YOKOGAWA ZX8D User Manual

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User ’s Manual

Model ZX8D Zirconia Oxygen Analyzer

IM 11G00E01-01EN

6th Edition

u Introduction

Thank you for purchasing the ZX8D Zirconia Oxygen Analyzer.

Please read the following respective documents before installing and using the ZX8D Zirconia Oxygen Analyzer.

The related documents are as follows.

General Specications

Model Contents Document number Note

IR202 Infrared Gas Analyzer GS 11G02Q02-01EN

IR400

The “E” or “EN” in the document number is the language code.

User’s Manual

Model Contents Document number Note

ZX8D Zirconia Oxygen Analyzer IM 11G00E01-01EN (This manual)

IR202 Infrared Gas Analyzer IM 11G02Q02-01EN

IR400 Infrared Gas Analyzer IM 11G02N01-01E

The “E” or “EN” in the document number is the language code.

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

manual.

NDIR TYPE INFRARED GAS ANALYZER (5-COMPONENT ANALYZER)

GS 11G02N01-01E

WARNING

• This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent

explosion, re or other serious accidents.

• When noxious gases such as CO or other gases are contained in the calibration gas, be careful when venting or handling the instrument to avoid poisoning.

• When combustible gases are contained in measuring gas, check the gas composition and

instrument specications before use, or else the best performance may not be obtained or

there may be a danger of explosion.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

CAUTION

• This unit should be installed in a place which conforms to the conditions noted in the

instruction manual. Otherwise, it may cause electric shocks, re or malfunction of the unit.

• During installation work, care should be taken to keep the unit free from entry of cable chips

or other foreign objects. Otherwise, it may cause re, trouble or malfunction of the unit.

• The unit must be earthed as specied. Otherwise, it may cause electric shocks, malfunction,

etc.

• Be sure to use a power supply of correct rating. Connection of power supply of incorrect

rating may cause re.

• Wiring work must be performed with all the power supplies to OFF to prevent electric shocks.

• Use wiring materials that match the rating of the unit. Use of wiring materials out of rating

may cause re.

• Wiring at a place which is exposed to water or rain, is prohibited in order to prevent electrical shock or damage to the instrument.

• To avoid electrical shock, be sure to turn OFF the source power supply before work.

• To prevent burning your hands, be sure to turn OFF the source power supply before

cleaning the piping outlet. After power o󰀨, wait until the piping outlet cools down.

• Beware of acid uid inside the pipe. If acid uid should contact your skin or clothes,

immediately wash them with large amount of tap water. If they should splash onto your eyes, seek medical attention at once.

• Do not use replacement parts other than those specied by the maker. Otherwise intended

performance may not be obtained, or accidents or faults may result.

• Replacement parts such as a maintenance part should be disposed of as incombustibles.

• If the cause of any fault cannot be determined despite reference to the instruction

manual, be sure to contact local sales representative or service o󰀩ce. If the instrument is

disassembled carelessly, you may have a shock hazard or injury.

• Do not use a replacement part other than specied by the instrument maker. Otherwise,

adequate performance will not be provided. Besides, an accident or fault may be caused.

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.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

u Safety Precautions

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

• In order to protect the system controlled by the product and the product itself and ensure safe operation, observe the safety precautions described in this user’s manual. We assume no liability for safety if users fail to observe these instructions when operating the product.

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

provided by this instrument may be impaired.

• If any protection or safety circuit is required for the system controlled by the product or for the product itself, prepare it separately.

• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to as YOKOGAWA) when replacing parts or consumables.

• Modication of the product is strictly prohibited.

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

WARNING

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

iii

CAUTION

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

CAUTION

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

NOTE

This symbol indicates information that complements the present topic.

n Warning and Disclaimer

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

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

n Notes on Handling User’s Manuals

• Please hand over the user’s manuals to your end users so that they can keep the user’s manuals on hand for convenient reference.

• Please read the information thoroughly before using the product.

• The purpose of these user’s manuals is not to warrant that the product is well suited to any particular purpose but rather to describe the functional details of the product.

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

• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at any time, without notice or obligation.

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

contact our sales representative or your local distributor.

n Drawing Conventions

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

description.

Some screen images depicted in the user’s manual may have di󰀨erent display positions or

character types (e.g., the upper / lower case). Also note that some of the images contained in this user’s manual are display examples.

n Product Disposal:

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

n Trademark Acknowledgments

• All other company and product names mentioned in this user’s manual are trademarks or registered trademarks of their respective companies.

• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this user’s manual.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

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 a packing box are essential parts of the

product. Keep them together in a safe place for future reference.

n Users

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

n Information of the WEEE Directive

This product is purposely designed to be used in a large scale xed installations only and,

therefore, is out of scope of the WEEE Directive. The WEEE Directive does not apply. This product should be disposed in accordance with local and national legislation/regulations. The WEEE Directive is only valid in the EU.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

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Model ZX8D Zirconia Oxygen Analyzer

IM 11G00E01-01EN 6th Edition

CONTENTS

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

u Safety Precautions ......................................................................................iii

u CE marking products ..................................................................................v

1. Overview ........................................................................................................1

2. Specications ...............................................................................................2

3. Name and Description of Each Part ...........................................................4

4. Installation .....................................................................................................5

4.1 Mounting method ................................................................................................. 5

4.2 Piping .................................................................................................................... 6

4.3 Sampling ............................................................................................................... 7

4.4 Wiring method ...................................................................................................... 8

Toc-1

5. Operation .......................................................................................................9

5.1 Operating procedure ........................................................................................... 9

5.2 Preparation for operation .................................................................................... 9

5.3 Start of measurement .......................................................................................... 9

5.4 Shutdown .............................................................................................................. 9

6. Maintenance ............................................................................................... 10

6.1 Daily inspection .................................................................................................. 10

6.2 Cleaning gas outlet ............................................................................................ 11

6.3 Replacement of fuse .......................................................................................... 12

6.4 Output characteristic ......................................................................................... 12

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

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1. Overview

The zirconia oxygen analyzer utilizes a solid electrolyte consisting mainly of zirconia (ZrO2) which conducts only oxygen ions at a high temperature. It is an oxygen sensor which measures, based on the principle of an oxygen concentration cell, the electromotive force produced due to the

di󰀨erence in oxygen concentration between the measured gas and reference air. By combining

this analyzer with a sampling system including an infrared gas analyzer, it can accurately measure oxygen concentration for a variety of applications including combustion equipment control, air separation plants and laboratory use.

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2. Specications

Measuring system: Zirconia solid electrolyte

Measuring range: Minimum range 0 to 5 vol% O

vol% O

Measurable component:

Output signal: 4 to 20mA DC and 0 to 1V DC linear connected to infrared gas

Sensor output:

Temperature alarm output: Contact output normally-closed contact,

Flow rate:

NOTE : The Zirconia system, due to its principle, may produce a measuring error due to relative concentration versus the

combustible O sensor.

Warm up time: Approx. 30 minutes

Ambient temperature: 0 to +45°C

Ambient humidity: 90% RH or less

Use environment: Indoors

Mounting method: Indoor wall mounting

Gas inlet/outlet: Rc1/4 or 1/4NPT

Enclosure: Steel casing

Indication: Temperature indication (LED)

Outer dimensions (H×W×D): 141×170×190 mm

Mass: Approx. 3 kg

Finish color: Munsell 5Y7/1

Power supply

Rated voltage: 100 to 115 V AC or 200 to 240V AC

Rated frequency: 50 Hz/60 Hz

Power consumption: Max. 215 W. Approx. 65 W for ordinary use.

Fluctuation of power supply voltage: 230V AC ±10%

Repeatability: ±0.5% FS (when connected with infrared gas analyzer)

Linearity: Within ± 1% of full scale

Zero drift: Within ± 1% of full scale/week

Span drift: Within ± 2% of full scale/week

Response speed: Approx. 20 seconds for 90% response

Oxygen in noncombustible gas or combustion exhaust gas (sensor will be burned and error will appear if combustible gas is mixed in sample gas)

analyzer or direct output from sensor of the ZX8D.

Logical output of zirconia sensor (with sensor temperature of 800°C)

E = 50.74 log

Contact capacity: 220V AC, 1A (resistive load)

0.5±0.25 liter/minute (when connected with infrared gas analyzer)

gas concentration. Also, a corrosive gas (SO2 of 250 ppm or more, etc.) may a󰀨ect the life of the

(when connected with infrared gas analyzer)

and maximum range of 0 to 25

, if used in combination with infrared gas analyzer

20.6 – B

E: Logical output (mV) X: Measured gas concentration (%O B: Blank voltage (mV)

)

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Safety, EMC and RoHS conforming standards (Only ZX8D-□*D)

Installation altitude: 2000 m or less

Pollution degree: 2

Installation category: II

Note: Installation category, called overvoltage category, species impulse withstanding voltage. Category II is for electrical

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

Safety: EN61010-1

EMC: EN61326-1 Class A, Table 2 (For use in industrial locations), EN61326-2-3,

EN61000-3-2, EN61000-3-3 EMC Regulatory Arrangement in Australia and New Zealand Korea Electromagnetic Conformity Standard Class A

Note: The product mounted in a steel enclosure conforms to the requirements of EMC directive.

한국 전자파적합성 기준

Caution: The 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: EN50581

Information of the WEEE Directive

This product is purposely designed to be used in a large scale xed installations only and,

therefore, is out of scope of the WEEE Directive. The WEEE Directive does not apply. The WEEE Directive is only valid in the EU.

n Model and Su󰀩x codes

Model Su󰀩x code Option code Description

ZX8D - - - - - - - - - - - - - - - - - - - - - Zirconia Oxygen Analyzer Power supply -3

-5

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

- - - - - - - - - - -

200−240 V AC, 50/60 Hz 100−115 V AC, 50/60 Hz

For IR202, IR400 For IR202, IR400 (CE conformity)

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

3. Name and Description of Each Part

n Name and description of each part on case

2 8

OXYGEN ANALYZER

TEMP.

3 4 5 6 72

AC250V T3.15A

INPUT

OUT

ALM

4 5 6 73

Front view

No. Name Function

1 Case cover Protects the internal components. 2 Retaining screw Fix the case cover. 3 Main switch Turn ON to supply power to the interior. 4 Fuse 250V AC/3.15A 5 Terminal board Used to connect input/output 6 Sample gas inlet Connect tube for gas to be measured.

(Rc1/4 internal thread or 1/4NPT internal thread)

7 Sample gas outlet Connect tube for discharging measured gas.

(Rc1/4 internal thread or 1/4NPT internal thread)

8 Temperature indicator Indicates the sensor temperature. 9 Specication nameplate Indicates type and specications.

n Name and description of internal parts

Side view

F0301.ai

F0302.ai

No. Name Function

10 Oxygen sensor Provides output according to oxygen concentration in sample gas. 11 Temperature controller Controls heater of oxygen sensor at operating temperature of 800°C. 12 Relay Control relay for heater. 13 Gas feeding case Introduces gas to be measured to the oxygen sensor.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

4. Installation

WARNING

This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent

explosion, re or other serious accidents.

CAUTION

This unit should be installed in a place which conforms to the conditions noted in the instruction

manual. Otherwise, it may cause electric shocks, re or malfunction of the unit.

4.1 Mounting method

OXYGEN ANALYZER

141

TEMP.

3 4 5 6 72

AC250V T3.15A

OUT

INPUT

110

ALM

150 or

Unit: mm

170

190

4-M4

150 or more

OXYGEN ANALYZER

131

152

TEMP.

3 4 5 6 72

AC250V T3.15A

ALM

OUT

INPUT

150 or moreMounting dimensions

F0401.ai

Maintenance space

• Mount the unit on a metal plate, such as steel plate, of more than 3 mm thick using M4 screws or bolts. Do not mount it on materials such as plasterboard or lumber, which do not

have su󰀩cient strength for mounting. If the unit is to be mounted on a metal plate of less than 3 mm thick, it is recommended to x the unit using nuts.

• Mount on a vertical wall with the gas inlet and outlet facing down.

• Provide space for maintenance and heat dissipation at the top, bottom, front and right side.

• To protect the oxygen sensor, avoid supplying power with the front of the unit facing upward.

• Select a proper installation location.

• Select a place where temperature will not uctuate too much, and remains near the normal

temperature and humidity.

• Select a place which is free from heat radiation or direct sunlight.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

• This analyzer is of an indoor structure. When installing outdoors, select a place which is not exposed to rain or water or use a protective cover.

• Select a clean place which is free from corrosive gas or combustible gas.

4.2 Piping

Connect pipes to the gas inlet and outlet at the bottom of the unit.

Use anticorrosive tubes such as Teon, stainless steel or polyethylene for connecting this

instrument and the sampling system.

The inlet pipe should be kept as short as possible to allow a fast response. A suitable inner diameter is around 4 mm. The pipes and joints should be clean, because dust entering the instrument may cause faulty operation.

Since sulfuric acid mist or oxides may be discharged through the outlet pipe, this pipe should have an inner diameter of about 8mm and be easily detachable for cleaning. A branch should also be provided midway on this pipe for eliminating mist and the like. The outlet pipe should be open to the atmosphere to avoid connecting it to another analyzer, sampling device, etc.

Sample gas inlet (Rc1/4 or 1/4NPT): Connect pipe here for introducing gas to be measured.

OUTLET

Sample gas outlet (Rc1/4 or 1/4NPT):

Connect pipe here for discharging measured gas.

n Piping conguration diagram

Following is a typical example of piping.

Check

Sample gas

Permapure dryer

valve Filter

Oxygan

analyzer

INLET

Bottom view

Flowmeter

F0402.ai

Infrared gas

analyzer

Inlet

Outlet

Changeover valve

Inlet

Water sealed

Exhaust (open to atmosphere)

NO SO2Air O2/N

(Standard gas)

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

F0403.ai

4.3 Sampling

WARNING

• This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent

explosion, re or other serious accidents.

• When combustible gases are contained in measuring gas, check the gas composition and

instrument specications before use, or else the best performance may not be obtained or

there may be a danger of explosion.

n Sample gas conditions

• Dust included in sample gas should be completely eliminated with a lter. Use a lter capable of eliminating dust particles of 0.3 μm at the nal stage.

• The dew point of sample gas must be lower than the ambient temperature to avoid condensation of drain inside the analyzer. If water vapor is included in sample gas, then use

a dehumidier to lower the dew point to about 0°C.

• If SO

• Strongly corrosive gases like Cl

• Sample gas temperature should range from 0 to 50°C. Do not introduce a high temperature

• Combustible gases such as H

mist is included in sample gas, then use a mist lter, cooler or the like to exclude it.

Other types of mist should also be excluded.

life of the instrument. Harmful components such as Si vapor, alkaline metals, P, Pb and SO at high concentrations (1000ppm or more) will also shorten its service life.

gas directly into the instrument.

reaction and produce a measuring error.

, F2 and HCl included in sample gas will shorten the service

and CO included in sample gas will consume O2 via a

n Sample gas ow rate

Set the sample gas ow rate at 0.5±0.25 L/min.

n Preparation of standard gas

Prepare standard gas for zero point and span calibration.

Zero gas (span gas in rule of measuring) Air Span gas (zero gas in rule of measuring) 1 to 2% O

2/N2

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

4.4 Wiring method

Ground terminal

CAUTION

• Wiring work must be performed with all the power supplies to OFF to prevent electric shocks.

• Be sure to perform class D grounding. Otherwise electric shock or malfunction may result.

• During installation work, care should be taken to keep the unit free from entry of cable chips

or other foreign objects. Otherwise, it may cause re, trouble or malfunction of the unit.

• Use wiring materials that match the rating of the unit. Use of the wiring materials out of rating

may cause electric shocks or re.

• Be sure to use a power supply of correct rating. Connection of power supply of incorrect

rating may cause re.

• Wiring at a place which is exposed to water or rain, is prohibited in order to prevent electrical shock or damage to the instrument.

External terminals are provided on the front of the instrument. Make connection to these terminals according to Figure 4.1. Be sure to perform class D grounding.

Terminal screws are M4. Keep the power supply wiring to 3 m or shorter, and use a polyvinyl chloride wire of 1.25 sq for 600V or equivalent.

Use shielded wiring for the output signal to reduce the inuence of external noise.

Oxygen analyzer

1 2 3 4 5 6 7

+ –

Power supply:

100 V or 220 V AC 50/60 Hz, approx. 200 VA

Figure 4.1 External wiring

Output from zirconia detector

Temperature alarm setting ±20°C

Infrared gas analyzer

F0404.ai

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

5. Operation

WARNING

• When noxious gases such as CO or other gases are contained in the calibration gas, be careful when venting or handling the instrument to avoid poisoning.

• When combustible gases are contained in measuring gas, check the gas composition and

instrument specications before use, or else the best performance may not be obtained or

there may be a danger of explosion.

CAUTION

• Do not use a replacement part other than specied by the instrument maker. Otherwise,

adequate performance will not be provided. Besides, an accident or fault may be caused.

• Wiring at a place which is exposed to water or rain, is prohibited in order to prevent electrical shock or damage to the instrument.

5.1 Operating procedure

Read through the instruction manual for the infrared gas analyzer to be combined with this analyzer, then proceed to operation accordingly.

The oxygen analyzer requires a warmup of at least 30 minutes.

5.2 Preparation for operation

(1) Check of piping and wiring

Make sure all the piping and wiring have been made correctly.

(2) Turning on power

Turn on the power switch and the temperature will be indicated.

(3) Warmup

Flow zero gas (air) and warm up the instrument for at least 30 minutes. The warmup is

nished when the temperature reaches 800±5°C.

(4) Calibration

Calibrate the zero point (air) and span with reference to the instruction manual for the

infrared gas analyzer.

5.3 Start of measurement

Flow the sample gas into the instrument.

5.4 Shutdown

When shutting down the instrument, supply air or the like for at least 5 minutes to replace the measured gas inside the sensor.

The turn OFF the power switch.

IM 11G00E01-01EN 6th Edition : May. 21, 2018-00

6. Maintenance

WARNING

When noxious gases such as CO or other gases are contained in the calibration gas, be careful when venting or handling the instrument to avoid poisoning.