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SICK ZIRKOR Series, Operating Instructions Manual

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8024252/AE00/V1-0/2020-07| SICK

O P E R A T I N G   I N S T R U C T I O N S   |  ZIRKOR200  Ex-D

Subject to change without notice

MAINTENANCE

8

8

Maintenance

8.1

Technical knowledge necessary for maintenance work

8.2

Safety instructions for maintenance work  

Note: Malfunction hazard

Only technicians with special ZIRKOR200 Ex-D training are allowed to perform 
maintenance tasks on the ZIRKOR200 Ex-D.

DANGER: Danger of explosion due to damaged probe tube

A cold probe can be damaged by condensed, corrosive flue gas, as a result of which the 
probe is no longer encapsulated in a flameproof enclosure and can lead to explosions.

▸

The probe must be in operation while in the process.

DANGER: Danger of explosions through hot surfaces

The probe can be heated by the process. When withdrawn from the process, the 
temperature of the probe may be higher than the surface temperature certified for the 
environment (see Ex-marking) and lead to an explosion.

▸

Only remove the hot probe from the duct in an Ex-free environment.

WARNING: Hot surface

The probe is heated by the process and may cause burns during and after removal from 
the duct.

▸

Wear suitable protective clothing.

▸

Perform work on the probe after it has cooled down.

DANGER: Hazard by voltage

There is a risk of electric shock when working on the device with the power supply 
switched on.

▸

Only carry out maintenance work when the device is disconnected form the power 
supply.

▸

The power supply may only be switched on again after work completion or for test 
purposes by the persons carrying out the work under consideration of the valid safety 
regulations.

WARNING: Risk of chemical burns/poisoning through caustic/toxic residues 
on components with sample gas contact

After the device has been decommissioned or removed from the measuring channel, 
process gas residues can exist as deposits on components with sample gas contact 
(e.g., gas filter, gas-carrying lines etc.). These residues can be odorless or invisible 
depending on the gas mixture in the duct. Without protective clothing, contact with such 
contaminated components can lead to severe burns or poisoning.

▸

Take appropriate protective measures for work (e.g., by wearing a safety mask, 
protective gloves and acid resistant clothes).

▸

In case of contact with the skin or eyes, rinse the affected parts immediately with 
clear water and consult a doctor

▸

Decontaminate all contaminated components according to regulations after 
disassembly.

Summary of Contents for ZIRKOR Series

Page 1: ...MMMI MMMOPERATING INSTRUCTIONS OPERATI NG INSTRUCTIO NS ZIRKOR200 Ex D Oxygen Analyzer Title page ...

Page 2: ...ted by copyright Any rights derived from the copyright shall be reserved for SICK AG Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law Any modification shortening or translation of this document is prohibited without the express written permission of SICK AG The trademarks stated in this document are the proper...

Page 3: ...3 1 Purpose of the device 11 2 3 2 Operation in potentially explosive atmospheres 11 2 4 Responsibility of user 13 2 4 1 Designated users 13 2 4 2 Correct project planning 13 2 4 3 Correct use 13 2 4 4 Special local conditions 13 2 4 5 Read the Operating Instructions 13 3 Product description 14 3 1 Product identification 14 3 2 Type plates 14 3 3 Device versions 16 3 4 Device variants 18 3 5 Optio...

Page 4: ...the probe cable 30 5 10 Electrical installation 31 5 10 1 Accessing the terminals 33 5 10 2 Instructions for the function of the spring loaded terminal 33 5 10 3 Potential equalization PE ground 34 5 10 4 Fitting the ferrite sleeves EMC 34 5 10 5 Control unit electrical connections 35 5 10 6 Outputs functions and relay assignment 36 5 10 7 Digital inputs 37 5 10 8 Electrical connections on the pro...

Page 5: ...gs 51 7 2 16 Adjustment menu 51 7 2 17 Display Adjustment 51 7 2 18 1 point adjustment manual 52 7 2 19 2 point adjustment manual 53 7 3 System check 54 8 Maintenance 55 8 1 Technical knowledge necessary for maintenance work 55 8 2 Safety instructions for maintenance work 55 8 3 Information on use in Ex areas 56 8 4 Maintenance plan 56 8 5 Tools required 57 8 6 Maintenance work 57 8 6 1 Replace fu...

Page 6: ...de indicates a higher O2 value 72 12 Decommissioning 73 12 1 Safety information on decommissioning 73 12 2 Shutdown procedure 74 12 3 Removing the device 74 12 4 Environmentally compatible disposal 74 13 Technical data 75 13 1 Dimension drawings 75 13 1 1 Dimension sheets of the control unit 75 13 1 2 Dimension sheets of the probes 77 13 1 3 Counterflange dimensions 78 13 1 4 Probe components 79 1...

Page 7: ...ation requirements 1 4 Further information Observe the supplied documents Final inspection record ZIRKOR200 Ex D USB stick with technical information and certificates Work User groups Qualification Installation Operator system integrator E g plant operator untrained in measurement technology Qualification for explosion protection Electrical installation Qualified personnel Authorized electrician a...

Page 8: ...NG Risk or hazardous situation which could result in severe personal injury or death CAUTION Hazard or unsafe practice which could result in less severe or minor injuries NOTICE Hazard which could result in property damage Note Hints Symbol Significance Hazard general Hazard by electrical voltage Hazard in potentially explosive atmospheres Hazard by explosive substances mixtures Hazard by oxidizin...

Page 9: ... the integrity and confidentiality of data and rights involved in connection with using the products In all cases the customer is responsible for the implementation of safety measures suitable for the respective situation e g network separation firewalls virus protection and patch management Symbol Significance Information on the nature of the product in relation to Directive 2014 34 EU for device...

Page 10: ...ts can lead to unsafe operation of the measuring system and therefore endanger plant safety Only carry out the work on the device described in these Operating Instructions and associated documents DANGER Danger of explosion through incorrect performance of work described in these Operating Instructions Incorrect performance of work in potentially explosive atmospheres can cause serious injuries to...

Page 11: ...device measures continuously directly in the gas duct in situ 2 3 2 Operation in potentially explosive atmospheres The ZIRKOR200 Ex D measuring probe corresponds to the ATEX category according to ATEX 2014 34 EU II 2D Ex tb IIIC T133 C T141 C Db The ZIRKOR200 Ex D measuring probe fulfills the following IECEx qualification Ex tb IIIC T133 C T141 C Db CAUTION Danger of explosion through incorrect or...

Page 12: ...mperature of T133 C T141 C applies to an ambient temperature range of 20 C to 40 C 70 C The heating voltage of the probes must be switched off by a monitoring device independent of the controller and certified for this purpose when a limit temperature of 810 C is reached This task is performed by the heating monitoring system see Heat ing shutdown in case of malfunction page 69 The oxygen measurin...

Page 13: ...KOR200 Ex D as described in these Operating Instructions see Intended use page 11 The manufacturer bears no responsibility for any other use Carry out the prescribed maintenance work see Maintenance plan page 56 Do not carry out any work or repairs on the ZIRKOR200 Ex D not described in these Operating Instructions Do not remove add or modify any components to or on the ZIRKOR200 Ex D unless descr...

Page 14: ...mponents as shown in the Figures below Fig 2 Type plates 1 Product name ZIRKOR200 Ex D DustEx Oxygen analyzer with probe and electonics Manufacturer SICK AG Erwin Sick Str 1 D 79183 Waldkirch Germany Type designation Z200EXD 70 for control unit and probe Z200EXD 71 for control unit Z200EXD 72 for probe Type plate of the control unit safe area inside Type plate of the control unit safe area outside...

Page 15: ...15 8024252 AE00 V1 0 2020 07 SICK O PE RA TI N G IN S T RUC T IO N S ZIRKOR200 Ex D Subject to change without notice PRODUCT DESCRIPTION 3 Fig 3 Type plates 2 Type plate of the Ex D probe ...

Page 16: ...lve LL Option and protection tube with special design flange Sensor technology optional ST 0 No option electronics only 2 With LongLife LL sensor protection for LongLife 2 LL 2 protective circuit Probe version optional SA 0 Electronics only 1 Standard device 2 SIL2 probe Reserve RE 1 Standard device Reserve RY 1 Standard device Housing required GE 0 Probe only Y Safe area ST37 Housing with window ...

Page 17: ...he probe Required Instrument air supply customer 2 Pump version Integrated flow meter control for reference air and test gas enabled fully and semi automatic calibration of the probe Expanded System Option optional EO 0 No Option probe only 1 LongLife 2 LL 2 sensor protection Current mode for reducing gas atmospheres Required Probe with LongLife sensor for LongLife 2 Application extension optional...

Page 18: ...e standard 3 5 Options Probe Solenoid valve for test gas feeding Counterflange Various interfaces RS232 RS485 HART Fieldbus 3 6 Expansion module The electronics are also available optionally with different interfaces RS232 RS485 HART Fieldbus If you have ordered one of these options a separate Manual Specification for this interface is included with the delivery ...

Page 19: ...6X B Hazardous area zone IIIC T133 C T141 C Max ambient temperature 20 C to 70 C 4 F to 158 F 3 Pneumatic cable C Hazardous area DustEx flue gas duct combustion chamber 4 O2 probe signal cable D Flue gas direction max flue gas temperature 600 C 1112 F 5 Counterflange optional 6 Insulation Customer 7 Duct wall 8 Probe junction unit a Power supply power voltage 230 V 115 V 10 50 to 60 Hz max 400 VA ...

Page 20: ...or the system is temporarily switched off e g at night or on weekends Frequent cooling and heating of the measuring probe leads to a thermal load on hot measuring probe components heater thermoelement and O2 sensor and shortens their service life SICK shall not be liable for any resulting damage NOTICE The system must not be used to determine the oxygen content of combustible gases because the mea...

Page 21: ...fault occurs the electronics must be reset The electronic card must be checked every three years by the manufacturer for safe operation The next test date is on the sticker on the electronic board see Heat ing shutdown in case of malfunction page 69 Fig 6 Sticker with test date Note To ensure the maximum permissible surface temperature the probe is switched off when the operating temperature excee...

Page 22: ...n through incorrect installation work Incorrect assessment of the installation location as well as all further installation work in potentially explosive atmospheres can cause serious injuries to people and damage during operation Installation commissioning maintenance and testing may be performed only by skilled persons who have knowledge of the rules and regulations for potentially explo sive at...

Page 23: ...s Cable preparation NOTICE Basis for determining the measuring point Preceding project planning e g based on the SICK application questionnaire Regulations of local authorities Responsibility of the plant operator Determining the measuring point Preparing the measuring point DANGER Danger of explosion through electrostatic charges There is a danger of explosion due to sparks caused by electrostati...

Page 24: ...efore storage Wear protective clothing in accordance with regulations when working with a contaminated measuring probe Clean all components of the measuring system with slightly moistened cleaning cloths Use a mild cleaning agent here Pack all components for storage or transport Preferably use the original packing Store all components of the measuring system in a dry clean room Storage temperature...

Page 25: ...uring assembly work on the gas duct depending on plant conditions Work on the gas duct may only be performed by skilled persons who based on their technical training and knowledge as well as knowledge of the relevant regulations can assess the tasks given and recognize the hazards involved The system is switched off when working on the gas duct or on the basis of a risk assessment the operator det...

Page 26: ...ratures Min 20 C Max 55 C Min 4 F Max 131 F Pump version 20 C to 50 C Heavy device ensure correct lifting and carrying Secure the enclosure on a structure that can safely carry the weight of the enclosure Use expansion anchors when fitting the enclosure on concrete When fitting the enclosure in a steel frame use vibration proof assembly material Protect the device from long or strong mechanical vi...

Page 27: ...ry to leave sufficient assembly space for the probe and protection tube Access to the measuring probe or the connection unit must be ensured Before breaking through the flue gas duct wall make sure there is enough space inside and outside the duct for installation that there are no fixtures in the vicinity and no other obstacles in the way 1 Gas tight welded adapter plate 2 Probe protection tube 2...

Page 28: ...connection piece 3a by the customer at the angle shown The insulation 5 is also provided by the customer The flange must be mounted at an angle of 1 3 2 so that condensed flue gas elements can flow back into the duct Fig 9 Fitting the counterflange Observe ambient temperature on the connection unit and process temperature Avoid vibrations greater than 2 g Observe protection class Heavy device ensu...

Page 29: ...harges Static charges on the lines can cause an explosion Protect lines against electrostatic charges Lay lines in the Ex area firmly for example by means of cable trays NOTICE The system is not equipped with a power switch A disconnecting device e g a circuit breaker must be installed in the power supply line The disconnecting device must comply with local safety standards be easily accessible lo...

Page 30: ... Connect the probe cable shielding in the electronics housing on one side to the protective conductor PE terminal Never connect the probe cable shielding to the probe otherwise the measured value will be distorted The probe cable is suitable for an ambient temperature of 40 C to 90 C The probe cable may only be installed at temperatures in the range of 5 C to 50 C Observe maximum possible cable le...

Page 31: ...s not switched off Before starting work on the device ensure the power supply can be switched off using a power isolating switch circuit breaker Make sure the isolating switch is easily accessible located near the system and clearly marked on off switch An additional disconnecting device is mandatory when the power isolating switch cannot be accessed or only with difficulty after installation of t...

Page 32: ...vice The internal electronics can be damaged when signal connections are established and the power supply is switched on Only carry out work on the device when the power supply is switched off DANGER Danger of explosion and expiration of the Ex approval for the device when using cable inlets and closures on the probe junction unit that are not approved for operation in explosive environments The l...

Page 33: ...ic diagram WARNING Disconnect the power voltage from the system before removing the terminal cover Do not restore the power supply to the system until all enclosure covers have been closed Live parts may not be accessible after installation Follow steps 1 to 3 to connect the wires For the spring loaded terminal position see Control unit electrical connections page 35 and see Electrical connections...

Page 34: ...n the enclosure parts of the control unit and the supply unit probe enclosure the optionally installed solenoid valves directly to the main potential ground The required conductor cross section is 4 mm 5 10 4 Fitting the ferrite sleeves EMC Mount the ferrite sleeves supplied as follows to avoid line bound interference influencing the control unit EU conformity is void when these ferrite sleeves ar...

Page 35: ...115 230 V AC 50 60 Hz 7 Analog outputs active 4 20 mA L 1 17A O2 2 N Neutral conductor 17B O2 3 PE Protective conductor 8 Relay contacts for status signals potential free 2 Functional grounding 18 A B Maintenance 4 PE Protective conductor 19 A B System fault 5 PE Protective conductor 20 A B Output O2 measuring range 6 PE Protective conductor 21A B O2 limit value alarm 1 3 Shielding 22A B O2 limit ...

Page 36: ... critical errors X5 18A B Maintenance NO contact System code was entered system in Maintenance mode X5 20A B Measuring range NO contact Closed Measuring range 1 active Open Measuring range 2 active X5 24A B Probe valve NO contact Control of the probe valve X5 21A B Limit value 1 NC contact Signal an O2 limit value exceeds 1st limit value X5 22A B Limit value 2 NC contact Signal an O2 limit value e...

Page 37: ...asuring line Under no circumstances should the shielding of the probe cable be connected to the probe side as this will lead to measurement inaccuracies DANGER Danger of explosion through damaged seals Damaged seals on the enclosure cover can allow explosive air to enter the enclosure and cause an explosion Check seals for damage and replace if necessary 1 mV O2 Measuring cell white brown 2 mV O2 ...

Page 38: ...7 Electrical connection plan ZIRKOR200 Ex D O2 analyzer 0 1 2 3 1 3 4 5 6 7 58 7 9 5 6 7 58 7 6444 444 3 6 5 7 5 7 6 44 0 6 0 6 2 69 6 6 6 0 6 6 6 0 6 6 6 0 0 6 2 0 6 2 6 2 6 6 6 0 9 9 9 9 9 9 9 9 9 5 25 D 2 0 1 2 3 1 3 4 5 6 7 58 7 9 5 6 7 58 7 6444 444 3 6 5 7 5 7 6 44 0 6 0 6 2 69 6 6 6 0 6 6 6 0 6 6 6 0 0 6 2 0 6 2 6 2 6 6 6 0 9 9 9 9 9 9 9 9 9 ZIRKOR200 Ex D 2 Electronic Unit ...

Page 39: ...th support sleeves 4 clamping rings 3 and cap nuts 2 Tighten the nuts hand tight and turn a further 1 turns tight with a wrench 5 11 3 Pneumatic connections probe Fig 19 Electrical connections on the probe junction unit Observe minimum bending radius Hose Rmin 138 mm Temperature range installation Temperature range operation 1 Pneumatic hosing 2 Cap nut 3 Clamping ring 4 Support sleeve 1 Cable gla...

Page 40: ...nstrument air version A 1 4 Test gas inlet Test gas inlet B 1 4 Test gas outlet Test gas outlet C 1 4 Reference air inlet Instrument air inlet D 1 4 Reference air outlet Reference air outlet E 1 4 Test air inlet No Tube Pump version Instrument air version A 1 4 Test gas inlet Test gas inlet B 1 4 Test gas outlet Test gas outlet C 1 4 Reference air inlet Instrument air inlet D 1 4 Reference air out...

Page 41: ...Is the allocation of the pneumatic connections correct and are the connections gas tight See Sections 5 15 and see Pneumatic connections and settings page 39 Make sure there are no leaks on the probe is the counterflange welded gas tight to the flue gas duct are the flange bolts sufficiently tightened Were flange gaskets used See Section 5 8 Installing the measuring probe Do the conditions on site...

Page 42: ...software version is displayed in the lower right corner 6 3 Display heating process Fig 23 Display heating process 6 4 Display Measuring mode Fig 24 Display Measuring mode Only when O2 limit value alarms are switched on and the defined limit values are within the measuring range The heating process starts with heating up the O2 sensor 1 TAG No 2 Temperature analog display 3 Last access with date R...

Page 43: ...es a selection down one position Exit selection Cancel function or entry Select or confirm a function value Note The system code is 0000 on delivery In this state system changes are possible without code entry The system code protects the configuration data of the system against unau thorized users Functions that can influence the O2 measurement are also secured in this way Caution After commissio...

Page 44: ...nput mV Terminal temperature C F Internal temperature C F Process pressure rel mbar psi O2 Sensor life expectancy Lambda Adjustment results e g 2012 05 11 select data time Performed on Adjustment method O2 sensor adjustment Adjustment results O2 value with test air O2 adjusted to O2 value with test gas O2 Only visible when performed adjusted to Adjustment data O2 Sensor offset mV O2 Sensor slope m...

Page 45: ...on and option Software ZIRKOR200 Options System configuration O2 measuring range Measuring range 1 from O2 ppm O2 Measuring range 1 to O2 ppm O2 Measuring range 2 from O2 ppm O2 Measuring range 2 to O2 ppm O2 Measuring range selection with Dig input key Measured value average over s Conversion wet dry H2O mA output type 0 20 mA 4 20 mA mA output for system fault mA O2 limit value alarms O2 limit v...

Page 46: ... only for 2 point adjustment Only visible when ON Start by time digital input both Only visible when ON Interval days Only on time and both Adjustable Next AJUST date Process pressure input range Pressure range from mbar Pressure range to mbar Site altitude above sea level m System clock TAG No System data yyyy mm dd System time hh mm ss TAG REMOTE settings optional Visible when REMOTE interface i...

Page 47: ...put signal is limited to a minimum of 3 60 mA for the O2 measured value output A measuring range overflow 5 exists when the O2 measured value rises above the value specified in O2 measuring range to The analog output signal is limited to a maximum of 20 40 mA for the O2measured value output Measuring range underflows and overflows are shown on the display measuring mode 7 2 2 Measured value averag...

Page 48: ... value alarm is reset when the O2 measured value drops below the O2 limit value minus hysteresis value 6 If the hystere sis is set to 0 00 O2 the O2 limit value alarm must be reset manually on the device 7 2 5 O2 sensor adjustment values A 1 point adjustment should be carried out every 4 6 weeks and a 2 point adjustment every 6 months With EMI a 1 point adjustment should be carried out every 3 day...

Page 49: ...h two test gases test air test gas The required concentrations of the test gases can be entered depending on the adjustment method Test air ambient air is preset with a fixed O2 concentration of 20 95 this value is therefore neither displayed nor can it be changed The automatic adjustment starts via Time Time controlled start with fixed intervals The interval time in days as well as the time of th...

Page 50: ... SICK REMOTE connection to the analyzer is active the connection is shown in the upper right corner of the display 1 7 2 11 Units of measure Sets the units of measurement for temperature C F and pressure psi mbar 7 2 12 Language Sets the language for all display texts The languages German English French Spanish and Polish are available Note REMOTE is disabled by default so the password and range a...

Page 51: ...ined service technicians They are protected by their own service code which is independent of the system code 7 2 16 Adjustment menu 7 2 17 Display Adjustment Fig 29 Display here a 1 point adjustment Note The system code is 0000 on delivery Note the new system code and keep the information in a place accessible only to those authorized to make changes to the system If the system code is lost it ca...

Page 52: ... necessary readjusted Sequence 1 System code entry 2 Maintenance signal is set 3 Prompt for test air feed only appears for systems without flow monitoring 4 Performing the adjustment with test air 5 Prompt to terminate test air feed only appears for systems without flow monitoring 6 Display of the process return when the difference between the previously measured O2 concentration in the process an...

Page 53: ... gas flows must be checked and if necessary read justed Sequence 1 System code entry 2 Maintenance signal is set 3 Prompt for test gas feed only appears for systems without flow monitoring 4 Adjustment with test gas test gas 1 5 Prompt for test air feed only appears for systems without flow monitoring 6 Adjustment with test air 7 Prompt to terminate test gas feed only systems without internal flow...

Page 54: ... h Source Test gas O2 sensor mV Flow 3 bar max l h Source Process O2 sensor mV Check mA outputs Set mA output 17A B mA Check relay outputs Relay contact on 18A B open closed Relay contact on 19A B open closed Relay contact on 20A B open closed Relay contact on 21A B open closed Relay contact on 22A B open closed Check digital inputs Input status on 25A B Input status on 27A B Check mA inputs Check...

Page 55: ...e duct Wear suitable protective clothing Perform work on the probe after it has cooled down DANGER Hazard by voltage There is a risk of electric shock when working on the device with the power supply switched on Only carry out maintenance work when the device is disconnected form the power supply The power supply may only be switched on again after work completion or for test purposes by the perso...

Page 56: ...nd those presently anticipated A visual inspection of the probe which includes cleaning the filter element if necessary should be conducted at least once a year Deviating from these recommendations the operator must define a suitable maintenance interval for his process and measuring location that is appropriate to the safety relevance of the measurement and the conditions of the process DANGER Da...

Page 57: ...month s Y year s Deviating from these recommendations the operator must define a suitable maintenance interval for his process and measuring location that is appropriate to the safety relevance of the measurement and the conditions of the process Maintenance interval 1 Maintenance work 1M 6M 1Y Tools 3 mm Allen key 4 mm Allen key Phillips screwdrivers in different sizes Fuse Rated current SICK Par...

Page 58: ...nlet pressure is higher than 6 bar The air volume should be within the following ranges Test air 150 l h 180 l h Reference air 30 l h 40 l h 8 6 3 Setting the flow volume Safe Area control unit On systems with integrated pneumatics it is possible to set the reference or test air volume on the electronics A distinction is made here between the pump and instrument air version The pump version uses a...

Page 59: ... PE RA TI N G IN S T RUC T IO N S ZIRKOR200 Ex D Subject to change without notice MAINTENANCE 8 Fig 32 Controller positions for test air 1 pump version Fig 33 Controller positions for reference air 1 and test air 2 instrument air version ...

Page 60: ...ume on the electronics A distinction is made here between the pump and instrument air version Only the test air volume can be set for the pump version With an instrument air version it is possible to set both the reference and test air volume Fig 35 19 rack setting the flow volumes Arrows show the position of the setting valves for reference air and test air Setting valve Reference air 30 l h to 4...

Page 61: ...agon socket screw can damage the flameproof enclosure by damag ing the flameproof joint and thus lead to an explosion Loosen and tighten the hexagon socket screw completely Replace damaged hexagon socket screws WARNING Danger of burns on hot components which are in the process gas The temperature of the probe filter head and all parts in the process gas is 150 C to 800 C 302 F to 1472 F during ope...

Page 62: ...probe cable in the connection unit 5 Switch on the supply voltage and wait until the probe has reached the setpoint temperature 6 Perform a 2 point adjustment under process conditions WARNING Risk of burns The temperature of the probe filter head and all parts in the process gas is 150 C to 800 C 302 F to 1472 F during operation Directly touching the parts for disassembly or maintenance causes ser...

Page 63: ...en assembling the volume reducer must be installed so that the product is Ex compliant Screw the new measuring cell to the measuring cell flange of the probe tube with a new gasket and 4 new screws Note It is only necessary to replace the measuring cell if it leaks jumping or incorrect measured values and a two point adjustment was faulty WARNING Risk of burns The temperature of the probe filter h...

Page 64: ...e retaining plate 5 Remove the thin transparent reference air hose from the feed through screw connection on the connection unit The inner part of the probe 4 hole ceramic rod with measuring signal wire thermoelement and heater can now be carefully pulled out Now push the new inner part carefully into the probe tube and screw on the retaining plate make sure the inner part remains movable The inne...

Page 65: ...ia The last measured value is stored temporarily If the next value is out of tolerance the internal timer is reset and the new value is stored temporarily This means that if the timer has not been reset the value is stable This means that the last measured value after the timer 2 minutes is used to calculate the constants or slope Terminal Color Description Polarity Unit 1 White brown Signal cable...

Page 66: ...0 C 68 F below the setpoint temperature The O2 sensor heating is switched off It can be reset by the user to start a new heating attempt Possible causes Fuse F2 defective contact problem of the O2 sensor heating cable at the terminals of the electronics or the probe probe cable damaged short circuit thermoelement reference air flow volume greater than 60 l h power voltage too low flow volume too h...

Page 67: ...successful adjustment also resets the error Possible causes Wrong test gas not with test air test gas flow volume too low O2 sensor defective O2 sensor slope too low System error open The error can only occur during an O2 sensor adjustment It can be reset by the user A new successful adjustment also resets the error Possible causes Wrong test gas not with test air test gas flow volume too low O2 s...

Page 68: ...The ambient temperature of the control unit falls below the specified lower limit The measured value tolerances specified for the system are no longer guaranteed Electronics temp too high Possible cause The ambient temperature of the control unit falls below the specified lower limit The measured value tolerances specified for the system are no longer guaranteed Clock battery low This cannot can b...

Page 69: ... thermoelements The electronics go into self holding mode which means that if a fault occurs the electronics must be reset The error free operating status is indicated by two green LEDs see Display and operating elements page 69 The error case is indicated by three red LEDs In case of an error the device must be reset manually The position of the Reset button is shown in the Figure see Display and...

Page 70: ...hes a relay when the specified maximum temperature is reached The contacts of both relays are connected in series so that the heating is switched off when the temperature in one channel is exceeded The heating is also switched off when the operating voltage is lost Furthermore the difference between the two channels is monitored the heating is switched off when the difference is more than 32 C 10 ...

Page 71: ...nal mV tap Broken filter element Visual inspection by removing the probe Incorrectly installed V shield Probe was installed without filter head Possible cause Notes Leakage on the measuring cell or measuring cell flange seal Check all flanges and screw connections for leaks Replace the measuring cell or renew the measuring cell flange seal If there is a leak in the area of the O2 measuring cell it...

Page 72: ...oelement defective check resistance approx 2 80 Ohm Replace the inner part of the probe Fuse of the heating voltage defective Replace the fuse Transformer 230 115 V defective Check voltages Line short circuit Electronics inlet defective Wire break Check wiring Measure the probe cable mV tap in the probe measuring signal wire is not available or interrupted Check the inner part of the probe for goo...

Page 73: ...presentative DANGER Danger of explosion through residual voltages and hot surfaces in the device After switching off the device there is a danger of explosion due to the residual voltage and hot surfaces Only perform work on the device in an Ex free environmant DANGER Health hazard due to contaminated probe Depending on the composition of the gas in the measuring channel the measuring probe after ...

Page 74: ...oosen the connection screws between the probe and the gas channel and remove the probe 6 Close the flanges on the gas duct with a cover 7 Loosen the connecting screws of the pneumatic unit and remove the pneumatic unit 8 Loosen the connecting screws of the control unit and remove the control unit 9 Pack components in containers suitable for transport Information on storage see Storage information ...

Page 75: ...G IN S T RUC T IO N S ZIRKOR200 Ex D Subject to change without notice TECHNICAL DATA 13 13 Technical data 13 1 Dimension drawings 13 1 1 Dimension sheets of the control unit Fig 42 Dimensions of the control unit Safe Area in mm All dimensions in mm ...

Page 76: ...1 0 2020 07 SICK O P ERA TI N G I NS TRU CT IO N S ZIRKOR200 Ex D Subject to change without notice 13 TECHNICAL DATA Fig 43 19 rack dimensions in mm Fig 44 GRP enclosure option All dimensions in mm All dimensions in mm ...

Page 77: ...ts of the probes Fig 45 Dimensions of probes for ZIRKOR200 Ex D 0 24 24 35 35 52 52 90 90 Ø 191 Ø 191 Ø 230 Ø 230 Ø 139 7 Ø 139 7 Ø 19 Ø 19 177 177 FF FF L 0 40 40 80 80 124 124 160 160 Ø 139 7 Ø 139 7 1 Connection unit 2 Protection tube flange 3 Protection tube 4 V shield FF L kg 80 mm 540 mm 24 4 120 mm 960 mm 32 8 with counterflange All dimensions in mm ...

Page 78: ...52 Flange type Part No Ø D b Ø k Ø d2 Drill holes ANSI 4 150 lbs A 228 6 9 00 12 5 0 50 190 5 7 5 19 0 0 75 8 ANSI 2 150 lbs only with cooling pipe B 153 0 6 0 12 5 0 50 121 0 4 75 20 0 0 78 4 ANSI 3 150 lbs C 190 5 7 5 23 9 0 94 152 4 6 00 19 1 0 75 4 ANSI 3 300 lbs D 209 5 8 25 28 6 1 13 168 3 6 63 22 2 0 87 8 Ø 155 18 45 Ø 191 Ø 230 45 M16 4 2 kg All dimensions in mm Ø 191 Ø 230 Ø 150 154 Ø 232...

Page 79: ...N50 PN16DIN2527 only with cooling protec tion tube G 165 0 6 47 18 0 0 71 125 0 4 90 18 0 0 71 4 DN65 DIN2527 only with cooling protec tion tube H 160 0 6 27 14 0 0 55 130 0 5 12 14 0 0 55 4 DN65 DIN2527 only with cooling protec tion tube I 185 0 7 28 18 0 0 71 145 0 5 71 18 0 0 71 4 DN80 PN6 K 190 0 7 48 18 0 0 71 150 0 5 91 18 0 0 71 4 DN80 PN16 DIN2527 L 200 0 7 87 20 0 0 79 160 0 6 29 18 0 0 7...

Page 80: ...tion unit 2 2089293 Probe flange seal 3 2105138 540 mm 2105139 960 mm Probe inner part 4 2105147 O2 measuring cell 4a 2105148 Metal O ring 5 2105161 Test gas distributor with insulating tube 6 2105150 Filter head 8 2105164 540 mm 2105165 960 mm Protection tube 9 Included in 8 Protection tube flange 9a 2105166 Protection tube flange seal 10 2105149 Sintered metal filter and flange 11 2105167 Mounti...

Page 81: ...umatic version with pumps 1 Pressure regulating valve 2 Throttle check valve 3 3 2 way solenoid valve 3a 3 2 way solenoid valve 4 Flow meter A Instrument air inlet B Test gas inlet C Test gas outlet D Reference air outlet 1 Filter 2 Throttle valve 3 Reference test air pump 4 3 2 way solenoid valve 5 Flow meter A1 Reference air inlet A2 Test gas inlet B Test gas inlet C Test gas outlet D Reference ...

Page 82: ... Test air pump 720 l h 3 2089324 Test gas solenoid valve P01 m Pneumatic version with screw connection 4 Throttle screw connection 5 2089327 Internal flow meter for test and reference gas 6 2089329 Reference air pump 30 l h Material list Test gas and reference air unit for instrument air No Part No Designation 1 2089317 Toroidal core transformer 2x115 V Secondary 115 V 330 VA 2 2089324 Test gas so...

Page 83: ...oard Material list Installation plate 2 No Part No Designation 1 2105158 Heating shutdown 2 2116780 Power board 3 Installation plate 4 X10 terminal strip Note The 19 inch group carrier spare parts are identical with the spare parts shown above Material list Display and control unit Part No Designation 2089320 Display board with software for systems without pneumatics 2089321 Display board with sof...

Page 84: ...2 measuring ranges 2 measuring ranges 0 2 O2 to 0 25 O2 O2 accuracy 0 5 of the measured value or 0 02 Vol O2 higher value valid Manual or automatic adjustment 1 point or 2 point automatic adjustment Power voltage Instrument air version 230 V 10 50 to 60 Hz 115 V 10 50 to 60 Hz Power input 400 VA heating up phase 200 VA typ measuring mode Recommended back up fuse 10 A Output signal O2 Active 0 4 to...

Page 85: ... 20 C to 70 C Maximum surface temperature depending on the ambient temperature The specification of the maximum surface temperature T133 C T141 C applies to the above mentioned ambient temperature range Reaction time stopping time 1 s test gas T90 5 s test gas Probe material Stainless steel SS316 Protection class ATEX II 2D Ex tb IIIC T133 C T141 C Db IECEx Ex tb IIIC T133 C T141 C Db Protection c...

Page 86: ...he same composition as specified in the Test protocol The Test protocol is located on the probe sensor on deliv ery Flow volume Max 180 l h at 1 1 bar 0 1 Note The flow volume of the test gases must be adjusted on the test gas cylinders themselves WARNING Disposal of subassemblies containing residual substances harmful to the environment The following subassemblies could contain substances that ha...

Page 87: ...87 8024252 AE00 V1 0 2020 07 SICK O PE RA TI N G IN S T RUC T IO N S ZIRKOR200 Ex D Subject to change without notice TECHNICAL DATA 13 ...

Page 88: ...3 8080 7425 E Mail enquiry my sick com Mexico Phone 52 472 748 9451 E Mail mexico sick com Netherlands Phone 31 0 30 229 25 44 E Mail info sick nl New Zealand Phone 64 9 415 0459 0800 222 278 tollfree E Mail sales sick co nz Norway Phone 47 67 81 50 00 E Mail sick sick no Poland Phone 48 22 539 41 00 E Mail info sick pl Romania Phone 40 356 17 11 20 E Mail office sick ro Russia Phone 7 495 283 09 ...

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