YOKOGAWA ZR22G, ZR402G, ZR202G User Manual

<<Contents>> <<Index>>

General Speciﬁ cations

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

GS 11M12A01-01E

Overview

This analyzer consists basically of a probe and a converter that are used as both a Zirconia Oxygen Analyzer and High Temperature Humidity Analyzer. The probe is of direct insertion type, and the converter uses a digital display.

Two types of analyzers are available: separate type and integrated type. As its name implies, the integrated type combines probe and converter.

Separate and integrated type Zirconia oxygen analyzers need not use a sampling device, and allow direct installation of the probe in the wall of a ﬂ ue or furnace to measure the concentration of oxygen in the stack gas. The converter displays the cell temperature and cell emf in addition to the oxygen concentration.

This analyzer is most suitable for monitoring the oxygen concentration of combustion gases in large or small boilers, various industrial furnace and combustion devices, or for the control of low-oxygen combustion.

Separate type and integrated type Zirconia High Temperature Humidity Analyzers are used to measure the humidity of hot gases continuously in driers which use an electrical heater or hot gas as the heat source. They can also be used in a variety of manufacturing applications in humidiﬁ ers, as well as in driers, for humidity measurement and control. They can help improve productivity in these application ﬁ elds.

• The built-in heater assembly of the probe can be replaced on site, reducing maintenance costs.

• The probe uses a long-life, high-reliability Zirconia sensor.

• The probe uses three-reference air supply methods (natural air convection, instrument air, and pressure compensated) in its applications.

• The separate type converter incorporates a LCD touchscreen for ease of operation.

and

Features:

• This converter can be used as an oxygen analyzer as well as a high temperature humidity analyzer.

• The integrated type integrates both probe and converter, to reduce wiring, piping, and installation costs. This type of unit uses an optical switch for ease of operation at the site.

• Remote maintenance using digital communications (HART) reduces maintenance costs. *1

*1: HART is a registered trademark of HART Communication Foundation

ZR202G

EXA

ZR402G

4 to 20 mA DC signal line with superimposed HART AC signal

Ao+

–

Ao-

ZR402G

Ao1+

Ao1-

HART

Communicator

Model 275

Yokogawa Electric Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5617 Fax.: 81-422-52-6792

Relaying terminals

HART

Communicator

Model 275

Terminal board

Control room

HART

Communicator

Model 275

Receiving instrume load resistance: 250 Ω to 550 Ω

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GS 11M12A01-01E

©Copyright June. 2000

10th Edition Oct. 2010

<<Contents>> <<Index>>

Basic System Conﬁ guration

System conﬁ guration - Separate type

System configuration Example 1 of Separate type Analyzer

Automatic calibration system uses instrument air for reference gas. For the calibration gas, a standard gas cylinder may be used for more accurate calibration.

Applications: Oxygen concentration monitoring and control in large boilers

(for private power generation and for business use) and in heating furnaces, and the like. Humidity monitoring and control in drying furnaces and humidifiers.

Model ZR22G Separate type Zirconia Oxygen/ High Temperature Humidity Analyzer, Detector

Signal

Check valve

Calibration gas

(6-core shield cable)

Heater (2-core)

Reference gas

Model ZR40H Auto Calibration unit

System conﬁ guration - Integrated type

System configuration Example 1 of Integrated type Analyzer

For an integrated type as shown in the figure above. Applications:

Oxygen concentration monitoring and control in large boilers (for private power generation and for business use) and in heating furnaces, and the like. Humidity monitoring and control in drying furnaces and humidifiers

Auto Calibration unit

ZR20H

Calibration gas (Zero)

Calibration gas pressure regulator

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

Model ZR402G Converter

EXA

flowmeter

Reference gas

Span gas

ZR402G

100 to 240 V AC

Needle

valve

Model ZR202G Integrated type Zirconia Oxygen/ High Temperature Humidity Analyzer

with auto calibration (ZR202G-

100 to 240 V AC

Air Set

Calibration gas pressure regulator

Contact input Analog output, contact output

Digital output (HART)

Air Set

Instrument air

Calibration gas unit case

Zero gas cylinder

Contact input Analog output, contact output

Digital output (HART)

Instrument air

Calibration gas unit case

Zero gas cylinder

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□□□-□-□

-A-□-□-□-□-A)

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*1 Shield cable:

Use shielded signal cables, and connect the shields to the FG terminal of the converter. *2 Select the desired probe from the Probe Conﬁ guration table on page 4. *3 When a zirconia oxygen analyzer is used, 100% N

1 vol% O

gas (N2-balanced).

gas cannot be used as the zero gas. Use approx.

GS 11M12A01-01E 10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

Basic System Conﬁ guration

System conﬁ guration — Separate type

System configuration Example 2 of Separate type Analyzer

Instrument air is used as the reference gas. A standard gas cylinder can be used for the calibration gas for more accurate calibration.

Application example:

Oxygen concentration monitoring and control in large boilers (for private power generation and for business use) and in heating furnaces. Humidity monitoring and control in drying furnaces and humidifiers.

Model ZR22G Separate type Zirconia Oxygen/ High Temperature Humidity Analyzer, Detector

Stop valve

Check valve

Calibration gas

*4 Calibration gas unit same as for zero gas.

Model ZA8F flow setting unit

flowmeter

Reference gas

Calibration gas pressure regulator

Model ZR402G Converter

EXA

ZR402G

Needle

valve

Calibration gas unit case

Air Set

100 to

240 V AC

Instrument air

Span gas (*4)

Zero gas

cylinder

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System conﬁ guration — Integrated type

System configuration Example 2 of Integrated type Analyzer

Instrument air is used as the reference gas. A standard gas cylinder can be used for the calibration gas for more accurate calibration.

Application example:

Model ZR202G Intgrated type Zirconia Oxygen / High Temperature Humidity Analyzer

Stop valve

Check valve

Calibration gas

100 to 240 V AC

Model ZA8F flow setting unit

flowmeter

Reference gas

Calibration gas pressure regulator

Calibration gas unit case

Needle

valve

Air Set

Instrument air

Span gas (*4)

Zero gas

cylinder

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System configuration Example 3 of Separate type Analyzer

Instrument air is used as the reference gas. A portable standard gas unit (ZO21S) is used for the calibration. This unit is connected only when the calibration is made.

Application example: Oxygen concentration monitoring and control in

packaged boilers Humidity monitoring and control in drying furnaces or a humidifiers

Model ZR22G Separate type Zirconia Oxygen

/ High Temperature Humidity Analyzer, Detector

Stop valve

Calibration gas

Model ZR402G Converter

EXA

ZR402G

Model ZO21S Standard gas unit

100/110/115

200/220/240 V AC

100 to 240 V AC

F02_01.ai

System configuration Example 3 of Integrated type Analyzer

Instrument air is used as the reference gas. A portable standard gas unit (ZO21S) is used for the calibration. This unit is connected only when the calibration is made.

Application example:

Oxygen concentraion monitoring and control in packaged boilers Humidity monitoring and control in drying furnaces or a humidifiers

Model ZR202G Intgrated type Zirconia Oxygen

Analyzer/ High Temperature Humidity Analyzer

Stop valve

Calibration gas

100 to 240 V AC

Model ZO21S Standard gas unit

100/110/115

200/220/240 V AC

F02_02.ai

Note: The installation temperature limits range for integrated type

analyzer is -20 to 55 °C.

GS 11M12A01-01E

10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

System Components

Model ZR22G Separate type Zirconia Oxygen Analyzers/ High Temperature Humidity Analyzers,Detector

Model ZR402G Separate type Zirconia Oxygen / High Temperature Humidity Analyzer, Converter(*1)

Model ZR202G Integrated type Zirconia Oxygen Analyzers/ High Temperature Humidity Analyzers

Model ZO21P Adapter for High Temperature Probe of separate type Zirconia Oxygen Analyzer

E7046EC, E7046EN Auxiliary Ejector for High Temperature Probe of separate type Oxygen Analyzer

Model ZO21R Probe Protector for Zirconia Oxygen Analyzers

K9471UA Filter for Oxygen Analyzer

K9471UC Dust Guard Protector

Model ZH21B Dust Protector for High Temperature Humidity Analyzers

Model ZO21S Standard Gas Unit

Model ZA8F Flow setting unit for manual calibration

Model ZR40H Automatic Calibration Unit for Separate type Analyzer

Model ZR20H Automatic Calibration Unit for Integrated type Analyzer (*2)

L9852CB, G7016XH Stop Valve for Calibration-gas line

K9292DN,K9292DS Check Valve for Calibration-gas line

G7003XF/K9473XK , G7004XF/K9473XG Air Set

G7001ZC Zero-gas Cylinder

G7013XF, G7014XF Pressure Regulator for Gas Cylinder

E7044KF Case Assembly for Calibration-gas Cylinder

ZR22A, ZR202A Heater Assembly for Spare Parts

: Items required for the above system example

: To be selected depending on each application. For details, refer to Chapter of Options.

( )

: Select either (*1): When used as a high temperature humidity analyzer, specify /HS options. (*2): When Auto Calibration of (-A) or (-B) code is speified , ZR20H is installed in ZR202G.

Separate type Integrated type

System config. System config.

Ex.1 Ex.2 Ex.3 Ex.1 Ex.2 Ex.3

( )

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Detector Components

Process gas temperature 0 to 700°C Process gas temperature 0 to 1400˚C

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 to

2 m

2.5 m

or more

General-use Probe

Gas Flow

Sample inlet

Dust filter for

Oxygen Analyzer

(K9471UA)

Dust guard

protector

(K9471UC)

Probe Protector

(ZO21R)

Detector(ZR22G or ZR202G)

Detector (ZR22G or ZR202G)

Application Application

Boiler

Heating furnace

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

Black liquid recovery boiler

Cement Kiln

High temperature detector

Sample outlet

Absorption

structure

Probe protector for high temperature use ZO21P-H

Sample inlet

Temperature: Probe material SUS310S 800 Probe material SiC 1400 Mounting: Vertical downwards Insertion length: 1.0 m, 1.5 m When duct pressure is atmospheric or negative, attach air ejector. High temperature auxiliary ejector (E7046EC, E7046EN)

Needle valve

Inlet

High temperature detector

˚C

Pressure gauge

Ejector

assy.

Blow

Heating furnace

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Application Example:

Separate and integrated type Zirconia Oxygen Analyzers

• Large, medium and small boilers (boilers for power generation: heavy oil, gas or coal)

•

Various industrial furnaces (reﬁ nery process/iron manufacture heating furnace, coal kiln, and black liquid recovery boilers) For other applications, contact Yokogawa Electric Corporation.

• May not be applicable corrosive gas such as ammonia, chlorine is present-check with YOKOGAWA.

GS 11M12A01-01E 10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

■STANDARD SPECIFICATIONS

(Oxygen Analyzer)

General Speciﬁ cations

Oxygen Analyzer

Measurement Object: Oxygen concentration in

Measurement System: Zirconia system Oxygen Concentration: 0.01 to 100 vol% O Output Signal: 4 to 20 mA DC (maximum load

Measurement Range: Any setting in the range of 0 to

Digital Communication (HART): 250 to 550 ,

Note: HART is a registered trademark of the HART

Display Range: 0 to 100 vol% O Warm-up Time: Approx. 20 min.

Repeatability: (Excluding the case where the

Linearity: (Excluding standard gas tolerance)

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

Response Time: Response of 90% within 5 seconds.

combustion exhaust gas and mixed gas (excluding inﬂ ammable gases). May not be applicable corrosive gas such as ammonia, chlorine is present-check with YOKOGAWA.

resistance 550 )

5 through 0 to 100 vol% O

(in 1 vol% O2),

or partial range

depending on number of ﬁ eld devices connected to the loop (multi-drop mode).

Communication Foundation.

reference air is by natural convection) ± 0.5% Maximum value of set range. (less than 0 to 25 vol% O

range)

± 1% Maximum value of set range. (0 to 25 vol% O 100 vol% O

or more and up to 0 to

range)

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

range

(Sample gas pressure: within ± 4.9 kPa) ± 3% Maximum value of set range.; 0 to 25 vol% O vol% O

or more and less than 0 to 50

range

(Sample gas pressure: within ± 0.49 kPa) ± 5% Maximum value of set range.; 0 to 50 vol% O vol% O

or more and up to 0 to 100

range

(Sample gas pressure: within ± 0.49 kPa)

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

(Measured after gas is introduced from calibration gas inlet and analog output starts changing.)

1. ZR22G Separate type Zirconia Oxygen

Analyzer, Detector

Oxygen Analyzer

Sample Gas Temperature: 0 to 700°C (Probe only)

Sample Gas Pressure: - 5 to + 250 kPa (When the

Note: When the detector is used in conjunction with a

Probe Length: 0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0,

Probe Material: SUS 316 (JIS) Ambient Temperature: -20 to +150°C Reference Air System: Natural Convection,

Instrument Air System (excluding Natural Convection):

Material in Contact with Gas: SUS 316 (JIS),

Construction: Heater and thermocouple replaceable

Terminal Box Case: Material; Aluminium alloy Terminal Box Paint Color: Case; Mint green (Munsell

Finish: Polyurethane corrosion-resistance coating Gas Connection:Rc 1/4 or 1/4 FNPT Wiring Connection: G1/2, Pg13.5, M20 by 1.5 mm,

Installation: Flange mounting

Probe Mounting Angle:

When the probe insertion length is 2.5 or

It is necessary to mount the cell using Inconel cell-bolts when the temperature is greater than 600°C. 700 to 1400°C (with High Temperature Probe Adapter) For high-temperature sample gas, apply 0.15 m length probe and High Temperature Probe Adapter ZO21P-H.

pressure in the furnace exceeds 3 kPa, it is recommended that you compensate the pressure. When the pressure in the furnace exceeds 5 kPa, you must perform pressure compensation.) . For

0.15 m probe, 0.5 to 5 kPa. No pressure ﬂ uctuation in the furnace should be allowed.

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.

3.6, 4.2, 4.8, 5.4 m

Instrument Air, pressure compensated (other than for probe length 0.15 m)

Pressure; 200 kPa + the pressure inside the furnace (It is recommended to use air which has been dehumidiﬁ ed by cooling to dew point -20°C or less, and dust or oil mist removed.) Consumption; Approx. 1 Nl/min

Zirconia, SUS 304 (JIS) (ﬂ ange), Hastelloy B, (Inconel 600, 601)

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 recirculationpressure compensated version.)

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

1/2 NPT

When the probe insertion length is 2 m or less, installing at angles from horizontal to vertical downward is possible.

more, mount vertically downward (within

GS 11M12A01-01E 10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

±5°), and if installing at angles from horizontal to verticalIy downward (within ±5°), use a probe protector.

Weight:

Insertion length of 0.4 m:approx. 6 kg (JIS 5K 65) /

approx. 11 kg (ANSI 150 4)

Insertion length of 1.0 m:approx. 8 kg (JIS 5K 65) /

approx. 13 kg (ANSI 150 4)

Insertion length of 1.5 m:approx. 10 kg (JIS 5K 65) /

approx. 15 kg (ANSI 150 4)

Insertion length of 2.0 m:approx. 12 kg (JIS 5K 65) /

approx. 17 kg (ANSI 150 4)

Insertion length of 3.0 m:approx. 15 kg (JIS 5K 65) /

approx. 20 kg (ANSI 150 4)

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. ZR402G Separate type Zirconia Oxygen Analyzer, Converter

Oxygen Analyzer

Operated using an LCD touchscreen on the converter.

Display: LCD display of size 320 by 240 dot with

Output Signal: 4 to 20 mA DC, two points (maximum

Contact Output Signal: four points (one is fail-safe,

Contact Input: two points Auto-calibration Output: Two points (for dedicated

Ambient Temperature: -20 to +55°C Storage Temperature: -30 to +70°C Humidity Range: 0 to 95% RH (non-condensing) Installation Altitude: 2000 m or less Category based on IEC 1010: II (Note) Pollution degree based on IEC 1010: 2 (Note)

Note: Installation category, called over-voltage

Power Supply Voltage: Ratings; 100 to 240 V AC

Power Supply Frequency: Ratings; 50/60 Hz

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

Safety and EMC conforming standards

Safety: Conforms to EN 61010-1: 1993

EMC: Conforms to EN 61326: 1998

KC mark: KCC-REM-YHQ-EEN103-1-R1

Maximum Distance between Probe and Converter:

touchscreen.

load resistance 550 )

normally open)

auto-calibration unit)

category, speciﬁ es impulse Category II is for 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.

electrical equipment.

withstand voltage.

Acceptable range; 85 to 264 V AC

Acceptable range; 45 to 66 Hz

ordinary use.

CSA C22.2 No.1010-1 certiﬁ ed UL 3111-1 certiﬁ ed

Conductor two-way resistance must be 10 or less (when a 1.25 mm

cable or

equivalent is used, 300 m or less.

Construction: Outdoor installation, equivalent to

NEMA 4X/IP66 (with conduit holes completely sealed with a cable gland)

Wiring Connection: G1/2, Pg13.5, M20 by 1.5 mm,

1/2 NPT (with plug), eight holes Installation: Panel, wall or 2-inch pipe mounting Case: Aluminum alloy Paint Color:Door: Silver gray (Munsell 3.2PB7.4/1.2)

Case: Silver gray (Munsell 3.2PB7.4/1.2) Finish: Polyurethane corrosion-resistance coating Weight: Approx. 6 kg

Functions

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 ﬂ ashing of the corresponding icon. Indicates status such as warming-up, calibrating, or the like by icons.

Alarm, Error Display; Displays alarms such as

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

Calibration Functions:

Auto-Calibration; Requires the Auto-calibration Unit.

It calibrates automatically at speciﬁ ed intervals.

Semi-auto Calibration; Requires the Auto-calibration

Unit. Input calibration direction on the touchscreen or contact, then it calibrates automatically afterwards.

Manual Calibration; Calibration with opening/closing

the valve of calibration gas in operation interactively with an LCD touchscreen.

Blowback Function:

Output through the contact in the

set period and time. Auto/semi-auto

selectable. Maintenance Functions:

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. Setup Functions:

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. Self-diagnosis:

This function diagnoses conditions of the

converter or the probe and indicates when

any abnormal condition occurs. Password Functions:

Enter your password to operate the

analyzer excepting data display. Individual

passwords can be set for maintenance

and setup.

GS 11M12A01-01E 10th Edition Jan.12,2012-02

<<Contents>> <<Index>>

Display and setting content:

Measuring related items: Oxygen concentration

(vol% O

), Output current value (mA),

air ratio, moisture quantity (in hot gases) (vol% H

Display Items: Cell temperature (°C), thermocouple

reference junction temperature (°C), maximum/minimum/average oxygen concentration (vol% O

), cell e.m.f. (mV),

cell internal resistance (), cell condition (in four grades), heater on-time rate (%), calibration record (ten times), time (year/month/day, hour/minute)

Calibration Setting Items: Span gas concentration

(vol% O (vol% O

), zero-gas concentration

), calibration mode (auto,

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

hour/minute) Equipment Related Items: Measuring gas selection Output Related Items: Analog output/output mode

selection, output conditions when

warmingup/ maintenance/calibrating

(during blowback)/abnormal, 4 mA/20

mA point oxygen concentration (vol%

), 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%

), Oxygen concentration low-alarm/

low-low alarm limit values (vol% O

Oxygen concentration alarm hysteresis

(vol% O

), Oxygen concentration alarm

detection, alarm delay (seconds) Contact Related Items: Selection of contact input 1

and 2, selection of contact output 1 to 4

(abnormal, high-high alarm, high-alarm,

low-alarm, low-low alarm, maintenance,

calibrating, range switching, warming-

up, calibration-gas pressure decrease,

temperature high-alarm, blowback,

ﬂ ameout gas detection)

Converter Output:

Two points mA analog output (4 to 20 mA DC (maximum load resistance of 550 )) and one mA digital output point (HART) (minimum load resistance of 250 ).

Range: any setting between 0 to 5 through 0

to 100 vol% O

in 1 vol% O2, or partial

range is available (Maximum range value/minimum range value 1.3 or more) For the log output, the minimum range value is ﬁ xed at 0.1 vol% O

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: Four points, contact capacity 30 V

DC 3 A, 250 V AC 3 A (resistive load) Three 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%O

can be added to high/low alarms. The following functions are programmable for contact outputs.

(1) Abnormal, (2) High-high alarm, (3)

Highalarm, (4) Low-low alarm, (5) Lowalarm, (6) Maintenance, (7) Calibration, (8) Range switching answer-back, (9) Warm-up, (10) Calibration-gas pressure decrease (answerback of contact input), (11) Temperature high-alarm, (12) Blowback start, (13) Flameout gas detection (answerback of contact input), (14) Calibration coefﬁ cient alarm, (15) Startup power stabilization timeout alarm Contact output 4 is set to normally operated, ﬁ xed error status.

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) Blow-back start

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

less

Self-diagnosis: Abnormal cell, abnormal cell

temperature (low/high), abnormal calibration, defective A/ D converter, defective digital circuit

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% O

(0.01 vol% O2 in

smallest units).

Span calibration-gas concentration setting range;

4.5 to 100 vol% O

(0.01 vol% O2 in

smallest units). Use nitrogen-balanced mixed gas containing 0 to10 % scale of oxygen, and 80 to 100 % scale of oxygen for standard zero-gas and standard spangas respectively.

Calibration period; date/time setting:

maximum 255 days

GS 11M12A01-01E 10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

3. ZR202G Integrated type Zirconia Oxygen Analyzer

Oxygen Analyzer

Display: 6-digit LCD Switch: Three optical switches Output Signal: 4 to 20 mA DC, one point (maximum

load resistance 550 )

Digital Communication (HART): 250 to 550 ,

depending on quantity of ﬁ eld devices connected to the loop (multi-drop mode).

Note: HART is a registered trademark of the HART

Communication Foundation.

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

normally open) Contact Input Signal: Two points Sample Gas Temperature: 0 to 700°C

It is necessary to mount the cell using

Inconel cell-bolts when the temperature

measures more than 600°C.

High-temperature service - greater than

700°C - is not available. Sample Gas Pressure: - 5 to + 250 kPa (When the

pressure in the furnace exceeds 3 kPa,

it is recommended that you compensate

the pressure. When the pressure in the

furnace exceeds 5 kPa, you must perform

pressure compensation.)

No pressure ﬂ uctuation in the furnace

should be allowed.

Note: When the detector is used in conjunction with a

Probe Length: 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m Probe Material: SUS 316 (JIS) Ambient Temperature: -20 to +55°C (- 5 to +70°C on

the case surface) Storage Temperature: -30 to +70°C Humidity Range: 0 to 95 %RH (non-condensing) Installation Altitude: 2000 m or less Category based on IEC 1010: II (Note) Pollution degree based on IEC 1010: 2 (Note)

Note: Installation category, called over-voltage category,

speciﬁ es impulse withstand voltage. Category II is for electrical equipment. Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric strength. Degree 2 is the normal indoor environment.

Power Supply Voltage: Ratings; 100 to 240 V AC

Acceptable range; 85 to 264 V AC Power Supply Frequency: Ratings; 50/60 Hz

Acceptable range; 45 to 66 Hz Power Consumption: Max. 300 W, approx. 100 W for

ordinary use. Safety and EMC conforming standards

Safety: Conforms to EN 61010-1: 1993

CSA C22.2 No.1010-1 certiﬁ ed UL 3111-1 certiﬁ ed

EMC: Conforms to EN 61326: 1998

KC mark: KCC-REM-YHQ-EEN103-2-R1

Reference Air System: Natural Convection,

Instrument Air, or Pressure Compensated

Instrument Air System (excluding Natural Convection):

Pressure; 200 kPa + the pressure inside the furnace (It is recommended to use air which is dehumidiﬁ ed to dew point -20°C or less, and dust or oil mist are removed.) Consumption; Approx. 1 Nl/min

Material in Contact with Gas: SUS 316 (JIS),

Zirconia, SUS 304 (JIS) (ﬂ ange), Hastelloy B, (Inconel 600, 601)

Construction: Heater and thermocouple replaceable

construction. Non explosion-proof JIS C0920 / equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculationpressure

compensated version.) Gas Connection:Rc 1/4 or 1/4 FNPT Wiring Connection: G1/2, Pg13.5, M20 by 1.5mm, 1/2

NPT select one type (4 pieces) Installation: Flange mounting Probe Mounting Angle:

Horizontal to vertically downward.

When the probe insertion length is 2 m or

less, installing at angles from horizontal to

vertical downward is available.

When the probe insertion length is 2.5 m

more, mount vertically downward (within

± 5), and if installing at angles from

horizontal to vertically downward (within

± 5), use a probe protector.

When the probe insertion length exceeds

2.5 m, mount vertically downward (within

± 5) and use a probe protector. Case: Aluminum alloy Paint Color:Cover; Mint green (Munsell 5.6BG3.3/2.9) Case: Mint green (Munsell 5.6BG3.3/2.9) Finish: Polyurethane corrosion-resistance coating Weight:

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

approx. 13 kg (ANSI 150 4)

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

approx. 15 kg (ANSI 150 4)

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

approx. 17 kg (ANSI 150 4)

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

approx. 19 kg (ANSI 150 4)

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

approx. 22 kg (ANSI 150 4)

Functions

Display Function: Displays values of the measured

Alarm, Error Display: Displays alarms such as “AL-

Calibration Functions:

Auto-calibration; Requires the Auto-calibration Unit.

Semi-auto Calibration; Requires the Auto-calibration

Manual Calibration; Calibration with opening/closing

oxygen concentration, etc.

06” or errors such as “Err -01” when any

such status occurs.

It calibrates automatically at speciﬁ ed intervals.

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

the valve of calibration gas in operation interactively with the optical switch.

GS 11M12A01-01E

10th Edition Jan.12,2012-02

<<Contents>> <<Index>>

Maintenance Functions:

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

Setup Functions:

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

Display and setting content:

Display Related Items: Oxygen concentration

(vol% O

), Output current value (mA),

air ratio, moisture quantity (in hot gases) (vol% H

O), Cell temperature

(°C ), thermocouple reference junction temperature (°C ), maximum/minimum/ average oxygen concentration (vol% O

), cell e.m.f. (mV), cell internal

resistance (), cell condition (in four grades), heater on-time rate (%), calibration record (ten times), time (year/month/day/hour/minute)

Calibration Setting Items: Span gas concentration

(vol% O (vol% O

), zero-gas concentration

), calibration mode (auto,

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

Output Related Items: Analog output/output mode

selection, output conditions when warming- up/maintenance/calibrating/ abnormal, 4 mA/20 mA point oxygen concentration (vol% O

), time constant,

preset values when warming-up/ maintenance/calibrating/ abnormal, output preset values on abnormal

Alarm Related Items: Oxygen concentration

highalarm/ high-high alarm limit values (vol% O

), Oxygen concentration

lowalarm/ low-low alarm limit values (vol% O alarm hysteresis (vol% O

), Oxygen concentration

), Oxygen

concentration alarm detection, alarm delay (seconds)

Contact Related Items: Selection of contact input

1 and 2, selection of contact output 1 and 2 (abnormal, high-high alarm, high-alarm, low-alarm, low-low alarm, maintenance, calibrating, range switching, warming-up, calibrationgas pressure decrease, ﬂ ameout gas detection (answerback of contact input)

Converter Output: One mA analog output point (4

to 20 mA DC (maximum load resistance of 550 )) with mA digital output point (HART) (minimum load resistance of 250 ).

Range: any setting between 0 to 5 through 0 to

100 vol% O

in 1 vol% O2, and partial

range is available (Maximum range value/ minimum range value 1.3 or more) For the log output, the minimum range value is ﬁ xed at 0.1 vol% O

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

Output damping: 0 to 255 seconds.

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

Contact Output: Two points, contact capacity 30 V

DC 3 A, 250 V AC 3 A (resistive load) One of the output points can be selected to ether normally energized or normally deenergized status. Delayed functions (0 to 255 seconds) and hysteresis function (0 to 9.9 vol% O can be added to high/low-alarms. The following functions are programmable for contact outputs. (1) Abnormal, (2) High-high alarm, (3) High-alarm, (4) Low-low alarm, (5) Lowalarm, (6) Maintenance, (7) Calibration, (8) Range switching answer-back, (9) Warmup, (10) Calibration-gas pressure decrease (answerback of contact input), (11) Flameout gas detection (answerback of contact input).

Contact Input: Two points, voltage-free contacts

The following functions are programmable for contact inputs: (1) Calibration-gas pressure decrease alarm, (2) Range switching (switched range is ﬁ xed), (3) External calibration start, (4) Process alarm (if this signal is received, the heater power turns off)

Self-diagnosis: Abnormal cell, abnormal cell

temperature (low/high), abnormal calibration, A/D converter abnormal, digital circuit abnormal

Calibration:

Method; zero/span calibration Calibration mode; automatic, semiautomatic and

manual (All are operated using optical switches). Either zero or span can be skipped.

Zero-calibration gas concentration setting range;

0.3 to 100 vol% O

(in 0.01 vol% O2).

Span-calibration gas concentration setting range;

4.5 to 100 vol% O

(in 0.01 vol% O2).

Use nitrogen-balanced mixed gas

containing 0 to10 % scale of oxygen for standard zero-gas, and 80 to 100 % scale of oxygen for standard span-gas.

Calibration period; date/time setting:

maximum 255 days

)

GS 11M12A01-01E 10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

■STANDARD SPECIFICATIONS (High

Temperature Humidity Analyzer)

Examples of Application

Separate/Integrated type Zirconia High Temperature Humidity Analyzer

• Coloring processes in the textile industry

• Steam curing processes for concrete products

• Manufacturing processes in the cigarette, food, paper or pulp industries

• Drying processes in various manufacturing of building materials, lumber, plasterboard, food or the like

• Humidifying processes in various manufacturing of food or the like

Please contact us for other applications.

General Speciﬁ cations

High Temperature Humidity Analyzer

Oxygen concentration in mixed gas which consists of water vapor and air is proportional to the volumetric ratio of oxygen in the air, so the volumetric ratio of water vapor can be calculated from the oxygen concentration.

Measurement output: Water vapor (in vol%) in mixed

Measurement System: Zirconia system Measurement Range: 0.01 to 100 vol% O

Output Signal: 4 to 20 mA DC (maximum load

Digital Communication (HART): 250 to 550 ,

Note: HART is a registered trademark of the HART

Display Range: Oxygen concentration 0 to100 vol%

Note: These values are affected by temperature and

Warm-up Time: Approx. 20 min. These characteristics are calculated by oxygen

Repeatability: (see Note1) ± 1 vol% H

Linearity: (Excluding standard gas tolerance)

± 2 vol% H

± 3 vol% H

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

gases (air and water vapor)

,0 to 100

vol% H

O or 0 to 1.000 kg/kg

resistance 550 ) Oxygen concentration; Any setting in the range of 0 to 5 through 0 to 100 vol% O (in 1 vol% O

), or partial range. Moisture

quantity; 0 to 25 through 0 to 100 vol% H

O (in 1 vol% H2O), or partial range.

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

depending on quantity of ﬁ eld devices connected to the loop (multi-drop mode).

Communication Foundation.

, Moisture quantity 0 to 100 vol% H2O

Mixture ratio 0 to 1 kg/kg Relative humidity 0 to 100% RH (Note) Dew point -40 to 370°C (Note)

absolute pressure, So accurate temperature and pressure values must be inputted to the converter.

concentration measured in air which include water vapor.

O (sample gas pressure 2 kPa

or less)

(see Note1), (Use oxygen of known concentration (in the measuring range) as the zero and span calibration gas.)

O; (Sample gas pressure:

within ± 0.49 kPa)

O; (Sample gas pressure:

2 kPa or less)

(see Note1) both zero and span ± 3 vol% H

O/month

Response Time: Response of 90% within 5 seconds.

(Measures after gas is introduced from calibration-gas inlet and analog output start changing.)

(Note1) These tolerances do not apply to the pressure

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

1. ZR22G Separate type Zirconia High Temperature Humidity Analyzer,Detector

High Temperature Humidity Analyzer

Sample Gas Temperature: 0 to 700°C (Probe only)

Sample Gas Pressure: - 5 to + 20 kPa (When the

Probe Length: 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m Probe Material: SUS 316 (JIS) Ambient Temperature: -20 to +150°C Reference Air System: Natural Convection,

Instrument Air System (excluding Natural

Material in Contact with Gas: SUS 316 (JIS),

Construction: Heater and thermocouple replaceable

Terminal Box Case: Material; Aluminium alloy Terminal Box Paint Color: Case; Mint green (Munsell

Gas Connection: Rc 1/4 or 1/4 FNPT Wiring Connection: G1/2, Pg13.5, M20 by 1.5mm, 1/2

Installation: Flange mounting Probe Mounting Angle: Horizontal to vertically

Weight:

Insertion length of 0.4 m: approx. 6 kg (JIS 5K 65) /

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

pressure in the process exceeds 3 kPa, it is recommended that you compensate the pressure. When the pressure in the process exceeds 5 kPa, you must perform pressure compensation.) No pressure ﬂ uctuation in the process should be allowed.

Instrument Air,or pressure compensated

Convection): Pressure; 200 kPa + the pressure inside the furnace, (It is recommended to use air which is dehumidiﬁ ed to dew point - 20°C or less, and dust or oil mist are removed.) Consumption; Approx. 1 Nl/min

Zirconia, SUS 304 (JIS) (ﬂ ange), Hastelloy B, (Inconel 600, 601)

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

NPT

downward. When the probe insertion length is 2 m or less, installing at angles from horizontal to vertically downward is available. When the probe insertion length exceeds

2.5 m, mount vertically downward (within ± 5°) and use a probe protector.

approx. 11 kg (ANSI 150 4)

GS 11M12A01-01E 10th Edition Oct.29,2010-00

<<Contents>> <<Index>>

Insertion length of 1.0 m: approx. 8 kg (JIS 5K 65) /

approx. 13 kg (ANSI 150 4)

Insertion length of 1.5 m: approx. 10 kg (JIS 5K 65) /

approx. 15 kg (ANSI 150 4)

Insertion length of 2.0 m: approx. 12 kg (JIS 5K 65) /

approx. 17 kg (ANSI 150 4)

Insertion length of 3.0 m: approx. 15 kg (JIS 5K 65) /

approx. 20 kg (ANSI 150 4)

2. ZR402G Separate type Zirconia High Temperature Humidity Analyzer, Converter

High Temperature Humidity Analyzer

Operated using an LCD touchscreen on the converter.

Display: LCD display of size 320 by 240 dot with

Output Signal: 4 to 20 mA DC, two points (maximum

Contact Output Signal: four points (one is fail-safe,

Contact Input: two points Analog Input: one point (thermal input 4-20 mA) Auto-calibration Output: Two points (for dedicated

Ambient Temperature: -20 to +55°C Storage Temperature: -30 to +70°C Ambient Humidity : 0 to 95 %RH (non-condensing) Installation Altitude: 2000 m or less Category based on IEC 1010: II (Note) Pollution degree based on IEC 1010: 2 (Note)

Note: Installation category, called over-voltage category,

Power Supply Voltage: Ratings; 100 to 240 V AC

Acceptable range; 85 to 264 V AC

Power Supply Frequency: Ratings; 50/60 Hz

Acceptable range; 45 to 66 Hz

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

Safety and EMC conforming standards

Safety: Conforms to EN 61010-1: 1993

EMC: Conforms to EN 61326: 1998

Maximum Distance between Probe and Converter:

Construction: Outdoor installation, NEMA 4X/IP66 or

Wiring Connection: G1/2, Pg13.5, M20 by 1.5mm, 1/2

, eight holes Installation: Panel, wall or pipe mounting Case: Aluminum alloy Paint Color:Door; Silver gray (Munsell 3.2PB7.4/1.2)

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

touchscreen.

load resistance 550  )

normally open)

autocalibration unit)

ordinary use.

CSA C22.2 No.1010-1 certiﬁ ed UL 3111-1 certiﬁ ed

Conductor two-way resistance must be 10  or less (when a 1.25 mm

cable or

equivalent is used, 300 m or less.)

equivalent (with conduit holes completely sealed with a plastic cable gland optional)

NPT (with plug)

Case; Silver gray (Munsell 3.2PB7.4/1.2)

Functions

Display Functions:

Value Display; Displays values of the measured

Graph Display; Displays trends of measured

Data Display; Displays various useful data for

Status Message; Indicates an alarm or error

Alarm, Error Display: Displays alarms such as

Calibration Functions:

Auto-Calibration; Requires the Auto-calibration Unit.

Semi-auto Calibration; Requires the Auto-calibration

Manual Calibration; Calibration with opening/closing

Blowback Function:

Maintenance Functions:

Setup Functions:

Self-diagnosis:

Password Functions:

Display and setting content:

Measuring Related items: Oxygen concentration

Display Related Items: Oxygen concentration (vol%

Oxygen concentration, moisture quantity,mixture ratio etc

oxygen concentration moisture quantity, mixture ratio etc.

maintenance, such as cell temperature, reference junction temperature, maximum/ minimum moisture quantity, or the like.

occurrence by ﬂ ashing of the corresponding icon. Indicates status such as warming-up, calibrating, or the like by the marks.

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

It calibrates automatically at speciﬁ ed intervals.

Unit. Input calibration direction on the touchscreen or contact, then it calibrates automatically afterwards.

the valve of calibration gas in operation interactively with an LCD touchscreen.

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

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.

(vol% O

), moisture quantity (vol% H2O),

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

), Moisture quantity (vol% H2O),

mixture ratio (kg/kg), relative humidity

GS 11M12A01-01E 10th Edition Oct.29,2010-00

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