure 4.3. Mount the pressure gauge as close as possible to the auxiliary ejector. However, if the ambient temperature is too high, mount the gauge in a location with a temperature below 408C.

Auxiliary ejector for high temperature use

Adapter for high temperature probe

Detector

F4.3E.EPS

Figure 4.3 Mounting the auxiliary ejector

• If the temperature of a sample gas is high and its pressure exceeds 0.49 Pa, the temperature of the sample gas at the detector may not be below 7008C. In this case, connect a needle valve (commercially available) through a nipple (commercially available) to the sample gas outlet (Rc1/2) of the probe adapter so that the sample gas exhaust volume can be restricted. In cases where condensation is likely to occur in the probe adapter when the sample gas is cooled, protect the probe adapter with an insulating material as shown in Figure 4.5.

4-4

IM 11M12D01-01E

4. Piping

Reducing nipple (R1/2-R1/4 or R1/2-1/4NTP)

Needle valve

F4.4E.EPS

Figure 4.4 Mounting the needle valve for restricting exhaust flow of the sample

gas

Cover flange

Sample gas outlet

Adapter for high temperature probe

Detector

Probe

Figure 4.5 Preventing to condensation

Insulating material

F4.5E.EPS

IM 11M12D01-01E

4-5

4.1.5 Pipinf for Blowback

This piping is required when the blow back function is carried out. The piping described below provides automatic blow back operation when the “ blow back start “ command is entered to the converter.

Pipe coupling

Blowback air

Solenoid valve

Regulator valve

Solenoid valve

Blow pipe

Note

If blowback is done under control of a contact output from the averaging converter, a hold is placed on analog output signals from all detector while blowback is in progress. See Section 10.5 for details on the blowback function. Wiring for solenoid valves is described in Section 5.3.

F4302.EPS

Figure 4.6 Blowback Piping

The following parts are required for blow back piping.

• Blow pipe (to be prepared as illustrated in Figure 4.7.)

• Two-way solenoid valve: “ Open “ when electric current is on. (Found on the open market)

• Air set (recommended by YOKOGAWA, G7011XF / E7040EL or G7004XF / K9473XG)

Manufacture the blow pipe as illustrated in Figure 4.7, and mount it on the hightemperature probe adapter.

4-6

Blind flange of the adapter for

Rc1/4

Approximately 200

high temperature probe

Welded

8 (O.D.) by 6 (I.D.) Stainless steel pipe

Figure 4.7 Blow pipe Construction

Unit : mm

F4.11E.EPS

IM 11M12D01-01E

4.1.6 Piping for Indication check

To perform an indication check using the third check gas, the piping to allow the third gas to flow into the calibration gas line is required for the ZA8F Flow Setting Unit in addition to the system configuration shown in Figure 4.1.

Connect the piping from the third check gas cylinder through a pressure reducing valve and a stop valve, along with the span gas line, to the zero gas inlet of the ZA8F Flow Setting Unit. To perform an indication check, open the stop valve on the line from the third gas cylinder, while open the stop valve on the span gas line to perform span point calibration.

Flowmeter

Reference gas line

Calibration gas line

Needle valve

ZA8F flow setting unit

4. Piping

Reference gas line

Calibration gas line

Flowmeter

Needle valve

ZA8F flow setting unit

Air Set

Stop valve

Pressure regulator

Instrument air

Span gas cylinder (Instrument air)

Zero gas cylinder

Third check gas cylinder

Figure 4.8 Piping to ZA8F Flow Setting Unit for Indication Check Using 3rd

Check Gas

F3.eps

IM 11M12D01-01E

4-7

4.1.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs

When a process gas alarm (an input contact signal of unburnt gas detection) occurs, the averaging converter will cut off the power supply to the heater of the detector, and at the same time it will send a contact output to activate a solenoid valve for introducing a purge gas to the detector.

In addition to the system configuration shown in Figure 4.1, a purge gas cylinder and a pressure reducing valve, and where necessary, a stop valve, a flowmeter, and a needle valve are required. Also, a check valve should be installed on the calibration gas inlet of the detector. A typical piping diagram for purging is shown in Figure 4.9.

It is recommended that each instrument be installed to allow for minimum piping between the ZA8F Flow Setting Unit and the detector and between the solenoid valve for introducing the purge gas and the detector.

Flowmeter

Needlu valve

Detector

Signal

Heater

Check valve

Calibration gas line

To ZA8F

Reference gas line

Check valve

Calibration gas line

To ZA8F

Reference gas line

Solenoid valve

Figure 4.9 Typical Piping for Purging

Averaging Converter (AV550G)

Contact output

Stop valve

Pressure regulator

Analog outputs: (Averaged and individual outputs)

Contact output Contact input

Power supply

purging gas cylinder

4-8

IM 11M12D01-01E

4. Piping

4.2 Piping for a System to Perform Automatic Calibration

The piping for a system to perform automatic calibration is shown in Figure 4.10.

Detector

Reference gas line

Averaging Converter (AV550G)

Calibration contact outputs

Solenoid valve

Flowmeter

Analog outputs:

Averaged and individual outputs

Contact output Contact input

Power supply

Span gas cylinder (Instrument air)

Pressure regulator

Stop valve

Zero gas cylinder

Solenoid valve

Flowmeter

Signal Heater

Calibration gas line

Needle valve

Instrument air

Air set

Figure 4.10 Typical Piping for a System to perform Automatic Calibration

The following outlines some points to note regarding the piping for this system.

• Install a solenoid valve through a nipple on the calibration gas inlet of the detector.

Note: The solenoid valve should be connected directly to the detector. If any piping is

present between the detector and the solenoid valve, condensation may develop in the pipe, causing damage to the detector by rapid cooling when the calibration gas is introduced.

4.1.4.)

Note: This is to lower the temperature of a sample gas below 7008C. When both

the temperature and the pressure of a sample gas are high, the temperature of the sample gas may not fall below 7008C before the gas reaches the detector. On the other hand, the temperature of a sample gas may drop too much and thus condensation develops in the high temperature probe ejector. During wintertime, it is recommended that the probe adapter be protected with an insulating material to prevent condensation.

Note: If optional 24 V outputs are specified for solenoid valves (Option Code "/24"),

no external power supply for solenoid valve is required. The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valves.

Note: If a sample gas contains much dust (e.g., in recovery boilers or cement kilns),

IM 11M12D01-01E

4-9

4.2.1 Parts Required for Piping in a System to Perform Automatic Calibration

Referring to Table 4.2, check that the parts required for your system are ready.

Table 4.2 Parts Required for Piping in a System to Perform Automatic Calibration

Detector

General purpose detector

High temperature detector

Note: Parts marked with an asterisk (*) are used when requored. General parts are commercially available

Piping Location

Calibration gas inlet

Reference gas inlet

Calibration gas inlet

Reference gas inlet

Sample gas outlet

Solenoid valve * Nipple Flowmeter Needle valve Tee fitting

Solenoid valve

* Stop valve Zero gas cylinder Pressure reducing valve

Connection fitting Flowmeter * Needle valve

Air set

Connection fitting Solenoid valve * Nipple Flowmeter Needle valve Tee fitting

Solenoid valve

* Stop valve Zero gas cylinder Pressure reducing valve

Connection fitting Flowmeter * Needle valve

Air set

Connection fitting * Auxiliary ejector

* Equal tee, connection fitting * Needle valve * Reducing nipple

Part Description

Yokogawa recommended: E7057Gh, G700hXP R1/4 or 1/4NPT(M-M) 0 to 1 L /min For flow control For branch connection. Manifold substitutable 3{way valve for zero/span gas switching

Yokogawa recommended: G7001ZC Yokogawa recommended: G7013XF or G7014XF R1/4 or 1/4NPT (M) 0 to 1 L /min For flow control. Unnecessary if supplied with flowmeter Yokogawa recommended: G7011XF/E7040EL or G7004XF/K9473XG R1/4 or 1/4NPT (M) Yokogawa recommended: E7057Gh, G700hXP R1/4 or 1/4NPT(M-M) 0 to 1 L /min For flow control For branch connection. Manifold substitutable 3{way valve for zero/span gas switching

Yokogawa recommended: G7001ZC Yokogawa recommended: G7013XF or G7014XF R1/4 or 1/4NPT (M) 0 to 1 L /min For flow control. Unnecessary if supplied with flowmeter Yokogawa recommended: G7011XF/E7040EL or G7004XF/K9473XG R1/4 or 1/4NPT (M) Yokogawa recommended: E7046EC or E7046EN R1/4 or 1/4NPT (male) Rc1/4 or 1/4NPT R1/2-R1/4 or R1/2-1/4NPT

General General General General

General

General General General

General

General General General General

General

General General General

General

General General General

T4.2E.eps

4-10

IM 11M12D01-01E

4.2.2 Piping for the Calibration Gases

The piping for the calibration gases should be installed between the calibration gas cylinders (or instrument air source) and the detectors with a flowmeter, solenoid valves, needle valves, and stop valves for performing automatic calibration.

• Place the calibration gas cylinders in a place not exposed to direct sunlight as much as possible, e.g., house in a gas unit case. The cylinder should be equipped with a pressure reducing valve (Yokogawa recommended part) and where necessary, a stop valve.

• Install a normally closed solenoid valve (Yokogawa recommended part) through a nipple (commercially available) on the calibration gas inlet of the detector as shown in Figure 4.11. This solenoid valve is activated by a contact signal from the averaging converter. (Power wiring is separately required.)

Note: If the solenoid valve cannot be connected directly to the calibration gas inlet of

the detector, install a dedicated check valve (K9292DN or K9292DS) on the inlet and then route the piping to the solenoid valve.

• After installing the solenoid valve on the calibration gas inlet of the detector, route the piping through a flowmeter, a needle valve, a solenoid valve for switching zero and span gases, a stop valve, and a pressure reducing valve for the cylinder, in this order, to the cylinder.

• Install the piping for the solenoid valve for switching zero and span gases so that the zero gas is introduced to the detector when powered. This solenoid valve is activated by a contact signal from the averaging converter. (Power wiring is separately required.)

• Install the needle valve and flowmeter in close proximity as much as possible.

• Use stainless steel pipes with 6 OD x 4 ID mm (or nominal 1/4 inch) or larger inside diameter for the piping for the calibration gases.

4. Piping

Solenoid valve (nomal close)

Nipple

F4202.EPS

Connect directly to piping inlet

Calibration gas piping [6 3 [4mm stainless steel pipe

Reference gas piping [6 3 [4mm (or nominal 1/4-inch) stainless steel pipe

Figure 4.11 Piping for the Calibration Gas Inlet

IM 11M12D01-01E

4-11

4.2.3 Piping for the Reference Gas

The piping for the reference gas should be installed between the air source (instrument air) and the detector through flowmeters and needle valves for flow control of the reference air, and an air set.

• Install the piping from the reference gas inlet of the detector to the air source with a flow meter, a needle valve where necessary, and an air set in this order.

• Install the flowmeter, needle valve and air set in close proximity.

• Use stainless steel pipes with 6 OD x 4 ID mm (or nominal 1/4 inch) or larger inside diameter for the piping for the reference gas.

4.2.4 Piping to the High Temperature Probe Adapter

The piping to the high temperature probe adapter is required when a high temperature detector is used.

This piping is the same as the one in the system using flow setting units for manual calibration. See Subsection 4.1.4.

4.2.5 Piping for Blowback

The piping for blowback is required only when the blowback is conducted in a system using a high temperature detector. This piping is the same as the one in the system using flow setting units for manual calibration. See Subsection 4.1.5.

4.2.6 Piping for Indication Check

Detector

Reference gas line

To perform an indication check using the third check gas, the piping to allow the third gas to flow into the calibration gas line is required in addition to the system configuration shown in Figure 4.9.

Route the piping from the third check gas cylinder through a pressure reducing valve and a stop valve to the solenoid valve for switching the span gas and the third check gas, as shown in Figure 4.12.

It is recommended that the piping and wiring for the solenoid valve for switching the span gas and the third check gas be installed to allow the third check gas to be introduced when powered. This solenoid valve is activated by a contact signal from the averaging converter (Power wiring is separately required.)

Averaging converter(AV550G)

Calibration contact outputs

Contact output

Pressure regulator

Solenoid valve

Stop valve

Analog outouts: (Averaged and individual output)

Contact output Contact input

Power supply

Span gas cylinder (Instrument air)

Zero gas cylindr

Third check gas cylinder

Solenoid valve

Flowmeter

Signal

Heater

Calibration gas line

Needle valve

Flowmeter

Instrument air

Air set

4-12

p: If optional 24 V outputs are specified for solenoid valve (MS Code "/24"), no external power supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valves.

Figure 4.12 Piping for Automatic Indication Check Using 3rd Check Gas

IM 11M12D01-01E

4.2.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs

The piping for purging in a system to perform automatic calibration is the same as the one in the system using flow setting units for manual calibration. As instructed in Subsection 4.1.7, this piping also requires that a check valve be installed on the calibration gas inlet of the detector. A typical piping diagram for purging is shown in Figure 4.13.

It is recommended that each instrument be installed to allow for minimum piping between the solenoid valve for introducing the calibration gases and the check valve, and between the solenoid valve for introducing the purge gas and the check valve.

4. Piping

Detector

Check valve

Calibration gas line

Reference gas line

Check valve

Calibration gas line

Reference gas line

Signal

Heater

To calibration gas flow setting needle valve and flowmeter.

To reference gas flow setting flowmeter and needlre valve.

To calibration gas flow setting needle valve and flowmeter. To reference gas flow setting flowmeter and needle valve.

Averaging converter (AV550G)

Calibration contact outputs

Contact output

Analog output (Averaged and individual outputs)

Contact output Contact input

Power supply

Flowmeter

Needle valve

p: If optional 24 V outputs are specified for solenoid valve (MS Code "/24"), no external power supply for solenoid valves is required. The solenpid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valvas.

Solenoid valve

Stop valve

Pressure regulator

Purge gas cylinder

Figure 4.13 Typical Piping for Purging

IM 11M12D01-01E

4-13

4-14

IM 11M12D01-01E

5. Wiring

This chapter describes the wiring connections to the EXAxt AV550G Averaging Converter.

5.1 General

* Never apply power to the averaging converter and other instruments connected to the

5. Wiring

DANGER

averaging converter until all wiring is completed.

WARNING

• This product complies with the CE marking.

Where compliance with the CE marking is necessary, the following wiring is required.

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

2. Use an external switch or circuit breaker rated 20A and conforming to IEC 947-1 or IEC 947-3.

3. It is recommended that the external switch or circuit breaker be installed in the same room as the averaging converter.

4. The external switch or circuit breaker should be installed within reach of the operator and identified with marking as a power supply switch to the averaging converter.

5. Power lines such as power cables and heater wires should be fixed securely onto a wall or construction using cable racks, conduit tubing, nylon bands or other appropriate ways. Accidental removal from terminals by pulling may result in electric shock.

IM 11M12D01-01E

5-1

5.1.1 Wiring Precautions

5.1.1.1 Precautions Concerning the Correspondence Between Detectors and Channel Cards

Multiple detectors are connected to the averaging converter. Make sure that the wiring is run properly between the detector and its corresponding channel card on the averaging converter. Special care should be exercised so that the channel number of the detector signal line from the channel card corresponds the one of the detector heater line from the power supply unit. Disagreement may result in malfunction of the detector as well as invalid operation. (A channel number is indicated in the channel card slot.)

The specified number of channel cards per purchase order is factory installed in channels in order from CH1. The factory-installed channels can be changed as desired. All the channels are the same. Note that in a 4-channel base averaging converter (AV550G-A-), channels CH5 to CH8 cannot be used.

To remove a channel card, loosen the 2 screws attached to the top and bottom of the card, and then while holding the loosened screws, pull straight away from the slot. To install a channel card, insert the card by sliding along the guide rail in the slot, and then securely tighten the 2 screws.

WARNING

• Using a channel card installed without 2 screws tightened, may result in poor resistance to noise.

5.1.1.2 Precautions in Processing Shields

When a shielded cable is required for wiring, follow the instructions below to process the shield.

(1) All the shields should be connected on the averaging converter side: Connect to the

cable shield ground terminals inside the averaging converter.

(2) The shields should not be connected on the other side of the cable. To avoid any

possible contact with housings of instruments connected or metal parts, conductors of the shields should be processed using insulating tapes or in an appropriate way.

(3) The shields should be connected to the cable shield ground terminals immediately

after the cable is inserted into the averaging converter through the wiring hole. Having a long distance between the wiring hole and the cable end where the shield goes out, may result in poor resistance to noise.

5-2

IM 11M12D01-01E

5. Wiring

Cores

Shield

Cable Shield Ground Terminal

Cable Sheath

Figure 5.1 Shield Processing

Good

To Terminals

Short

Wiring Holes

Bad

To Terminals

Long

IM 11M12D01-01E

Cable Shield Groud Terminals (M4)

Figure 5.2 Cable Shield Ground Terminals

5-3

5.1.2 Wiring Holes

The averaging converter has 30 wiring holes. Use holes near the rear for power wiring (e.g., power cables, detector heater wires, and wiring for solenoid valve contacts and other contact outputs). For signal wiring (e.g., detector signal lines and analog output signal lines), use holes near the front.

If more than 30 cables are used and thus more than one cable has to be passed through one wiring hole, do not allow signal lines and power lines to pass the same hole. Also, in the averaging converter, the signal lines and power lines should be routed so they can avoid contact and interference.

A grommet is attached, as standard, to the wiring hole of the averaging converter. An optional cable gland is available. When a cable gland is not used, make a cable hole in a grommet.

Wiring Connections: 30 holes Applicable Cable Hole: [17 mm maximum for grommet

[6 to [12 mm for cable gland (optional)

5.1.3 External Wiring Connection Terminals of the Averaging Converter

The connection diagram of the averaging converter is shown in Figure 5.3. The terminal numbers are indicated on the converter. Care should be taken to make the wiring connections correctly.

Averaged analog outputs

External ground terminal

Contact input

Power supply

Ground

If 230 V AC is selected, channel cards are expandable up to 4.

Control Card

+ 1 + 1 + 1 + 1 + 1

Ave-a

- 2 - 2 - 2 - 2 - 2 + 3 + 3 + 3 + 3 + 3

Ave-b

- 4 - 4 - 4 - 4 - 4

+ 5 + 5 + 5 + 5 + 5

Ave-c

- 6 - 6 - 6 - 6 - 6 DI1 7 + 7 + 7 + 7 + 7 DI2 8 - 8 - 8 - 8 - 8

COM 9

C NC NO C NC NO C NC NO C NC NO C NC NO

11 12 13 14 15 16 17 19 20 21 22 24 25 26 27 28 29 61 62 63 64 65 66 68 70 71 72

31 32 33 34 35 36 37 39 40 41 42 44 45 46 47 48 49 81 82 83 84 85 86 L N G

C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO

DO-CH1

Channel Card (CH1)

CELL

Detector Output

signals

Individual Analog

output

Functional Contact Output

DO1 DO2 DO3

DO-CH2

Individual Error Contact Output

Grounding plate

DO-CH3

51 52 53 54 55 56 57 58 101102 103 104 108

CH1

Common Error output

DO4

18 38

DO-CH4

CH4

CH3

CH2

Cell Heater

Channel Card (CH4) Channel Card (CH5)

Detector Output signals

Individual Analog output

CELL

Detector Output signals

Individual Analog output

Basic Power Supply

Solenoid Valve output

DO5

23 43

SV-COM

Solenoid Valve Contact Output

SV-CH1

SV-CH3

SV-CH2

SV-CH4

CELL

Individual Error Contact Output

DO-CH5

C NC NO C NC NO

DO-CH7

Individual Error Contact Output

CH5

DO-CH6

DO-CH8

CH6

Cell Heater

Detector Output signals

Individual Analog output

Expansion Power Supply

Solenoid Valve Contact Output

67 69 87 89

Solenoid Valve Contact Output

105 106

Channel Card (CH8)

CELL

-CH6

SV-CH5

90 91 92

SV-CH8

SV-CH7

107

CH8

CH7

M3.5 screws

M4 screws

G terminal and

Power supply and Ground terminals are M4 screw.

p1 Averged analog output with digital communication (HART) when suffix code

p2 Used exclusively for communication when suffix code Fieldbus communication) is selected.

terminal are connected by jumper plate.

“-E”

(HART communication) is selected.

Figure 5.3 External Wiring Connection Terminals of the Averaging Converter

5-4

“-F”

(FOUNDATION

1 2 3 4 5 6 2 4 5 6

7 8 7 8

Detector

CH1 CH5

Detector

IM 11M12D01-01E

5.1.4 Types of Wiring and Cables

Types of wiring and cables to be used are listed in Table 5.1. The purpose of a shield is not only to prevent the effect from noise disturbance but also to restrict the noise emitted from the converter. Specified cables must be used.

Table 5.1 Types of Wiring and Cables

5. Wiring

Terminal

Power, internal grounding

External grounding

Detector heater

Detector signal

Individual analog output Averaging analog output

Solenoid output

Individual error contact output Common contact

Indication

L, N,

HTR1 to HTR8

CELL, TC, CJ

A ve-a, A ve-b, A v3-c SV-COM, SV-CH1 to SV-CH8

DO-CH1 to DO-CH8

DO1 to DO4

Shield Requirement

Unshielded

Shielded

Unshielded

Number of Cores

2 or 3

Note

output Common error

DO5

Unshielded

Note

contact output Contact input

DI1, DI2, DI-COM

Unshielded

2 or 3

Note: The number of cores is determined by number of contacts to be used.

Requirements

Size: 2 mm

(14 AWG) or larger per core

Either internal grounding or external grounding will do.

Size: 1.25 mm

(16 AWG) or larger, Conductor two-way resistance: †10 ‰ Conductor two-way resistance: †10 ‰

†550 ‰, including load resistance

Loop resistance when contact is closed: †200 ‰

IM 11M12D01-01E

5-5

5.2 Wiring for the Averaging Converter and Peripheral Devices

5.2.1 Preparation for Wiring to the Averaging Converter

Follow the instructions below when connecting cables to the averaging converter.

(1) The terminal screws on the control and channel cards are M3.5, and all the other

terminal screws are M4. Each wire should be terminated with a crimp terminal appropriate to the screw.

(2) If a silicone rubber insulated glass fiber braided wire is used for wiring to the

detector, run the wiring through a terminal box. It is recommended that a cable such as a PVC insulated PVC sheathed control cable be used between the terminal box and the averaging converter. This is to prevent moisture or corrosive gases from entering into the averaging converter and to ensure the grounding of the detector.

5.2.2 Preparation for Wiring to Detectors

Follow the instructions below when connecting cables to detectors. (1) Install a conduit or cable gland appropriate to the specified screw size to the cable

inlet of a detector. Allow for the sufficient length of a cable in case that the detector needs to be removed for maintenance.

(2) If the ambient temperature around the wiring lines exceeds 80˚C, a flexible metal

conduit tube must be used. If an unshielded 600 V silicon rubber insulated glass fiber braided wire, route the wiring so that the wire cannot pick up external noise.

(3) Figure 5.4 shows the layout of the detector terminals.

TC 1(with Si TUBE)

CELL 1

TC 2

123456

TCCELL CJ

Figure 5.4 Detector Terminals

CELL

(+)

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

To Converter, or Terminal Box

To Ground

HTR HTR

To Converter, or Terninal Box

5-6

IM 11M12D01-01E

5. Wiring

The sizes of the terminal screws are M3.5. Each wire should be terminated with a crimp terminal appropriate to the screw.

WARNING

• If the ambient temperature at the detector installation site exceeds 608C, use bare

crimp terminals.

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

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

Lock Screw

Figure 5.5

Detector Cover

F5.8E.EPS

IM 11M12D01-01E

5-7

5.2.3 Power and Ground Wiring

Connect the power wiring to the L and N terminals in the averaging converter. Use wires with a size of 2 mm2 (14 AWG) or larger. If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. A lock washer must be installed.

Connect the ground wiring to the protective ground terminal in the averaging converter or the external ground terminal on the side of the case. Run the ground wiring so the ground resistance is 100 Ω or less (equivalent to Class D grounding).

Make sure that the jumper plate is connected between the G terminal and the protective ground terminal.

Grounding to the ground terminal

on the Averaging converter case

Converter Case

Crimp T erminal

FG T erminal

Lock Washer

Figure 5.6 Grounding to the Ground Terminal

WARNING

Operating the instrument with the jumper plate disconnected may result in poor

resistance to noise.

5.2.4 Power Wiring to Detector Heaters

This wiring provides electric power from the averaging converter to the heater for heating the sensor in a detector. Use 2-core shielded PVC insulated PVC sheathed control cables. The wire size should be 1.25 mm2 (16 AWG) or larger and the conductor two-way resistance should be 10 Ω or less. If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. The shields should be connected to cable shield ground terminals on the case of the averaging converter.

5-8

IM 11M12D01-01E

5. Wiring

Detector #1

Averaging Converter

Basic Power Unit

CH1 CH2 CH3 CH4

51 52 53 54 55 56 57 58 7 8

Shield

ZR22G / ZO21D

Detector #2

Detector #3

Detector #4

Figure 5.7 Power Wiring to Detector Heaters

If the ambient temperature at the detector installation site exceeds 80˚C, install a terminal box and connect to the detector using 600 V silicon rubber insulated glass braided wires. The distance between the detector and the terminal box should be minimized.

Detector #1

Averaging Converter

Basic Power Unit

ZR22G / ZO21D

CH1 CH2 CH3 CH4

51 52 53 54 55 56 57 58 7

Shield

Terminal Box

Silicon Rubber Insulated Glass Braided Wire

Figure 5.8 Power Wiring to Detector Heaters (Using Terminal Box)

To Detector #2

To Detector #3

To Detector #4

IM 11M12D01-01E

5-9

5.2.5 Signal Wiring to Detectors

This wiring is for transmitting signals of cell electromotive force, thermocouple output and cold junction compensation from a detector to the averaging converter. Use 6-core shielded PVC insulated PVC sheathed control cables. The conductor two-way resistance should be 10 Ω or less. Keep the cables away from the power wiring. If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. The shields should be connected to cable shield ground terminals on the case of the averaging converter.

Channel Card

CH1

1 1 1 1

CELL

2 2 2 2 1 2 3 4 5 6 3 3 3 3

4 4 4 4 5 5 5 5

Averaging Converter

CH2

6 6 6

CH3

CH4

Shield

Detector #1

ZR22G / ZO21D

Figure 5.9 Signal Wiring to Detectors

To Detecter #2

5-10

IM 11M12D01-01E

5. Wiring

Channel Card

CH1

CELL

Figure 5.10 Signal Wiring to Detectors (Using Terminal Box)

5.2.6 Ground Wiring of Detectors

Connect the ground wiring to the external ground terminal on the detector case or the internal ground terminal. Follow the instructions below. The ground terminal screw is M4.

Averaging Converter

CH2

1 2 3 4 5 6

CH3

Shield

Detector #1

CH4

1 2 3 4 5 6

Terminal Box

ZR22G / ZO21D

3456

Silicon Rubber Insulated Glass Braided Wire

To Detector #2

(1) The ground resistance should be 100 Ω or less (equivalent to Class D grounding). (2) If the ambient temperature of the wiring installation exceeds 80˚C, use appropriate

heat resistant wires.

WARNING

The flange bolts alone do not provide durable grounding of the detector. Be sure to

grounded the ground terminal.

IM 11M12D01-01E

5-11

5.2.7 Wiring for Individual and Average Concentration Analog Outputs

For the signal wiring to analog outputs, use shielded PVC insulated PVC sheathed control cables. The number of cores is determined by the number of outputs. If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. Like the signal wiring to detectors, the shields should be connected to cable shield ground terminals on the case of the averaging converter.

The load resistance from the averaging converter, including the wiring resistance, should be 550 Ω or less.

Averaging Converter

Control Card

Averaged Analog Output

Ave-a

Ave-b

Ave-c

CH1 CH2 CH4

Individual Analog output

7 7 7 7

8 8 8 8

Channel Card

CH3

Receiver

Shield

Figure 5.11 Wiring for Individual and Average Concentration Analog Outputs

5.2.8 Wiring for Solenoid Valve for Automatic Calibration

This wiring is for operating the solenoid valve to switch zero and span calibration gases during calibration in the automatic calibration system and for operating the solenoid valve installed on the calibration gas line to the detector of each channel. The contact output for solenoid valve is also used for operating the solenoid valve on the blowback piping. For the wiring and piping of the system, refer to Section 5.3, Wiring and Piping Examples.

Use shielded PVC insulated PVC sheathed control cables for the wiring for solenoid valves. The shields should be connected to cable shield ground terminals on the case of the averaging converter.

If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. Like the signal wiring to detectors, the shields should be connected to cable shield ground terminals on the case of the averaging converter.

All contact outputs for solenoid valves are voltage free, dry contacts (mechanical relay contact outputs). The contacts are open under normal conditions (when deenergized).

The contact rating is 250 VAC, 1A or 30 VDC, 1A.

5-12

If optional 24 V outputs are specified for solenoid valves (Option Code "/24"), no external power supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging Converter. The maximum current that can be supplied to the solenoid valve is 50 mA. Use solenoid valves that consume not more than 1.2 W to operate.

IM 11M12D01-01E

Averaging Converter

Basic Power Unit Expansion Power Unit

26 27 28 29 69 70 71 72

44 45 46 47 48 49

89 90 91 92

5. Wiring

Solenoid Valve for Switching Zero/Span Cal Gases

Power Supply to Solenoid Valve

Solenoid Valve for Cal Gas to Detector #1

Power Supply to Solenoid Valve

Solenoid Valve for Cal Gas to Detector #2

Power Supply to Solenoid Valve

: If optional 24 V outputs are specified for solenoid valves (Option Code "/24"),

Shield

no external power supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valves.

5.2.9 Wiring for Individual/Common Error Contact Outputs and Common Contact Outputs

The averaging converter has the following contact outputs. (1) Common function-specific contact outputs (DO1 to DO4): User specified functions

can be assigned. (2) Common error contact output (DO5): Activated when any error occurs. (3) Individual error contact outputs (DO-CH1 to DO-CH8): Channel-specific contacts.

One output is provided per channel. For details on errors, refer to Section 12.1, "Display and Remedies When Error Occur." All contact outputs are Form C (transfer contact) and consist of 3 terminals of COM, NC, and NO. All contacts are voltage free, dry contacts (mechanical relay contact outputs). The contact rating is 250 VAC, 3A or 30 VDC, 3A.

The individual and common error contacts are set to normally energized and cannot be changed. The "NC" and "NO" indications on the terminal show energized states. States of common contacts 1 to 4 are user selectable: normally energized or normally deenergized. The "NC" and "NO" indications on the terminal show deenergized states.

IM 11M12D01-01E

5-13

Use PVC insulated PVC sheathed control cables for the wiring for these outputs. There is no need to use shielded cables. If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm.

Averaging Converter

Basic Power Supply

11 12 13 14 15 16 17 18 19 20 21 22 23 24 61 62 63 64 65 66 31 32 33 34 35 36 37 38 39 40 41 42 43 44 81 82 83 84 85 86

Expansion Power Unit

CH1 Error

CH2 Error

CH3 Error

CH4 Error

Annunciator, etc.

Figure 5.13 Wiring for Individual/Common Error Contact Outputs and Common

Contact Outputs

5-14

IM 11M12D01-01E

5.2.10 Wiring for Contact Inputs

The averaging converter receives contact inputs to perform the specified functions. Follow the instructions below to run the wiring for contact inputs.

Use 2-core or 3-core PVC insulated PVC sheathed control cable for this wiring. The number of cores is determined by the number of contacts to be used. There is no need to use shielded cables. If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. Like the signal wiring to detectors, the shields should be connected to cable shield ground terminals on the case of the averaging converter.

Contact inputs should be voltage free. The open/closed state of the contact is determined by the resistance from the averaging converter side. Note that the resistance should include the wiring resistance.

Closed contact: 200 V or less Open contact: 100 kV or more

Averaging Converter

Control Card

5. Wiring

7 8 9

Contact Input 1

Contact Input 2

Figure 5.14 Wiring for Contact Inputs

IM 11M12D01-01E

5-15

5.3 Wiring and Piping Examples

5.3.1 Wiring and Piping for Automatic Calibration

Detector

Solenoid Valve

Averaging Converter (AV550G)

Calibration Gas Line

Reference Gas Line

Flowmeter

Air Set

Needle Valve

: If optional 24 V outputs are specified for solenoid valves (Option Code 0/240), no external

power supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valves.

Figure 5.15 Typical Diagram for Automatic Calibration

Needle Valve

Flow meter

Instrument Air

Solenoid Valve

Stop Valve

Pressure Regulator

Zero Gas Cylinder

Power Supply

Span Gas Cylinder

(Instrument Air)

5.3.2 Wiring and Piping for Automatic Calibration and 3rd Gas Indication Check

Detector

Solenoid Valve

Calibration Gas Line

Referece Gas Line

Flowmeter

Needle Valve

: If optional 24 V outputs are specified for solenoid valves (Option Code 0/240), no external

power supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valves.

Figure 5.16 Typical Diagram for Automatic Calibration and 3rd Gas Indication

Averaging Converter (AV550G)

Air Set

Needle Valve

Instrument Air

Flow meter

Solenoid Valve

Stop Valve

Check

Power Supply

Span Gas Cylinder

Pressure Regulator

Third Check Gas Cylinder

Analog Output

(Averaged and Individual Output)

Contact Output Contact Input

(Instrument Air)

Zero Gas Cylinder

5-16

IM 11M12D01-01E

5.3.3 Wiring and Piping for Blowback

Blowback Solenoid Valve

High Temperature Detector

Stop Valve

Averaging Converter (AV550G)

5. Wiring

Analog Output

(Averaged and Individual Output)

Contact Output Contact Input

Power Supply

Calibration Gas Line

Reference Gas Line Calibration Gas Line

Reference Gas Line

To ZA8F Flow Setting Unit

Instrument Air

Air Set

: If optional 24 V outputs are specified for solenoid valves (Option Code 0/240), no external

power supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for solenoid valves.

Figure 5.17 Typical Diagram for Blowback

5.3.4 Wiring and Piping for Automatic Calibration and Blowback

Blowback Solenoid Valve

High Temperature Detector

Solenoid Valve

Averaging Converter (aV550G)

Analog Output

(Averaged and Individual Output)

Contact Output Contact Input

Note : If optional 24 V outputs are specified for solenoid valves (Option Code 0/240), this system cannot be established. This is because the contact to activate a solenoid valve is used in common for autocalibration and blowback.

IM 11M12D01-01E

Reference Gas Line

Power Supply

Air Set

Needle Valve

Instrument Air

Flowmeter

Solenoid Valve

Pressure Regulator

Span Gas Cylinder

(Instrument Air)

Zero Gas Cylinder

Calibration Gas Line

Flowmeter

Needle Valve

Figure 5.18 Typical Diagram for Automatic Calibration and Blowback

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IM 11M12D01-01E

6. Components

In this Chapter, the names and functions of components are described for the major equipment of the AV550G Averaging Converter.

6.1 ZR22G Detector

6.1.1 General-purpose Detector (except for Model ZR22G-015)

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.)

6. Components

Bolt

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

0.7, 1.0, 1.5, 2.0, 2.5 or 3.0

3.6, 4.2, 4.8 or 5.4 m.

Contact

Metal O-ring

Pipe support

U-shaped pipe

Sensor (cell)

Filter

Washer (or plain washer)

Figure 6.1 General-use Detector (standard type)

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

Dust filter mounting screw

Calibration gas pipe opening

Probe

Screw

F0601e.eps

IM 11M12D01-01E

6-1

6.1.2 High-Temperature Detector (Model ZR22G-015)

Sample gas outlet When a negative measurement gas pressure is used, connect the auxiliary ejector assembly. When the measurement gas is high-temperature and high-pressure, and does not fall below 7008C, connect a pressure control valve (e.g. a needle valve). (Refer to Section 3.2.2.)

Flange Selectable from JIS standards or ANSI standards

Separate type High-temperature Detector (ZR22G-015) When the temperature of the measurement gas is between 7008 and 14008C, mount this detector with a ZO21P-H probe adapter.

High-temperature Probe Adapter (ZO21P-H) The probe is made of either SUS 310S or silicon carbide (SiC). Its length is either 1.0 m or 1.5 m. When using an SiC probe, mount it vertically downward.

6-2

F0602e.eps

Figure 6.2 High-temperature Detector

IM 11M12D01-01E

Yokogawa ZR22-AV550G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual