YOKOGAWA ZR22S, ZR402G User Manual

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User ’s Manual

Model ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen Analyzer

IM 11M13A01-02E

7th Edition

Introduction

Thank you for purchasing the ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen Analyzer.

Please read the following respective documents before installing and using the ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen Analyzer.

The related documents are as follows.

General Specications

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

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

User’s Manual

Model ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen Analyzer

Model ZR22A, ZR202A Heater Assembly

Model EXAxt ZR Series HART Protocol

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

Contents Document number Note

GS 11M13A01-01E

Contents Document number Note

IM 11M13A01-02E (This manual)

IM 11M12A01-21E

IM 11M12A01-51E

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

manual.

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

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

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

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

IM 11M12A01-04E <Before using the equipment, please read any descriptions in this manual related to the

equipment and system that you have, on appropriate use and operation of the EXAxt ZR.>

Models and descriptions in this manual

Model Product Name

ZR22S General-purpose detector ZR22S High temperature detector

(0.15 m) ZR402G Converter ZO21R Probe protector ZO21P High temperature probe

adapter

Specication Installation Operation

    

   

    

 

  

Description in this manual

Maintenance

CMPL

IM 11M13A01-02E

ZA8F Flow setting unit

(for manual calibration use) ZR40H Automatic Calibration unit

   

- Auxiliary ejector assembly for high temperature use

  

(Part No. E7046EC, E7046EN)

- Calibration gas unit case (Part No. E7044KF)

- Check valve (Part No. K9292DN, K9292DS)

ZO21S Standard gas unit

CMPL : Customer Maintenance Parts List

 

   

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

Table of Contents

Chapter Outline

1. Overview Equipment models and system conguration examples

Installation Operation Maintenance

B C B

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

part number), dimension drawing for each

A B B

equipment

3. Installation Installation method for each equipment A C

4. Piping Examples of piping in two standard system

congurations

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

6. Components and

Their Functions

Major parts and function are described in this manual

A C

C B B

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

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

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

10. Other Functions Other functions described B C

11. Inspection and

Maintenance

How to conduct maintenance of EXAxt ZR and procedures 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 C B

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

Relates to

A C

B C

B A

C A

IM 11M13A01-02E

n ATEX Documentation

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

iii

EST

SLO

IM 11M13A01-02E

n Precautions in Handling Explosion-proof Zirconia Oxygen Analyzer

The explosion-proof zirconia oxygen analyzer (Model ZR22S) are designed as explosion-proof instruments.

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

Use only the supplied, the explosion-proof zirconia oxygen analyzer (Model ZR22S) and

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

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

CAUTION

Only trained persons use this instrument in industrial locations.

Explosion-proof Approval followings:

ZR22S-A (ATEX); Ex db IIB+H

2 T2 Gb, Ex tb IIIC T300°C Db

ZR22S-B (FM); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,

Groups E, F and G, T2

ZR22S-C (CSA); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,

Groups E, F and G, T2

ZR22S-D (IECEx); Ex db IIB+H

2 T2 Gb, Ex tb IIIC T300°C Db

n For the safe use of this equipment

WARNING

EXAxtZR is very heavy. Handle it with care. Do not drop it. Handle safely to avoid injury.

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

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

CAUTION

Requirements for explosion-proof use: The ZR22S is connected to a ZR402G or AV550G* The ambient temperature is in the range -20 to +60°C. The surface temperature of the ZR22S is

not over the temperature class T2 (300°C)*

*1: Refer to IM 11M12D01-01E *2: The terminal box temperature does not exceed 150ºC

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

that is mounted in a non-hazardous area.

IM 11M13A01-02E

NOTE

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 sample gas may damage the sensor.

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

(1) About This Manual

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

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

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

permission.

• This manual explains the functions contained in this product, but does not warrant that those will

suit the particular purpose of the user.

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

nearest Yokogawa Electric representative or sales ofce.

• This manual does not cover the special specications. This manual may not be changed on any change of specication, construction and parts when the change does not affect the functions or

performance of the product.

• If the product is used in a manner not specied in this manual, the safety of this product may be

impaired.

NOTE

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

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

(2) Safety and Modication Precautions

• Follow the safety precautions in this manual when using the product to ensure protection and

safety of personnel, product and system containing the product.

IM 11M13A01-02E

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

WARNING

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

CAUTION

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

NOTE

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

Protective Ground Terminal

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

ground terminal.)

Alternating current

• Special descriptions in this manual

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

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

(Ex. [MODE] key)

(Ex. selection display (Ex. data display

“ BASE “)

“ 102” lit, “ 102” ashing)

• Drawing for ashing

Indicated in light print. (Flashing)

(lit)

IM 11M13A01-02E

n NOTICE

l Specication check

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

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

l Details on operation parameters

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

l Product Disposal:

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

vii

n Trademark Acknowledgments

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

registered trademarks of their respective companies.

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

user’s manual.

IM 11M13A01-02E

u CE marking products

n Authorized Representative in EEA

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

n Identication Tag

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

n Users

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

l How to dispose the batteries:

This is an explanation about the EU Battery Directive. This directive is only valid in the EU. Batteries are included in this product. Batteries incorporated into this product cannot be removed by yourself. Dispose them together with this product.

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

dispose them as domestic household waste.

viii

Battery type: Manganese dioxide lithium battery

Notice:

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

IM 11M13A01-02E

u After-Sales Warranty

l Do not modify the product.

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

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

standard.

l During the warranty period, for repair under warranty carry or send the

product to the local sales representative or service ofce. Yokogawa will

replace or repair any damaged parts and return the product to you.

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

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

• If we replace the product with a new one, we won’t provide you with a repair report.

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

warranty period.

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

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

not supply.

• Failure due to improper or insufcient maintenance by user.

• Failure due to modication, misuse or outside-of-specications operation which Yokogawa

does not authorize.

• Failure due to power supply (voltage, frequency) being outside specications or abnormal.

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

• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,

radiation and other natural changes.

l Yokogawa does not warrant conformance with the specic application at the

user site. Yokogawa will not bear direct/indirect responsibility for damage due to a specic application.

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

into systems or resells the product.

l Maintenance service and supplying repair parts will be covered for ve years

after the production ends. For repair for this product, please contact the

nearest sales ofce described in this instruction manual.

IM 11M13A01-02E

Blank Page

Model ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen Analyzer

IM 11M13A01-02E 7th Edition

CONTENTS

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

u CE marking products ................................................................................viii

u After-Sales Warranty ...................................................................................ix

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

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

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

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

1.2 < EXAxt ZR > System Components ................................................................ 1-3

1.2.1 System Components ......................................................................... 1-3

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

Toc-1

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

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

2.2 Separate type Explosion-proof Detector and Related Equipment .............. 2-3

2.2.1 ZR22S Separate type Explosion-proof Detector ............................... 2-3

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

2.3 Separate type Explosion-proof Detector for High Temperature and Related

Equipment .......................................................................................................... 2-9

2.3.1 ZR22S (0.15 m) Separate type Explosion-proof Detector for High

Temperature ....................................................................................... 2-9

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

2.4 ZR402G Separate type Converter ................................................................. 2-12

2.4.1 Standard Specication ..................................................................... 2-12

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

2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit ................ 2-17

2.5.1 ZA8F Flow Setting Unit .................................................................... 2-17

2.5.2 ZR40H Automatic Calibration Unit ................................................... 2-19

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

2.7 Other Equipments ........................................................................................... 2-22

2.7.1 Ejector Assembly for High Temperature (E7046EC, E7046EN) ..... 2-22

2.7.2 Stop Valve (L9852CB, G7016XH) ................................................... 2-23

2.7.3 Check Valve (K9292DN, K9292DS) ................................................ 2-24

2.7.4 Air Set ............................................................................................... 2-25

2.7.5 Cylinder Pressure Reducing Valve (G7013XF, G7014XF) .............. 2-26

2.7.6 ZR22A Heater Assembly..................................................................2-27

IM 11M13A01-02E

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

3.1 Installation of General-purpose Detector ....................................................... 3-2

3.1.1 Installation Location ........................................................................... 3-2

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

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

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

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

3.1.6 Probe Insertion Hole .......................................................................... 3-7

3.1.7 Installation of the Detector ................................................................. 3-7

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

3.2 Installation of High Temperature Detector (Model ZR22S--015) ............... 3-8

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

3.2.2 Usage of High Temperature Probe Adapter

(Model ZO21P) ..................................................................................3-9

3.2.3 Probe Insertion Hole ........................................................................ 3-10

3.2.4 Mounting of High Temperature Detector .......................................... 3-11

3.3 Installation of ZR402G Converter .................................................................. 3-12

3.3.1 Installation Location ......................................................................... 3-12

3.3.2 Mounting of the Converter ............................................................... 3-12

3.4 Installation of ZA8F Flow Setting Unit .......................................................... 3-14

3.4.1 Installation Location ......................................................................... 3-14

3.4.2 Mounting of ZA8F Flow Setting Unit ................................................ 3-14

3.5 Installation of ZR40H Automatic Calibration Unit ....................................... 3-15

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

3.5.2 Mounting of ZR40H Automatic Calibration Unit ............................... 3-15

3.6 Insulation Resistance Test ............................................................................. 3-17

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

4.1 Piping for a System Using Flow Setting Unit for Manual Calibration ........ 4-2

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 Gas Inlet .................................................... 4-4

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

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

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

4.2 Piping for a System to Perform Automatic Calibration ................................ 4-6

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

4-7

4.2.2 Piping for the Calibration Gases ........................................................ 4-8

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

4.2.4 Piping to the High Temperature Probe Adapter ................................. 4-9

4.2.5 Piping for Blow back........................................................................... 4-9

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

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

IM 11M13A01-02E

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

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

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

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

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

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

5.2.3 Connection to the Converter .............................................................. 5-6

5.3 Wiring for Power to Detector Heater ............................................................... 5-7

5.3.1 Cable Specications .......................................................................... 5-7

5.3.2 Connection to Detector ...................................................................... 5-7

5.3.3 Connection to Converter .................................................................... 5-8

5.4 Wiring for Analog Output ................................................................................. 5-9

5.4.1 Cable Specications .......................................................................... 5-9

5.4.2 Wiring Procedure ............................................................................... 5-9

5.5 Power and Grounding Wiring .......................................................................... 5-9

5.5.1 Power Wiring ...................................................................................... 5-9

5.5.2 Grounding Wiring ............................................................................. 5-10

5.6 Contact Output Wiring .................................................................................... 5-10

5.6.1 Cable Specications ........................................................................5-10

5.6.2 Wiring Procedure ............................................................................. 5-11

5.7 Wiring for ZR40H Automatic Calibration Unit .............................................. 5-11

5.7.1 Cable Specications ........................................................................ 5-11

5.7.2 Wiring Procedure ............................................................................. 5-12

5.8 Contact Input Wiring ....................................................................................... 5-12

5.8.1 Cable Specications ........................................................................5-12

5.8.2 Wiring Procedure ............................................................................. 5-12

6. Components and Their Functions .......................................................... 6-1

6.1 ZR22S Detector ................................................................................................. 6-1

6.1.1 General-purpose Explosion-proof Detector (except for ZR22S--015) 6-1

6.1.2 High Temperature Detector (ZR22S--015) ..................................... 6-2

6.2 ZR402G Converter ............................................................................................ 6-3

6.3 Touchpanel Switch Operations ....................................................................... 6-4

6.3.1 Basic Panel and Switch ..................................................................... 6-4

6.3.2 Display Conguration (for Oxygen Analyzer) ....................................6-5

6.3.3 Display Functions ............................................................................... 6-6

6.3.4 Entering Numeric and Text Data ........................................................ 6-6

6.4 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit ........................ 6-8

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

7.1 Startup Procedure ............................................................................................. 7-1

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

7.3 Checking Valve Setup ....................................................................................... 7-2

IM 11M13A01-02E

Toc-4

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

7.5 Conrmation of Converter Type Setting ........................................................7-3

7.6 Conrmation of Detector Type Setting ........................................................... 7-4

7.7 Selection of Sample Gas .................................................................................. 7-4

7.8 Output Range Setting ....................................................................................... 7-4

7.9 Setting Display Item .......................................................................................... 7-5

7.10 Checking Current Loop .................................................................................... 7-6

7.11 Checking Contact I/O ........................................................................................ 7-7

7.11.1 Checking Contact Outputs ................................................................. 7-7

7.11.2 Checking Calibration Contact Outputs .............................................. 7-8

7.11.3 Checking Contact Inputs .................................................................... 7-8

7.12 Calibration ......................................................................................................... 7-9

7.12.1 Calibration Setup ............................................................................... 7-9

7.12.2 Manual Calibration ........................................................................... 7-10

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

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

8.1.1 Setting Minimum Current (4 mA) and Maximum Current (20 mA) .... 8-1

8.1.2 Input Ranges ...................................................................................... 8-1

8.1.3 Setting Output Smoothing Coefcient ...............................................8-2

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

8.1.5 Default Values .................................................................................... 8-2

8.2 Output Hold Setting .......................................................................................... 8-3

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

8.2.2 Preference Order of Output Hold Value ............................................. 8-4

8.2.3 Output Hold Procedure ...................................................................... 8-4

8.2.4 Default Values .................................................................................... 8-5

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

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

8.3.2 Alarm Output Actions ......................................................................... 8-6

8.3.3 Alarm Setting Procedure .................................................................... 8-7

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

8.4 Contact Output Setting ..................................................................................... 8-8

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

8.4.2 Setting Procedure .............................................................................. 8-9

8.4.3 Default Values .................................................................................. 8-11

8.5 Contact Input Setting ...................................................................................... 8-12

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

8.5.2 Setting Procedure ............................................................................ 8-13

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

8.6 Other Settings ................................................................................................. 8-14

8.6.1 Setting the Date-and-Time ............................................................... 8-14

IM 11M13A01-02E

Toc-5

8.6.2 Setting Periods over which Average Values Are Calculated and Periods

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

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

8.6.4 Setting Purging ................................................................................ 8-20

8.6.5 Setting Passwords ........................................................................... 8-21

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

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

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

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

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

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

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

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

9.2.2 Default Values .................................................................................... 9-8

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

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

10.1 Detailed-data 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’s Internal Resistance ................................................................10-2

10.1.5 Software Revision ............................................................................ 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 Temperature .............................................................................. 10-3

10.1.10 C. J. Temperature............................................................................. 10-4

10.1.11 Maximum Oxygen Concentration .................................................... 10-4

10.1.12 Minimum Oxygen Concentration ..................................................... 10-4

10.1.13 Average Oxygen Concentration ......................................................10-4

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

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

10.1.16 History of Calibration Time ............................................................... 10-4

10.1.17 Power Supply Voltage ......................................................................10-4

10.1.18 Power Frequency .............................................................................10-4

10.2 Trend Graph ..................................................................................................... 10-5

10.2.1 Setting Display Items ....................................................................... 10-5

10.2.2 Sampling Interval ............................................................................. 10-5

10.2.3 Setting Upper and Lower Limit Values on Graph ............................10-6

10.2.4 Default Setting.................................................................................. 10-6

10.3 Other Display-related Functions ................................................................... 10-7

10.3.1 Auto-Return Time .............................................................................10-7

IM 11M13A01-02E

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10.3.2 Entering Tag Name ..........................................................................10-7

10.3.3 Language Selection ......................................................................... 10-7

10.4 Blow Back ........................................................................................................ 10-8

10.4.1 Mode of Blow back ...........................................................................10-8

10.4.2 Operation of Blow back .................................................................... 10-8

10.4.3 Setting Output Hold Time and Blow back Time ............................... 10-9

10.4.4 Setting Interval, Start Date, and Start Time .....................................10-9

10.4.5 Default Setting................................................................................10-10

10.5 Parameter Initialization ................................................................................. 10-10

10.6 Reset ...............................................................................................................10-13

10.7 Handling of the ZO21S Standard Gas Unit ................................................. 10-14

10.7.1 Standard Gas Unit Component Identication ................................ 10-14

10.7.2 Installing Gas Cylinders ................................................................. 10-15

10.7.3 Calibration Gas Flow ......................................................................10-15

10.8 Methods of Operating Valves in the ZA8F Flow Setting Unit ...................10-18

10.8.1 Preparation Before Calibration ......................................................10-18

10.8.2 Operating the Span Gas Flow Setting Valve .................................10-18

10.8.3 Operating the Zero Gas Flow Setting Valve ..................................10-18

10.8.4 Operation After Calibration ............................................................10-19

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

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

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

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

11.1.3 Replacement of the Heater Unit (Assembly) ................................... 11-5

11.1.4 Replacement of Flame Arrestor Assembly ...................................... 11-8

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

11.1.6 Cleaning the High Temperature Probe Adapter ............................... 11-9

11.1.7 Stopping and Re-starting Operation ................................................ 11-9

11.2 Inspection and Maintenance of the Converter .......................................... 11-10

11.2.1 Replacing Fuses ............................................................................ 11-10

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

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

11.3 Replacing Flowmeter in ZR40H Automatic Calibration Unit .................... 11-12

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

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

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

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

12.2 Displays and Remedies When Alarms are Generated ................................ 12-5

12.2.1 Alarm Types ..................................................................................... 12-5

12.2.2 Remedies When Alarms are Generated ..........................................12-6

12.3 Countermeasures When Measured Value Shows Error ........................... 12-11

12.3.1 Measured Value Higher Than True Value ...................................... 12-11

IM 11M13A01-02E

Toc-7

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

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

Customer Maintenance Parts List .....................................CMPL 11M13A01-02E

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

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

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

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

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

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

IM 11M13A01-02E

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<1. Overview>

1. Overview

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

ZR22S Separate type Explosion-proof Detector uses a high-reliability Zirconia sensor, and its heater assembly can be replaced on site. The detector is mounted, for example, on the wall of a

ue and can measure the gases directly.

For use in combustion gases at temperatures up to 1400°C, choose the general-purpose 0.15 m long detector, which is combined with ZO21P, the high temperature probe protector. The converter is equipped with an LCD touch screen which has various setting displays, a calibration display, oxygen concentration trend display, with easier operation and improvement of display functions. The converter is equipped with various standard functions such as measurement and calculation as well as maintenance functions including self-test. Analyzer calibration can also be fully automated ─ and ZR40H, an automatic calibration unit, is available. Choose the detector version which best suits your needs so that an optimal combustion control system can be obtained.

2, SOx and NOx.

1-1

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

1.1 < EXAxt ZR > System Conguration

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

1.1.1 System 1

This system is for monitoring and controlling oxygen concentration in the combustion gases of a large-size boiler or heating furnace. Clean (dry) air (21%O

the span gas for calibration. Zero gas is fed in from a cylinder during calibration. The gas ow is controlled by the ZA8F ow setting unit (for manual valve operation).

Hazardous Area

ZR22S Separate type Explosion-proof

Zirconia Oxygen Analyzer, Detector

Stop valve

Check valve

Reference gas

Flowmeter

Calibration gas

Needle

valve

Air Set

Instrument air Span gas (*)

2) is used as the reference gas and

Non-hazardous Area

ZR402G Converter

EXA

ZR402G

100 to 240 V AC

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

Flow Setting Unit

* Calibration gas unit same as for zero gas.

Figure 1.1 System conguration 1

ZA8F

Pressure reducing

valve

Calibration gas unit case

Zero gas

cylinder

F01-1E.ai

IM 11M13A01-02E

<1. Overview>

1.1.2 System 2

This example, System 2, represents typical applications in large boilers and heating furnaces, where there is a need to monitor and control oxygen concentration. The reference gas and calibration-time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder.

System 2 uses the ZR40H automatic calibration unit, with auto-switching of the calibration gas. A “combustible gas detected” contact input turns off power to the heater. There’s also contact output from the converter that can be used to operate a purge gas valve to supply air to the sensor.

1-2

Hazardous Area

ZR22S Separate type Explosion-proof

Zirconia Oxygen Analyzer, Detector

Check valve

Signal (6-core shield cable)

Heater (2-core cable)

Reference gas

Calibration gas

Non-hazardous Area

ZR402G Converter

Flowmeter

Needle

valve

ZR40H

Automatic Calibration Unit

EXA

ZR402G

Air Set

Pressure regulating

valve

Calibration gas unit case

*1: Shield cable;Use shielded signal cables, and connect the shield to the FG terminal of the converter. *2: When a zirconia oxygen analyzer is used, 100% N

Use approximately 1% of O

gas (N2-based).

gas cannot be used as the zero gas.

Figure 1.2 System conguration 2

100 to 240 V AC

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

Instrument air

Zero gas cylinder

F01-2E.ai

IM 11M13A01-02E

<1. Overview>

Detector (ZR22S)

F01-3E.ai

High temperature High temperature probe adapter ZO21P

F01-5E.ai

Sample

Pressure gauge

Inlet

F01-6E.ai

Detector

)

Probe Protector

Gas Flow

F01-4E.ai

1.2 < EXAxt ZR > System Components

1.2.1 System Components

System Components

ZR22S Separate type Explosion-proof Zirconia Oxygen Analyzers, Detector ZR402G Separate type Zirconia Oxygen Analyzer, Converter ZO21P High Temperature Probe Adapter for separate type Zirconia Oxygen Analyzer E7046EC, E7046EN Ejector Assembly for High Temperature ZO21R Probe Protector for Zirconia Oxygen Analyzers ZO21S Standard Gas Unit ZA8F Flow Setting Unit for manual calibration ZR40H Automatic Calibration Unit for Separate type Analyzer L9852CB, G7016XH Stop Valve for Calibration gas line ( ) K9292DN, K9292DS Check Valve for Calibration gas line ( G7003XF/K9473XK, G7004XF/K9473XG Air Set G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder ZR22A, Heater Assembly (Spare Parts for ZR22S)

: Items required for the above system example

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

(

) : Select either

System conguration

System 1 System 2

1-3

Separate type

)

1.2.2 Detectors and Accessories

Sample gas temperature 0 to 700°C Sample gas temperature 700 to 1400°C

Mounting

Horizontal

vertical

Insertion

length

2 m

or less

General-purpose detector Application High temperature detector Application

Boiler Heating furnace

For

(ZO21R)

(ZR22S

pulverized coal boiler with gas

Sample inlet

ow velocity 10 m/sec or more

outlet

Absorption

structure

detector

Sample inlet

Probe material and Temperature: SUS310S; 800

°C, SiC; 1400°C

Mounting: Vertical downwards Insertion length: 0.5, 0.6, 0.7, 0.8,

0.9, 1.0, 1.5 m When duct pressure is atmospheric or negative, attach ejector assembly.

Ejector assembly for high temperature (E7046EC, E7046EN)

Needle valve

Ejector

Heating furnace

Blow

IM 11M13A01-02E

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  <2.Specications>

2. Specications

This chapter describes the specications for the following:

ZR22S Separate type explosion-proof detector (See Subsection 2.2.1) ZO21R Probe protector (See Subsection 2.2.2) ZR22S (0.15 m) Separate type explosion-proof detector for high temperature

(See Subsection 2.3.1) ZO21P High temperature probe adapter (See Subsection 2.3.2) ZR402G Separate type converter (See Section 2.4) ZA8F Flow setting unit (See Subsection 2.5.1) ZR40H Automatic calibration unit (See Subsection 2.5.2) ZO21S Standard gas unit (See Section 2.6) Other Equipments (See Section 2.7)

CAUTION

Requirements for explosion-proof use:

2-1

The ZR22S is connected to a ZR402G or AV550G*1 that is mounted in a non-hazardous area. The ambient temperature is in the range -20 to + 60°C. The surface temperature of the ZR22S is not over the temperature class T2 (300°C)*2.

*1: Refer to IM 11M12D01-01E *2: The terminal box temperature does not exceed 150°C.

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

2.1 General Specications

Standard Specications

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

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

as ammonia and chlorine is present — Contact with YOKOGAWA and

its agency.) Measurement System: Zirconia system Measurement range: 0.01 to 100 vol%O

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

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

or partial range

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

to the loop (multi-drop mode).

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

(in 1 vol%O2),

Display Range: 0 to 100 vol%O Warm-up Time: Approx. 20 min. Repeatability: ±0.5% Maximum value of set range; Range from 0 to 5 vol%O

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

and less than 0 to 25 vol%O

and up to 0 to 100 vol%O

or more

IM 11M13A01-02E

  <2.Specications>

Linearity: (Excluding standard gas tolerance)

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

25 vol%O

(Sample gas pressure: within ±4.9 kPa)

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

and less than 0 to 50 vol%O

. (Sample gas pressure: within

±0.49 kPa)

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

100vol%O

. (Sample gas pressure: within ±0.49 kPa)

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

Both zero and span ±2% Maximum value of range setting/month

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

from calibration gas inlet and analog output starts changing.)

Safety, EMC, and RoHS conformity standards of ZR22S and ZR402G Installation altitude based on IEC 61010: 2000 m or less Category based on IEC 61010: II (Note) Pollution degree based on IEC 61010: 2 (Note)

Not Installation category, called over-voltage category, species impulse withstand voltage. Category II is for electrical

equipment. Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric strength. Degree 2 is the normal indoor environment.

to 0 to

or more

to 0 to

2-2

Safety: Conforms to EN 61010-1, EN61010-2-030,

CAN/CSA-C22.2 No. 61010.1 certied, UL Std. No. 61010-1 certied

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

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

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

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

Korea Electromagnetic Conformity Standard

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

use this instrument in the industrial environment only.

RoHS: EN 50581

IM 11M13A01-02E

  <2.Specications>

2-3

2.2 Separate type Explosion-proof Detector and Related Equipment

Separate type Explosion-proof detector ZR22S can be used in combination with the probe protector ZO21R (see Subsection 2.2.2).

2.2.1 ZR22S Separate type Explosion-proof Detector

Flameproof Type

ATEX Flameproof: ZR22S-A

Applicable Standard:

EN 60079-0: 2012+A11: 2013, EN 60079-1: 2014 EN 60079-31: 2014

Certicate Number: KEMA 04ATEX2156 X

Type of protection: Ex db IIB+H Equipment Group: II

Category: 2GD Temperature class for Ex “db”: T2 The maximum surface temperature for Ex “tb”: T300°C Degree of protection of enclosure: IP66

2 T2 Gb, Ex tb IIIC T300°C Db

NAME PLATE

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

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

The country of origin

*1: The third to seventh figure from the last shows the year of production. e.g. 27D327560 2005.02

*2: "180-8750" is a zip code which represents the following address. 2-9-32 Nakacho, Musashino-shi, Tokyo Japan

The year of production

F02-1.1E.ai

IM 11M13A01-02E

  <2.Specications>

FM Explosion-proof: ZR22S-B

Applicable Standard: FM3600 1998, FM3615 1989, FM3810 2005,

ANSI/NEMA 250 1991

2-4

Type of protection: Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G Enclosure Rating: NEMA 4X Temperature Class: T2

CSA Explosion-proof: ZR22S-C

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

C22.2 No.0.5-1982, C22.2 No.25-1966, C22.2 No.30-M1986, C22.2 No.94-M91, C22.2-No.61010-1-04

Certicate Number: 1649642

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

IECEx Flameproof: ZR22S-D

Applicable Standard:

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

Certicate Number: IECEx KEM 06.0006X

Type of protection: Ex db IIB+H

Explosion-proof for Class I, Division 1, Groups B, C and D

2 T2 Gb, Ex tb IIIC T300°C Db

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

NAME PLATE

No. IECEx KEM 06.0006X Ex db IIB+H Ex tb IIIC T300°C Db

2 T2 Gb,

The country of origin.

*1: The third to seventh figure from the last shows the year of production. e.g. 27D327560 2005.02

*2: "180-8750" is a zip code which represents the following address. 2-9-32 Nakacho, Musashino-shi, Tokyo Japan

F02-2E.ai

IM 11M13A01-02E

  <2.Specications>

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

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

Sample Gas Pressure: -5 to +5 kPa

For 0.15 m probe, -0.5 to +5 kPa.

No pressure uctuation in the furnace should be allowed.

Oxygen concentration of sample gas:

For explosion-proof use, not more than that found in normal air, typically 21 vol% Probe Length: 0.15, 0.4, 0.7, 1.0, 1.5, 2.0 m Probe Material: 316 SS (JIS) Ambient Temperature: -20 to +60°C (-20 to +150°C on the terminal box surface) Reference Gas System: Instrument Air Instrument Air System:

Pressure; 50 kPa + the pressure inside the furnace

(It is recommended to use air which has been dehumidied by cooling to

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

Consumption; Approx. 1 NL/min

Oxygen concentration of calibration gas:

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

Wetted Material: 316L SS (JIS), Zirconia, 304 SS (JIS) or ASTM grade 304 (ange),

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

Equivalent to NEMA 4X/IP66 (Achieved when pipes are installed at

calibration gas and reference gas inlets and pipe is installed so that

reference gas can be exhausted to clean atmosphere. Excluding probe

top. And achieved when the cable entry is completely sealed with a cable gland.) Terminal Box Case: Material; Aluminum alloy Terminal Box Paint Color: Case; Mint green (Munsell 5.6BG3.3/2.9)

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

Finish: Polyurethane corrosion-resistant coating Gas Connection: Rc1/4 or 1/4 FNPT

Wiring Connection:

ATEX; M20 by 1.5 mm or 1/2 NPT select one type (2 pieces) FM; 1/2 NPT (2 pieces) CSA; 1/2 NPT (2 pieces) IECEx; M20 by 1.5 mm or 1/2 NPT select one type (2 pieces)

Installation: Flange mounting Probe Mounting Angle: Horizontal to vertically downward. Weight: Insertion length of 0.4 m: Approx. 13kg (ANSI 150 4)

Insertion length of 0.7 m: Approx. 14 kg (ANSI 150 4)

Insertion length of 1.0 m: Approx. 15 kg (ANSI 150 4)

Insertion length of 1.5 m: Approx. 17 kg (ANSI 150 4)

Insertion length of 2.0 m: Approx. 19 kg (ANSI 150 4) Available Converter: ZR402G, AV550G

2-5

CAUTION

The ZR22S must be used in conjunction with a ZR402G or AV550G. If used with a converter other than a ZR402G or AV550G, the ZR22S does not operate as an explosion-proof equipment.

IM 11M13A01-02E

  <2.Specications>

Model and Codes

Model Sufx code Option code Description

ZR22S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Separate type Explosion-proof Zirconia Oxygen Analyzer, Detector

Explosion-proof Approval (*12)-A-B

Length -015

Wetted material -S

Flange (*2)

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

Connection box thread -M

Instruction manual -E - - - - - - - - - - - English ─ -A - - - - - - - - - - - Always -A Options

-C

-D

-Q

-R

-040

-070

-100

-150

-200

-C

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-Q

-R

-S

-W

-T

Tag plates

*1 Used with the ZO21P High Temperature Probe Adapter. Select ange (-Q). *2 The thickness of the ange depends on its dimensions*3 The thickness of the ange depends on its dimensions. *3 The ange thickness does not conform to JIS specication.

*4 Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to 700ºC). *5 Specify either /CV or /SV option code. *6 Specify either /SCT or /PT option code. *7 Recommended if sample gas contains corrosive gas like chlorine.

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

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

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

*12 When using ZR22S as CE marking compliance product, select -A (ATEX certied ameploof). *13 “-Q” is the explosion-proof type of EAC with Pattern Approval for Russia. “-R” is the explosion-proof type of EAC for Kazakhstan

and Belarus.

Valves

- - - - - - - - - - -

/C /CV /SV /SCT /PT

ATEX certied ameproof (*11) FM certied explosion-proof CSA certied explosion-proof IECEx certied ameproof (*11) EAC with PA certied explosion-proof (*13) EAC certied explosion-proof (*13)

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

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m Stainless steel

Stainless steel with Inconel calibration gas tube (*7) ANSI Class 150 2 RF (*10)

ANSI Class 150 3 RF ANSI Class 150 4 RF (*10) DIN PN10 DN50 A DIN PN10 DN80 A DIN PN10 DN100 A JIS 5K 65 FF JIS 10K 65 FF JIS 10K 80 FF JIS 10K 100 FF JIS 5K 32 FF (for high temperature use) (*3) JPI Class 150 4 RF JPI Class 150 3 RF Westinghouse

Rc1/4 1/4 NPT (Female)

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

Inconel bolt (*4) Check valve (*5) Stop valve (*5) Stainless steel tag plate (*6) Printed tag plate (*6)

2-6

Standard Accessory

Item Parts No. Q'ty Description

Allen wrench L9827AB 1 For lock screw

IM 11M13A01-02E

  <2.Specications>

F02-3E.ai

Unit : mm

External Dimensions

ZR22S Separate type Explosion-proof Zirconia Oxygen Analyzer, Detectors

±3 ±3

311

2-7

±3

50.8 Ø

±3

87 Ø

±3

L (m)

tolerance (mm)

0.15

0.4

0.7

1.0

1.5

2.0

±4 ±5 ±7

±8 ±10 ±12

±3

156 95 ±3

±2

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

2-M20 × 1.5 or 2-1/2 NPT (F) Cable connection port

±3

124 Ø

Flange

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

±3

48 Rc1/4 or 1/4 NPT (F) Reference gas outlet

Flange

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

A B n

152.4

120.6

190.5

152.4

228.6

190.5

165

125

200

160

220

180

155

130

175

140

185

150

210

175 115 229 190 155

190.5

152.4 127

n-ØC

19 19 19 18 18 18 15 19 19 19 15 19 19

11.5

19 24 24 18 20 20 14 18 18 18

24 24 14

FLANGE

4 8 4 8 8 4 4 8 8 4 8 4 4

IM 11M13A01-02E

  <2.Specications>

2.2.2 ZO21R Probe Protector

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

detector from wearing by dust particles. Insertion Length: 1.05, 1.55, 2.05 m. Flange: JIS 5K 65A FF equivalent. ANSI Class 150 4 FF (without serration)

equivalent. However, ange thickness is different.

Material: 316 SS (JIS), 304 SS (JIS) or ASTM grade 304 (Flange) Weight: 1.05 m; Approx. 6/10 kg (JIS/ANSI),

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

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

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

process-side ange.

Model and Codes

2-8

Model Sufx code

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

Insertion length

Flange ( *1) -J

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

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

-100

-150

-200

-A

Option code

- - - - - - - - - -

1.05 m (3.5 ft)

1.55 m (5.1 ft)

2.05 m (6.8 ft) JIS 5K 65 FF

ANSI Class 150 4 FF

External Dimension

Washer (M12)

Gas flow

l (Insert length)

l=1050,1550,2050

Mounting nut (M12)

316 SS (JIS)

Ø60.5

Description

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

Gasket (Thickness 3.0)

ØA

ØB

Unit: mm

Dimensions of holes on opposing surface

Flange<1> A B C t D

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

F02-4E.ai

IM 11M13A01-02E

  <2.Specications>

2-9

2.3 Separate type Explosion-proof Detector for High Temperature and Related Equipment

2.3.1 ZR22S (0.15 m) Separate type Explosion-proof

Detector for High Temperature

Standard Specications

Construction: Water-resistant Probe length: 0.15 m Terminal box: Aluminum alloy Probe material: Probe material in contact with gas: 316 SS (JIS), 316L SS (JIS) (Probe),

304 SS (JIS) or ASTM grade 304 (Flange), Zirconia (Sensor),

Hastelloy B, (Inconel 600, 601) Weight: Approx. 6 kg Installation: Flange mounting (When using high temperature detector, high

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

probe is tted with an adapter)

Reference gas and calibration gas piping connection: Rc1/4 or 1/4 NPT female Ambient temperature: -20 to +60°C (-20 to +150°C on the case surface) Sample gas temperature: 0 to 700°C (temperature at the measuring point of the sampling gas.)

When sample gas is 700°C to 1400°C, the high temperature probe adapter is used.

Temperature of the high temperature probe adapter shall not exceed 300°C to protect the gasket and avoid the bolts seizing together.

Sample gas pressure: -0.5 to +5 kPa. When using in the range of 0 to 25 vol%O

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 assembly is necessary.)

Refer to Subsection 2.2.1. for the explosion-proof and other specications.

Model and Code

Refer to “Model and Codes” in page 2-6.

External Dimensions

Refer to the Figure in page 2-7.

2 or more,

IM 11M13A01-02E

  <2.Specications>

2.3.2 ZO21P High Temperature Probe Adapter

Measuring O2 in the high temperature gases (exceeds 700°C) requires a explosion-proof detector ZR22S of 0.15 m length and a high temperature probe adapter.

Sample gas temperature:

0 to 1400°C (when using SiC probe)

0 to 800°C (when using 310S SS probe)

2-10

Sample gas pressure: -0.5 to +5 kPa. When using in the range of 0 to 25 vol%O

2 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 assembly is necessary.) Insertion length: 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5 m Material in Contact with Gas: 316 SS (JIS), SiC or 310S SS,

304 SS (JIS) or ASTM grade 304 (ange)

Probe Material: SiC, 310S SS (JIS) Installation: Flange mounting (FF type or RF type) Probe Mounting Angle: Vertically downward within ± 5°. Where the probe material is 310S SS,

horizontal mounting is available. Construction: Non-explosion-proof. Rainproof construction Weight(example): Insertion length of 1.0 m: approx. 5.3 kg (JIS) / approx. 11.3 kg (ANSI)

Insertion length of 1.5 m: approx. 5.8 kg (JIS) / approx. 11.8 kg (ANSI)

Model and Codes

Model Sufx code Option code Description

ZO21P -H - - - - - - - High Temperature Probe Adapter

Material -A

Insertion length

Flange -J

Style code *B - - - - - - - Style B Option /EJ1

Note:The Insertion length 0.15 m of the ZR22S should be specied.

-B

-050

-060

-070

-080

-090

-100

-150

-N

-M

-L

-A

-R

-Q

-T

-S

-E

- - - - - - -

/EJ2 /SCT

- - - - - -

SiC SUS310S

0.5 m

0.6 m

0.7 m

0.8 m

0.9 m

1.0 m

1.5 m

JIS 5K 50 FF JIS 10K 65 FF JIS 10K 80 FF JIS 10K 100 FF ANSI Class 150 4 RF ANSI Class 150 2 1/2 RF ANSI Class 150 3 RF JPI Class 150 3 RF JPI Class 150 4 RF DIN PN10 DN50 A

Ejector Assy with E7046EC Ejector Assy with E7046EN Stainless steel tag plate

IM 11M13A01-02E

  <2.Specications>

F02-5E.ai

Unit: mm

External Dimension

Approx. 351

2-11

Sample gas outlet

Rc1/2(Note2)

170

Approx. 215

Approx. 100

(Insertion length) (Note1)

Ø60.5

Approx. 48

Ø30

ØA

ØB

ØA

Ø52 over

High temperature Probe SiC pipe

180

Ø115

Ø60.5

Flange <1>

Flange provided by customer

(Note 1) L = 0.5、0.6、0.7、0.8、0.9、1.0、1.5 (m) (Note 2) Sample gas outlet (if the sample gas pressure is negative, connect the ejector assembly.)

Flange (Thickness 5) JIS 5K 32 FF equivalent

Gasket (Thickness 1.5)

110

95±3

25±3

Calibration gas inlet Rc1/4 or 1/4 NPT

Ø124±3

85±3

Detector (ZR22S)

Reference gas inlet Rc1/4 or 1/4 NPT

48±3

Pipe hole (2- M20, 2-1/2 NPT)

<1> Flange A B C t

JIS 5K 50 FF 130 105 4 - Ø15 14 JIS 10K 65 FF 175 140 4 - Ø19 18 JIS 10K 80 FF 185 150 8 - Ø19 18 JIS 10K 100 FF 210 175 8 - Ø19 18 ANSI Class 150 2 1/2 RF 177.8 139.7 4 - Ø19 22.4 ANSI Class 150 3 RF 190.5 152.4 4 - Ø19 24 ANSI Class 150 4 RF 228.5 190.5 8 - Ø19 24 JPI Class 150 3 RF 190 152.4 4 - Ø19 24 JPI Class 150 4 RF 229 190.5 8 - Ø19 24 DIN PN10 DN50 A 165 126 4 - Ø18 18

IM 11M13A01-02E

  <2.Specications>

2.4 ZR402G Separate type Converter

CAUTION

Converter (Model ZR402G) must not be located in hazardous area.

2.4.1 Standard Specication

The ZR402G Separate type Converter can be controlled by LCD touchscreen on the converter.

Display: LCD display of size 320 by 240 dot with touchscreen.

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

Contact Output Signal: Four points (one is fail-safe, normally open) Contact Input: Two points Auto-calibration Output: Two points (for dedicated automatic calibration unit) Ambient Temperature: -20 to +55°C

2-12

Storage Temperature: -30 to +70°C Ambient Humidity: 0 to 95%RH (Non-condensing) Power Supply Voltage: Ratings; 100 to 240 V AC, Acceptable range; 85 to 264 V AC Power Supply Frequency: Ratings; 50/60 Hz, Acceptable range; 45 to 66 Hz Power Consumption: Max. 300 W, approx. 100 W for ordinary use. Maximum Distance between Detector and Converter:

Conductor two-way resistance must be

10 Ω or less (when a 1.25 mm

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

cable or equivalent is used, 300 m or

IM 11M13A01-02E

  <2.Specications>

2.4.2 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 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:

Automatic calibration; Requires the ZR40H Automatic Calibration Unit. It calibrates

automatically at specied intervals.

Semi-auto Calibration; Requires the Automatic 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.

2-13

Blow back 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, blow back data settings, current output loop check, contact input/output 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 detector 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.

IM 11M13A01-02E

  <2.Specications>

Display and setting content:

2-14

Measuring Related Items: Oxygen concentration (vol%O

moisture quantity (in hot gases) (vol% H

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

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 (Ω), cell condition (in four grades),

heater on-time rate (%), calibration record (ten times), time (year/month/

day, hour/minute) Calibration Setting Items: Span gas concentration (vol%O

), zero gas concentration (vol%O2),

calibration mode (automatic, semi-automatic, manual), calibration type

and method (zero-span calibration, zero calibration only, span calibration

only), stabilization time (min.sec), calibration time (min.sec), calibration

interval (day/hour), starting time (year/month/day, hour/minute) Equipment Related Items: Sample (Measuring) gas selection Output Related Items: Analog output/output mode selection, output conditions when warming-

up/maintenance/calibrating (during blow back)/abnormal, 4 mA/20 mA

point oxygen concentration (vol%O

), time constant.

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

oxygen concentration low alarm/low-low alarm limit values (vol%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, blow back, ameout gas

detection, calibration coefcient (correction ratio) alarm, stabilization

timeout)

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

of 550 Ω)) and one mA digital output point (HART) (minimum load

resistance of 250 Ω).

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

in 1 vol%O2, or

partial range is available (Maximum range value/minimum range

value 1.3 or more).For the log output, the minimum range value is xed

at 0.1 vol%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 de-energized status.

Delayed functions (0 to 255 seconds) and hysteresis function (0 to 9.9

vol%O

) can be added to high/low alarms.

The following functions are programmable for contact outputs.

(1) Abnormal, (2) High-high alarm, (3) High alarm, (4) Low-low alarm,

(5) Low alarm, (6) Maintenance, (7) Calibration, (8) Range switching

answer-back, (9) Warm-up, (10) Calibration gas pressure decrease

(answer-back of contact input), (11) Temperature high alarm,

(12) Blow back start, (13) Flameout gas detection (answer-back of

contact input), (14) Calibration coefcient (correction ratio) alarm,

(15) Startup power stabilization timeout alarm

Contact output 4 is set to normally operated, and xed error status.

IM 11M13A01-02E

  <2.Specications>

Contact Input: Two points (voltage-free)

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%O2 (in increments of

0.01 vol%O

2 in smallest units).

2-15

Span calibration gas concentration setting range: 4.5 to 100 vol%O

0.01 vol%O

2 in smallest units).

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

oxygen, and 80 to 100 vol%O

scale of oxygen for standard zero gas

and standard span gas respectively.

Calibration interval; date/time setting: maximum 255 days

Model and Codes

Model Sufx code Option code Description

ZR402G - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Converter thread

Display -J

Instruction manual -J

—

Options /H Hood (*2)

*1 Specify either /SCT or /PT option code. *2 Sun shield hood is still effective even if scratched. *3 Output signal limits: 3.8 to 20.5 mA. Specify either /C2 or /C3 option code.

*4 “/EQ” is EAC with Pattern Approval for Russia. “/ER” is EAC for Kazakhstan and Belarus.

-P

-G

-M

-T

-E

-G

-F

-C

NAMUR NE43

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

-E

-C

Tag plates /SCT

compliant

Standard /EQ

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

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

/PT /C2

/C3

/ER

Separate type Zirconia Oxygen Analyzer, Converter

G1/2 Pg13.5 M20x1.5 1/2NPT

Japanese English German French Chinese

Japanese English Chinese

Stainless steel tag plate (*1) Printed tag plate (*1)

Failure alarm down-scale: Output status at CPU failure and hardware error is 3.6 mA or less (*3) Failure alarm up-scale: Output status at CPU failure and hardware error is 21.0 mA or more (*3)

EAC with PA (*4) EAC (*4)

2 (in increments of

scale of

Standard Accessories

Item Parts No. Q’ty Description

Fuse A1113EF 1 3.15A Bracket for mounting F9554AL 1 For pipe, panel or wall mounting Screw for Bracket F9123GF 1

IM 11M13A01-02E

  <2.Specications>

20.2

F02-6E.ai

Unit: mm

243

205.5

±4

F02-7E.ai

External Dimensions

1 to 6 (Panel Thickness)

2B mounting pipe

EXA

ZR402G

280

4 - Ø6 holes for Wall mounting

126.5

100

2-16

(*1/2NPT)

228

40 40

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

*: 1/2NPT with plug

36 23

( for wall mounting)

4 - Ø6 holes

126.5

4-R8 to R10 or 4-C5 to C8

190

Wall mounting

With sun shield hood (option code /H)

57.3

136.3

Panel Cut-out

183

54.7

+2 0

111

274

±3±2

12355

±2±3

155.5

±3

3994.5

ZR402G

±4

251.5

Material of Hood : Aluminum

IM 11M13A01-02E

  <2.Specications>

2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit

2.5.1 ZA8F Flow Setting Unit

This ow setting unit is applied to the reference gas and the calibration gas in a system conguration (System 1). Used when instrument air is provided.

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

and reference gas.

Standard Specications

Construction: Dust-proof and rainproof construction Case Material: SPCC (Cold rolled steel sheet) FIowmeter Scale: Calibration gas; 0.1 to 1.0 L/min.

Reference gas; 0.1 to 1.0 L/min. Painting: Baked epoxy resin, Dark-green (Munsell 2.0 GY 3.1/0.5 or equivalent) Tube Connections: Rc1/4 or 1/4FNPT Reference Gas Pressure: Clean air supply of sample gas pressure plus approx. 50 kPaG

(or sample gas pressure plus approx. 150 kPaG when a check valve

is used). Pressure at inlet of the Flow Setting Unit.(Maximum 300 kPaG)

2-17

Reference Gas Consumption:

Approx. 1.5 L/min Calibration Gas (zero gas, span gas) Consumption:

Approx. 0.7 L/min (at calibration time only) Weight: Approx. 2.3 kg

NOTE

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

Model and Codes

Model Sufx code Option code Description

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

Joint

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

-J

-A

- - - - - - - - -

Rc 1/4 With 1/4 NPT adapter

IM 11M13A01-02E

  <2.Specications>

External Dimensions

2-18

ø6 Hole

235.8

222.8

Calibration gas outlet

Reference gas outlet

REFERENCE CHECK

Span gas inlet

CHECK

REF

OUT

180

140

REFERENCE

SPAN

AIR

SPAN

Instrument air inlet

ZERO

Zero gas inlet

Piping connection port A

ZERO

2035

Model

ZA8F-J*C

ZA8F-A*C

Unit : mm

JIS 50A (60.5mm) mounting pipe

Piping connection port A

5 - Rc1/4

5 - 1/4 NPT

Weight : Approx. 2.3 kg

PIPNG INSIDE THE FLOW SETTING UNIT

CHECK OUT

Flowmeter Flowmeter

ZERO

GAS IN

SPAN

GAS IN

REF OUT

AIR IN

Air Set

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

Instrument air Approx. 1.5 L/min.

F02-8E.ai

IM 11M13A01-02E

  <2.Specications>

2.5.2 ZR40H Automatic Calibration Unit

CAUTION

Automatic Calibration Unit (Model ZR40H) must not be located in hazardous area.

This automatic calibration unit is applied to supply specied ow of reference gas and calibration gas during automatic calibration to the detector in a system conguration (System 2).

• Specications

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

Construction: Dust-proof and rainproof construction:

NEMA4X/IP67-only for case coating solenoid valve (excluding

owmeter)

Mounting: 2-inch pipe or wall mounting, no vibration Materials: Body; Aluminum alloy,

Piping; 316 SS (JIS), 304 SS (JIS), Flowmeter; MA (Metha acrylate resin). Bracket; 304 SS (JIS)

2-19

Finish: Polyurethane corrosion-resistance coating, mint green (Munsell

5.6BG3.3/2.9) Piping Connection: Refer to Model and Codes Power Supply: 24 V DC (from ZR402G), Power consumption; Approx.1.3 W Reference Gas Pressure: Sample gas pressure plus approx. 150 kPa (690 kPa max.), (Pressure

at inlet of the Automatic Calibration Unit) Air Consumption: Approx. 1.5 L/min Weight: Approx. 3.5 kg Ambient Temperature: -20 to +55°C, no condensation or freezing Ambient Humidity: 0 to 95%RH Storage Temperature: -30 to +65°C

• Model and Codes

Model Sufx code Option code Description

ZR40H - - - - - - - - - - - - - - - - - - - - -

Gas piping connection-R-T

Wiring connection

—

-P

-G

-M

-T

- - - - - - - -

-A - - - - - - - -

Automatic calibration unit for ZR402G

Rc 1/4 1/4 NPT

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

Always -A

IM 11M13A01-02E

  <2.Specications>

External Dimensions

2-20

2B pipe mounting example

*1 with four ISO M6 screws can wall-mount

41.2 41.2

2B mounting pipe

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

Connection port

Flowmeter

Needle valve

Setting Valve for

reference gas

Setting Valve for

calibration gas

Wiring inlet ; 2-G1/2,Pg13.5,M20X1.5 or 1/2NPT(Female)

(wiring inlet is at same position on rear)

90 116.5

4 - Ø6.5

140

71.5

12223

OCK

250

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

Unit: mm

49.5

Terminal box

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

Piping Diagram

ZR402G Converter

AC-Z

AC-S

AC-C

102 MAX58

ZR40H Automatic

Calibration Unit

Zero

EV1

Span

EV2

3040 47.5 25

EV1 EV2

Solenoid valve

ZERO GAS IN

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

CHECK OUT

Flowmeter

Solenoid valve

AIR IN

46 16

F02-9E.ai

REF OUT

Flowmeter

Instrument air Approx. 1.5 L/min

*Needle valve is supplied as an accessory with flowmeter

IM 11M13A01-02E

F02-10E.ai

  <2.Specications>

Zero gas cylinder (6 cylinder): E7050BA

2.6 ZO21S Standard Gas Unit

CAUTION

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

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

The ZO21S does not conform to CE marking.

Standard Specications

2-21

Function:

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

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

Sealed Zero Gas Cylinders (6 provided): E7050BA Capacity: 1 l Filled pressure: Approx. 686 kPaG (at 35°C) Composition: 0.95 to 1.0 vol%O

2 + N2 balance

Power Supply: 100, 110, 115, 200, 220, 240 V AC ±10%, 50/60 Hz Power Consumption: Max. 5 VA Case material: SPCC (cold rolled steel sheet) Paint Color: Mainframe; Munsell 2.0 GY3.1/0.5 equivalent

Cover; Munsell 2.8 GY6.4/0.9 equivalent

Piping: Ø6 х Ø4 mm exible tube connection

Weight: Approx. 3 kg

Model and Codes

Model Sufx code Option code Description

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

-2

Power supply

Panel

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

-3

-4

-5

-7

-8

-J

-E

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

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

Japanese version English version

External Dimensions

1600

354

228

253

Unit: mm

Flow checker Span gas valve

Zero gas valve Gas outlet

F02-11E.ai

IM 11M13A01-02E

  <2.Specications>

2.7 Other Equipments

2.7.1 Ejector Assembly for High Temperature (E7046EC, E7046EN)

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

Standard Specications

Needle Valve

Connection: Rc1/4 or 1/4 FNPT Material: 316 SS (JIS)

Pressure Gauge Assembly

Material in Contact with Gas: 316 SS (JIS) Case Material: Aluminum alloy (Paint color; black) Connection: G3/8 x R1/4 or 1/4 FNPT Scale: 0 to 100 kPaG

2-22

Ejector

Ejector Inlet Air Pressure: 29 to 69 kPaG Air Consumption: Approx. 30 to 40 L/min

Suction gas ow rate: 3 to 7 L/min

Connection to Blow: Rc1/4, 304 SS (JIS) Tube Connection: Ø 6 / Ø 4 mm or 1/4 inch copper tube (stainless tube)

(Note) Pipe and connections are not provided.

Part No. Description

E7046EC Needle valve; Rc1/4, Ejector; Ø6 / Ø4 TUBE joint, Pressure gauge; R1/4 E7046EN Needle valve; 1/4 FNPT, Ejector; 1/4 TUBE joint, Pressure gauge; 1/4 NPT

Dimension

Pressure gauge assembly

Pressure gauge

Needle valve

Ø43

Instrument air inlet

<1>

Connector (Tee) is not included in ejector assembly.

(Note1) The connecter of ejector is a dedicated

connecter with nozzle function.

Approx. 88 39

Approx. 67

Full open

height

Tee

Ejector

<3>

Blow Rc1/4

<2>

Approx. 70

Nozzle (Note1)

R1/2

<1> Rc1/4 or 1/4 FNPT <2> Ø6/Ø4 or 1/4 inch copper tube (stainless) with ejector to connect <3> R1/4 or 1/4 NPT

Detector

F02-12E.ai

IM 11M13A01-02E

  <2.Specications>

2-23

Pressure gauge

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

Ejector

Sample Gas

F02-13E.ai

P= 0.5

L (m)

P (kPa)

Graph 1

Graph 3

Po (kPa)

200

100

Pg (kPa)

-1.0

-0.5

Suction pressure characteristics

Needle valve

Air source

Qa (l/min)

P (kPa)

Air consumption characteristicsPressure setting characteristics

Qg (l/min)

Gas pressure: 0 kPa

P (kPa)

Suction flow characteristics

Graph 2

Graph 4

Gas pressure : -150 Pa

< Pressure setting for the ejector for high temperature use >

Pressure supply for the ejector should be set so that the suction ow of the sample 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 ow:

Qg) toward the gas pressure line to be used, to nd the point of intersection. Draw a line vertically down from the point of intersection to the axis to nd 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 ow) may require change according to the conditions of use. Refer to Subsection

3.2.2 and Subsection 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 nd 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 sample gas inlet of the ejector is closed).

4) Graph 4 shows correlation between P (drive pressure) and Qg (suction ow) for each gas

pressure.

2.7.2 Stop Valve (L9852CB, G7016XH)

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

manual calibration.

IM 11M13A01-02E

  <2.Specications>

Standard Specications

Material: 316 SS (JIS) Connection: Rc 1/4 or 1/4 FNPT Weight: Approx. 200 g

Part No. Description

L9852CB Joint: Rc 1/4, Material: 316 SS (JIS) G7016XH Joint: 1/4 FNPT, Material: 316 SS (JIS)

Unit : mm

Analyzer

Approx. 100

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

Ø48

(Full open length)

L9852CB 2-Rc1/4 G7016XH 2-1/4NPT

2-24

2.7.3 Check Valve (K9292DN, K9292DS)

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

F02-14.1E.ai

IM 11M13A01-02E

  <2.Specications>

Standard Specications

Material: 304 SS (JIS) Connection: Rc1/4 or 1/4 FNPT Pressure: 150 kPaG or more and 350 kPaG or less Weight: Approx. 90 g

Part No. Description

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

2-25

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

Approx. 19

2.7.4 Air Set

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

Standard Specications

• G7003XF, K9473XK

Primary Pressure: Max. 1 MPaG Secondary Pressure: 0.02 to 0.2 MPaG Connection: Rc1/4 or 1/4 FNPT (with joint adapter) Weight: Approx.1 kg

Part No. Description

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

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

Unit: mm

Approx. 54

F02-15E.ai

• G7004XF, K9473XG

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

Weight: Approx. 1 kg

Part No. Description

G7004XF Joint: Rc 1/4, Material: Zinc alloy

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

IM 11M13A01-02E

  <2.Specications>

External Dimensions

Unit : mm

Panel cut dimensions

Horizontal mounting

ø15

Vertical mounting

View A

2-26

2-ø6.5

max. 55

Secondary

Max. 210

Secondary pressure gauge

2-ø6 screw depth 8

Approx. 122

Panel (Horizontal mounting)

Panel (Vertical mounting)

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

F02-16E.ai

Primary

Ø74

2-ø2.2

+0.5

-0

2.7.5 Cylinder Pressure Reducing Valve (G7013XF,

G7014XF)

This pressure reducing valve is used with the zero gas cylinders.

Standard Specications

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

Outlet; Rc1/4 or 1/4 FNPT

Material: Brass body

IM 11M13A01-02E

  <2.Specications>

Secondary pressure gauge Primary pressure gauge

2-27

Unit : mm

Reducing valve handle

Approx.112

Approx. 59

Approx. 163

G7013XF G7014XF

2.7.6 ZR22A Heater Assembly

Model and Codes

Style:2

Model Sufx code Option code Description

ZR22A - - - - - - - - - - - - - - - - - - - - Heater Assembly for ZR22S

Length (*1) -015

-040

-070

-100

-150

-200

Jig for change -A

-N

—

*1 Sufx code of length should be selected as same as ZR22S installed.

*2 Jig part no. is K9470BX to order as a parts after purchase. (Note) The heater is made of ceramic, do not drop or subject it to pressure stress.

Yokogawa shall not guarantee the heater assembly after its replacement.

- - - - - - - - - - -

0.15 m

0.4 m

0.7 m 1 m

1.5 m 2 m

with Jig (*2) None

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

Stop valve

* Outlet

Primary safety valve

Part No.

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

Approx. 174

W22 (Right hand screw)

Secondary safety valve

Approx. 82

F02-17E.ai

Inlet

IM 11M13A01-02E

  <2.Specications>

External Dimensions

2-28

∅43

Jig for change

(K9470BX)

Model & Codes

ZR22A-015

ZR22A-040

ZR22A-070

ZR22A-100

ZR22A-150

ZR22A-200

∅21.7

302

552

852

1152

1652

2152

K9470BX

Weight (kg)

Approx. 0.5

Approx. 0.8

Approx. 1.2

Approx. 1.6

Approx. 2.2

Approx. 2.8

Unit : mm

L ± 12

F02-18E.ai

IM 11M13A01-02E

  <2.Specications>

2-29

IM 11M13A01-02E

<3. Installation>

3. Installation

This chapter describes installation of the following equipment:

Section 3.1 General-purpose Detector (except ZR22S--015) Section 3.2 High Temperature Detector (ZR22S--015) Section 3.3 ZR402G Converter Section 3.4 ZA8F Flow Setting Unit Section 3.5 ZR40H Automatic Calibration Unit

CAUTION

ZR402G Converter and ZR40H Automatic Calibration Unit must not be located in hazardous area.

CAUTION

3-1

Requirement for explosion-proof use: The ZR22S is connected to a ZR402G or AV550G*

that is mounted in a non-hazardous area. The ambient temperature is in the range -20 to +60°C. The surface temperature of the ZR22S is not over the temperature class T2 (300°C)*

*1: Refer to IM 11M12D01-01E *2: The terminal box temperature does not exceed 150°C.

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

CAUTION

• When connecting an AV550G, the AV550G should be installed in a non-hazardous area.

• When using options like automatic calibration or blow back, if the corresponding solenoid valves

are to be mounted in a hazardous location then be sure to use explosion-proof solenoid valves and appropriate wiring in explosion-proof conduit.

Non-hazardous areaHazardous area

Detector

Signal

Heater

Solenoid valve

Averaging Converter (AV550G)

Calibration contact outputs

Contact output

Analog outputs: Averaged and individual outputs

Contact output

Contact input

Air set

Needle valve

Flowmeter

Instrument air

Solenoid valve

Pressure reducing valve

Stop valve

Reference gas line

Flowmeter

Calibration gas line

Needle valve

Figure 3.1 Connection with AV550G

Regarding the AV550G installation procedure, refer to IM 11M12D01-01E.

Power supply

Span gas cylinder (Instrument air)

Zero gas cylinder

F03-1E.ai

IM 11M13A01-02E

<3. Installation>

3.1 Installation of General-purpose Detector

3.1.1 Installation 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) An ambient temperature of not more than 60°C, and the terminal box should not be affected

by radiant heat. (3) A clean environment without any corrosive gases. (4) No vibration.

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

(6) No sample gas pressure uctuations.

3.1.2 ATEX Flameproof Type

ZR22S-A Detector for use in hazardous locations:

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

EN 60079-31: 2014

3-2

Certicate Number: KEMA 04ATEX2156 X

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

Type of protection: Ex db IIB+H2 T2 Gb, Ex tb IIIC T300°C Db Equipment Group: II Category: 2GD Temperature class for Ex “db”: T2 The maximum surface temperature for Ex “tb”: T300°C Degree of protection of enclosure: IP66 Note 2: Wiring

• All wiring shall comply with local installation requirement.

Note 3: Operation

• Keep to “WARNING” on the Detector.

WARNING: DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE

IS PRESENT POTENTIAL ELECTROSTATIC CHARGING HAZARD-READ USER’S MANUAL (IM11M13A01-02) FOR INSTALLATION AND SAFE USE, READ IM11M13A01-02 USE AT LEAST 150°C HEAT RESISTANT CABLES & CABLE GLANDS

subjected to special conditions for safe use. Refer to Note 6.

• Take care not to generate mechanical sparking when accessing to the detector

and peripheral devices in hazardous location

Note 4: Maintenance and Repair

• The detector modication or parts replacement by other than authorized

representative of Yokogawa Electric Corporation is prohibited and will void the

certication.

IM 11M13A01-02E

<3. Installation>

Note 5: Cable Entry

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

the following markings.

Threaded type : Marking

M20 x 1.5 : M 1/2 NPT : N

• The cable entry devices (cable glands etc.) and blind plugs shall be in type of

protection Ex “db” or Ex “tb”, suitable for the conditions of use and correctly installed. They shall provide a degree of ingress protection of at least IP66.

Note 6: Special conditions for safe use

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

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

propagating brush discharges caused by rapid ow of dust is avoided.

Note 7: Special fastener

Hexagon socket head cap screws below are special fastener according to

EN60079-0: 2012+A11: 2013 (see the gure below). Material property classes

of them are A2-50 or better.

3-3

Special fastener

Figure 3.2 Special fastener

3.1.3 FM Explosion-proof Type

ZR22S-B Detector for use in hazardous locations:

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

NEMA 250 1991

Type of protection:

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

Enclosure Rating: NEMA 4X

Temperature Class: T2

Explosion-proof for Class I, Division 1, Groups B, C and D

Note 2: Wiring

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

Electrical Code.

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

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

IM 11M13A01-02E

<3. Installation>

3-4

Hazardous Locations Division 1

18 inches (475 mm) MAX.

ZR22S Detector

Figure 3.3 Wiring of ZR22S-B

Conduit

Sealing Fitting

Note 3: Operation

• Keep the “WARNING” label to the Detector.

WARNING: OPEN CIRCUIT BEFORE REMOVING COVER. USE AT LEAST

150°C HEAT RESISTANT CABLES.

• Take care not to generate mechanical sparking when accessing to the detector and

peripheral devices in hazardous location

Note 4: Maintenance and Repair

• The detector modication or parts replacement by other than authorized

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

3.1.4 CSA Explosion-proof Type

Non-hazardous Location Equipment ZR402G or AV550G

F03-2E.ai

ZR22S-C Detector for use in hazardous locations:

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

C22.2 No.0.5-1982, C22.2 No.25-1966, C22.2 No.30-M1986, C22.2 No.94-M91, C22.2-No.61010-1-04

Certicate Number: 1649642

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

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

Enclosure: Type 4X

Temperature Class: T2

Note 2: Wiring

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

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

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

UN SELLE DOIT ÊTRE INSTALLÊ ÁMOINS DE 50 cm DU BÎTIER.

Hazardous Locations Division 1

50 cm MAX.

Non-hazardous Location Equipment ZR402G or AV550G

ZR22S Detector

Figure 3.4 Wiring of ZR22S-C

Conduit

Sealing Fitting

F03-3E.ai

IM 11M13A01-02E

<3. Installation>

Note 3: Operation

• Keep the “WARNING” label to the Detector.

WARNING: OPEN CIRCUIT BEFORE REMOVING COVER. REFER

TO IM 11M13A01-02E. USE AT LEAST 150ºC HEAT RESISTANT CABLES.

OUVRIR LE CIRCUIT AVANT D’ENLEVER LE COUVERCLE.

UTILISEZ DES CÁBLES RÉSISTANTS Á 150ºC MINIMUM. VEUILLEZ VOUS RÉFÉRER AU IM 11M13A01-02E.

• Take care not to generate mechanical sparking when accessing to the detector and peripheral devices in hazardous location

Note 4: Maintenance and Repair

• The detector modication or parts replacement by other than authorized

representative of Yokogawa Electric Corporation is prohibited and will void Canadian

Standards Explosion-proof Certication.

3.1.5 IECEx Flameproof Type

ZR22S-D Detector for use in hazardous locations:

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

2013

3-5

Certicate Number: IECEx KEM 06.0006X

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

subjected to special conditions for safe use. Refer to Note 6.

Type of protection: Ex db IIB+H2 T2 Gb, Ex tb IIIC T300°C Db Temperature class for Ex “db”: T2 The maximum surface temperature for Ex “tb”: T300°C Degree of protection of enclosure: IP66 Note 2: Wiring

• All wiring shall comply with local installation requirement.

Note 3: Operation

• Keep to “WARNING” on the Detector.

WARNING: DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE

IS PRESENT POTENTIAL ELECTROSTATIC CHARGING HAZARD-READ USER’S MANUAL (IM11M13A01-02) FOR INSTALLATION AND SAFE USE, READ IM11M13A01-02 USE AT LEAST 150°C HEAT RESISTANT CABLES & CABLE GLANDS

• Take care not to generate mechanical sparking when accessing to the analyzer

and peripheral devices in hazardous area.

Note 4: Maintenance and Repair

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

representative of Yokogawa Electric Corporation is prohibited and will void the

certication.

IM 11M13A01-02E

<3. Installation>

Note 5: Cable Entry

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

the following markings.

Threaded type : Marking

M20 × 1.5 : M 1/2 NPT : N

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

screw in.

• The cable entry devices (cable glands etc.) and blind plugs shall be in type of

protection Ex “db” or Ex “tb”, suitable for the conditions of use and correctly installed. They shall provide a degree of ingress protection of at least IP66.

Note 6: Special conditions for safe use

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

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

propagating brush discharges caused by rapid ow of dust is avoided.

Note 7: Special fastener

Hexagon socket head cap screws below are special fastener according to IEC

60079-0: 2011 (see the gure below). Material property classes of them are A2-

50 or better.

3-6

Special fastener

Figure 3.5 Special fastener

IM 11M13A01-02E

<3. Installation>

3.1.6 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 consideration:

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 3.6 for the dimensions.

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

should face downwards.

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

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

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

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

tip should point downstream.

3-7

(vertical)

100 mm

Figure 3.6 Example of forming probe insertion hole

Bounds of the probe insertion hole location

Flange matches the detector size

(horizontal)

100 mm

3.1.7 Installation of the Detector

CAUTION

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

detector, as impact will damage it.

Type Outside diameter of detector

Standard With probe protector 60.5 mm in diameter

Four-hole flange Eight-hole flange

52 mm in diameter

F03-4E.ai

• A gasket should be used between the anges to prevent gas leakage. The gasket material

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

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

<General-purpose detector>

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

inlet should face downward.

IM 11M13A01-02E

<3. Installation>

3.1.8 Installation of Probe Protector (ZO21R)

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

particles when there is a high concentration of dust and gas ow exceeds 10 m/sec (pulverized coal boiler or uidized-bed furnace).

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

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

downstream of the sample gas ow.

(2) Make sure that the sensor assembly mounting screws (four bolts) at the tip of the detector

are not loose.

(3) When the detector mounted horizontally, the reference gas and calibration gas inlet should

face downward.

1050, 1550, 2050

Direction of the sample gas flow

Gasket (t1.5)

3-8

Unit: mm

Probe top

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

Figure 3.7 Mounting of detector with a probe protector

F03-5E.ai

3.2 Installation of High Temperature Detector

(Model ZR22S--015)

3.2.1 Installation Location

This detector is used with the High Temperature Probe Adapter (Model ZO21P) when the temperature of sample gas exceeds 700°C, 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 60°C and the terminal box should not be exposed to

radiant heat. (3) A clean environment without any corrosive gases. (4) No vibration.

(5) The sample gas should satisfy the specications described in Chapter 2.

CAUTION

Be sure to read Subsection 3.1.2 to 3.1.5 where the important information on writing is provided.

IM 11M13A01-02E

<3. Installation>

3.2.2 Usage of High Temperature Probe Adapter (Model ZO21P)

During analysis, the surface temperature of the probe adapter should be within the range from more than the dew point of the sample gas and 300°C or less to prevent ejector clogging, gasket deterioration or bolt scoring.

Where the dew point of the sample gas is not known, keep within the range of more than 200°C to less than 300°C.

The temperature shall be measured at the probe in the probe adapter and the surface of the blind

ange at the opposite side.

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

CAUTION

When the surface temperature of ZR22S or ZO21P exceeds temperature class T2(300°C), this system shall not satisfy explosion-proof requirement for outside of the furnace.

3-9

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

of the sample gas. Refer to Subsection 2.7.1, Ejector Assembly for High Temperature, for the setting of

induction ow. When you reduce induction ow, ensure that the ejector inducts air when the furnace pressure uctuates.

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

reduce the exhaust gas ow. Refer to Subsection 4.1.5, 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 ange as far

from the wall of the furnace as possible.

CAUTION

When a heater is used in hazardous area, then be sure to use appropriate explosion-proof heater and wiring conduit.

IM 11M13A01-02E

<3. Installation>

< When the surface temperature is less than 200°C or below the dew point of the sample

gas>

(1) When the furnace pressure is negative, raise the pressure setting to increase induction ow

of the sample gas. Refer to Subsection 2.7.1, Ejector Assembly for High Temperature, for the setting of

induction ow. If there is much dust in the gas, the ejector may become clogged as induction ow increases.

(2) When the furnace pressure is positive, open the needle valve of the sample gas outlet to

increase the gas ow. Refer to Subsection 4.1.5, Piping to the High Temperature Probe Adapter.

(3) Warm the probe adapter. Refer to Subsection 4.1.5, Piping to the High Temperature Probe

Adapter.

(4) When the surface temperature is still less than 200°C or below the dew point of the sample

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 ZR22S--015 Detector and ZO21P High Temperature Probe Adapter. When forming the probe insertion hole, the following should be taken into consideration:

3-10

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

probe is mounted vertically (within ± 5° 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 3.8 illustrates examples of the probe insertion hole.

JIS 5K 50 FF (equivalent) or

100mm

The allowable margin for probe tilt is within ± 5°.

An SiC probe shall be mounted vertically.

Figure 3.8 Examples of the probe insertion hole

ANSI Class 150 4 RF (equivalent) flange

A space of 52 mm or more in diameter, and long enough for 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

F03-6E.ai

IM 11M13A01-02E

<3. Installation>

3.2.4 Mounting of High Temperature Detector

CAUTION

• 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 the high temperature probe adapter with a probe made of silicon

carbide (SiC).

• A gasket should be used on the ange 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 3.1.

Table 3.1 Accessories for mounting high temperature probe adapter

Mounting ange specication Parts name Q’ty Note

JIS 5K 50 FF (equivalent) Gasket 1 Heatproof and corrosion-proof

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

ANSI Class 150 4RF (equivalent) Gasket 1 Heatproof and corrosion-proof

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

3-11

A high temperature detector should be mounted as follows: (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

anges to prevent gas leakage. When the furnace pressure is negative, ensure that there is no leakage of air into the detector.

(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

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

Figure 3.9 Mounting of the High Temperature Detector

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IM 11M13A01-02E

<3. Installation>

3.3 Installation of ZR402G Converter

CAUTION

Converter (Model ZR402G) must not be located in hazardous area.

3.3.1 Installation Location

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

display. Easy and safe access to the converter for operating keys on the panel and for checking and maintenance work.

(2) An ambient temperature of not more than 55 °C and little change in temperature

(recommended within 15 °C in a day).

(3) The normal ambient humidity (recommended between 40 to 75% RH) and without any

corrosive gases. (4) No vibration. (5) Near to the detector.

3-12

(6) Not in direct rays of the sun. If the sun shines on the converter, prepare the hood (/ H) or

other appropriate sunshade. (7) Non-hazardous location.

3.3.2 Mounting of the Converter

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

Mount the converter as follows. <Pipe Mounting>

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

the converter. (Converter weighs approximately 6 kg.) (2)

Mount the converter on the pipe. Fix it rmly on the pipe in the procedure described in Figure 3.9.

 Mounting procedure

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

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

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

A pipe to be mounted (nominal JIS 50A)

*Fitting

*Washer

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

Figure 3.10 Pipe Mounting

*Bolt

Bolt

Washer

Bracket

Nut

F03-8E.ai

IM 11M13A01-02E

<3. Installation>

(1) Drill mounting holes through the wall as shown in Figure 3.11.

Unit: mm

Four holes 6 mm in diameter for M5 screws

126.5

3-13

190

F03-9E.ai

Figure 3.11 Mounting holes Figure 3.12 Wall Mounting

(2) Mount the converter. Secure the converter on the wall using four screws.

Note: For wall mounting, the bracket and bolts are not used.

(1) Cut out the panel according to Figure 3.13.

Unit: mm

274

183

Figure 3.13 Panel cutout sizes Figure 3.14 Panel mounting

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Clamp screw

Fitting

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Washer

Bolt

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(2) Remove the tting from the converter by loosening the four screws.

(3) Insert the converter case into the cutout hole of the panel.

(4) Attach the mounting tting which is once removed in step (2) again to the converter. (5) Firmly x the converter to the panel. Fully tighten the two clamp screws to hold the panel with

the tting.

IM 11M13A01-02E

<3. Installation>

3.4 Installation of ZA8F Flow Setting Unit

3.4.1 Installation Location

The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector or the converter (3) No corrosive gas. (4) An ambient temperature of not more than 55 °C and little changes of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain.

3.4.2 Mounting of ZA8F Flow Setting Unit

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

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

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

3-14

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

tting is rmly attached to the pipe.

F03-13E.ai

Figure 3.15 Pipe Mounting

(1) Make a hole in the wall as illustrated in Figure 3.16.

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

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

Unit : mm

223

140

4 - Ø6.5 hole, or M5 screw

Figure 3.16 Mounting holes Figure 3.17 Wall mounting

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IM 11M13A01-02E

<3. Installation>

3-15

3.5 Installation of ZR40H Automatic Calibration Unit

CAUTION

Automatic Calibration Unit (Model ZR40H) must not be located in hazardous area.

3.5.1 Installation Location

The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector or the converter (3) No corrosive gas. (4) An ambient temperature of not more than 55 °C and little change of temperature. (5) No vibration. (6) Little exposure to rays of the sun or rain. (7) Non-hazardous location.

3.5.2 Mounting of ZR40H Automatic Calibration Unit

The automatic calibration unit can be mounted either on a pipe (nominal JIS 50 A ) or on a wall.

It should be positioned vertically so that the owmeter works correctly.

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

of automatic calibration unit. (The unit weights approximately 3.5 kg.)

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

the metal tting is rmly attached to the pipe.

F03-16E.ai

Figure 3.18 Pipe Mounting

IM 11M13A01-02E

<3. Installation>

(1) Make a hole in the wall as illustrated in Figure 3.19.

Unit : mm

223

140

4 - Ø6.5 hole, or M6 screw

F03-17E.ai

Figure 3.19 Mounting holes

(2) Mount the automatic calibration unit. Remove the U-bolt from the automatic calibration unit

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

4-Ø6.5

3-16

Figure 3.20 Wall Mounting

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IM 11M13A01-02E

<3. Installation>

3.6 Insulation Resistance Test

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

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

short a time as practicable to confirm that insulation resistance is 20 MΩ or more.

Remove wiring from the converter and the detector.

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

2. Connect crossover wiring between L and N.

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

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

5. After testing, remove the tester and connect a 100 kΩ resistance between the crossover wiring and ground, to discharge for over 1 min. During discharge, do not touch the terminal.

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

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

3-17

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

Insulation resistance tester

crossover wiring

1FG2

12FG13

DI-114DI-215DI-C16AI

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

Remove wiring to connect external circuits and Connect crossover wiring

AO1

(+)

Contact input 1

AO1

(-)

AO2

(+)

Contact input 2

AO2

(-)

ZR402G Converter

(+)

(-)

AC-

(-)

AC-

ZERO

SPAN

Solenoid valve for automatic calibration

Span gas

Solenoid valve for automatic calibration Zero gas

Automatic Calibration Unit ZR40H

(+)

(-)

AC-

COM

CELL

(+)

21FG22

CELL

(-)

CELL

Remove jumper plate

crossover wiring

ZR22S Detector

CELL

(+)

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

HTR HTR

Insulation resistance tester

F03-19E.ai

IM 11M13A01-02E

Blank Page

<4. Piping>

CAUTION

4. Piping

This chapter describes piping procedures based on two typical system congurations for EXAxt

ZR Separate type Explosion-proof Zirconia Oxygen Analyzer.

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

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

• Be sure to conduct leakage test after piping.

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

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

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

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

4-1

Flame Arrestor

F04E.ai

IM 11M13A01-02E

<4. Piping>

4-2

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

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

Hazardous Area

ZR22S Separate type Explosion-proof

Zirconia Oxygen Analyzer, Detector

Stop valve

Check valve

Reference gas

Calibration gas

* Calibration gas unit same as for zero gas.

Flowmeter

Flow Setting Unit

Needle

ZA8F

valve

Air Set

Instrument air Span gas (*)

Pressure

reducing

valve

Calibration gas unit case

Zero gas

cylinder

Figure 4.1 Typical Piping for System Using Flow Setting Unit for Manual Calibration

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

• Connect a stop valve or check valve to the nipple at the calibration gas inlet of the detector.

Non-hazardous Area

ZR402G Converter

EXA

ZR402G

100 to 240 V AC

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

F04-1E.ai

• When a high temperature detector is used and the sample gas pressure is negative,

connect an auxiliary ejector to the sample gas exhaust hole of the high temperature probe adapter (see Subsection 4.1.5, Figure 4.3).

• When a high temperature detector is used and the pressure of the measured gas is 0.5

kPa or higher, it is recommended that a needle valve (throttle) be used in the sample gas exhaust of the high temperature probe adapter (see Subsection 4.1.5, Figure 4.4).

CAUTION

This is for lowering the sample gas temperature below 700°C. If the gas temperature is high and

the pressure is also signicantly high, the sampled gas temperature may not reduced below

700ºC when reaching the detector. On the other hand, if the sample gas temperature is lowered too much, condensation may be produced in the high temperature probe adapter. During wintertime, it is recommended that the high temperature probe adapter should be protected with an insulating material to prevent condensation (see Figure 4.5). For the usage of the high temperature probe adapter, refer to Subsection 3.2.2.

• When a high temperature detector is used and blow back is required to eliminate dust

accumulating in the probe of the high temperature probe adapter, air supply piping for purging should be installed.

IM 11M13A01-02E

<4. Piping>

CAUTION

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 blow back piping. See Subsection 4.2.5 for the installation of blow back piping.

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 Parts Name Remark

General-purpose detector

High temperature detector (0.15 m)

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

Calibration gas inlet Stop valve or check

valve

Nipple * R1/4 or 1/4 NPT General parts Zero gas cylinder User´s scope Pressure reducing valve Recommended by YOKOGAWA

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

Reference gas inlet Air set Recommended by YOKOGAWA

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

Calibration gas inlet Stop valve or check

valve

Nipple * R1/4 or 1/4 NPT General parts Zero gas cylinder User´s scope Pressure reducing valve Recommended by YOKOGAWA

Joint for tube connection R1/8 or 1/8 NPT

Reference gas inlet Air set Recommended by YOKOGAWA

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

Sample gas outlet Ejector assembly * Recommended by YOKOGAWA

T-shaped joint of the same diameter *

Needle valve * Rc1/4 or 1/4 NPT General parts Reducing nipple * R1/2 to R1/4 or R1/2 to 1/4 NPT General parts

Recommended by YOKOGAWA (L9852CB or Provided by

(G7013XF or G7014XF)

(G7003XF/K9473XK or G7004XF/K9473XG)

Recommended by YOKOGAWA (L9852CB or G7016XH) Provided by

(G7013XF or G7014XF)

(G7003XF/K9473XK or G7004XF/K9473XG)

(E7046EC or E7046EN) Rc1/4 or 1/4 NPT General parts

G7016XH)

YOKOGAWA

(K9292DN or K9292DS)

(K9292DN or K9292DS

4-3

IM 11M13A01-02E

<4. Piping>

4.1.2 Piping for the Calibration Gas Inlet

This piping is to be installed between the zero gas cylinder and the ZA8F ow setting unit, and between the ZA8F ow setting unit and the ZR22S 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 40°C. Mount a pressure

reducing valve (specied by YOKOGAWA) on the cylinder.

Mount a check valve or stop valve (specied by YOKOGAWA) on the nipple (found on the local

market) at the calibration gas inlet of the detector as illustrated in Figure 4.2. (The check valve or the stop valve may have been mounted on the detector when shipped.)

Connect the ow setting unit and the detector to a stainless steel pipe 6 mm (O.D.) × 4 mm (I.D.)

or larger (or nominal size 1/4 inch).

Check valve

Stop valve

Tube connection joint

Nipple

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

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

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

4-4

F04-2E.ai

Figure 4.2 Piping for the Calibration Gas Inlet

4.1.3 Piping for the Reference Gas Inlet

Reference gas piping is required between the air source (instrument air) and the ZA8F ow setting unit, and between the ZA8F ow setting unit and the ZR22S detector.

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

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

the ow setting unit and the detector.

4.1.4 Piping for the Reference Gas Outlet

If the ZR22S is exposed to rain or water splash, connect the pipe outlet on downward.

4.1.5 Piping to the High Temperature Probe Adapter

• The sample gas should be at a temperature below 700°C before reaching the detector sensor. If the gas is under negative pressure, it should be fed to the detector by suction.

• For usage of the high temperature probe adapter when using high temperature detector,

refer to Subsection 3.2.2.

• If the sample gas is under negative pressure, connect the ejector assembly (E7046EC/

E7046EN) as illustrated in Figure 4.3. Mount the pressure gauge as close as possible to the ejector. However, if the ambient temperature is too high, mount the gauge in a location with a temperature below 40°C.

IM 11M13A01-02E

<4. Piping>

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Pressure gauge

Ejector

Ejector assembly for

high temperature

High temperature

probe adapter

Detector

F04-3E.ai

Figure 4.3 Mounting the ejector assembly

If the temperature of the sample gas is high and its pressure exceeds 0.49 kPa, the temperature of the sample gas at the detector may not be below 700°C. In such a case, connect a needle valve (found on the local market) through a nipple (also found on the local market) to the sample gas outlet (Rc1/2) of the probe adapter so that the sample gas exhaust volume is 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 illustrated in Figure 4.5.

4-5

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

Needle valve

F04-4E.ai

Figure 4.4 Mounting the needle valve for restricting exhaust ow of the sample gas

Cover flange

Sample gas outlet

High temperature probe adapter

Detector

Figure 4.5 Preventing to condensation

Insulating material

Probe

IM 11M13A01-02E

<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 4.6.

The piping is basically the same as that of a system using ow setting unit for manual calibration.

Refer to Section 4.1.

4-6

Hazardous Area

ZR22S Separate type Explosion-proof

Zirconia Oxygen Analyzer, Detector

Check valve

Signal (6-core shield cable)

Heater (2-core cable)

Reference gas

Calibration gas

Non-hazardous Area

ZR402G Converter

Flowmeter

Automatic Calibration Unit

Needle

valve

ZR40H

EXA

ZR402G

Air Set

Pressure

reducing

Calibration gas unit case

Figure 4.6 Typical Piping for a System to perform Automatic Calibration

100 to 240 V AC

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

Instrument air

valve

Zero gas cylinder

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IM 11M13A01-02E

<4. Piping>

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

Detector Piping location Parts Name Remark

General-purpose detector

High temperature detector (0.15 m)

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

Calibration gas inlet Check valve Recommended by YOKOGAWA

Nipple * R1/4 or 1/4 NPT General parts Zero gas cylinder User´s scope Pressure reducing valve Recommended by YOKOGAWA

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

Reference gas inlet Air set Recommended by YOKOGAWA

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

Calibration gas inlet Check valve Recommended by YOKOGAWA

Nipple * R1/4 or 1/4 NPT General parts Zero gas cylinder User´s scope Pressure reducing valve Recommended by YOKOGAWA

Joint for tube connection R1/8 or 1/8 NPT

Reference gas inlet Air set Recommended by YOKOGAWA

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

Sample gas outlet Ejector assembly * Recommended by YOKOGAWA

T-shaped joint of the same diameter *

Needle valve * Rc1/4 or 1/4 NPT General parts Reducing nipple * R1/2 to R1/4 or R1/2 to 1/4 NPT General parts

(K9292DN or K9292DS)

(G7013XF or G7014XF)

(G7003XF/K9473XK or G7004XF/K9473XG)

(L9852CB or G7016XH) Provided by

(G7013XF or G7014XF)

(G7003XF/K9473XK or G7004XF/K9473XG)

(E7046EC or E7046EN) Rc1/4 or 1/4 NPT General parts

YOKOGAWA

(K9292DN or K9292DS

4-7

IM 11M13A01-02E

<4. Piping>

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 the ZR40H automatic calibration unit.

Figure 4.7 shows the ZR40H Automatic Calibration Unit piping diagram. Adjust secondary pressure of both the air set and the zero gas pressure reducing valve so that

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

instrument air) are set by a single needle valve. After installation and wiring, check the calibration contact output (see Subsection 7.11.2), and

adjust zero gas pressure reducing valve and calibration gas needle valve so that zero gas ow is

within the permitted range. Next check span gas calibration contact output and adjust air set so

that span gas ow is within the permitted range.

4-8

CHECK OUT

flowmeter

*Needle valve *

Solenoid valve

ZERO GAS IN

To zero gas pressure reducing valve

*: Needle valve is supplied as an accessory with flowmeter

Figure 4.7 ZR40H Automatic Calibration Unit piping diagram

AIR IN

Air set

REF OUT

flowmeter

Instrument air Approx.1.5 L/min.

F04-7E.ai

If the contact input to the converter is used for the blow back function, prepare blow back piping according to Subsection 4.2.5.

NOTE

Blow back function means the function to get rid of dust inside a probe in a high temperature probe adapter by using compressed air, when a high temperature detector is used.

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 owmeters, needle valves of the ZR40H Automatic Calibration Unit.

• Use stainless steel pipes with 6 O.D. x 4 I.D. mm (or nominal 1/4 inch) or larger inside

diameter for the piping for the reference gas.

IM 11M13A01-02E

<4. Piping>

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 ow setting unit for manual calibration.

See Subsection 4.1.5.

4.2.5 Piping for Blow back

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.

4-9

Solenoid valve

Pipe junction

Blow pipe

Figure 4.8 Blow back Piping

Pressure reduction valve

F04-8E.ai

CAUTION

When mounting solenoid valves (e.g. used with options like automatic calibration or blow back) in a hazardous area, then be sure to use explosion-proof solenoid valves and appropriate wiring in explosion-proof conduit.

The following parts are required for blow back piping.

• Blow pipe (to be prepared as illustrated in Figure 4.11.)

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

• Air set (Yokogawa recommended: G7003XF / K9473XK or G7004XF / K9473XG)

IM 11M13A01-02E

<4. Piping>

Manufacture the blow pipe as illustrated in Figure 4.9, and mount it on the high temperature probe adapter.

4-10

4-Φ9

Φ90

Rc1/4

Φ73

8 ~ 10

Approximately

200

Figure 4.9 Blow pipe Construction

Unit : mm

Blind flange of the high temperature probe adapter

Welded

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

F04-9E.ai

IM 11M13A01-02E

<5. Wiring>

5. Wiring

In this Chapter, the wiring necessary for connection to the EXAxt ZR Separate type Explosionproof Zirconia Oxygen Analyzer is described.

5.1 General

CAUTION

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

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

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

2. Use an external switch or circuit breaker rated 5 A and conforming with IEC 947-1 or IEC 947-3.

5-1

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

4. The external switch or circuit breaker should be installed within the reach of the operator, and marked as the power supply switch of this equipment.

Wiring procedure

Wiring should be performed according to the following procedure:

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

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

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

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

5. Metal conduit should be grounded.

6. The following cables are used for wiring:

Table 5.1 Cable specications

Terminal name of converter Name Need for shields Number of cores

CELL+, CELLHTR TC+, HTR TC- CJ+, CJ-

HEATER Detector heater 2 L, N Power supply 2 or 3 * AO-1+, AO-1-, AO-2+, AO-2- Analog output О 2 or 4 DO-1, DO-2, DO-3, DO-4 Contact output 2 to 8 AC-Z, AC-S, AC-C Automatic calibration unit 3 DI-1, DI-2, DI-C Contact input 3

Detector signal О 6

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

IM 11M13A01-02E

<5. Wiring>

WARNING

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

CAUTION

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

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

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

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

5.1.1 Terminals for the External Wiring in the Converter

Open the front door and remove the terminal covering plate to gain access to the converter external wiring terminals (see Figure 5.1).

5-2

CAUTION

After wiring necessary cable to the converter terminals, be sure to x the terminal covering plate

with two screws again.

Front door

Terminals are visible when the terminal cover is removed.

Cable inlet

Figure 5.1 Terminals for external wiring in the converter

F05-1E.ai

IM 11M13A01-02E

<5. Wiring>

5.1.2 Wiring

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

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

5-3

ZR402G Separate type Zirconia Oxygen Analyzer, Converter

Analog

output 1 4-20 mA DC Digital output

1FG2

AO-1

(+)

12FG13

DI-114DI-215DI-C16AI

Contact input 2

Contact input 1

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

Contact output 1

The ground wiring of the converter should be connected to either the protective ground terminal in the equipment or

AO-1

(-)

Contact output 2

Analog output 2

4-20 mA DC

AO-2

(+)

(-)

(+)

Contact output 3

(+)

17 AI (-)

(-)

AC-

ZERO

SPAN

Solenoid valve for automatic calibration

Span gas

Solenoid valve for automatic calibration Zero gas

Automatic Calibration Unit ZR40H

Contact output 4

(+)

AC-

COM

(-)

CELL

(+)

21FG22

CELL

(-)

100-240V AC 50/60 Hz

ZR22S Separate type Explosion-proof Zirconia Oxygen Analyzer, Detector

CELL

(+)

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

HTR HTR

the ground terminal of the converter case.

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

Figure 5.2 Wiring connection to the converter

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<5. Wiring>

5.1.3 Mounting of Cable Gland

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

EXA

ZR402G

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

Ground terminal (M4)

5-4

Figure 5.3 Cable gland mounting

Adaptor for 1/2 NPT thread

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<5. Wiring>

5.2 Wiring for Detector Output

This wiring enables the converter to receive cell output from the detector, output from a

thermocouple and a reference junction compensation signal. Install wires that allow for 10 Ω of

loop resistance or less. Keep detector wiring away from power wiring.

CAUTION

Be sure to read Subsection 3.1.2 to 3.1.5 where the important information on writing is provided.

(1) Surface temperature of the detector terminal box: 75°C or less

Detector Converter

Hazardous area

Non-hazardous area

5-5

CELL(+)

CELL(-)

TC(+)

TC(-) CJ(+)

CJ(-)

Shielded cables

(2) Surface temperature of the detector terminal box: exceeding 75°C

Detector Converter

CELL(+)

CELL(-)

TC(+)

TC(-) CJ(+)

CJ(-)

Heat-resistant wiring

Figure 5.4 Wiring for detector output

Hazardous area

Terminal box

Shielded cables

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

Non-hazardous area

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

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CAUTION

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

5.2.1 Cable Specications

During operation of the process, the terminal box may get quite hot and may reach temperatures of up to 150°C. The cable may be exposed to even higher temperatures, so be sure to use suitably heat-resistant cable.

Basically, a cable (six core) that withstand temperatures of at least 80°C is used for this wiring. When the ambient temperature of the detector exceeds 75°C, install a terminal box, and connect with the detector using six-piece 600V silicon rubber insulated glass braided wire.

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<5. Wiring>

5.2.2 Connection to the Detector

To connect cables to the detector, proceed as follows:

(1)

Mount conduits of the specied thread size or cable glands to the wiring connections of the detector.

The detector may need to be removed in future for maintenance, so be sure to allow

sufcient cable length.

(2) If the ambient temperature at the location of wire installation is 75 to 150°C, be sure to use a

exible metallic wire conduit. If a non-shielded “ 600 V silicon rubber insulated glass braided

wire “ is used, keep the wire away from noise sources to avoid noise interference.

(3) Figure 5.5 shows the layout of the detector terminals.

TC +

5-6

CELL +

1 2 3 4 5 6

TC -

TCCELL CJ

CELL

(+)

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

HTR HTR

To converter, or terminal box

To ground

To converter, or terminal box

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Figure 5.5 Detector terminals

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

*1: If the surface temperature of the detector terminal box installation site exceeds 60°C, use a “ bare crimp-on terminal”.

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

shield to the FG terminal of the converter.

5.2.3 Connection to the Converter

To connect the wiring to the converter, proceed as follows:

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

terminated corresponding to crimp-on terminals.

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

box. For wiring between the terminal box and the converter, basically use a cable that withstand temperatures of at least 80°C, rather than individual wires.

NOTE

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

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<5. Wiring>

5.3 Wiring for Power to Detector Heater

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

CAUTION

Refer to section 3.1.

(1) Surface temperature of the detector terminal box: 75 °C or less

Detector Converter

Hazardous area

Non-hazardous area

5-7

HTR 7 HTR 8

(2) Surface temperature of the detector terminal box: exceeding 75 °C

Hazardous area

Detector Converter

HTR 7 HTR 8

Heat-resistant wiring

Figure 5.6 Wiring for power to detector heater

5.3.1 Cable Specications

HEATER

Non-hazardous area

Terminal box

HEATER

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Basically, cables (2 cores) that withstand temperatures of at least 80°C are used for this wiring. When the ambient temperature of the detector exceeds 75°C, install a terminal box, and connect to the detector using six-piece 600 V silicon rubber insulated glass braided wires.

5.3.2 Connection to Detector

When connecting the cable to the detector, proceed as follows:

(1) Mount cable glands or conduits of the specied thread size to the wiring connections of the

detector. The detector may need to be removed in future for maintenance, so be sure to

allow sufcient cable length.

(2) If the ambient temperature at the location of wire installation is 75 to 150°C, be sure to use a

exible metallic conduit for the wire. If a non-shielded “ 600 V silicon rubber insulated glass

braided wire” is used, keep the wire away from noise sources to avoid noise interference.

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

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

*1 If the surface temperature of the detector terminal box installation site exceeds 60 °C, use a “ bare crimp-on terminal”.

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<5. Wiring>

CAUTION

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

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

Lock screw

5-8

Detector cover

Figure 5.7 Detector

5.3.3 Connection to Converter

To connect the wiring to the converter, proceed as follows:

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

the corresponding size crimp-on terminals.

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

box. For wiring between the terminal box and the converter, basically use a cable that withstand temperatures of at least 80°C, rather than wire.

CAUTION

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

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WARNING

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

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<5. Wiring>

5.4 Wiring for Analog Output

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

Maintain the load resistance including the wiring resistance at 550 Ω or less.

5-9

ZR402G

Converter

AO-1(+) AO-1(-) AO-2(+) AO-2(-)

Shielded cable

Figure 5.8 Wiring for analog output

5.4.1 Cable Specications

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

5.4.2 Wiring Procedure

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

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

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

Receiver 1

+ –

Receiver 2

+ –

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5.5 Power and Grounding Wiring

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

ZR402G

Converter

Grounding to the ground terminal

on the converter case

Converter case

Crimp-on terminal of

FG terminal

Figure 5.9 Power and Grounding wiring

Lock washer

5.5.1 Power Wiring

Connect the power wiring to the L and N terminals of the converter. Proceed as follows:

(1) Use a 2-core or a 3-core cable. (2) The size of converter terminal screw threads is M4. Each wire in the cable should be

terminated corresponding to crimp-on terminals.

the ground wire

L N G

Jumper plate

100 - 240V AC

50/60Hz

ZR22S

Detector

Ground

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<5. Wiring>

5.5.2 Grounding Wiring

The ground wiring of the detector should be connected to the ground terminal of the detector case. The ground wiring of the converter should be connected to either the ground terminal of the converter case or the protective ground terminal in the equipment. The grounding terminals of the detector are of size of M4 (inside) and M5 (outside), and the grounding terminals of the converter are of size M4. Proceed as follows:

(1) Keep ground resistance to 100 Ω or less.

(2) When the ambient temperature of the wiring installation is 75 to 150°C for the wiring of the

detector, use wiring material with sufcient heat resistance.

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

that the lock washer is in contact with the case surface (see Figure 5.9.).

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

terminal of the converter.

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

terminal for connection to the internal ground terminal in order to avoid corrosion by high contact potentials.

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

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

M5).

5-10

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

5.6 Contact Output Wiring

Contact outputs 1 to 3 can be freely assigned to “low limit alarm”, “high limit alarm”, etc. user

selectable, but the assignment of contact output 4 is xed (“error output”). And the action (contact

closed on error output) also cannot be changed. When using these contact outputs, install the wiring as follows:

Converter

DO-1 DO-1

DO-2 DO-2

DO-3 DO-3

DO-4 DO-4

Terminal box Annunciator or the like

#1 Output

#2 Output

#3 Output

#4 Output

Figure 5.10 Contact output wiring

5.6.1 Cable Specications

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

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<5. Wiring>

5-11

5.6.2 Wiring Procedure

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

terminated corresponding to crimp-on terminals.

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

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

5.7 Wiring for ZR40H Automatic Calibration Unit

This wiring is for operating the solenoid valve for the zero gas and the span gas in the ZR40H

Automatic Calibration Unit, in a system where the calibration gas ow rate is automatically controlled (e.g. System conguration 2). When installing this wiring, proceed as follows:

Wiring inlet

Span gas solenoid valve

Zero gas solenoid valve

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

COMMON SPAN ZERO

to ZR402G terminal "AC-COM"

to ZR402G terminal "AC-SPAN"

to ZR402G terminal "AC-ZERO"

Terminal screw : M4

Use a 3-core cable or equivalent

Figure 5.11 Automatic Calibration Unit

5.7.1 Cable Specications

Use a 3-core cable for the above wiring.

COMMON

SPAN

ZERO

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<5. Wiring>

5.7.2 Wiring Procedure

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

5-12

ZR402G

Converter

AC-Z

AC-S

AC-C

Figure 5.12 Wiring for Automatic Calibration Unit

ZR40H Automatic

Calibration unit

Zero

Span

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5.8 Contact Input Wiring

The converter can execute specied function when receiving contact signals. To use these contact signals, proceed wiring as follows:

ZR402G

Converter Terminal box

DI-1

DI-2

DI-C

Figure 5.13 Contact Input Wiring

Contact input 1

Contact input 2

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5.8.1 Cable Specications

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

5.8.2 Wiring Procedure

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

terminated corresponding to crimp-on terminals.

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

input that satises the specications in Table 5.2.

Table 5.2 Identication of Contact Input ON/OFF

Closed Open

Resistance 200 Ω or less 100 kΩ or more

IM 11M13A01-02E

<6. Components and Their Functions>

6-1

6. Components and Their Functions

In this Chapter, the names and functions of components are described for the major equipment of the EXAxt ZR Separate type Explosion-proof Zirconia Oxygen Analyzer.

6.1 ZR22S Detector

6.1.1 General-purpose Explosion-proof Detector (except for

ZR22S--015)

Pipe support

Bolt

Flame arrestor assembly

U-shaped pipe

Washer

Probe This part is inserted in the furnace. Select length from 0.15, 0.4,

0.7, 1.0, 1.5 or 2.0 m.

Calibration gas

Contact

Metal O-ring

Sensor (cell)

Filter

pipe opening

Flange Used to mount the detector. Select from JIS, ANSI or DIN standard models.

Flame arrestor assembly mounting screw

Probe

Screw

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Figure 6.1 General-purpose Explosion-proof Detector (Standard type)

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<6. Components and Their Functions>

6.1.2 High Temperature Detector (ZR22S--015)

Sample gas outlet When a sample gas pressure is negative, connect the auxiliary ejector assembly. When the sample gas is high temperature and high pressure, and does not fall below 700°C, connect a pressure control valve (e.g. a needle valve).

Flange Selectable from JIS, ANSI or DIN standards

Separate type High Temperature Detector (ZR22S--015) When the temperature of the sample gas is between 700°C and 1400°C, mount this detector with a ZO21P probe adapter.

6-2

Figure 6.2 High Temperature Detector

High Temperature Probe Adapter (ZO21P) The probe is made of either SUS310S or silicon carbide (SiC). Its length is 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 or 1.5 m. When using an SiC probe, mount it vertically downward.

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<6. Components and Their Functions>

6.2 ZR402G Converter

Complete Operation Display

■ Interactive operations along with operation display.

■ A variety of display modes - enabling you to select

the operation mode freely.

■ Back-lit LCD allows viewing even in the darkness.

■ Error codes and details of errors can be checked in

the field without the need to refer to appropriate instruction manual.

■ Password for security

●

This data display provides for interactive operation.

●

— displays data changes

Touch Screen Display

Example of basic display

Example of trend display

6-3

Self-testing suggests countermeasures for problems

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

Error code Reason for error

Error 1 Cell failure

Error 2 Abnormal heater temperature

Error 3 Defective A/D converter

Error 4 Faulty EEPROM

Alarm 1 Abnormal oxygen concentration

Alarm 2 Abnormal moisture

Alarm 3 Abnormal mixing ratio

Alarm 6 Abnormal zero calibration ratio

Alarm 7 Abnormal span calibration ratio

Alarm 8 Stabilization time over

Figure 6.3 Converter

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

●

Example of setting data display

Commissioning

Basic setup

 mA-output setup

 Alarms setup

 Contact setup

 Others

Enter

● One-touch interactive display operation

● User-friendly design providing easy operation

without having to use the instruction manual

Disp3_1.ai

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<6. Components and Their Functions>

6.3 Touchpanel Switch Operations

6.3.1 Basic Panel and Switch

The converter uses a touchpanel switch which can be operated by just touching the panel display. Figure 6.4 shows the Basic panel display. The switches that appear in the switch display area vary depending on the panel display, allowing all switch operations. Table 6.1 shows the switch functions.

6-4

Tag name display area

Primary value

Tag:

Switch display area

21.0

% O2

Secondary value

Tertiary value

Figure 6.4 Basic Panel Display

Tag name display area: Displays the set tag name (Refer to Subsection 10.3.2, Entering Tag

Primary to tertiary value: Displays the selected item. (Refer to Section 7.9, Setting Display Item.) Switch display area: Displays switches and functions selected according to the panel display. Alarm and error display area: Displays an error if an alarm or error occurs. If you touch this area,

Table 6.1 Switches and Their Functions

17.43mA -Output1

17.43mA -Output2

Name).

the details of the error or alarm are then displayed.

Alarm and error display area

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Home key: Returns to the Execution/Setup display.

Reject key: Moves back to the previous display.

Cursor key: Moves the cursor down.

Graph display key: Displays a trend graph.

Alarm: Displayed if an alarm arises.

Enter

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

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

Detailed-data key: Displays the analog input value.

Cursor: Points the cursor at the currently selected item.

Error: Displayed if an error occurs.

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<6. Components and Their Functions>

6.3.2 Display Conguration (for Oxygen Analyzer)

Figure 6.5 shows the conguration. A password the displays positioned below enables display “Execution/Setup” to be protected. If a password has not been set, press the [Enter] key to proceed to the next panel display. The [Home] key enables you to return to Execution/Setup from

any panel display..

[Basic panel display]

6-5

[Detailed-data display]

Calibration execution

Returns to the Execution/Setup display.

[Execution/Setup display]

[Password Entry display]

Blow back execution Reset panel display

Returns to the Execution/Setup display.

[Trend Graph display]

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

Commissioning display Basic setup mA-output setup mA-output1 mA-output2 Set presets Alarms setup Hysteresis Contact delay Setpoints Contact setup Output contact 1 Output contact 2 Output contact 3 Input contacts Others Clock Averaging Fuel setup Purging Unit setup Passwords Defaults

Figure 6.5 Display Conguration

Returns to the Execution/Setup display.

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<6. Components and Their Functions>

6.3.3 Display Functions

Individual panel displays in the display conguration provide the following functions:

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

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

force and cell temperature. (see Section 10.1, “Detailed-data Display”, later in this manual).

(4) Trend Graph display: Displays a trend graph. (see Section 10.2, “Trend Graph”, later in this

manual).

(5) Calibration execution: Makes zero and span calibrations. (see Chapter 9, “Calibration”, and

the associated sections later in this manual).

(6) Blow back execution: Executes a “Blow back setup”. (see Section 10.4, “Blow Back”, later in

this manual).

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

more details, see Section 10.6, “Reset”, later in this manual).

(8) Maintenance panel display: Sets the data for equipment maintenance or makes a loop

check.

6-6

(9) Commissioning display: Sets up the operation data. (For details, see Chapter 8, “Detailed

Data Setting”, and the associated sections later in this manual.)

6.3.4 Entering Numeric and Text Data

This section sets out how to enter numeric and text data. If only numeric values are entered, a numeric-data entry display as in Figure 6.6 then appears. Press the numeral keys to enter numeric values. If those values include a decimal point as in Figure 6.6, the decimal point need

not be entered because the decimal point position is already xed, so just enter 00098.

New value: 000.98 % O

Figure 6.6 Numeric-data Entry Display

5 6

Enter

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To enter a password (in combination with text data, numeric values and codes), the alphabetic

character entry panel display rst appears. If you press any numeral key [0 - 9], the current

display then changes to the numeric-value entry panel display, enabling you to enter numeric

values. If you press the [other] key, the current display then changes to the code-entry display,

enabling you to enter codes. These displays alternate between the three. Figure 6.7 shows the relationship between these three displays. Three alphabetic characters and three codes are assigned for each individual switch. If the alphabetic character key is pressed and held, three characters appear in turn. Move the cursor to the desired character and release the key to enter it. If an incorrect character is entered, move the cursor to re-enter the characters. The following shows an example of entering “abc%123.”

IM 11M13A01-02E

<6. Components and Their Functions>

Operation Display Press the [ABC] key once. A

Press and hold the [ABC] key. A A

B C

6-7

Release the [ABC] key when the character B AB

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

as above. Press the [other] key.

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

Then press the [0-9] key.

Enter the numeric characters 1, 2 and 3 in turn. ABC%123 Press the [Enter] key to complete the entry.

Enter your password

0-9

other

Space

- $

B C

K L

T U

E F

N O

W X

H I

Q R

Z @

Enter

Siki06E.ai

Enter your password

A-Z

other

5 6

Figure 6.7 Text Entry Display

Enter

Enter your password

A-Z

0-9

{ [ }

0 #

+ ,

? @

% &

–

. /

[

\ ]

( )

; <

_ `

Enter

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<6. Components and Their Functions>

6.4 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit

Reference gas flow setting valve

Span gas flow setting valve

Zero gas flow setting valve

Flowmeter for reference gas

6-8

Flowmeter for calibration gas

Figure 6.8 ZA8F Flow Setting Unit

Flowmeter for calibration gas

Flowmeter for reference gas

Reference gas flow setting valve

CAL.OUTREF.OUT

Made in Japan

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Terminal Box

ZERO INSPAN IN

Calibration gas flow setting valve

Figure 6.9 ZR40H Automatic Calibration Unit

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IM 11M13A01-02E

YOKOGAWA ZR22S, ZR402G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

u CE marking products

u After-Sales Warranty

1. Overview

1.1.1 System 1

1.1.2 System 2

1.2 < EXAxt ZR > System Components

1.2.1 System Components

1.2.2 Detectors and Accessories

2.2 Separate type Explosion-proof Detector and Related Equipment

2.2.1 ZR22S Separate type Explosion-proof Detector

2.2.2 ZO21R Probe Protector

2.3 Separate type Explosion-proof Detector for High Temperature and Related Equipment

2.3.2 ZO21P High Temperature Probe Adapter

2.4 ZR402G Separate type Converter

2.4.2 Functions

2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit

2.5.1 ZA8F Flow Setting Unit

2.5.2 ZR40H Automatic Calibration Unit

2.6 ZO21S Standard Gas Unit

2.7 Other Equipments

2.7.1 Ejector Assembly for High Temperature (E7046EC, E7046EN)

2.7.2 Stop Valve (L9852CB, G7016XH)

2.7.3 Check Valve (K9292DN, K9292DS)

2.7.4 Air Set

2.7.6 ZR22A Heater Assembly

3. Installation

3.1 Installation of General-purpose Detector

3.1.1 Installation Location

3.1.2 ATEX Flameproof Type

3.1.3 FM Explosion-proof Type

3.1.4 CSA Explosion-proof Type

3.1.5 IECEx Flameproof Type

3.1.6 Probe Insertion Hole

3.1.7 Installation of the Detector

3.1.8 Installation of Probe Protector (ZO21R)

3.2.1 Installation Location

3.2.2 Usage of High Temperature Probe Adapter (Model ZO21P)

3.2.3 Probe Insertion Hole

3.2.4 Mounting of High Temperature Detector

3.3 Installation of ZR402G Converter

3.3.1 Installation Location

3.3.2 Mounting of the Converter

3.4 Installation of ZA8F Flow Setting Unit

3.4.1 Installation Location

3.4.2 Mounting of ZA8F Flow Setting Unit

3.5 Installation of ZR40H Automatic Calibration Unit

3.5.1 Installation Location

3.5.2 Mounting of ZR40H Automatic Calibration Unit

3.6 Insulation Resistance Test

4. Piping

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

4.1.2 Piping for the Calibration Gas Inlet

4.1.3 Piping for the Reference Gas Inlet

4.1.4 Piping for the Reference Gas Outlet

4.1.5 Piping to the High Temperature Probe Adapter

4.2 Piping for a System to Perform Automatic Calibration

4.2.2 Piping for the Calibration Gases

4.2.3 Piping for the Reference Gas

4.2.4 Piping to the High Temperature Probe Adapter

4.2.5 Piping for Blow back

5. Wiring

5.1 General

5.1.1 Terminals for the External Wiring in the Converter

5.1.2 Wiring

5.1.3 Mounting of Cable Gland

5.2 Wiring for Detector Output

5.2.2 Connection to the Detector

5.2.3 Connection to the Converter

5.3 Wiring for Power to Detector Heater

5.3.2 Connection to Detector

5.3.3 Connection to Converter

5.4 Wiring for Analog Output

5.4.2 Wiring Procedure

5.5 Power and Grounding Wiring

5.5.1 Power Wiring