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YOKOGAWA av550g, User Manual

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< 11. Inspection and Maintenance >

11-1

IM 11M12D01-01E

11.  Inspection and Maintenance

This chapter describes the inspection and maintenance procedures that are performed to maintain 

reliable performance of the AV550G Averaging Converter and to keep it in good operating condition. 

The procedure for adding channel cards is also explained in this chapter.

 WARNING

Do NOT touch the probe if it has been in operation immediately just before being checked. (The 

sensor at the tip of the probe heats up to 750°C during operation. If you touch it, you will get burned.)

 CAUTION

When checking the detector, carefully observe the following:

(1) Do not subject the probe to shock or cool it rapidly. 

 

The sensor is made of ceramic (zirconia). If the detector is dropped or bumped into something, 

the sensor may be damaged and no longer work.

(2) Do not reuse a metal O-ring to seal the cell assembly. If you replace the cell or remove it from 

the probe for checking, be sure to replace the metal O-ring. Otherwise, the furnace gas may 

leak, and then the leaking corrosive gas will cause the built-in heater or thermocouple to go open 

circuit, or the detector may corrode.

(3) Handle the probe with care so that the dust-filter mounted screws on the tip of the probe do not 

hurt your finger(s).

(4) Before opening or closing the terminal box, first remove dust, sand, or the like from the terminal 

box cover.

Summary of Contents for av550g

Page 1: ...User s Manual Model AV550G Zirconia Oxygen Analyzer Averaging Converter IM 11M12D01 01E IM 11M12D01 01E 7th Edition ...

Page 2: ...RT communication refer to IM 11M12D01 51E IM 11M12D01 51E has been published as Model EXAxt AV550G HART protocol Regarding the FOUNDATION Fieldbus communication refer to IM 11M12D01 61E IM 11M12D01 61E has been published as Model EXAxt AV550G Fieldbus communication The models and description items in this manual are as follows Models and descriptions in this manual Model Product Name Description i...

Page 3: ...ion Operation Maintenance 1 Overview Equipment models and system configuration examples 2 Specifications Standard specification model code or part number dimension drawing for each equipment 3 Installation Installation method for each equipment 4 Piping Examples of piping in three standard system configurations 5 Wiring Wiring procedures such as Power supply wiring output signal wiring or others 6...

Page 4: ...ck the calibration gas piping before introducing the calibration gas to ensure that there is no leakage of the gas If there is any leakage of the gas the moisture drawn from the sample gas may damage the sensor The detector especially at the tip becomes very hot Be sure to handle it with gloves 1 About This Manual This manual should be passed on to the end user The contents of this manual are subj...

Page 5: ...e operation and functions NOTICE l Specification 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 specification matches the order and required accessories are not missing Specifications can be checked by the model codes on the nameplate Refer to Chapter 2 Specifications for the ...

Page 6: ...person with specialized knowledge n How to dispose the batteries This is an explanation about the new EU Battery Directive DIRECTIVE 2006 66 EC This directive is only valid in the EU Batteries are included in this product Batteries incorporated into this product cannot be removed by yourself Dispose them together with this product When you dispose this product in the EU contact your local Yokogawa...

Page 7: ...nty stated in instruction manual l Failure caused by usage of software hardware or auxiliary equipment which Yokogawa did not supply l Failure due to improper or insufficient maintenance by user l Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize l Failure due to power supply voltage frequency being outside specifications or abnormal l Fail...

Page 8: ... 7 2 3 Separate type Detector for High Temperature and Related Equipment 2 8 2 3 1 ZR22G 0 15m Separate type Detector for High Temperature 2 8 2 3 2 ZO21P High Temperature Probe Adapter 2 9 2 4 AV550G Averaging Converter 2 11 2 4 1 Standard Specifications 2 11 2 4 2 Functions 2 12 2 5 ZA8F Flow Setting Unit 2 18 2 6 Other Equipments 2 20 2 6 1 Dust Filter for the Detector K9471UA 2 20 2 6 2 Dust G...

Page 9: ...ation Location 3 12 3 5 2 Mounting 3 12 4 Piping 4 1 4 1 Piping for a System Using Flow Setting Units for Manual Calibration 4 1 4 1 1 Parts Required for Piping in a System Using Flow Setting Units for Manual Calibration 4 2 4 1 2 Piping for the Calibration Gas Inlet 4 3 4 1 3 Piping for the Reference Gas Inlet 4 3 4 1 4 Piping to the High Temperature Probe Adapter 4 3 4 1 5 Piping for Blow back 4...

Page 10: ... 5 3 2 Wiring and Piping forAutomatic Calibration and 3rd Gas Indication Check 5 13 5 3 3 Wiring and Piping for Blow back 5 14 5 3 4 Wiring and Piping for Automatic Calibration and Blow back 5 14 6 Components 6 1 6 1 ZR22G Detector 6 1 6 1 1 General purpose Detector except for Model ZR22G 015 6 1 6 1 2 High Temperature Detector Model ZR22G 015 6 2 6 2 AV550G Averaging Converter 6 3 6 2 1 Component...

Page 11: ...tings 8 14 8 5 1 Date and Time 8 14 8 5 2 Average Value Max and Min Monitoring Time 8 14 8 5 3 Fuel Setup Humid Exhaust Gas or Dry Equivalent Oxygen Content 8 15 8 5 4 Setting Password 8 20 9 Calibration 9 1 9 1 Calibration Briefs 9 1 9 1 1 Principle of Measurement 9 1 9 1 2 Calibration Gas 9 2 9 1 3 Compensation 9 3 9 1 4 Characteristic Data from a Sensor Measured During Calibration 9 4 9 2 Calib...

Page 12: ...n Time 10 9 10 3 2 Selecting Language 10 9 10 3 3 LCD Auto Off 10 10 10 3 4 Display Contrast Adjustment 10 10 10 3 5 Tag Name Entry 10 10 10 4 Indication Check 10 11 10 4 1 Mode 10 11 10 4 2 Procedure for Performing an Indication Check 10 12 10 4 3 Setting Contacts for Operating Third Check Gas Solenoid Valve 10 12 10 4 4 Setting Indication Check Timing 10 13 10 4 5 Running an Indication Check 10 ...

Page 13: ...nel Cards 11 14 11 6 Adding the Expansion Power Supply Unit 11 15 11 7 Replacing Limited Life Components 11 16 12 Troubleshooting 12 1 12 1 Displays and Remedies When Errors Occur 12 1 12 1 1 Error Types 12 1 12 1 2 Operations When an Error Occurs 12 1 12 1 3 Error Displays 12 2 12 1 4 Remedies When an Error Occurs 12 3 12 2 Displays and Remedies When Alarms are Generated 12 6 12 2 1 Alarm Types 1...

Page 14: ... higher temperature applications up to 1400 C the ZO21P High Temperature Probe Adapter is available for use in conjunction with a 0 15 m ZR22G general purpose detector The averaging converter system is ideal for combustion control in large utility boilers or various industrial furnaces This chapter explains system configurations with some typical examples 1 1 System Configuration The AV550G Zircon...

Page 15: ...ystem Configuration Using Flow Setting Units for Manual Calibration 1 1 2 System Configuration to Perform Automatic Calibration A typical system configuration to perform automatic calibration is illustrated in Figure 1 2 The system consists of detectors an averaging converter solenoid valves needle valves for flow control and a float type flowmeter Averaging Converter AV550G Heater power Output si...

Page 16: ...1R Gas Flow F1 3E ai With dust filter K9471UA or With dust guard protector K9471UC Process gas temperature 0 to 700 C Process gas temperature 700 to 1400 C Mounting Item Temp Insertion length General purpose detector High temperature detector Application Application Horizontal to vertical Horizontal to vertical Horizontal to vertical Vertical Vertical 0 4 to 2 m 0 4 to 2 m 2 5 m or more 3 m or les...

Page 17: ...Blank Page ...

Page 18: ...asurement Range Any setting in the range of 0 to 5 through 0 to 100 vol O2 in 1 vol O2 or partial range Digital Communication HART 250 to 550 Ω depending on number of field devices connected to the loop multi drop mode Note HART is a registered trademark of the HART Communication Foundation Display Range 0 to 100 vol O2 Warm up Time Approx 20 min Repeatability Excluding the case where the referenc...

Page 19: ... pressure When the pressure in the furnace exceeds 5 kPa you must perform pressure compensation For 0 15 m probe 0 5 to 5 kPa No pressure fluctuation in the furnace should be allowed Note When the detector is used in conjunction with a check valve and a ZA8F Flow Setting Unit the maximum pressure of sample gas is 150 kPa When with a check valve and a ZR40H Automatic Calibration Unit it is 200 kPa ...

Page 20: ...es from horizontal to vertically downward is available When the probe insertion length is exceeds 2 5 m mount vertically downward within 5 and use a probe protector Weight Insertion length 0 4 m approx 6 kg JIS 5K 65 approx 11 kg ANSI 150 4 1 0 m approx 8 kg JIS 5K 65 approx 13 kg ANSI 150 4 1 5 m approx 10 kg JIS 5K 65 approx 15 kg ANSI 150 4 2 0 m approx 12 kg JIS 5K 65 approx 17 kg ANSI 150 4 3...

Page 21: ... M20 x1 5 mm 1 2 NPT Quick connect 8 Instruction manual J E C Japanese English Chinese A Always A Options Valves Filter Tag plates C Inconel bolt 5 CV SV Check valve 6 Stop valve 6 F1 F2 Dust Filter Dust Guard Protector SCT PT Stainless steel tag plate 7 Printed tag plate 7 1 Used with the ZO21P High Temperature Probe Adapter Select flange Q 2 When installing horizontally the probe whose insertion...

Page 22: ...t mm Flange A B C t ANSI Class 150 2 RF SUS304 152 4 120 6 4 Ø19 19 ANSI Class 150 3 RF SUS304 190 5 152 4 4 Ø19 24 ANSI Class 150 4 RF SUS304 228 6 190 5 8 Ø19 24 DIN PN10 DN50 A SUS304 165 125 4 Ø18 18 DIN PN10 DN80 A SUS304 200 160 8 Ø18 20 DIN PN10 DN100 A SUS304 220 180 8 Ø18 20 JIS 5K 65 FF SUS304 155 130 4 Ø15 14 JIS 10K 65 FF SUS304 175 140 4 Ø19 18 JIS 10K 80 FF SUS304 185 150 8 Ø19 18 JP...

Page 23: ...on port t 303 85 L ø124 Flange A B C t PIPING ANSI Class 150 2 RF SUS304 152 4 120 6 4 Ø19 19 A ANSI Class 150 3 RF SUS304 190 5 152 4 4 Ø19 24 B ANSI Class 150 4 RF SUS304 228 6 190 5 8 Ø19 24 B DIN PN10 DN50 A SUS304 165 125 4 Ø18 18 A DIN PN10 DN80 A SUS304 200 160 8 Ø18 20 B DIN PN10 DN100 A SUS304 220 180 8 Ø18 20 B JIS 5K 65 FF SUS304 155 130 4 Ø15 14 A JIS 10K 65 FF SUS304 175 140 4 Ø19 18 ...

Page 24: ...IS ANSI DIN 1 55 m Approx 9 13 11 5 kg JIS ANSI DIN 2 05 m Approx 12 16 14 5 kg JIS ANSI DIN Installation Bolts nuts and washers are provided for detector probe protector and process side flange Model and Codes Model Suffix code Option code Description ZO21R L Probe Protector 0 to 700 C Insertion length 100 150 200 1 05 m 3 5 ft 1 55 m 5 1 ft 2 05 m 6 8 ft Flange 1 J A E JIS 5K 65 FF SUS304 ANSI C...

Page 25: ...ing angle Any angle between horizontal and vertical high temperature probe is fitted with an adapter Reference gas and calibration gas piping connection Rc 1 4 or 1 4 FNPT Cable inlet G 1 2 Pg 13 5 M20 x 15 1 2 FNPT Ambient temperature 20 to 150 C Sample gas temperature 0 to 700 C temperature at the measuring point of the sampling gas When sample gas is 700 C to 1400 C the high temperature probe a...

Page 26: ... type Probe Mounting Angle Vertically downward within 5 Where the probe material is SUS 310S horizontal mounting is available Construction Non explosion proof Rainproof construction Weight example Insertion length of 1 0 m approx 5 3 kg JIS approx 11 3 kg ANSI Insertion length of 1 5 m approx 5 8 kg JIS approx 11 8 kg ANSI Model and Codes Model Suffix code Option code Description ZO21P H High Temp...

Page 27: ... Ø124 3 85 Sample gas outlet Flange provided by customer Unit mm L t Flange Thickness 5 JIS 5K 32 FF equivalent Gasket Thickness 1 5 Flange 1 Ø60 5 ØB ØA Pipe hole 2 G1 2 2 1 2NPT etc ØA Ø115 Flange 1 A B C t JIS 5K 50 FF SUS304 155 130 4 Ø15 14 JIS 10K 65 FF SUS304 175 140 4 Ø19 18 JIS 10K 80 FF SUS304 185 150 8 Ø19 18 JIS 10K 100 FF SUS304 210 175 8 Ø19 18 ANSI Class 150 4 RF SUS304 228 6 190 5 ...

Page 28: ...ve load Normally open normally closed selectable Common Contact Output 5 points Four of the output points can be selected to either normally energized or normally deenergized status Contact output 5 is normally energized Contact Output for Individual Channel Fail Output to each channel Normally energized Solenoid Valve Contact Output Contact capacity 30V DC 1A 250V AC 1A voltage free contacts DC 2...

Page 29: ...ll mounting Case Aluminum alloy 100 V type Steel plate and Aluminum alloy 200 V type Paint Color Silver Gray Munsell 3 2PB7 4 1 2 Finish Polyurethane corrosion resistance coating Weight Approx 13 kg 100 V type Approx 25 kg 200 V type 2 4 2 Functions Display Functions Value Display Displays values of the measured oxygen concentration etc Graph Display Displays trends of measured oxygen concentratio...

Page 30: ...ol O2 calibration record ten times internal temperature rise alarm record Calibration Setting Items Span gas concentration vol O2 zero gas concentration vol O2 calibration mode auto semi auto manual calibration type and method zero span calibration zero calibration only span calibration only stabilization time minute second calibration time minute second calibration period day hour starting time y...

Page 31: ...or contact inputs 1 Calibration gas pressure decrease alarm 2 Range switching 3 External calibration start 4 Process alarm if this signal is received the heater power turns off 5 Validation start 6 Blow back start Self diagnosis Abnormal cell abnormal cell temperature high low abnormal channel card abnormal control card abnormal card communication Calibration Method zero span calibration Calibrati...

Page 32: ...Oxygen Channel Cards Individual Isolation 5 Oxygen Channel Cards Individual Isolation 6 Oxygen Channel Cards Individual Isolation 7 Oxygen Channel Cards Individual Isolation 8 Oxygen Channel Cards Individual Isolation Display J E F G Japanese English French German Power supply 1 2 100 115 V AC 230 V AC 3 Communication E F HART communication FOUNDATION Fieldbus communication 4 Options SCT 24 G Stai...

Page 33: ...rds Individual Isolation 5 Oxygen Channel Cards Individual Isolation 6 Oxygen Channel Cards Individual Isolation 7 Oxygen Channel Cards Individual Isolation 8 Oxygen Channel Cards Individual Isolation A Always A Option K1 K2 Expansion power supply unit for dry contact output of solenoid valve output 2 Expansion power supply unit for 24 volt output of solenoid valve output 3 1 A are common Isolatio...

Page 34: ...5 R3 R3 5 R3 R3 5 165 1 266 7 35 5 150 300 17 3 480 without knob 465 457 166 5 480 without cable gland and grommet Distance between mounting hole 150 300 165 1 266 7 465 10 M5 holes 7 6 4 knobs Extension view Unit mm 800 300 200 200 200 Maintenance space F2 5E ai ...

Page 35: ... 5 or equivalent FIowmeter Scale Calibration gas 0 1 to 1 0 l min Reference gas 0 1 to 1 0 l min Tube Connections Rc1 4 or 1 4 FNPT Reference Gas pressure Clean air supply of sample gas pressure plus approx 50 kPa G or sample gas pressure plus approx 150 kPa G when a check valve is used Pressure at inlet of the Flow Setting Unit Maximum 300 kPaG Reference Gas Consumption Approx 1 5 l min Calibrati...

Page 36: ...ent air Approx 1 5 l min Air Set REF OUT SPAN GAS IN 20 20 35 35 35 35 35 70 32 7 222 8 235 8 140 180 7 Reference gas outlet Calibration gas outlet ø6 Hole Span gas inlet Zero gas inlet JIS 50A 60 5mm mounting pipe Instrument air inlet F2 6E ai Air pressure without check valve sample gas pressure approx 50 kPaG with check valve sample gas pressure approx 150 kPaG Piping connection port A ZA8F J C ...

Page 37: ...Carborundum Filter SUS316 JIS Mesh 30 microns Weight Approx 0 2 kg Part No Description K9471UA Filter K9471UX Tool Ø51 32 10 Carborundum filter SiC Detector Unit mm Screw Increasing of insertion length F2 7E ai Attach the filter unit to the tip of the detector by screwing it clockwise 2 6 2 Dust Guard Protector K9471UC Recommended to be used when sample gas is likely to flow directly into the cell...

Page 38: ...ressure 29 to 68 kPa G Air Consumption Approx 30 to 40 l min Suction gas flow rate 3 to 7 l min Connection to Blow Rc1 4 SUS304 JIS Tube Connection Φ 6 Φ 4 mm or 1 4 inch copper tube stainless tube Note Pipe and connections are not provided Part No Description E7046EC Needle valve Rc1 4 Ejector Ø6 Ø4 TUBE joint Pressure gauge R1 4 E7046EN Needle valve 1 4 FNPT Ejector 1 4 TUBE joint Pressure gauge...

Page 39: ...izontal line from the 5 l min point on the vertical axis Suction flow Qg toward the gas pressure line to be used to find the point of intersection Draw a line vertically down from the point of intersection to the axis to find the drive pressure P at the ejector entrance 2 In Graph 1 determine Po pressure setting from L the distance between the ejector and the pressure gauge 3 Open the needle valve...

Page 40: ... the calibration gas line directly connected to the detector This valve prevents the sample gas from entering the calibration gas line Although it functions as a stop valve operation is easier than a stop valve as it does not require opening closing at each calibration Screw a check valve instead of a stop valve into the calibration gas inlet of the detector Standard Specifications Material SUS304...

Page 41: ...apter SUS 316 G7004XF K9473XG Primary Pressure Max 1 MPa G Secondary Pressure 0 02 to 0 5 MPa G Connection Rc1 4 or 1 4 FNPT with joint adapter Weight Approx 1 kg Part No Description G7004XF Joint Rc 1 4 Material Zinc alloy K9473XG Joint 1 4 FNPT with joint adapter Material Zinc alloy Adapter SUS 316 External Dimensions Ø74 Primary Secondary 88 Max 210 max 55 Approx 122 Secondary pressure gauge Pa...

Page 42: ... 2 6 8 Cylinder Pressure Reducing Valve G7013XF G7014XF This pressure reducing valve is used with the zero gas cylinders Standard Specifications Primary Pressure Max 14 8 MPa G Secondary Pressure 0 to 0 4 MPa G Connection Inlet W22 14 threads right hand screw Outlet Rc1 4 or 1 4 FNPT Material Brass body H I H AC A K T O Reducing valve handle W22 Right hand screw Stop valve Approx 112 Inlet F2 15E ...

Page 43: ...blique line is an opening portion Unit mm Note The zero gas cylinder and the reducing valve are not included in the E7044KF case assembly 2 6 10 ZR22A Heater Assembly Model and Codes Style S2 Model Suffix code Option code Description ZR22A Heater Assembly for ZR22G Length 1 015 040 070 100 150 200 250 300 0 15 m 0 4 m 0 7 m 1 m 1 5 m 2 m 2 5 m 3 m Jig for change A N with Jig 2 None Reference gas 3...

Page 44: ...kg ZR22A 015 ZR22A 040 ZR22A 070 ZR22A 100 ZR22A 150 ZR22A 200 ZR22A 250 ZR22A 300 302 552 852 1152 1652 2152 2652 3152 Approx 0 5 Approx 0 8 Approx 1 2 Approx 1 6 Approx 2 2 Approx 2 8 Approx 3 4 Approx 4 0 Jig for change L 12 K9470BX Ø21 7 30 Unit mm Ø45 Model Codes F2 17E ai ...

Page 45: ...Blank Page ...

Page 46: ...sample gas satisfies the specifications described in Chapter 2 3 1 2 Probe Insertion Hole Includes those analyzers equipped with a dust filter a dust guard protector and probe protector When preparing the probe insertion hole the following should be taken into consideration CAUTION The outside dimension of detector may vary depending on its options Use a pipe that is large enough for the detector ...

Page 47: ...or cannot perform pressure compensation Where necessary make a notch in the flange gasket Confirm the outside dimensions of the detector in Section 2 2 before installation Figure 3 1 Example of the probe insertion hole 3 1 3 Installation of the Detector CAUTION The cell sensor at the tip of the detector is made of ceramic zirconia Do not drop the detector as impact will damage it A gasket should b...

Page 48: ...he assembly to fasten or remove it Apply a heat resistant coating see Note 1 to the threads on the detector When remounting filter assembly after having once removed it from the detector reapply the heat resistant coating Note 1 As the detector is heated to 700 C it is recommended to use heat resistant coating on the threads to prevent seizing up Name of the heat resistant coating material NEVER S...

Page 49: ... 5 Probe top Detector with a probe protector Model ZO21R L B for dust wear protect The detector is used with a probe protector to prevent the sensor from being worn by dust particles when there is a high concentration of dust and gas flow exceeds 10 m sec pulverized coal boiler or fluidized bed furnace 1 Put a gasket provided by the user between the flanges and mount the probe protector in the pro...

Page 50: ...of the High Temperature Probe Adapter ZO21P During analysis the surface temperature of the probe adapter should be within the range from more than the dew point of the sample gas and 300 C or less to prevent ejector clogging gasket deterioration or bolt scoring Where the dew point of the sample gas is not known keep within the range of more than 200 C to less than 300 C The temperature shall be me...

Page 51: ... even if the above measures have been taken warm the probe adapter using a heat source such as steam 3 2 3 Probe Insertion Hole A high temperature detector consists of a ZR22G 015 Detector and ZO21P High Temperature Probe Adapter When forming the probe insertion hole the following should be taken into consideration 1 If the probe of the ZO21P is made of silicon carbide SiC the probe hole should be...

Page 52: ... 1 It is recommended to mount the detector vertically When it is impossible due to the physical arrangements and the detector is mounted horizontally ensure that the probe tip be placed no higher than the probe base 2 When mounting a high temperature probe adapter be sure to insert a gasket between the flanges to prevent gas leakage When the furnace pressure is negative ensure that there is no lea...

Page 53: ... the front cover Attach the front cover aligning the slots on the sides of the cover with the knob bolts on the case and then pull the cover down until it is seated firmly Hand tighten the knob bolts and then securely tighten the lock screw with the Allen wrench supplied Knob Bolt Lock Screw F3 8E ai Figure 3 7 How to Remove Attach the Front Cover 3 3 1 Installation Location Follow the guidelines ...

Page 54: ...nvironmental resistance should be considered 1 Installation Space and Relationship to Peripheral Devices Follow the instructions below to determine the positions of the averaging converter and peripheral devices Do not place heat generating devices in close proximity of the averaging converter specially avoid a place under the averaging converter Do not place power related devices such as transfor...

Page 55: ... to cool the inside of an instrument panel down to within the converter operating temperature range 3 3 3 Outdoor Installation The averaging converter is designed for indoor installation For outdoor installation the averaging converter should be housed in an outdoor case protected from direct sunlight and the weather The outdoor case should be equipped with a cooling system for controlling the int...

Page 56: ...be positioned vertically so that the flowmeter works correctly Pipe Mounting 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The unit weighs approximately 2 to 3 5 kg 2 Mount the flow setting unit on the pipe by tightening the nuts with the U bolt so that the metal fitting is firmly attached to the pipe F3 11E ai Figure 3 10 Pipe Moun...

Page 57: ...case should not exceed 40 C due to rays of the sun or radiated heat 5 No vibration 3 5 2 Mounting Mount case assembly on a pipe nominal JIS 50A as follows 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the case assembly The sum of the case assembly and the calibration gas cylinder weights approximately 4 2 kg 2 Mount the case assembly on the pipe by tight...

Page 58: ...del AV550G Averaging Converter F4 1E ai Needle Valve Flowmeter Pressure reducing valve Figure 4 1 Typical Piping for System Using Flow Setting Units for Manual Calibration The following outlines some points to note regarding the piping for this system Install a stop valve or a check valve through a nipple on the calibration gas inlet of the detector CAUTION The stop valve should be connected direc...

Page 59: ...low Setting Units for Manual Calibration Referring to Table 4 1 check that the parts required for your system are ready Table 4 1 Parts Required for Piping in a System Using Flow Setting Units for Manual Calibration Detector Piping Location Parts Name Remark General purpose detector Calibration gas inlet Stop valve or Check valve Yokogawa recommended L9852CB G7016XH or K9292DN K9292DS Nipple R1 4 ...

Page 60: ...1 3 Piping for the Reference Gas Inlet Reference gas piping is required between the air source instrument air and the ZA8F flow setting unit and between the ZA8F flow setting unit and the ZR22G detector Insert the air set next to the flow setting unit in the piping between the air source and the flow setting unit Use a 6 mm O D x 4 mm or larger I D or nominal size 1 4 inch stainless steel pipe bet...

Page 61: ...so that the sample gas exhaust volume can be restricted In cases where condensation is likely to occur in the probe adapter when the sample gas is cooled protect the probe adapter with an insulating material as shown in Figure 4 5 Reducing nipple R1 2 R1 4 or R1 2 1 4 NPT Needle valve Rc1 4 or 1 4 NPT F4 4E ai Figure 4 4 Mounting the needle valve for restricting exhaust flow of the sample gas Samp...

Page 62: ...s See Section 10 5 for details on the blow back function Wiring for solenoid valves is described in Section 5 3 Note Figure 4 6 Blow back Piping The following parts are required for blow back piping Blow pipe to be prepared as illustrated in Figure 4 7 Two way solenoid valve Open when electric current is on Found on the local market Air set Yokogawa recommended G7003XF K9473XK or G7004XF K9473XG B...

Page 63: ...ine to the zero gas inlet of the ZA8F Flow Setting Unit To perform an indication check open the stop valve on the line from the third check gas cylinder while open the stop valve on the span gas line to perform span calibration Span gas cylinder Instrument air Zero gas cylinder Air Set Pressure reducing valve Instrument air Stop valve Flowmeter Flowmeter Needle valve Needle valve Reference gas lin...

Page 64: ...ired Also a check valve should be installed on the calibration gas inlet of the detector A typical piping diagram for purging is shown in Figure 4 9 It is recommended that each instrument be installed to allow for minimum piping between the ZA8F Flow Setting Unit and the detector and between the solenoid valve for introducing the purge gas and the detector Check valve Check valve To ZA8F Calibrati...

Page 65: ...s some points to note regarding the piping for this system Install a solenoid valve through a nipple on the calibration gas inlet of the detector CAUTION The solenoid valve should be connected directly to the detector If any piping is present between the detector and the solenoid valve condensation may develop in the pipe causing damage to the detector by rapid cooling when the calibration gas is ...

Page 66: ...on Code 24 no external power supply for solenoid valve is required The solenoid valves are powered from the AV550G Averaging Converter Never connect external power sources in the wiring for solenoid valves When a high temperature detector is used and blow back is required to eliminate dust accumulating in the probe of the high temperature probe adapter air supply piping for purging should be insta...

Page 67: ... K9473XK or G7004XF K9473XG Connection fitting R1 4 or 1 4 NPT male General parts High temperature detector 0 15 m Calibration gas inlet Solenoid valve Yokogawa recommended E7057GS E7057GT E7057GR G7001XP G7002XP G7003XP Nipple R1 4 or 1 4 NPT male male General parts Flowmeter 0 to 1 L min General parts Needle valve For flow control General parts Tee fitting For branch connection Manifold substitu...

Page 68: ...r switching zero and span gases a stop valve and a pressure reducing valve for the cylinder in this order to the cylinder Install the piping for the solenoid valve for switching zero and span gases so that the zero gas is introduced to the detector when powered This solenoid valve is activated by a contact signal from the averaging converter Power wiring is separately required Install the needle v...

Page 69: ...e span gas and the third check gas as shown in Figure 4 12 It is recommended that the piping and wiring for the solenoid valve for switching the span gas and the third check gas be installed to allow the third check gas to be introduced when powered This solenoid valve is activated by a contact signal from the averaging converter Power wiring is separately required Stop valve Analog outputs Averag...

Page 70: ...g the calibration gases and the check valve and between the solenoid valve for introducing the purge gas and the check valve To reference gas flow setting flowmeter and needle valve Check valve Check valve Calibration gas line Reference gas line To calibration gas flow setting needle valve and flowmeter To reference gas flow setting flowmeter and needle valve To calibration gas flow setting needle...

Page 71: ...Blank Page ...

Page 72: ... Accidental removal from terminals by pulling may result in electric shock 5 1 1 Wiring Precautions Precautions Concerning the Correspondence Between Detectors and Channel Cards Multiple detectors are connected to the averaging converter Make sure that the wiring is run properly between the detector and its corresponding channel card on the averaging converter Special care should be exercised so t...

Page 73: ...on the other side of the cable To avoid any possible contact with housings of instruments connected or metal parts conductors of the shields should be processed using insulating tapes or in an appropriate way 3 The shields should be connected to the cable shield ground terminals immediately after the cable is inserted into the averaging converter through the wiring hole Having a long distance betw...

Page 74: ... 83 84 85 86 88 90 91 92 L COM NO COM NO COM NO COM NO C NC NO C NC NO N G 51 52 53 54 55 56 57 58 101102 103 104 108 1 2 3 4 5 6 2 4 5 6 7 8 7 8 SV CH1 SV CH2 DO1 DO2 DO3 DO4 DO5 SV CH6 SV CH5 CELL TC CJ TC CJ AO TC CJ AO TC CJ AO Ave a Ave b Ave c CELL CELL CELL CH1 CH5 SV COM SV CH3 SV CH4 DO CH1 DO CH2 DO CH3 DO CH4 HTR1 HTR2 HTR3 HTR4 HTR5 HTR6 HTR7 HTR8 DO CH7 DO CH8 DO CH5 DO CH6 SV CH8 SV ...

Page 75: ...nal grounding will do Cell heater HTR1 to HTR8 Shielded 2 Size 1 25 mm2 16 AWG or larger Conductor two way resistance 10 Ω or less Detector output signal CELL TC CJ Shielded 6 Conductor two way resistance 10 Ω or less Individual analog output AO Shielded 2 550 Ω or less including load resistance Averaged analog output Ave a Ave b Ave c Shielded Note Solenoid valve contact output SV COM SV CH1 to S...

Page 76: ...ration for Wiring to Detectors Follow the instructions below when connecting cables to detectors 1 Install a conduit or cable gland appropriate to the specified screw size to the cable inlet of a detector Allow for the sufficient length of a cable in case that the detector needs to be removed for maintenance 2 If the ambient temperature around the wiring lines exceeds 75 C a flexible metal conduit...

Page 77: ...gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm A lock washer must be installed Connect the ground wiring to the protective ground terminal in the averaging converter or the external ground terminal on the side of the case Run the ground wiring so the ground r...

Page 78: ... on the case of the averaging converter 51 52 53 54 55 56 57 58 7 8 CH1 CH2 CH3 CH4 Shield Averaging Converter ZR22G ZO21D To Detector for CH2 To Detector for CH3 To Detector for CH4 Detector for CH1 Basic Power Unit F5 7E ai Figure 5 7 Power Wiring to Detector Heaters If the ambient temperature at the detector installation site exceeds 75 C install a terminal box and connect to the detector using...

Page 79: ...eld ground terminals on the case of the averaging converter 1 1 1 1 2 2 2 2 1 2 3 4 5 6 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 To Detector for CH2 ZR22G ZO21D CH1 CH2 Detector for CH1 CH3 CH4 Shield Averaging Converter Channel Card CELL TC CJ F5 9E ai Figure 5 9 Signal Wiring to Detectors If the ambient temperature at the detector installation site exceeds 75 C install a terminal box and connect to the d...

Page 80: ... outputs use shielded cables that withstand temperatures of at least 80 C The number of cores is determined by the number of outputs If a cable gland is not installed on the wiring hole of the averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm Like the signal wiring to detectors the shields should be connected ...

Page 81: ...onverter All contact outputs for solenoid valves are voltage free dry contacts mechanical relay contact outputs The contacts are open under normal conditions when deenergized The contact rating is 250 V AC 1A or 30 V DC 1A If optional 24 V outputs are specified for solenoid valves Option Code 24 no external power supply for solenoid valves is required The solenoid valves are powered from the AV550...

Page 82: ...r contacts are set to normally energized and cannot be changed The NC and NO indications on the terminal show energized states States of functional contact outputs DO1 to DO4 are user selectable normally energized or normally deenergized The NC and NO indications on the terminal show deenergized states Use cables that withstand temperatures of at least 80 C for the wiring for these outputs There i...

Page 83: ...he averaging converter use a wire with an outside diameter of 17 mm or smaller If installed use a wire with an outside diameter of 6 to 12 mm Like the signal wiring to detectors the shields should be connected to cable shield ground terminals on the case of the averaging converter Contact inputs should be voltage free The open closed state of the contact is determined by the resistance from the av...

Page 84: ...ntact Input Contact Output SV COM Figure 5 15 Typical Diagram for Automatic Calibration 5 3 2 Wiring and Piping for Automatic Calibration and 3rd Gas Indication Check Averaging Converter AV550G Analog Output Averaged and Individual Output Contact Output Contact Input Power Supply Flowmeter Needle Valve Calibration Gas Line Air Set Needle Valve Flowmeter Instrument Air Reference Gas Line Solenoid V...

Page 85: ...solenoid valves F5 17 ai SV CH1 SV CH8 Figure 5 17 Typical Diagram for Blow back 5 3 4 Wiring and Piping for Automatic Calibration and Blow back Averaging Converter AV550G Analog Output Averaged and Individual Output Contact Output Contact Input Power Supply Span Gas Cylinder Instrument Air Zero Gas Cylinder Pressure Reducing Valve Solenoid Valve Flowmeter Needle Valve Calibration Gas Line Instrum...

Page 86: ... 1 5 2 0 2 5 or 3 0 3 6 4 2 4 8 or 5 4 m Flange used to mount the detector Select from JIS ANSI DIN standard models F6 1E ai Bolt Washer Pipe support U shaped pipe Metal O ring Dust filter mounting screw Sensor cell Filter Contact Probe Calibration gas pipe opening Terminal box Non explosion proof JIS C0920 equivalent to IP44D Equivalent to NEMA 4X IP66 Achieved when the cable entry is completely ...

Page 87: ... g a needle valve Separate type High temperature Detector ZR22G 015 When the temperature of the measurement gas is between 700 C and 1400 C mount this detector with a ZO21P high temperature probe adapter F6 2E ai Flange Selectable from JIS standards ANSI standards or DIN standards High Temperature Probe Adapter ZO21P The probe is made of either SUS 310S or silicon carbide SiC Its length is 0 5 0 6...

Page 88: ...7 89 88 87 DO CH6 NO NC COM 86 85 84 DO CH5 NO NC COM 83 82 81 108 107 106 105 104 103 102 101 HTR8 HTR7 HTR6 HTR5 FUSE HTR6 HTR6 FUSE FUSE HTR5 HTR5 FUSE FUSE HTR8 HTR8 FUSE FUSE HTR7 HTR7 FUSE 250V T2 5A X 8 250V T2 5A X 8 FUSE HTR3 HTR3 FUSE FUSE HTR4 HTR4 FUSE FUSE HTR1 HTR1 FUSE FUSE HTR2 HTR2 FUSE HTR1 HTR2 HTR3 HTR4 51 52 53 54 55 56 57 58 13 NO 14 15 16 COM NC NO DO2 17 18 19 COM NC NO DO3...

Page 89: ... channel display touch the area enclosed by dotted line The operation status of the averaging converter is indicated by yellow marking at the bottom of the display Table 6 1 shows the types and conditions of the markings Warmup Tag Hold Ch1 514 C Ch2 515 C Ch3 513 C Ch4 514 C Warmup Tag Ch1 514 C Ch2 515 C Ch3 513 C Ch4 514 C Ch5 514 C Ch6 514 C Ch7 513 C Ch8 Hold Warmup Tag Ch1 514 C Ave a Ave b ...

Page 90: ...displayed on the right side of the display vary depending on the panel display allowing all switch operations Table 6 2 shows the functions of the switches Table 6 2 Switches and Their Functions Enter T6 2E ai Reject key Cursor key Detailed data key Graph display Graph display key Alarm Error Page scroll key Channel scroll key Update key Cursor Moves back to the previous display Moves to the Execu...

Page 91: ...password Password protection is factory set to disabled Password Entry for Maintenance Password Entry for Commissioning F6 5E ai Enter Execution Setup Calibration Indication check Blow back Setup Maintenance Commissioning Execution Ch1 Cell voltage 0 9 mV Thermo voltage 2 9 4 mV C J resistance 1 1 7 0 2 Ω Cell temperature 7 5 0 C C J temperature 4 3 C Enter Commissioning Basic setup mA output setu...

Page 92: ...evant icon will be flashing in its display area If an error and an alarm occurs at the same time the error icon display takes precedence For details on errors and alarms refer to Chapter 12 Troubleshooting Tag Ch1 21 0 Ch2 21 0 Ch3 21 0 Ch4 21 0 Ch5 21 0 Ch6 21 0 Ch7 21 0 Ch8 20 7 Tag Ch1 21 0 O2 Ave a 21 0 O2 Ave b 21 0 O2 Ave c 21 0 O2 Tag Ch1 Err2 Ch2 0 96 Ch3 0 96 Ch4 0 96 Ch5 0 96 Ch6 Err1 Ch...

Page 93: ...mV Thermo voltage 2 9 4 mV C J resistance 1 1 7 0 2 Ω Cell temperature 7 5 0 C C J temperature 4 3 C F6 7E ai Figure 6 7 Detailed Data Display 3 Trend graph display Up to 11 user selected data from among the individual outputs from each channel and average concentration outputs groups a b and c can be viewed in graphical format at a time in a single screen To move to the trend graph display touch ...

Page 94: ...appear Calibration can be performed from the menu on this display F6 11E ai Enter Manual calibration Semi auto calibration Calibration Figure 6 11 Calibration Display 6 Indication check display From the menu on the Execution Setup display select Indication check The Indication check display will appear Indication check can be performed from the menu on this display 7 Blow back display From the men...

Page 95: ...verage group setup 6 Others clock setup password setup etc Enter Maintenance Display setup F6 14E ai Calibration setup Indication check setup Blow back setup mA output loop check Contact check Channel card power Enter Commissioning Basic setup F6 15E ai mA output setup Alarm setup Contact setup Average group setup Others Figure 6 14 Maintenance Display Figure 6 15 Commissioning Display Entering Nu...

Page 96: ...ssed and held three characters appear in turn Move the cursor to the desired character and release the key to enter it If an incorrect character is entered move the cursor to re enter the characters The following shows an example of entering abc 123 Operation Display Press the ABC key once A Press and hold the ABC key A A B C Release the ABC key when the character B AB appears in the cursor positi...

Page 97: ...2D01 01E 6 3 ZA8F Flow Setting Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve Flowmeter for reference gas Flowmeter for calibration gas F6 18E ai Figure 6 18 ZA8F Flow Setting Unit ...

Page 98: ...rs then you need to change the detector parameters Before connecting power refer to Section 7 4 Setting Detector Model Check valve type setting Check piping wiring Check settings F7 1E ai If connecting ZO21D Briefly power on Set detector to ZO21D front panel Power OFF If all detectors are ZR22G Permanent power wiring Start set parameters Warmup then calibrate Figure 7 1 Startup Procedure 7 2 Check...

Page 99: ...llows you change the detector model settings without detector warm up 1 Touch the Setup key and the Execution Setup display appears 2 Use the pointer cursor key to move the pointer to Maintenance and touch the Enter key 3 On the Maintenance display select Channel card power and touch the Enter key A display like that shown in Figure 7 3 appears 4 On the Channel card power display select the channe...

Page 100: ...ors 2 Apply power to the averaging converter 3 Error messages are displayed for these channels but you can set their parameters 4 Touch the Setup key and the Execution Setup display appears 5 Select Commissioning Basic setup Detector then the Detector Selection display Figure 7 2 appears 6 Select channels to be connected to ZO21D and change ZR22G to read ZO21D 7 After changing the channels setting...

Page 101: ...play shown in Figure 7 4 appears Confirm that the displayed temperatures of each channel gradually increase After the cell temperatures reach their target setting of 750 C and stabilize the display switches to show oxygen concentration When all the channels have switched to display oxygen concentration the red Warmup and Hold alarm marks at the bottom of the display disappear Warmup Tag Ch1 514 C ...

Page 102: ...settable Ranges are switched by contact input Contact OFF results in Range 1 and contact ON results in range 2 For details refer to Section 8 4 Setting Contact Inputs Shipping time default is for each range to be set to 0 to 25 O2 The ratio of the maximum range setting to the minimum is restricted as described in Section 8 1 Setting Analog Outputs Setting Procedure 1 Touch the Setup key to switch ...

Page 103: ...nnels that are set to ON belong to that group Use the pointer cursor keys to move the pointer to any channel whose status you want to toggle then touch the Enter key The ON OFF selection window opens and you can toggle status 5 Any or all channels may belong to both groups a and b Enter Average group a Ch1 ON Ch2 ON Ch3 ON Ch4 ON Ch5 OFF Ch6 OFF Ch7 OFF Ch8 OFF F7 8E ai Figure 7 8 Setting Averagin...

Page 104: ...n However even if only one of the gases is normally used calibration using both gases should be done at least once The zero gas normally used has an oxygen concentration of 0 95 to 1 0 percent oxygen by volume with a balance of nitrogen gas N2 The span gas widely used is clean air at a dew point temperature below 20 C and free of oily mist or dust as in instrument air For best accuracy as the span...

Page 105: ...el Manual cal Figure 7 10 Channel Select for Manual Calibration 5 Select the channels to be calibrated channels in warmup or error status can t be selected Here we describe the situation for Channel 1 6 Select Span calibration and touch the Enter key A display like Figure 7 11 appears Enter Manual cal Check the span gas concentration value Next F7 11E ai Ch1 Cancel calibration Change value 2 1 0 0...

Page 106: ...valve and tighten the lock nut used to prevent it from loosening during measurement Even if span calibration is executed the span calibration will not be completed normally if a check mark is not placed in the Span calibration box on the Zero calibration Start Display shown in Figure 7 14 Even if zero calibration is executed subsequently the results will not be applied 11 Next perform zero calibra...

Page 107: ...corresponding preset value For details of Output hold refer to Subsection 8 1 2 Output Hold Setting Shipping time default setting is for stabilization settling time to be set to 3 minutes After the stabilization settling time has elapsed then the display reverts to channel select Figure 7 10 so that you can select another channel for calibration If you touch the enter key during stabilization sett...

Page 108: ...ay shown in Figure 7 18 allows you to select contacts to check To check the individual error contacts for channels 1 to 8 select Output contact ch Channel contact output or to select Function contacts contacts 1 to 5 select Output contact ctrl Common contact outputs 5 Next the Contact no select display is displayed Select the contact you want to check then touch the Enter key and the OFF ON select...

Page 109: ...ve select its channel Ch1 through Ch8 and touch the Enter key to open the OFF valve closed ON valve open selection window Selecting an output and touching Enter key allows you to test Open Close the corresponding solenoid valve NOTE You cannot check a Channel Select valve if the corresponding Channel unit is not installed Enter Ch1 Zero Com Ch2 OFF Ch3 OFF Ch4 OFF Ch5 OFF Ch6 OFF Ch7 OFF Ch8 OFF F...

Page 110: ...ction 8 4 Setting Contact Inputs Factory default setting is 0 to 25 O2 for all ranges Setting Procedure 1 Touch the Setup key and the Execution Setup display appears 2 From the Commissioning display select mA output setup then Set range See Figure 8 1 3 Use and keys to select the channel 4 Set min O2 concentration corresponding to 4 mA output then set max O2 concentration corresponding to 20 mA ou...

Page 111: ...s the valid setting range Setting example 1 If the range minimum corresponding to 4 mA output is set to 10 O2 then range maximum corresponding to 20 mA output must be at least 13 O2 Setting example 2 If the range minimum corresponding to 4 mA output is set to 75 O2 then range maximum corresponding to 20 mA output must be at least 75x1 3 98 O2 rounding decimal part up F8 3E ai Minimum oxygen concen...

Page 112: ...channels in the averaging group is set to disabled and the output of groups in this status will be in HOLD status CAUTION Disable means setting channel card power OFF so that card may be swapped Refer to Section 11 2 Hot Swap Function Table 8 1 Status 4mA 20mA Don t hold Hold last value Preset value 2 4 21 6mA Warmup Purging Under Maintenance Under Calibration Indication Check Blow back Process Ga...

Page 113: ...min 0 0 s Points Span Zero Go to setup to change value Start calibration Cancel calibration Figure 8 4 Manual Calibration display Figure 8 5 Semi Automatic Calibration display For Automatic Calibration Under calibration is the time that starts when calibration is started at a preset timing lasts while calibration is being performed sequentially and ends after a preset hold time for the last calibr...

Page 114: ... when you touch the Enter key on the Blow back display with Start blow back selected Figure 8 8 lasts while blow back is being performed for all installed channels and ends after a preset hold time has elapsed When blow back is started by a contact input during blow back is the time that starts when blow back is started by the contact input lasts while blow back is being performed sequentially for...

Page 115: ...he Enter key A display like Figure 8 9 is displayed 2 Select an item you want to change and touch the Enter key 3 In the selection window that appears select the desired Hold method and touch the Enter key 4 Select other items as desired and set as desired as in the previous step If you select Preset Value then you can set a current output value 5 Touch the Reject key to return to the mA output ho...

Page 116: ...nds to reduce the effect A single time constant setting applies to all analog outputs Setting Procedure 1 From mA output setup on the Commissioning display select Output damping and touch the Enter key A numerical data entry display is displayed 2 To set 30 sec enter 030 and touch the Enter key Default setting Factory default setting is 0 sec no smoothing 8 1 4 Setting Output Mode Applies to All A...

Page 117: ...ettings If the measured oxygen concentration fluctuates between the normal value and the alarm setting then alarm status will keep turning ON and OFF You can reduce this annoyance by setting alarm action delay and hysteresis Delayed alarm action prevents immediate alarm output after measurement value goes outside an alarm limit alarm status is entered only if the alarm stays outside the limit for ...

Page 118: ... 0 0 F8 13E ai Ch1 Alarm set points Figure 8 12 Alarm setting Figure 8 13 Alarm setting Setting Alarm Hysteresis 3 From the Alarm setup display select Hysteresis A numeric entry display appears for you to enter the hysteresis value The units are 0 1 O2 To enter 2 5 O2 enter 25 You can enter a hysteresis setting in the range 0 to 9 9 O2 Setting Alarm Delay Time 4 From the Alarm setup display select...

Page 119: ...g Group 9 From the Alarm setup display select Except alarm ch and touch the Enter key 10 AYes No selection window appears Default setting Alarm settings are set to defaults in Table 8 3 prior factory shipment or after data initialization Table 8 3 Item Default Hysteresis 0 1 O2 Delay time 3 sec High High HH Alarm OFF High High Alarm Setting 100 O2 High H Alarm OFF High Alarm Setting 100 O2 Low L A...

Page 120: ...pan coefficient error or an electrode potential stability error results in contact output CAL Gas Pressure Low If ON then a contact input indicating calibration gas pressure low results in contact output This is a calibration gas pressure low answerback signal Corresponding contact input must be allocated to calibration gas pressure low Process Gas Alarm If ON then a contact input indicating proce...

Page 121: ...t output Enter Low Low alarm Low alarm ON High alarm OFF High High alarm OFF Cal alarm OFF Cal gas low OFF Proc gas alarm OFF Error OFF Internal temp OFF F8 14E ai Contact1 Alarms OFF Figure 8 14 Alarm Function Allocation Default setting Contact output setting are set to defaults in Table 8 5 prior factory shipment or after data initialization Table 8 5 Contact function initial defaults Item Conta...

Page 122: ...ontact input is released then reapplied CAL Gas Pressure Low Contact input disables Semi Auto or Auto Calibration Process Gas Alarm While contact signal is input for safety reasons heater power is turned off When contact input is released heater power is reapplied and warmup begins When warmup ends then Measuring mode starts Setting Procedure This setting example shows how to set When contact inpu...

Page 123: ...urging Unit setup Asymmetry alarm Passwords Defaults Others Enter F8 18E ai Set date 2 1 0 6 0 4 Set time 1 6 4 4 2 1 J un 2 0 0 4 1 6 4 4 4 5 Clock Figure 8 17 Others setting display Figure 8 18 Day and Time setting 8 5 2 Average Value Max and Min Monitoring Time This instrument can compute and display Average Max and Min Oxygen concentrations in a specified time interval The Average Max and Min ...

Page 124: ...in Table 8 7 G Actual amount of exhaust gas including water vapor per unit quantity of fuel m3 kg or m3 m3 Gw Water vapor contained in exhaust gas per unit quantity of fuel by hydrogen and moisture content in fuel m3 kg or m3 m3 1 in Table 8 7 Gw1 Water vapor contained in exhaust gas per unit quantity of fuel moisture content in air m3 kg or m3 m3 Go Theoretical amount of dry exhaust gas per unit ...

Page 125: ...n in fuel weight percentage h2 Hydrogen in fuel weight percentage wv Moisture content in fuel weight percentage Hx Same as numeric value of Hl For solid fuel Amount of water vapor in exhaust gas Gw 1 100 1 24 9h w m kg Theoretical amount of air Ao 1 01 x Hl 1000 0 56 m kg Low calorific power Hl Hh 25 9h w kJ kg X value 1 11 0 106 1000 x Hx m m where w Total moisture content in use weight percentag...

Page 126: ...022 0 020 0 018 0 016 0 014 0 012 0 010 0 008 0 006 0 004 0 002 0 000 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 35 37 39 33 31 29 27 25 Wet bulb temperature C Absolute humidity kg kg Dry bulb temperature C F8 20E ai Figure 8 20 Absolute Humidity of Air ...

Page 127: ... 1 6 4 2 25 0 2 0 20 0 53 0 50 5 25 9 2 6 3 9 0 1 8 0 20428 18209 3391 3349 37883 34074 102055 93976 125496 115868 12767 12642 39750 69638 62991 99070 128452 10758 12642 35820 63744 59060 91255 118623 4 455 0 603 9 015 24 63 30 37 2 390 2 390 9 570 16 74 14 35 23 91 31 09 0 45 0 45 0 98 3 10 3 90 1 0 2 0 2 0 1 0 3 0 4 0 1 10 0 02 1 88 4 10 4 90 1 0 2 0 3 0 2 0 4 0 5 0 3 60 1 01 7 17 19 5 24 0 1 89...

Page 128: ...ty of the atmosphere then select finished to revert to the display of Figure 8 21 Enter Fuel setup F8 21E ai Theoretical air quantity required 1 0 0 m3 kg more Contents of moisture in exhaust gas 0 0 0 m3 kg Enter Fuel setup F8 22E ai Absolute humidity of the atmosphere 0 0 0 0 0 kg kg finished Value of the X coefficient 1 0 0 See Manual for details Figure 8 21 Fuel Setup display 1 Figure 8 22 Fue...

Page 129: ...Mainte 4 Select Calibration Ind check Blow back and Mainte 5 A text entry display appears Enter password as up to 8 alphanumeric characters You can enter a password for Commissioning by the same procedure 6 Record the passwords and look after them carefully Enter F8 23E ai Calibration Ind check Blow back and Mainte Commissioning Passwords Figure 8 23 Password Setting Default setting The passwords ...

Page 130: ...ive electrode on the opposite side There the electrons are released and the ions return to the oxygen molecules This reaction is indicated as follows Negative electrode O2 4e 2 O 2 Positive electrode 2 O 2 O2 4 e The electromotive force E mV between the two electrodes generated by the reaction is governed by Nernst s equation as follows E RT nF ln Px Pa Equation 1 where R Gas constant T Absolute t...

Page 131: ...nducted so that a calibration curve is obtained which corrects the deviation from the theoretical cell electromotive force 9 1 2 Calibration Gas A gas with a known oxygen concentration is used for calibration Normal calibration is performed using two different gases a zero gas of low oxygen concentration and a span gas of high oxygen concentration In some cases only one of the gases needs to be us...

Page 132: ...range 100 30 Span correction ratio C A x 100 Correctable range 0 18 Cell electromotive force mV Calibration curve before correction Corrected calibration curve theoretical calibration curve Zero origin Span gas concentration Zero gas concentration Span origin Oxygen concentration vol O2 F9 2E ai Figure 9 2 Calculation of a Two point Calibration Curve and Correction Ratios using Zero and Span Gases...

Page 133: ... resistance So the cell s degrading cannot be estimated from these values only When only a span calibration has been made these values will not be measured and previously measured values will remain 5 Robustness of a cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed in a number on four levels 9 2 Calibration Setup 9 2 1 Mode There are three ca...

Page 134: ...bration or either one or the other Normally select both Span Zero Setting Procedure From Maintenance Calibration setup display select Points then a selection window opens and you can select Span Zero Span or Zero Figure 9 5 Enter F9 5E ai Calibration setup Span Zero Span Zero Mode Auto Points Zero gas 9 8 Span gas conc 2 1 0 0 Timing Cal history initialize Figure 9 5 Procedure for Setting Points 9...

Page 135: ...ization settling time and their output is not included in averaging group calculations during this time If the mode is Semi Auto In addition to the above Hold time output stabilization settling time there is also a Cal time setting This is the settling time from when calibration gas flow is started until calibration is performed The same time setting is used for both Zero and Span calibration Sett...

Page 136: ... hold CAL time Stabilization time CAL time Ch1 removed from average Ch2 removed from average Stabilization time Figure 9 6 Calibration Timing Setting procedure 1 From the Calibration setup display select Timing and the display shown in Figure 9 7 appears In this example Mode is set to Auto 2 Select items and enter numerical values as required Enter F9 7E ai Hold time 2 min 0 0 s Cal time 2 min 0 0...

Page 137: ...HH 00 then Automatic Calibration will not be performed 5 If you set the start date before the current date then Automatic Calibration will not start 6 Cal time of Calibration timing display will be equalized to Check time of Semi auto ind chk display Table 9 1 When Auto Calibration conflicts with Other Commands Other commands Calibration Purging the channel Other channel CAL Indication check in ot...

Page 138: ...ated When started by an external contact all working channels can be calibrated one channel after another Here we give an example of the procedure for both of these cases with both Span and Zero calibration selected Calibration Procedure Starting Semi Auto Calibration from the Display 1 From the basic display if you touch the Setup key the Execution Setup display appears Select Calibration 2 Next ...

Page 139: ...me is skipped and stabilization settling time starts After that touch the reject key door with arrow icon again stabilization settling time is skipped and abort calibration completely If you touch the Enter key during stabilization settling time abort calibration of corresponding channel and next channel calibration will be started 9 3 3 Starting Automatic Calibration No user action is required to...

Page 140: ...f the indicated voltage approximates the ideal value corresponding to the measured oxygen concentration the sensor will be assumed to be normal The ideal value of the cell voltage E when the oxygen concentration measurement temperature is controlled at 750ºC may be expressed mathematically by E 50 74 log Px Pa mV where Px Oxygen concentration in the sample gas Pa Oxygen concentration in the refere...

Page 141: ...easuring the cell temperature When the ZR22 Detector is used the maximum C J temperature will be 150 C If the terminal box temperature exceeds this take measures to shield the terminal box from heat radiation The maximum C J temperature varies depending on the type of detector 10 1 6 Span gas and Zero gas Correction Ratios These are used to check for degradation of the sensor cell If the correctio...

Page 142: ...or and is expressed as one of four time periods during which the cell may still be used 1 more than a year 2 more than six months 3 more than three months 4 less than one month The above four time periods are tentative and only used for preventive maintenance not for warranty of the performance This cell s robustness can be found by a total evaluation of data involving the response time the cell s...

Page 143: ... three calibrations which however must be separated by at least five days or the data is ignored by the autopredictor the autopredictor starts operating CAUTION 1 This function does not guarantee accuracy it s just a guide 2 The recommended date for the next calibration with be within the range of between 5 and 90 days 3 If the predictor finds that the slope of the line becomes positive the line s...

Page 144: ...period of time is changed the current minimum oxygen concentration will be displayed for more details see Subsection 8 6 2 earlier in this manual 10 1 16 Average Oxygen Concentration The average oxygen concentration during the periods over which average values are calculated is displayed If the setup period elapses the average oxygen concentration that has been displayed so far will be cleared and...

Page 145: ...early in the trend graph display The function offsets the axes so that trend lines do not overlap The following describes graph setup 10 2 1 Trend Graph Screen Figure 10 5 shows how the Trend Graph is displayed Tag Ch1 21 0 Ch2 21 0 Ch3 21 0 Ch4 21 0 Ch5 21 0 Ch6 21 0 Ch7 21 0 Ch8 20 7 Enter Graph channel select Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Ch7 Ch8 Ave a Ave b Ave c F10 5E ai Touch anywhere in graph To...

Page 146: ...el no to color F10 6E ai Time per division calculated from sampling interval 1 2 3 4 5 6 7 8 a b c Figure 10 6 Plotting Graph for Sampling Interval NOTE If a rapid change in the measured value occurs during sampling no sampled data are plotted on the graph Use the graph indication tentatively Check the output current for accurate data 10 2 3 Trend Graph Display Settings Setting procedure Selecting...

Page 147: ... trend graph vertical scale 8 From the Trend graph display select Upper limit and touch the Enter key The numerical entry display appears and you can enter the upper limit value The lower limit value can be entered in a similar manner Both upper and lower limit values can be entered in the range 0 to 100 O2 however the upper limit value must be set higher than the lower limit value by at least 1 O...

Page 148: ...ime To set an auto return time of one hour enter 060 3 If you set 0 then the auto return function does not operate Default setting The Auto return time is set to 0 prior factory shipment or after data initialization 10 3 2 Selecting Language You can select a display language from among English Japanese German and French The display language is set to the one specified in the purchase order when th...

Page 149: ...t to 0 prior factory shipment or after data initialization 10 3 4 Display Contrast Adjustment Display contrast can be adjusted by the following procedure Setting Procedure 1 From Display setup select Display contrast 2 If you press the Enter key then the contrast adjustment display of Figure 10 8 appears 3 Use the and keys to adjust for best contrast then touch the Enter key 4 If you touch the Rej...

Page 150: ...performed Contact input used to start Semi Auto Indication Check has no effect Auto Indication Check does not start at Auto Indication Check start time When Semi Auto is selected In this mode Manual Indication Check or Semi Auto Indication Check can be performed Auto Indication Check does not start at Auto Indication Check When Auto is selected Indication Check can be performed in any of the three...

Page 151: ... Zero Span Zero Span Zero Third Third Figure 10 10 Indication Check Point Selection 10 4 3 Setting Contacts for Operating Third Check Gas Solenoid Valve When performing a three point Semi auto or Auto Indication Check you need to allocate a contact to operate the third check gas solenoid valve Setting Procedure 1 On the basic panel display if you touch the Setup key the Execution Setup display app...

Page 152: ...abled Manual Indication Check x x x x x x x x Semi auto Indication Check x x x x x x x x Auto Indication Check Wait Wait Wait Wait Wait x x x X Cannot perform indication check Wait Wait until other command finishes before starting indication check NOTE When setting observe the following cautions Observe the following cautions when setting the indication check timing 1 You can select Indication che...

Page 153: ... 3rd gas contact Ind check start Off On Off On Span gas ON Zero gas ON Span gas ON Zero gas ON Off On Off On Hold time Ch2 Output Hold Check time Check time Check time Hold time Ch1 Output Hold Ch1 removed from average Ch2 removed from average Figure 10 12 Indication Check timing Shipping time defaults Indication check parameters are set as shown in Table 10 4 prior factory shipment or after data ...

Page 154: ... selected Here Channel 2 is taken as an example 6 Select Span gas ind check and touch the Enter key A display like Figure 10 14 appears Enter Manual ind check Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Ch7 Ch8 F10 13E ai Select ind check channel Enter Zero gas ind check Third gas ind check F10 14E ai Manual ind check Span gas ind check Ch2 Figure 10 13 Channel select screen Figure 10 14 Manual Span Ind check 7 Open ...

Page 155: ... key 15 Open the third gas flow control valve and adjust flow rate to 600 60 ml min 16 Select Start ind check and touch the Enter key An oxygen concentration graph like Figure 10 18 is displayed and CHK TIME status mark flashes Wait for the graph measured value trace to stabilize Compare the measured third gas concentration displayed at the lower left of the display against the certified concentra...

Page 156: ... check time same as calibration time has elapsed Span indication check ends and Zero indication check begins Likewise when the preset check time has elapsed Zero indication check ends and third gas check begins 6 After check time calibration time ends stabilization time begins After the preset hold stabilization time the instrument reverts to measurement mode 7 Touch the Reject key to abort indica...

Page 157: ...indication check for the next channel starts Auto Indication Check No user action is required to start auto indication check Auto indication check starts at the preset time and is repeated at the preset interval same as calibration interval CAUTION Before starting Semi auto indication or Auto indication check operate the calibration gas and 3rd check gas solenoid valves and adjust gas flow to 600 ...

Page 158: ...hannel at a time until all channels have been covered The following restrictions apply When No function is selected Blow back is not performed When Semi auto is selected Semi automatic blow back can be performed Blow back does not start at Automatic blow back start time When Auto is selected Blow back can be performed in either Auto or Semi auto mode Setting Procedure 1 From the basic panel displa...

Page 159: ...alves refer to Subsection 4 1 5 Blow back piping and Section 5 3 Wiring and Piping Examples SV CH 1 SV CH 2 CH1 detector CH2 detector N C N O AV550G F10 24E ai Solenoid valve switch Blow back gas Blow back gas CAL gas CAL gas Figure 10 24 Setting procedure 1 From the basic panel display touch Setup key on the Execution Setup display which appears select Commissioning then Contact setup 2 Select a ...

Page 160: ...l channels Start date and start time specify the day and time that auto blow back is first performed To set June 21 2004 at 1 30 pm set Start date to 21 06 04 and Start time to 13 00 Setting procedure When the blow back mode is set to Semi auto on the Blow back setup display Hold time and Blow back time items appear Select Hold time and then touch the Enter key A numerical data entry display will ...

Page 161: ...se it with an on time period of 1 to 11 seconds Once blow back starts the SV CH contact output repeatedly opens and closes at an interval of approximately 10 seconds during the preset blow back time During the blow back time and hold time on a channel its individual analog output remains held at a value preset in the Output hold setup and excluded from averaging group calculations After the hold t...

Page 162: ...Start blow back and touch the Enter key Blow back is performed starting from Channel 1 2 If a display like Figure 10 27 appears then mode is set to No function Refer to Subsection 10 5 1 Mode and change the mode appropriately 3 During blow back a display like Figure 10 28 is displayed with the affected channel number blinking 4 To abort blow back you can touch the Reject key to skip the blow back ...

Page 163: ...g for a preset time before warmup in order to remove any such condensation If the cell temperature is 100 C or greater then purging cannot be performed While purging is being performed a Purge status mark is displayed on the basic panel display as shown in Figure 10 31 Purging is performed in sequence starting with the smallest channel number The timing of purging is shown in Figure 10 29 F10 29E ...

Page 164: ... is appears 4 Touch the Enter key and a numerical entry display appears Enter the desired purging time between 0 and 60 minutes If you enter 0 then purging is disabled Enter F10 30E ai Purging Purging time 0 min Purge Tag Ch1 30 C Ch2 31 C Ch3 29 C Ch4 30 C Ch5 29 C Ch6 29 C Ch7 29 C Ch8 34 C Hold F10 31E ai Figure 10 30 Purging Time Setting Figure 10 31 Display During Purging Shipping time defaul...

Page 165: ... next Others then Defaults A display like Figure 10 32 1 appears 3 Select the desired item to be initialized then a display like Figure 10 32 2 appears Select Defaults start then initialization starts 4 When initialization completes then you are returned to a display like Figure 10 32 2 CAUTION Do not turn off power during initialization Otherwise initialization will not be performed properly Disp...

Page 166: ...y month year 01 01 01 Start time 00 00 Blow back Mode No function disabled Hold time 3 min 00 sec Blow back time 10 min 00 sec Blow back interval 30 days 00 hours Start date day month year 01 01 01 Start time 00 00 mA output Output range Minimum oxygen concentration 0 O2 Maximum oxygen concentration 25 O2 Output smoothing time constant 0 sec disabled Output mode Linear Output hold setting During w...

Page 167: ...lay state when powered Energized Contact output 2 Alarms All OFF Other setting During warmup OFF During output range switching OFF During maintenance OFF During calibration ON During indication check OFF During blow back OFF 3rd check gas OFF Relay state when powered Energized Contact output 3 Alarms High High Alarm OFF High Alarm ON Low Alarm ON Low Low Alarm OFF Calibration coefficient alarm OFF...

Page 168: ...Preparation Before Calibration To operate the ZA8F Flow Setting Unit prepare for calibration as follows 1 Check for a complete closing of the zero gas flow setting valve in the unit and open the regulator valve for the zero gas cylinder until the secondary pressure equals sample gas pressure approx 50 kPa or sample gas pressure plus approx 150 kPa when a check valve is used maximum pressure rating...

Page 169: ... the valve shaft if the valve has a lock nut loosen the lock nut and slowly turn it counterclockwise To check the flowrate monitor the calibration gas flow meter If the measurement gas pressure is extremely high adjust the measurement gas pressure to obtain pressures Refer to Table 10 8 10 Enter F10 35E ai Ch1 Manual cal Open zero gas valve Set flow zero gas to 600ml min Valve opened Cancel calibr...

Page 170: ... detector carefully observe the following 1 Do not subject the probe to shock or cool it rapidly The sensor is made of ceramic zirconia If the detector is dropped or bumped into something the sensor may be damaged and no longer work 2 Do not reuse a metal O ring to seal the cell assembly If you replace the cell or remove it from the probe for checking be sure to replace the metal O ring Otherwise ...

Page 171: ...Swap Function The averaging converter features a function that allows a desired detector to be disconnected reconnected for inspection or maintenance just by turning off the power of the relevant channel without system shutdown This function is called hot swap While power to a channel is being removed the channel is automatically eliminated from the averaging groups and does not affect any other c...

Page 172: ...uch the Enter key 5 A dropdown menu Disable Enable will appear Select Disable and touch the Enter key Make sure that all status lamp s of disabled channel s have turned off Enter Ch1 ZR22G Ch2 Enable Ch3 Enable Ch4 Enable Ch5 Enable Ch6 Enable Ch7 Enable Ch8 Enable F11 3E ai Disable Channel card power Figure 11 3 Channel Card Power Hot Swap Display WARNING Before the inspection or maintenance of a...

Page 173: ...s tube inside the probe In doing this keep air flowing from the calibration gas inlet at about 600 ml min and insert the rod into the tube 3 mm inside diameter However be careful not to insert the rod deeper than 40 cm for a general purpose detector or 15 cm for a high temperature detector 4 Clean the U shaped pipe The pipe can be rinsed with water However it should be dried out thoroughly before ...

Page 174: ...d then sand further with a higher grade of sandpaper no 1500 or so or use an appropriate metal brush to eliminate any sharp protrusions on the groove The contact s resistance should be minimized Use sensor assemblies manufactured in or after Sept 2000 the serial number on the side of the sensor assembly should be 0J000 or later for example 0K123 1AA01 etc F11 5E ai Dust filter optional Bolts four ...

Page 175: ...eing careful not to cause irregularities in the pitch of the coil spirals i e not to bend the coil out of shape place it in the ringed groove properly so that it forms a solid contact Groove in which the contact E7042BS is placed F11 6E ai Figure 11 6 Installing the Contact 2 Next make sure that the O ring groove on the flange surface of the sensor is clean Install the metal O ring in that O ring ...

Page 176: ... subject it to strong vibrations or shock Additionally the heater unit reaches high temperatures and is subjected to high voltages So maintenance services should be performed after the power is off and the heater unit temperature has returned to normal room temperature For details refer to IM11M12A01 21E Heater Assembly NOTE If the heater strut assembly cannot be removed because a screw has fused ...

Page 177: ... 24 24 26 34 28 30 29 33 32 CELL TC TC F11 7E ai 10 11 12 24 23 View A A 14 16 14 35 A A 35 37 36 14 TC CELL CJ 1 2 3 4 5 6 8 7 H T R Figure 11 7 Exploded View of Detector When pressure compensation specified Note The parts marked by is not equipped with the types except the pressure compen sation type ...

Page 178: ...7ZA and tighten the screw for the heater assembly fixation 8 with a special wrench part no K9470BX or equivalent with a tightening torque of 12N m 10 percent Next to install the O rings 22 on the calibration gas and reference gas pipes disassemble the connector 13 in the following procedure First remove the screw 25 and then remove the plate 17 and two caps 20 If the O ring 22 remains in the hole ...

Page 179: ...ch may become damaged if it is subjected to a strong shock or thermal shock The high temperature detector is structured so that the gas to be measured is directed toward the detector with the high temperature probe adapter Therefore if the probe or the sample gas outlet clogs a precise measurement is no longer possible because of no gas flow If you use the high temperature detector you have to ins...

Page 180: ... sensor performance If a large amount of water is condensed the sensor can be broken and never re useful To prevent the above nonconformity take the following action when stopping operation 1 If possible keep on supplying the power to converter and flowing reference gas to the sensor If impossible to do the above remove the detector 2 If impossible to supply the power or remove the detector at lea...

Page 181: ...2 HTR1 FUSE HTR2 HTR2 FUSE FUSE HTR1 HTR1 FUSE FUSE HTR4 HTR4 FUSE FUSE HTR3 HTR3 FUSE 250V T2 5A X 8 250V T2 5A X 8 FUSE HTR7 HTR7 FUSE FUSE HTR8 HTR8 FUSE FUSE HTR5 HTR5 FUSE FUSE HTR6 HTR6 FUSE HTR5 HTR6 HTR7 HTR8 101 102 103 104 105 106 107 108 81 82 83 COM NC NO DO CH5 84 85 86 COM NC NO DO CH6 87 88 89 DO CH7 90 91 92 DO CH8 SV CH5 SV CH6 61 62 63 64 SV CH7 SV CH8 68 67 66 65 69 70 71 72 NO ...

Page 182: ...afety Law Part number A1112EF 5 It is recommended that the fuse be replaced every two years even if it has not blown 6 Position the power switch to I ON and attach the front cover Cap Flat blade screwdriver Fuse Socket F11 9E ai Figure 11 9 How to replace the fuse CAUTION If a replaced fuse blows out immediately there may be a problem in the internal circuit of the averaging converter the detector...

Page 183: ...ower switch to O OFF 3 Remove the channel slot cover from the desired channel by removing the screws holding the cover to the slot 4 Slowly insert a channel card into the slot sliding along the guide rail in the slot Make sure that the connector on the back of the channel card is seated properly and firmly in the slot 5 Securely tighten the screws on the channel card 6 Connect the wiring from an a...

Page 184: ...t cover and position the power switch to O OFF 3 The power cable to be connected to the expansion power supply unit is fixed inside the averaging converter with plastic bands See Figure 11 11 Cut a plastic band nearest to the connector on the end of the power cable with a nipper or relevant tool Take care not to damage the cable sheath 4 Insert the connector of the power cable into the expansion p...

Page 185: ...mended that these components be replaced at an approximate interval of 5 years 1 LCD panel 2 Switching power supply 2 types located on the left side of the frame not visible from outside For replacement of these components contact our service office When the control card or basic power supply unit breaks down also contact our service office for repair ...

Page 186: ...seconds or longer continuously 3 After warm up heater temperature falls below 730 C or exceeds 780 C for 10 seconds or longer continuously Each channel Error 3 Channel card failure 1 Failure is detected by memory check 2 Communication failure occurs between card and A D converter Each channel Error 4 Control card failure Failure is detected by memory check System Error 5 Inter card communication f...

Page 187: ...s are displayed in multiple pages On the detailed error description display touch the Update key to update the error occurrence condition When an error and an alarm occur at a time an error icon takes precedence Tag Ch1 Err2 Ch2 0 96 Ch3 0 96 Ch4 0 96 Ch5 0 96 Ch6 Err1 Ch7 0 96 Ch8 0 94 F12 1E ai Hold Channels Where Errors Occur displayed in red Error Icon Tag Ch1 Err2 Ave a 0 96 O2 Ave b 0 95 O2 ...

Page 188: ...Examine the wiring connection to converter terminals CELL and CELL Also check the wiring connection in the repeater terminal box if it is used Examine the wiring connection status to detector terminals 1 and 2 Also check that terminals and cable conductors are not corroded Replace the damaged portions Remove the sensor assembly from the detector and check for the presence of corrosion that may cau...

Page 189: ...averaging converter 2 Remove the cable from terminals 7 and 8 of the detector and measure the resistance between these terminals The heater unit is normal if the resistance is lower than about 90 Ω If the resistance value is higher failure of the heater unit is suspected In this case replace the heater unit refer to Subsection 11 3 4 Replacement of the Heater Unit In addition check that the two wa...

Page 190: ...ure Turn off and on power to the channel card by hot swap function If the error message is cleared the error was caused by a temporary communication failure continue the operation If the error message is not cleared the error was caused by a malfunction of the channel card Replace the channel card If Error 5 occurs in all channels the control card is malfunctioning Contact our service office ...

Page 191: ...ch channel Alarm 3 Span calibration coefficient alarm Span correction ratio is outside the range of 0 18 See Subsection 9 1 3 Compensation To stop alarm Recalibrate and stops if the ratio falls within the range Each channel Alarm 4 Calibration time over EMF stabilization time up alarm In Auto or Semi auto calibration cell voltage does not stabilize for 1 minute even after calibration time is up St...

Page 192: ...ero calibration coefficient alarm In automatic or semi automatic calibration Alarm 2 is generated when the zero correction ratio is out of the range of 100 30 refer to Subsection 9 1 3 Compensation The following are possible causes of this alarm 1 The zero gas oxygen concentration does not agree with the value of the zero gas concentration set in Calibration setup Otherwise the span gas is used as...

Page 193: ...eoretical value cannot be generally specified a reasonable one may be approximately 10 mV Table 12 3 Oxygen Concentration and Cell Voltage Oxygen Conc O2 Cell Voltage mV 1 67 1 21 0 4 Check whether the deterioration of or damage to the sensor assembly that caused the alarm has occurred suddenly during the current calibration by following the procedure below a Call up the Detailed data display b Us...

Page 194: ...of the span gas set Calibration setup 2 The flow of the span gas is out of the specified flow value 600 60 ml min 3 The sensor assembly is damaged and the cell voltage is abnormal Locating cause of failure and countermeasures 1 Confirm the following and carry out calibration again If the items are not within their proper states correct them a If the display Span gas conc is selected in Calibration...

Page 195: ...tion of the detector 5 Alarm 5 Cold junction temperature alarm This alarm is generated when the temperature of the cold junction located at the terminal block of the detector falls below 25 C or exceeds 155 C Check the following Display C J Temperature in the Detailed data display If C J Temperature is indicated as 200 C or 50 C the following can be considered 1 Breakage of the cold junction signa...

Page 196: ...sibly fail Contact the service personnel at Yokogawa Electric Corporation CAUTION The operating temperature range of the ZO21D detector is 10 C to 80 C except for the high temperature detector ZO21D H Since a cold junction temperature alarm for this analyzer is not generated until the temperature exceeds 155 C if the ZO21D is used be careful in controlling the ambient temperature of the terminal b...

Page 197: ...th the second the slope has not changed only the zero offset suggesting clogging and pressure effects Figure 12 11 Cause of Alarm 2 Conditions for generating an alarm When the current result and the two previous results for the oxygen concentration resulting in a given cell e m f are compared if both of the following conditions are satisfied then an alarm is issued A B C 21 0 51 O2 value Current c...

Page 198: ...etails Inside temp alarm log ON 2 4 Jun 2 0 0 4 16 25 OFF 2 4 Jun 2 0 0 4 16 25 ON 2 4 Jun 2 0 0 4 16 23 OFF 2 4 Jun 2 0 0 4 16 25 ON 2 4 Jun 2 0 0 4 16 22 OFF 2 4 Jun 2 0 0 4 16 23 F12 14E ai Ch1 Figure 12 13 Asymmetry Alarm Screen Figure 12 14 Inside Temperature Alarm Log NOTE For these alarm functions to be effective first enable them then calibrate three times at intervals of at least 5 days A...

Page 199: ...gas pressure internal pressure of a furnace 2 Moisture content in a reference gas changes increases greatly If air at the detector installation site is used for the reference gas large change of moisture content in the air may cause an error in measured oxygen concentration value vol O2 When this error is not ignored use a gas in which moisture content is constant such as instrument air in almost ...

Page 200: ...Check valves needle valves check valves solenoid valves for automatic calibration etc in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed states 4 Combustible components exist in the sample gas If combustible components exist in the sample gas they burn in the sensor and thus oxygen concentration decreases Check that there ar...

Page 201: ...rnace check whether or not there is a crack in the sensor or whether the sensor flange is sticking tightly to the probe attaching face with the metal O ring squeezed 6 There may be leakage in the calibration gas tubing In the case of a negative furnace inner pressure if the indication of concentration varies with the pressure change in the furnace check whether or not there is leakage in the calib...

Page 202: ... 16 15 14 NO 13 58 57 56 55 54 53 52 51 HTR4 HTR3 HTR2 HTR1 FUSE HTR2 HTR2 FUSE FUSE HTR1 HTR1 FUSE FUSE HTR4 HTR4 FUSE FUSE HTR3 HTR3 FUSE 250V T2 5A X 8 250V T2 5A X 8 FUSE HTR7 HTR7 FUSE FUSE HTR8 HTR8 FUSE FUSE HTR5 HTR5 FUSE FUSE HTR6 HTR6 FUSE HTR5 HTR6 HTR7 HTR8 101 102 103 104 105 106 107 108 81 82 83 COM NC NO DO CH5 84 85 86 COM NC NO DO CH6 87 88 89 DO CH7 90 91 92 DO CH8 SV CH5 SV CH6 ...

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Page 204: ...A G7109YC K9470BK E7042DW K9470ZF K9470ZG E7042BR K9470BM K9473AN ZR01A01 01 ZR01A01 02 ZR01A01 05 ZR01A01 10 E7042BS K9470BJ E7042AY K9470ZK K9470ZL 1 4 4 1 1 1 1 1 1 1 1 1 Dust Filter Option Bolt M5x12 SUS316 stainless steel M5x12 inconel for Option code C Washer SUS316 stainless steel Bolts and Washers G7109YC x 4 E7042DW x 4 K9470BK x 4 E7042DW x 4 for Option code C Plate Pipe Pipe for Option ...

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Page 206: ...ZO21DW L J E SV G7013XH 1 Stop Valve for ZO21DW L A SV E7042VR 1 Check Valve for ZO21DW L J E CV E7042VV 1 Check Valve for ZO21DW L A CV 11 G7067XA 1 Nipple for ZO21DW L J E SV G7248XA 1 Nipple for ZO21DW L A SV 12 G7007XH 1 Needle Valve Customer Maintenance Parts List Model ZO21DW L Zirconia Oxygen Analyzer Detector with Flameproof Terminal Box CMPL 11M06B02 01E 1st Edition Apr 1989 YK 7th Editio...

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Page 208: ...C L 0 9m Probe SiC L 1 0m Probe SiC L 1 5m Probe SUS L 0 5m Probe SUS L 0 6m Probe SUS L 0 7m Probe SUS L 0 8m Probe SUS L 0 9m Probe SUS L 1 0m Probe SUS L 1 5m 2 E7046FA E7046FE E7046FK E7046FD E7046FC E7046FB E7046FG E7046FF E7046FJ E7046FH 1 1 1 1 1 1 1 1 1 1 Probe Adaptor for JIS 5K 50 FF Probe Adaptor for ANSI CLASS150 4 RF Probe Adaptor for DIN PN10 DN50 A Probe Adaptor for JIS 10K 100 FF P...

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Page 210: ...C 1 Auxiliary Ejector Assembly Connection Rc1 4 E7046EN 1 Auxiliary Ejector Assembly Connection 1 4 NPT 2 L9852CB 1 Needle Valve Connection Rc1 4 G7016XH 1 Needle Valve Connection 1 4NPT 3 E7046EK 1 Pressure Gauge Connection Rc1 4 E7046EV 1 Pressure Gauge Connection 1 4NPT 4 E7046ED 1 Ejector Connection Rc1 4 E7046EP 1 Ejector Connection 1 4NPT 5 E7046EF 1 Nozzle Assembly Tube Connection Ø6хØ4 tub...

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Page 212: ...power supply Section 1 2 1 System Components and Their Applicability Change part numbers Section 2 4 1 Standard Specification Added 230 V AC power supply 195 5 to 253 V and FOUNDATION Fieldbus communication function Section 2 4 2 Model and Codes Revised Section 2 6 6 Air Set Changed part numbers and drawings Section 2 6 8 Cylinder Regulator Valve Part No G7013XF or G7014XF Changed drawings Section...

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