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SICK ZIRKOR200 Ex-G, Operating Instructions Manual

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SICK ZIRKOR200 Ex-G Operating Instructions Manual Download Page 31

31

8024250/18HT/V2-0/2020-12| SICK

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

Subject to change without notice

INSTALLATION

5

5

Installation

5.1

Determination of the requirements for explosion protection

Check with the marking of the device and its components whether all requirements 
regarding zone classification, temperature class, gas group, safety level, ambient 
temperatures and pressure conditions are met. 

5.2

Information on installation in potentially explosive atmospheres

Correct installation         

DANGER: Danger of explosion during installation work

There is a danger of explosion due to sparking during installation, for example when 
cables are connected of components are dropped.

▸

Perform installation work only in the Ex-free area.

DANGER: Danger of explosion 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 
experienced persons who have knowledge of the rules and regulations for potentially 
explosive atmospheres, particularly:
– Ignition protection types  
– Installation rules
– Zone classification

▸

Standards to be applied 

▸

Local work safety regulations

DANGER: Danger of explosion due to damaged probe tube

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

▸

The analyzer unit must be in operation while in the process.

CAUTION: Risk of injury when the device drops down

The device is heavy and may cause injury if dropped.

▸

Carry out assembly work on the device in pairs.

WARNING: Risk of damage to flameproof joints

▸

Do not damage the surfaces of the flameproof joints between enclosure and 
enclosure cover of control unit and analyzer unit while opening or closing the devices.

▸

When a surface of a flameproof joint is damaged, replace the enclosure and the 
enclosure cover.

▸

Prior to fitting the enclosure cover on the enclosure, protect the surfaces of the 
flameproof joint with a thin layer of a suitable protective grease.

NOTICE: Protect the device from atmospheric conditions

When using outdoors under weather conditions, equip the explosion-proof electrical 
equipment with a protective roof or wall. 

NOTICE: Pay attention to the distance between flameproof joint and obstacles

If there are other fixed obstacles outside the enclosure, the minimum distance between 
the flameproof joint of the enclosure and these obstacles shall not be less than the 
distance specified in IEC/EN 60079-14.

●

Gas group IIA: 10 mm

●

Gas group IIB: 30 mm

●

Gas group IIB+H2 or IIC: 40 mm

Summary of Contents for ZIRKOR200 Ex-G

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

Page 2: ...ected 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 prop...

Page 3: ...ns of use 15 2 4 Responsibility of user 16 2 4 1 Designated users 16 2 4 2 Correct project planning 16 2 4 3 Correct use 16 2 4 4 Special local conditions 16 2 4 5 Read the Operating Instructions 16 3 Product description 17 3 1 Product identification 17 3 2 Type plates 17 3 3 Device versions 20 3 4 Device variants 23 3 5 Options 23 3 6 Expansion modules 23 4 Layout and function 24 4 1 System overv...

Page 4: ...g the connection terminals 44 5 10 2 Instructions for the function of the spring loaded terminal 44 5 10 3 Potential equalization PE ground 44 5 10 4 Connecting the control unit 45 5 10 5 Electrical connection plan Ex control unit and Ex analyzer unit 46 5 10 6 Power connection 48 5 10 7 Connecting the connection cable to the control unit 49 5 10 8 Connecting the valve cable of the analyzer unit t...

Page 5: ...YS MENU 60 7 2 Menu explanations 63 7 2 1 O2 measuring ranges scaling 63 7 2 2 Measured value average over s 63 7 2 3 mA output for system error 63 7 2 4 O2 limit value alarms 64 7 2 5 O2 sensor adjustment values 64 7 2 6 Time per test gas feed 64 7 2 7 Stopping time until process O2 65 7 2 8 Auto Adjustment ACAL 65 7 2 9 Settings for auto adjustment 65 7 2 10 REMOTE 66 7 2 11 Units of measure 66 ...

Page 6: ... description 82 10 3 Maintenance 82 11 Troubleshooting 83 11 1 Strongly fluctuating O2 measured value 83 11 2 O2 display remains at end of measuring range or is higher than expected 83 11 3 Indications on the display are OK mA output signal is not correct 83 11 4 O2 display on 0 although the operating mode indicates a higher O2 value 84 12 Decommissioning 85 12 1 Safety information on decommission...

Page 7: ...ithout notice 13 2 Technical data 96 13 2 1 Installation location 96 13 2 2 Technical data of the control unit 96 13 2 3 Technical data of the analyzer unit 97 13 2 4 Data of the external pneumatics 97 13 2 5 Technical specification for the gas supply 98 13 3 Tightening torques for Ex relevant screw fittings 99 ...

Page 8: ... Final inspection record ZIRKOR200 Ex G USB stick with technical information and certificates Manual for solenoid valve test gas Data sheets for 1 2 NPT and 3 4 NPT screw fitting Processing instructions for sealing compound screw fittings Work User groups Qualification Installation Operator system integrator E g plant operator untrained in measurement technology Qualification for explosion protect...

Page 9: ...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 10: ... 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 11: ...e not described in these Operating Instructions Work on the device not described in these Operating Instructions or associated documents 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 desc...

Page 12: ...ion This can lead to burns or damage to health Always keep the process connection tightly closed Pay attention to hot surfaces Wear appropriate protective equipment CAUTION Danger of explosion through incorrect or missing grounding Incorrectly connected potential equalization can lead to potential differences which can create sparks due to transient phenomena discharges and lead to explosions in E...

Page 13: ...pneumatic valve Warning Risk of electrostatic charge see Instructions 2 3 Intended use 2 3 1 Purpose of the device The device is a stationary oxygen measuring device and serves continuous measurement of oxygen as emission and process monitoring in the industrial sector The device measures continuously directly in the gas duct in situ 2 3 2 Operation in potentially explosive atmospheres ZIRKOR200 E...

Page 14: ...ing to open the enclosure and the manufacturer s instructions must be strictly followed Only use the oxygen analyzer unit with associated protective pipe with flue gas feed in flue gases when the composition is not critical concerning the corrosion effect on the materials used If this cannot be ensured regular recurring checks must be carried out at sufficiently short intervals The flue gas temper...

Page 15: ...ed for a process side operating range of 800 mbar abs to 1100 mbar abs The use in different pressures is not conform to the EX certification and therefore not allowed Operate the ZIRKOR200 Ex G within the described specifications see Technical data page 96 If the ZIRKOR200 Ex G is operated outside the specifications it does not con form to the Ex certification and is therefore not allowed ...

Page 16: ...e ZIRKOR200 Ex G as described in these Operating Instructions see Intended use page 13 The manufacturer bears no responsibility for any other use Carry out the prescribed maintenance work see Maintenance plan page 72 Do not carry out any work on the ZIRKOR200 Ex G not described in these Operating Instructions Do not remove add or modify any components to or on the ZIRKOR200 Ex G unless described a...

Page 17: ...ditional information but has no reference for the approval 3 2 Type plates The type plate is located on the unit components as shown in the Figures below Product name ZIRKOR200 Ex G GasEx Oxygen analyzer with analyzer unit and control unit Manufacturer SICK AG Erwin Sick Str 1 D 79183 Waldkirch Germany Type designation Z200EXG y0 y 1 2 for control unit and analyzer unit Z200EXG y1 y 1 2 for contro...

Page 18: ...50 18HT V2 0 2020 12 SICK O P ERA TI N G I NS TRU CT IO N S ZIRKOR200 Ex G Subject to change without notice 3 PRODUCT DESCRIPTION Fig 2 Type plates 1 Control unit Z200EXG y1 y 1 2 Analyzer unit Z200EXG y2 y 1 2 ...

Page 19: ... P ER ATI N G I N S TRU C TI ON S ZIRKOR200 Ex G Subject to change without notice PRODUCT DESCRIPTION 3 Type plate of the automatic pneumatic unit Type plate of the semi automatic pneumatic unit See type plate of automatic pneumatic unit ...

Page 20: ...mm incl sinter metal filter Protection tube Cooling tube required optional SR Z without protection tube Electronics only Y Protection tube for 464 mm 500 C X Protection tube for 924 mm 500 C W Cooling tube SiSiC 500 mm with probe 464 mm immersion depth 1400 C V Cooling tube SiSiC 1000 mm with probe 464 mm immersion depth 1400 C Flange required FL Z without flange electronics only A ANSI 4 150 lbs ...

Page 21: ...ed GE 0 Probe only A Double housing IP 66 with failsafe heater control unit for Zone 2 2G B Double housing IP 66 with failsafe heater control unit for Zone 2 3G Power Supply required SV 0 Probe only 1 115 V 10 50 Hz 2 230 V 10 50 Hz 3 115 V 10 60 Hz 4 230 V 10 60 Hz Interfaces optional SS 0 No Option probe only 1 RS232 with interface protocol 2 RS485 with interface protocol 3 MODBUS RTU over RS232...

Page 22: ...ed instrument air supply provided by the customer 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 AE 0 No Option probe only 1 Additional module for pressure compensation Electronics version optional EA A Probe only B Standard devi...

Page 23: ...as feeding mounted in Ex area Analyzer unit Solenoid valve for test gas feeding mounted in Ex area Pneumatic unit manual mounted in Ex area Pneumatic unit automatic mounted in Ex area Counter flange Various interfaces RS 232 RS485 HART Fieldbus 3 6 Expansion modules The electronics are also available optionally with different interfaces RS 232 RS485 HART Fieldbus If you have ordered one of these o...

Page 24: ...e atmosphere Zone 1 2G IIC T3 Flue gas duct combustion chamber flue gas temperature up to 500 C 3 Pneumatic line C Flue gas direction 4 O2 connection cable analyzer electronics control unit 5 Solenoid valve optional 6 Counter flange optional 7 Insulation Customer a Output signals analog and digital 8 Duct wall b Power supply power voltage 230 V 115 V 10 50 to 60 Hz max 400 VA 9 Solenoid valve cont...

Page 25: ...Pneumatic line C Flue gas direction 4 O2 connection cable analyzer electronics control unit 5 Solenoid valve optional 6 Counter flange optional F Space requirements 2 0 m for straight construction 0 8 m for 90 angle construction 7 Insulation Customer 8 Duct wall a Output signals analog and digital 9 Solenoid valve control cable only with solenoid valve option b Power supply power voltage 230 V 115...

Page 26: ...ed or the system is temporarily switched off e g at night or on weekends Frequent cooling and heating of the analyzer unit leads to a thermal load on hot analyzer unit 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 meas...

Page 27: ...he supply voltage supply circuits for heating and solenoid vales as well as all signal circuits in rooms are fitted in ignition protection type Flameproof enclosure Ex d The sensor which is temperature stabilized at 800 C is also located inside the flameproof enclosure and thus does not represent an ignition source for the environment With ignition protection type flameproof enclosure Ex d the fun...

Page 28: ...y depending on the type ordered are part of the Ex d enclosure When a screw plug different from the one fitted at the factory is used use a suitable screw plug certified according to IEC60079 1 Openings not used must be closed off according to IEC 60079 1 The covers of the Ex d terminal compartments must be screwed in to the stop before commissioning It must be secured by screwing in the cover loc...

Page 29: ...mored or unarmored cable types Observe the delivered document on the relevant cable inlet Tightly screw the Ex d cable inlets into the enclosure The delivered cable inlets are suitable for the enclosure temperature range stated in the ZIRKOR200 Ex G certification If other cable inlets than those delivered are used they must have an Ex qualification ignition protection and the IP classification and...

Page 30: ...the lowest ambient temperature 4 7 2 Ignition source monitoring of the analyzer unit by means of temperature monitoring The temperature of the analyzer unit is monitored by an additional electronic system Part No 2105158 with two thermoelements The electronics are designed to be fail safe redundant These automatically switch off the analyzer unit heating when the operating temperature of the analy...

Page 31: ... be applied Local work safety regulations DANGER Danger of explosion due to damaged probe tube A cold analyzer unit can be damaged by condensed corrosive flue gas as a result of which the analyzer unit is no longer encapsulated in a flameproof enclosure and can lead to explosions The analyzer unit must be in operation while in the process CAUTION Risk of injury when the device drops down The devic...

Page 32: ...to account when selecting or replacing cable inlets see Connecting the control unit page 45 DANGER Danger through open drill holes or unused cable inlets Explosion protection endangered Always close off unused cable inlets with the approved sealing plugs Take the thread type and size into account when selecting or replacing suitable plugs see Connecting the control unit page 45 WARNING Danger due ...

Page 33: ...ed Required for Ferrules 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...

Page 34: ...thing for all work with a contaminated analyzer unit 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 for all components 40 C to 80 C Step Procedure Reference 1 Fit th...

Page 35: ... during 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 Switch the plant off when working on the gas duct On the basis of a risk assessment the operator determines...

Page 36: ...serve enclosure protection class Ambient temperatures Min 20 C Max 55 C Min 4 F Max 131 F Heavy device ensure correct lifting and carrying 1 2 3 Secure the enclosure on a structure that can safely carry the weight of the enclosure Use expansion anchors when fitting the enclosure on concrete Use vibration resistant fitting material when fitting the enclosure in a steel frame Protect the device from...

Page 37: ...to change without notice INSTALLATION 5 Fig 10 Installing and insulating the analyzer unit 1 3 d2 min 2 4 5 6 7 3 3 8 d 1 1 Analyzer electronics 2 Analyzer unit flange seal 3 Protective pipe 4 Protective pipe flange seal 5 Counter flange welded on gas tight 6 Process wall 7 Flue gas direction ...

Page 38: ...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 Note When using a cooling protection pipe the part of the protection pipe protruding from the duct wall must be insulated or if necessary heated in order to prevent it from falling below the dew point which...

Page 39: ... temperature on the connection unit and process temperature Avoid vibrations greater than 2 g Observe protection class Heavy device ensure correct lifting and carrying WARNING Danger of explosion through breaching the flameproof enclosure An Allen screw damaged due to incomplete loosening or during filter replacement or a loose Allen screw can damage the flameproof enclosure by damaging the flamep...

Page 40: ...n the immediate vicinity of the system and clearly marked as the disconnecting device of the system on off switch All other cables must be suitable for the ambient temperature onsite and must have the relevant cross section The connection terminals of the control unit are suitable for conductor cross sections from 0 08 mm AWG 28 to 2 5 mm AWG 12 Reduce the suitable cross sections by one size unit ...

Page 41: ...not connect the connection cable shielding to the analyzer unit as this will falsify the measured value The connection cable is suitable for an ambient temperature of 40 C to 90 C Only lay the connection cable in a temperature range of 5 C to 50 C Observe maximum possible signal cable length Observe minimum bending radius Rmin 330 mm Lay connection cable 1 only crosswise to cables 2 carrying the l...

Page 42: ... outside via a PE connection M8x15 Firmly install the cable between pneumatic unit and control unit Probe cable No Function Diameter Colors Additional information 1 Measuring cell 2 x 0 75 mm White brown brown With shielding 2 Thermoelement 2 x 0 75 mm Green white With shielding 3 Thermoelement 2 x 0 75 mm Green white With shielding 4 Measuring probe heater 3 x 1 5 mm Black blue yellow green 5 Sol...

Page 43: ...al data Section when replacing a removable power cable WARNING Danger of electrical accidents Incorrect performance of electrical work could result in serious electrical accidents Electrical work on the device may only be carried out by electricians familiar with the possible dangers NOTICE Device damage through short circuit on the device The internal electronics can be damaged when signal connec...

Page 44: ...loaded terminal Fig 14 Connecting conductors schematic diagram 5 10 3 Potential equalization PE ground Connect the external grounding connection on the enclosure parts of the control unit and the supply unit see ZIRKOR200 Ex G Electrical connection plan Ex measuring probe and Ex enclosure page 47 analyzer electronics enclosure pneumatic unit as well as the optionally installed solenoid valves dire...

Page 45: ...noid valve of the analyzer unit NPT 6 5 6 Solenoid valve automatic pneumatic unit NPT 6 5 7 I O customer interface NPT 6 5 7 6 5 1 2 3 4 No Terminal designation Terminal number Terminal type 1 Grounding terminals Screw terminal 2 Power connection terminals X3 1 X3 5 Spring terminals 3 Connection cable X3 6 X3 12 Spring terminals 4 Internal wiring X4 1 X4 16 Spring terminals 5 Signal connection ter...

Page 46: ...luences the control unit the supplied ferrite sleeves must be mounted as follows EU conformity is void when these ferrite sleeves are not installed Fig 15 Positions of the ferrite sleeves 10 8 6 B1 D D E E G F C A A B2 A A A A Ferrite sleeves B1 Pneumatic unit optional B2 Solenoid valve of the analyzer unit C Signal output 4 20 mA O2 value D Connection cable fitted at factory E Connection cable fi...

Page 47: ...al connection plan Ex measuring probe and Ex enclosure Z K G 01 2 1 3 4 5 2 6 6 2 6 6 7 2 6 6 2 6 6 7 8 5 9 8 9 8 5 9 8 9 6 5 2 2 2 1 5 8 6 6 29 5 2 6 6 2 2 0 5 5 A 0 B A 0 B A5 0 B A 0 B A 0 B 5 A 0 B A 0 B A5 0 B 2 C 6 C C C 5 D 5 5 5 5 5 D D A 5 A 5 C A5 A C A A A D A D A A A A A A A A A A A A 5 D D 5 5 C C 2 C 6 A D A D A 0 B A 0 B A 0 B A 0 B 5A5 5A C Z K G ...

Page 48: ...tive conductor Lead the power cable through a cable inlet to the lower enclosure section and connect to terminal strip TERM X3 see ZIRKOR200 Ex G Electrical connection plan Ex measuring probe and Ex enclosure page 47 and following Table Suitable power voltage power frequency see Technical data of the control unit page 96 Connection terminal Function TERM X3 1 L1 power voltage phase TERM X3 3 N pow...

Page 49: ... X2 3 Thermoelement 2a 0 75 Green With shielding X2 4 Thermoelement 2a 0 75 White With shielding X2 5 Thermoelement 2b 0 75 Green With shielding X2 6 Thermoelement 2b 0 75 White With shielding Connection terminal Function Wire bundle No Cross section mm Colors Additional information PWRB X5 24A Solenoid valve 1 Black PWRB X5 24B Solenoid valve 1 Blue X4 5 Solenoid valve 1 Green yellow Connection t...

Page 50: ... cables out of the potentially explosive atmosphere and connect outside the potentially explosive atmosphere 5 10 13 Connecting the connection cable Connect the signal cables to the desired connection terminals in the lower enclosure section Relay marking LED marking Function A a Main measuring probe heater relay B b Maintenance C c System error D d Limit value O2 1 E e Measuring range F f Limit v...

Page 51: ...l part of the enclosure Otherwise Touch a different blank metal surface that is connected to the protective conductor or has safe contact to the grounding Pay primary attention to any individual information provided No Connection terminals Polarity Function 17 PWRB X5 17A Current output 02 0 4 20 mA PWRB X5 17B 18 PWRB X5 18A Maintenance Active closed PWRB X5 18B 19 PWRB X5 19A System error Active...

Page 52: ...ing cell 1 0 75 White br Do not connect the shielding 2 Measuring cell 1 0 75 Brown Do not connect the shielding 3 Thermocouple 1 2a 0 75 Green Do not connect the shielding 4 Thermocouple 1 2a 0 75 White Do not connect the shielding 31 Thermocouple 2 2b 0 75 Green Do not connect the shielding 41 Thermocouple 2 2b 0 75 White Do not connect the shielding 6 Measuring probe heater 3 1 5 Black 7 Measur...

Page 53: ...he sealing compound is enclosed to the delivery and a detailed processing instruction can be found on the packaging of the sealing compound Connection terminal Function Wire bundle No Cross section mm Colors Additional information 1 Solenoid valve 0 75 Blue 3 Solenoid valve 0 75 Black PE Solenoid valve 0 75 Green yellow 1 Screw 2 Lock washer 3 Clamping bracket 4 Connection cable 5 Washer PE Connec...

Page 54: ...ce air blue and test gas green must be prepared with 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 on the analyzer unit Fig 22 Pneumatic connections on the analyzer unit Observe minimum bending radius Hose Rmin 138 mm Temperature range installation Temperature range operation 1 Pneumatic hos...

Page 55: ...volume Adjust the flow volume of reference air and test gas using the flow controller of the respective flowmeter in the pneumatic unit The pneumatic unit in a separate field housing can be installed locally next to the Ex d analyzer unit Instrument air and test gas are connected by the customer The built in flow meters for reference air and test gas allow flow monitoring during adjustment Pressur...

Page 56: ...a on the type plate see Type plates page 17 If not contact SICK Are the electrical connections made correctly see Electrical installation page 43 Note You are basically familiar with the ZIRKOR200 Ex G You are familiar with the national and local requirements regarding the installation and operation of equipment in Ex areas You are familiar with the local situation especially the potential hazards...

Page 57: ...e gaskets used see Fitting the analyzer unit page 36 Do the conditions on site correspond to the specifications in the Data Sheets see Technical data page 87 Does the heating monitoring still have a valid calibration function check see Heating shutdown in case of malfunction page 81 6 3 Operation In the Ex area the ZIRKOR200 Ex G can only be operated via SICK REMOTE using the ZIRKOR Remote App The...

Page 58: ...nd then measuring mode starts Fig 23 Initial commissioning The software version is displayed in the lower right corner 6 5 Display heating process Fig 24 Display heating process 6 6 Display Measuring mode Fig 25 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 ...

Page 59: ...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 unauthorized users Functions that can influence the O2 measurement are also secured in this way Caution After commission...

Page 60: ...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 61: ...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 62: ...only for 2 point adjust ment 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 63: ...tput signal is limited to a minimum of 3 60 mA for theO2 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 O2 measured value output Measuring range underflows and overflows are shown on the display measuring mode 7 2 2 Measured value avera...

Page 64: ...t value alarm is reset when the O2 measured value drops below the O2 limit value minus hysteresis value 6 If the hysteresis 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 65: ...t with 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 ...

Page 66: ... 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 Spanish Polish and French are available Note REMOTE is disabled by default so the password and range a...

Page 67: ...d 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 30 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 can o...

Page 68: ... and if 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 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 and the O2...

Page 69: ...t gas flows must be checked and if necessary readjusted 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 70: ... 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 71: ...ing and after removal from the duct Wear suitable protective clothing Perform work on the analyzer unit after it has cooled down DANGER Hazard by voltage There is a risk of electric shock when working on the device with the voltage supply switched on Only carry out maintenance work when the device is disconnected form the power supply The voltage supply may only be switched on again after work com...

Page 72: ...nit 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 Danger of explosion when using spare or expendable parts not a...

Page 73: ...sition of the fuses x x Check the calibration date of the heating monitoring x Visual check of the flameproof enclosure of the control unit see Visual check of the flameproof enclosure page 76 x Visual check of cables and hoses for external damage 1 M month s Y year s Deviating from these recommendations the operator must define a suitable maintenance interval for his process and measuring locatio...

Page 74: ...d due to incomplete loosening during filter replacement or a loose Allen screw can damage the flameproof enclosure by damaging 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 filter head and all parts in the pr...

Page 75: ...e Remove the thin transparent reference air hose from the feed through fitting on the analyzer electronics Now carefully pull out the inner part of the measuring probe 4 hole ceramics rod with measuring signal wire thermoelement and heating straight 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...

Page 76: ...art of the analyzer unit Perform replacement as described in Chapter Replacing the O2measuring cell to remove the inner part of the measuring probe An exception is the thermoelement replacement as the inner part of the measuring probe does not have to be removed here 8 6 6 Visual check of the flameproof enclosure Check the flameproof enclosure is ensured If the enclosure is damaged have the enclos...

Page 77: ...e is checked for stability This check works according to the following criteria 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...

Page 78: ... 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 problems of O2 sensor heating cable on the terminal points of the control unit and or analyzer unit connection cable damaged short circuit thermoelement reference air flow volume greater than 60 l h power voltage too low flo...

Page 79: ...ful 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 test gas flow volume too low filter damager filter head no...

Page 80: ...ure of the control unit falls below the specified lower limit The measured value tolerances specified for the system are no longer guaranteed Electronic 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 be reset by the user i...

Page 81: ...ult in one of the 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 81 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 Figur...

Page 82: ...eathed thermoelement The device has two independent channels Each of these channels switches 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 supply voltage is lost Furthermore the difference between the two chann...

Page 83: ...Broken filter element Visual inspection by removing the analyzer unit Incorrectly installed V shield Analyzer unit was installed without filter head Possible cause Notes Leakage on the measuring cell or mea suring cell flange seal Check all flanges and screw fittings 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...

Page 84: ...efective check resistance approx 2 80 Ohm Replace the inner part of the measuring 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 connection cable mV tap in the analyzer unit measuring signal wire is not available or interrupted Check the inner part of the ...

Page 85: ...ocal representative 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 environment DANGER Danger to health through contaminated measuring probe Depending on the composition of the gas in the measuring channel the m...

Page 86: ...en the connection screws between the analyzer unit and gas channel and remove the measuring 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 i...

Page 87: ...ange without notice TECHNICAL DATA 13 13 Technical data 13 1 Dimension drawings 13 1 1 Dimension sheets of the control unit Fig 35 Zone 1 control unit dimensions mm 120 70 0 55 5 110 5 165 5 225 5 220 5 165 5 110 5 50 5 0 95 316 670 640 236 571 700 M8 8 349 5 359 5 356 276 220 All dimensions in mm ...

Page 88: ...36 Dimensions of analyzer unit 1 Solenoid valve calibration gas valve Option 2 Protective pipe flange Analyzer unit type Length A Length B kg Z200EXG xxA 464 mm 586 mm 20 7 Z200EXG xxB 924 mm 1046 mm 23 5 with protection pipe and counter flange Ø 19 45 22 5 Ø 191 Ø 230 145 180 B Ø 76 1 144 122 157 131 A Ø 19 45 22 5 Ø 191 Ø 230 110 180 103 157 130 B Ø 76 1 122 A All dimensions in mm ...

Page 89: ...180 5 650 C Ø 45 Ø 76 1 103 159 130 Ø 19 45 22 5 Ø 191 Ø 230 145 180 5 650 C Ø 45 Ø 76 1 144 159 131 1 Analyzer electronics 2 Test gas shut off 3 Suction connection 1 4 4 Cooling protection pipe 5 Protective pipe flange 6 Counter flange 7 Duct wall 8 Gas outlet 9 Gas inlet Cooling protection pipe Immersion depth C kg Z200EXG xxxW 500 mm 23 0 Z200EXG xxxV 1000 mm 24 1 with measuring probe and count...

Page 90: ...nsions in mm 8 drill holes 6 drill holes 4 drill holes Protective pipe flange Mat DIN 1 4571 AISI 316 Ti Dimensions See Table Outer diameter of protective pipe 76 1 mm 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 protection 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...

Page 91: ...th cooling protec tion pipe 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 pipe 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 pipe 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 71 8 DN100 PN16 M 220 0 ...

Page 92: ...r LongLife with seals and screws 4a Measuring cell flange seal 2089295 5 Filter head 2105087 6 Test gas cock solenoid valve 2105088 2105089 Test gas cock Solenoid valve 7 Protective pipe Use the product code to ask your SICK contact for the part numbers Protective pipe length Z200ExG XXXY Z200ExG XXXX Z200ExG xxxW Z200ExG xxxV 8 Protective pipe flange Use the product code to ask your SICK contact ...

Page 93: ... N S TRU C TI ON S ZIRKOR200 Ex G Subject to change without notice TECHNICAL DATA 13 13 1 6 Dimension sheets of the pneumatic unit Fig 41 Dimensions and gas connections of the semi automatic pneumatic unit Semi automatic adjustment All dimensions in mm ...

Page 94: ... SICK O P ERA TI N G I NS TRU CT IO N S ZIRKOR200 Ex G Subject to change without notice 13 TECHNICAL DATA Fig 42 Dimensions and gas connections of the fully automatic pneumatic unit Fully automatic adjustment All dimensions in mm ...

Page 95: ...G Subject to change without notice TECHNICAL DATA 13 13 1 7 Display board Fig 43 Display board Material list Display and control unit Part No Designation 2089320 Display board with software for systems without pneumatics 2089321 Display board with software for systems with pneumatics ...

Page 96: ... E 002 X IECEx FTZU 19 0004X Display LC Dot Matrix 240 x 64 LED backlit Keypad Foil keyboard with pressure point Signal LED Alarm maintenance error Measuring ranges 0 00 to 2 00 Vol O2 0 00 to 25 00 Vol O2 Accuracy 0 5 of the measured value or 0 02 Vol O2 higher value valid Power voltage 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 Recomme...

Page 97: ...464 mm 924 mm Immersion depth with cooling pro tection pipe Measuring probe with cooling protective pipe 500 mm 1000 mm Measuring principle Zirconium oxide Process gas pressure 50 to 50 mbar Flow velocity 0 to 10 m s others on request Ambient temperature 20 C to 55 C 4 F to 131 F Reaction time O2 1 s test gas T90 O2 5 s test gas Probe material Stainless steel SS316 Voltage supply Via control unit ...

Page 98: ... instrument air Pneumatic version with pumps 1 Pressure regulating valve 2 3 2 way ball valve 3 Flow meter A Instrument air inlet B Test gas inlet C Test gas outlet D Reference air outlet 1 Pressure regulating valve 2 3 2 way solenoid valve 3 Flow meter A Instrument air inlet B Test gas inlet C Test gas outlet D Reference air outlet Instrument air as reference air supply test air supply Specificat...

Page 99: ...t available Specification Span gas 2 2 1 Vol O2 in N2 accuracy 2 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 them selves WARNING Disposal of subassemblies containing residual substances which are harmful to the environment The following subassemblies could contain substances that have to be disposed of sep arately Electro...

Page 100: ...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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