YOKOGAWA EXAxt ZR22G User Manual Download Page 14

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IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00

Customer Maintenance Parts List

......................................CMPL 11M12A01-02E

Customer Maintenance Parts List

......................................CMPL 11M12C01-01E

Customer Maintenance Parts List

......................................CMPL 11M03B01-10E

Customer Maintenance Parts List

......................................CMPL 11M03B01-05E

Customer Maintenance Parts List

......................................CMPL 11M12A01-11E

Customer Maintenance Parts List

..........................................CMPL 11M3D1-01E

Revision Information

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Summary of Contents for EXAxt ZR22G

Page 1: ...User s Manual Model ZR22G ZR402G Separate type Zirconia Oxygen Humidity Analyzer IM 11M12A01 02E IM 11M12A01 02E 16th Edition...

Page 2: ...402G converter and ZR22G detector together but it is to the High Temperature Humidity Analyzer when the option code HS Set for Humidity Analyzer of ZR402G is selected After that in this manaul the Hum...

Page 3: ...models and system configuration examples B C B 2 Specifications Standard specification model code or part number dimension drawing for each equipment A B B 3 Installation Installation method for each...

Page 4: ...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 be...

Page 5: ...well as in this manual WARNING This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks for the human body of injury electric shock or fa...

Page 6: ...ontact our sales representative or your local distributor n Drawing Conventions Some drawings may be partially emphasized simplified or omitted for the convenience of description Some screen images de...

Page 7: ...esigned to be used by a person with specialized knowledge n How to dispose the batteries This is an explanation about the EU Battery Directive This directive is only valid in the EU Batteries are incl...

Page 8: ...or 2 3 2 2 2 ZO21R Probe Protector 2 8 2 2 3 ZH21B Dust Protector 2 9 2 3 Separate type Detector for High Temperature and Related Equipment 2 10 2 3 1 ZR22G 0 15m Separate type Detector for High Tempe...

Page 9: ...3 5 Installation of ZR40H Automatic Calibration Unit 3 11 3 6 Installation of the Case Assembly E7044KF 3 12 3 7 Insulation Resistance Test 3 13 4 Piping 4 1 4 1 Piping for System 1 4 1 4 1 1 Parts Re...

Page 10: ...ntering Numeric and Text Data 6 6 6 4 ZA8F Flow Setting Unit ZR40H Automatic Calibration Unit 6 8 7 Startup 7 1 7 1 Startup Procedure 7 1 7 2 Checking Piping and Wiring Connections 7 2 7 3 Checking Va...

Page 11: ...ting 8 6 8 3 1 Setting the Alarm Values 8 7 8 3 2 Alarm Output Actions 8 7 8 3 3 Alarm Setting Procedure 8 8 8 3 4 Default Values 8 9 8 4 Output Contact Setup 8 9 8 4 1 Output Contact 8 9 8 4 2 Settin...

Page 12: ...10 1 5 C J Temperature 10 2 10 1 6 Cell Voltage 10 3 10 1 7 Thermocouple Voltage 10 3 10 1 8 Cold Junction Resistance C J Voltage 10 3 10 1 9 Cell s Internal Resistance 10 3 10 1 10 Software Revision...

Page 13: ...Cleaning the Calibration Gas Tube 11 1 11 1 2 Replacing the Sensor Assembly 11 2 11 1 3 Replacement of the Heater Unit 11 4 11 1 4 Replacement of Dust Filter 11 6 11 1 5 Replacement of O ring 11 6 11...

Page 14: ...L 11M12A01 02E Customer Maintenance Parts List CMPL 11M12C01 01E Customer Maintenance Parts List CMPL 11M03B01 10E Customer Maintenance Parts List CMPL 11M03B01 05E Customer Maintenance Parts List CMP...

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Page 16: ...and control It can help improve productivity in these application fields The converter is equipped with an LCD touch screen which has various setting displays a calibration display oxygen concentratio...

Page 17: ...detector The valve should be fully closed unless calibration is in progress 1 1 2 System 2 This system is for monitoring and controlling oxygen concentration in the combustion gases of a large size b...

Page 18: ...der System 3 uses the ZR40H automatic calibration unit with auto switching of the calibration gas A combustible gas detected contact input turns off power to the heater There s also contact output fro...

Page 19: ...ssembly for Calibration gas Cylinder A A B B Model ZR22A Heater Assembly Spare Parts for Model ZR22G B B B B B A Items required for the above system example B To be selected depending on each applicat...

Page 20: ...idity Analyzer Water vapor in vol in mixed gases air and water vapor Measurement System Zirconia system Measurement Range 0 01 to 100 vol O2 In case of Humidity Analyzer 0 to 100 vol H2O or 0 to 1 000...

Page 21: ...first two weeks in use Excluding the case where the reference gas is by natural convection Both zero and span 2 Maximum value of set range month In case of Humidity Analyzer Both zero and span 3 vol H...

Page 22: ...e 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 If the pressure of your sample gas exceeds the...

Page 23: ...approx 11 kg ANSI 150 4 Insertion length of 1 0 m approx 8 kg JIS 5K 65 approx 13 kg ANSI 150 4 Insertion length of 1 5 m approx 10 kg JIS 5K 65 approx 15 kg ANSI 150 4 Insertion length of 2 0 m appro...

Page 24: ...se 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 7 Dust Guard Protector 7 SCT PT Stainless steel tag plate 8 Printed t...

Page 25: ...c1 4 or 1 4NPT Calibration gas inlet Flange Flange Flange B A C Unit mm Flange ANSI Class 150 2 RF ANSI Class 150 3 RF ANSI Class 150 4 RF DIN PN10 DN50 A DIN PN10 DN80 A DIN PN10 DN100 A JIS 5K 65 FF...

Page 26: ...4 19 8 19 4 18 8 18 8 18 4 15 4 19 8 19 8 19 8 19 4 19 4 11 5 A B C 19 24 24 18 20 20 14 18 18 18 24 24 14 A B B A B B A A B B B B A t B A C Flange Flange B A Flange L 0 15 0 4 0 7 1 0 1 5 2 0 2 5 3...

Page 27: ...SUS304 JIS or ASTM grade 304 Flange Weight 1 05 m Approx 6 10 8 5 kg JIS ANSI 1 55 m Approx 9 13 11 5 kg JIS ANSI 2 05 m Approx 12 16 14 5 kg JIS ANSI Installation Bolts nuts and washers are provided...

Page 28: ...304 flange Weight Approximately 6kg JIS approximately 8 5kg ANSI Mounting Mounted on the probe or process flange with bolts and associated nuts and washers l Model and Codes Model Suffix code Option c...

Page 29: ...thickness varies Mounting 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 NPT female...

Page 30: ...FF type or RF 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 Weig...

Page 31: ...ressure is negative connect the auxiliary ejector 124 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 60 5 B A P...

Page 32: ...conduit holes completely sealed with a cable gland Wiring Connection G1 2 Pg13 5 M20 x 1 5 mm 1 2 NPT with plug eight holes Installation Panel wall or pipe mounting Case Aluminum alloy Paint Color Do...

Page 33: ...dew point C Display Items Cell temperature C thermocouple reference junction temperature C maximum minimum average oxygen concentration vol O2 maxi mum minimum average moisture quantity vol H2O maximu...

Page 34: ...DC 3 A 250 V AC 3 A resistive load Three of the output points can be selected to either normally energized or normally de energized status Delayed functions 0 to 255 seconds and hysteresis function 0...

Page 35: ...Display J E G F C P Japanese English German French Chinese Portuguese Instruction manual J E C Japanese English Chinese A Always A Options Tag plates NAMUR NE43compliant HS Set for Humidity Analyzer...

Page 36: ...ll mounting Panel Cut out 100 10 8 228 280 126 5 57 3 136 3 54 7 111 36 190 183 2 0 274 2 0 126 5 40 40 40 38 38 24 14 36 23 20 2 1 2NPT 1 2NPT with plug ZR402G Material of HOOD Aluminum 243 4 251 5 1...

Page 37: ...roof construction Case Material SPCC Cold rolled steel sheet Painting Baked epoxy resin Dark green Munsell 2 0 GY 3 1 0 5 or equivalent Tube Connections Rc1 4 or 1 4FNPT Reference Gas pressure Clean a...

Page 38: ...AS IN AIR IN Instrument air Approx 1 5 l min Air Set REF OUT SPAN GAS IN 20 20 35 35 35 35 35 70 32 8 222 8 235 8 140 180 7 Reference gas outlet Calibration gas outlet 6 Hole Span gas inlet Zero gas i...

Page 39: ...Materials Body Aluminum alloy Piping SUS316 JIS SUS304 JIS Flowmeter MA Metha acrylate resin Bracket SUS304 JIS Finish Polyurethane corrosion resistance coating mint green Munsell 5 6BG3 3 2 9 Piping...

Page 40: ...t 1 4 6 5 wiring inlet is at same position on rear Flowmeter Needle valve 2B mounting pipe Connection port Setting Valve for calibration gas Setting Valve for reference gas Wiring inlet 2 G1 2 Pg13 5...

Page 41: ...Portable unit for calibration gas supply consisting of span gas air pump zero gas cylinder with sealed inlet flow rate checker and flow rate needle valve Sealed Zero Gas Cylinders 6 provided E7050BA...

Page 42: ...ity dust in recovery boilers and cement kilns Sample gas flow rate is needed to be 1 m sec or more to replace gas inside zirconia sensor l Standard specification Applicable detector Standard type dete...

Page 43: ...negative This ejector assembly consists of an ejector a pressure gauge assembly and a needle valve l Standard Specifications Ejector Ejector Inlet Air Pressure 29 to 69 kPa G Air Consumption Approx 3...

Page 44: ...aph 1 determine Po pressure setting from L the distance between the ejector and the pressure gauge 3 Open the needle valve to supply air for the ejector to the pressure gauge until it indicates the pr...

Page 45: ...Pressure gauge Ejector Po Air source Gas Pg Qg Gas pressure 15 Pa Air consumption characteristics Pressure setting characteristics Suction pressure characteristics Suction flow characteristics F2 9E...

Page 46: ...n the calibration gas line directly connected to the detector This is applied to a system based on the System 2 and 3 system configuration This valve prevents the sample gas from entering the calibrat...

Page 47: ...aterial Zinc alloy Adapter SUS 316 G7004XF K9473XG Primary Pressure Max 1 MPa G Secondary Pressure 0 02 to 0 5 MPa G Connection Rc1 4 or 1 4NPT F with joint adapter Weight Approx 1 kg Part No Descript...

Page 48: ...5 325 140 Unit mm F2 13E ai 2 7 8 Cylinder Pressure Reducing Valve G7013XF G7014XF This pressure reducing valve is used with the zero gas cylinders l Standard Specifications Primary Pressure Max 14 8...

Page 49: ...eel sheet Case Paint Baked epoxy resin Jade green Munsell 7 5 BG 4 1 5 Weight Approx 10 kg with gas cylinder Note Export of such high pressure filled gas cylinder to most countries is prohibited or re...

Page 50: ...pensated for ZR22G S1 1 Suffix code of length should be selected as same as ZR22G installed 2 Jig part no is K9470BX to order as a parts after purchase 3 Select appropriately among A B C according to...

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Page 52: ...sure fluctuations 3 1 1 Probe Insertion Hole Includes those analyzers equipped with a probe supporter and probe protector When preparing the probe insertion hole the following should be taken into con...

Page 53: ...A gasket should be used between the flanges to prevent gas leakage The gasket material should be heatproof and corrosion proof suited to the characteristics of the sample gas The following should be t...

Page 54: ...dust guard protector when the option code F2 is specified in case of ordering the detector The protector should be used when preventing dusts and water drops from lowering the detector performance is...

Page 55: ...sure that the sensor assembly mounting screws four bolts at the probe tip are not loose 3 Where the detector is mounted horizontally the reference gas and calibration gas inlet should face downward C...

Page 56: ...ce 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 t...

Page 57: ...ter 4 When the surface temperature is still less than 200 C or below the dew point of the sample gas even if the above measures have been taken warm the probe adapter using a heat source such as steam...

Page 58: ...Nut M16 8 Washer for M16 16 A high temperature detector should be mounted as follows 1 It is recommended to mount the detector vertically When it is impossible due to the physical arrangements and th...

Page 59: ...nverter The converter can be mounted on a pipe nominal JIS 50A O D 60 5 mm a wall or a panel The converter can be mounted at an angle to the vertical however it is recommended to mount it on a vertica...

Page 60: ...ng Panel Mounting 1 Cut out the panel according to Figure 3 12 274 2 0 183 2 0 F3 10E ai Unit mm Clamp screw Washer Bolt Fitting F3 11E ai Figure 3 12 Panel cutout sizes Figure 3 13 Panel mounting 2 R...

Page 61: ...ositioned 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...

Page 62: ...n a wall It should 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 of automatic c...

Page 63: ...or or converter as well as the flow setting unit 4 The temperature of the case should not exceed 40 C due to rays of the sun or radiated heat 5 No vibration n Mounting Mount case assembly on a pipe no...

Page 64: ...protective grounding terminal 2 Connect crossover wiring between L and N 3 Connect an insulation resistance tester with its power OFF Connect terminal to the crossover wiring and terminal to ground 4...

Page 65: ...3 29 DO 4 30 DO 4 31 HTR 32 HTR 33 L 34 N 35 G 36 HTR HTR Contact input 2 Contact input 1 Solenoid valve for automatic calibration Solenoid valve for automatic calibration Span gas Zero gas Automatic...

Page 66: ...Zirconia Oxygen Humidity Analyzer Detector ZR402G Converter Stop valve Calibration gas F4 1E ai 100 to 240 V AC 100 110 115 200 220 240 V AC Contact input Analog output Contact output Digital output H...

Page 67: ...r On the other hand if the sample gas temperature is lowered too much condensation may be produced in the High Temperature Probe Adapter During wintertime it is recommended that the High Temperature P...

Page 68: ...ration 21 vol O2 cannot be obtained prepare piping the same as which described in Section 4 2 System 2 When the equipment uses instrument air for the reference gas piping is required as described in S...

Page 69: ...pter when the sample gas is cooled protect the probe adapter with an insulating material as illustrated in Figure 4 5 Sample gas outlet Cover flange Adapter for high temperature probe Detector Insulat...

Page 70: ...igure 4 3 If a high temperature detector is used and the pressure of the sample gas is 0 49 kPa or higher it is recommended that a needle valve throttle be used in the sample gas exhaust of the high t...

Page 71: ...ended by YOKOGAWA G7003XF K9473XK or G7004XF K9473XG Joint for tube connection Rc 1 4 or 1 4 NPT General parts Sample gas outlet Ejector assembly Recommended by YOKOGAWA E7046EC or E7046EN T shaped jo...

Page 72: ...for the piping 4 3 Piping for System 3 Piping in System 3 is illustrated in Figure 4 10 In System 3 calibration is automated however the piping is basically the same as that of System 2 Refer to Sect...

Page 73: ...H Automatic Calibration Unit ZR22G Separate type Zirconia Oxygen Humidity Analyzer Detector ZR402G Converter Calibration gas unit case F4 9E ai EXA ZR402G 100 to 240 V AC Contact input Analog output c...

Page 74: ...ompensation The ZR22G P Detector with Pressure Compensation may be used in System 2 and System 3 However it cannot use piping for high temperature probe adapter or blow back piping Use this detector w...

Page 75: ...ent air flow start furnace operation As furnace internal pressure rises confirm that instrument air continues to flow and adjust the valve or increase supply pressure if necessary 6 After furnace inte...

Page 76: ...ble 4 3 Piping Parts Detector Piping location Parts Name Note Detector with pressure compensation Calibration gas inlet Stop valve or check valve Recommended by YOKOGAWA L9852CB or G7016XH Provided by...

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Page 78: ...switch or circuit breaker be mounted in the same room as the equipment The external switch or circuit breaker should be installed within the reach of the operator and marked as the power supply switch...

Page 79: ...eratures of at least 80 C should be used for wiring CAUTION Select suitable cable O D to match the cable gland size Protective grounding should be connected in ways equivalent to JIS D style Class 3 g...

Page 80: ...1 2 Wiring Connect the following wiring to the converter It requires a maximum of seven wiring connections as shown below 1 Detector output connects the converter with the detector 2 Detector heater...

Page 81: ...ct output 1 Contact output 2 Contact output 3 Contact output 4 Solenoid valve for automatic calibration Solenoid valve for automatic calibration Automatic Calibration Unit ZR40H Zero gas Span gas 1 1...

Page 82: ...to Detector When connecting the cable to the detector proceed as follows 1 Mount cable glands or conduits of the specified thread size to the wiring connections of the detector The detector may need t...

Page 83: ...nding to crimp on terminals Grounding Wiring The ground wiring of the detector should be connected to the ground terminal of the detector case The ground wiring of the converter should be connected to...

Page 84: ...ZR402G Converter Figure 5 6 Wiring for power to detector heater Cable Specifications Basically cables 2 cores that withstand temperatures of at least 80 C are used for this wiring When the ambient te...

Page 85: ...ZR22G Detector ZR402G Converter Figure 5 7 Wiring for detector output CAUTION If shielded cables cannot be used between the detector and the terminal box for example when heat resistant wiring is used...

Page 86: ...be terminated corresponding to crimp on terminals Ensure that the cable shield is connected to the FG terminal of the converter 2 Be sure to connect and polarities correctly 5 2 7 Contact Output Wirin...

Page 87: ...tact signals wire as follows ZR402G Converter Terminal box DI 1 DI C DI 2 Contact input 1 Contact input 2 F5 14E ai Figure 5 10 Contact Input Wiring Cable Specifications Use 2 core or 3 core cable for...

Page 88: ...ZR402G terminal AC SPAN to ZR402G terminal AC ZERO Wiring inlet 2 G1 2 Pg13 5 M20 or 1 2NPT ZERO SPAN COMMON Span gas solenoid valve Zero gas solenoid valve Terminal screw M4 F5 12E ai Figure 5 11 Au...

Page 89: ...ter that is suit for the following interfaces Output signal 4 to 20 mA DC two wire system Maximum supply voltage from the analyzer 24 V DC Input resistance of the analyzer Maximum 250 V The load resis...

Page 90: ...1 1 General purpose Detector except for ZR22G 015 Probe This part is inserted in the furnace Select length from 0 4 0 7 1 0 1 5 2 0 2 5 3 0 3 6 4 2 4 8 or 5 4 m Flange Used to mount the detector Selec...

Page 91: ...ol valve e g a needle valve Refer to Section 3 2 1 Separate type High Temperature Detector ZR22G 015 When the temperature of the sample gas is between 700 C and 1400 C mount this detector with a ZO21P...

Page 92: ...ror E 1 Cell failure E 2 Abnormal heater temperature E 3 Defective A D converter E 4 Faulty EEPROM ALARM1 Abnormal oxygen concentration ALARM2 Abnormal moisture ALARM3 Abnormal mixing ratio ALARM6 Abn...

Page 93: ...tches and functions selected according to the panel display Alarm and error display area Displays an error if an alarm or error occurs If you touch this area the details of the error or alarm are then...

Page 94: ...check Calibration execution Blow back execution Reset panel display Display setup Returns to the Execution Setup display Returns to the Execution Setup display Figure 6 5 Display Configuration 6 3 3 D...

Page 95: ...oint need not be entered because the decimal point position is already fixed so just enter 00098 Enter New value 000 98 O2 0 1 4 7 2 3 5 6 8 9 F7 4E ai Figure 6 6 Numeric data Entry Display To enter a...

Page 96: ...e same manner ABC_ as above Press the other key Press and hold the key and enter ABC _ Then press the 0 9 key Enter the numeric characters 1 2 and 3 in turn ABC 123_ Press the Enter key to complete th...

Page 97: ...ng valve Zero gas flow setting valve Flowmeter for reference gas Flowmeter for calibration gas F6 4E ai Figure 6 8 ZA8F Flow Setting Unit CAL OUT REF OUT Made in Japan ZERO IN SPAN IN F6 5 ai Flowmete...

Page 98: ...n the case of the humidity analyzer unit indication may be different Please read it appropriately 7 1 Startup Procedure The startup procedure is as follows CAUTION If you connect Model ZO21D detectors...

Page 99: ...e setup be sure to tighten the lock nut NOTE The calibration gas flow setting is described later Fully close the needle valve in the flow setting unit 7 4 Supplying Power to the Converter CAUTION To a...

Page 100: ...y set converter type If the Humidity Analyzer option HS was selected at the time of purchase the converter was set for high temperature humidity use before shipment 6 If the converter type is to be ch...

Page 101: ...in this manual 7 8 1 Oxygen Analyzer Minimum Current 4 mA and Maximum Current 20 mA Settings To set the minimum and maximum current settings follow these steps 1 Select the Commissioning from the Exe...

Page 102: ...ing in Figure 7 12 appears 6 Perform the same setting in mA outpout2 if necessary Both outputs are 4 20mA mA output1 mA output2 Set presets Enter mA outputs F7 7E ai Parameter Humidity Set range Min h...

Page 103: ...tput1 17 43mA Output2 Primary value Secondary value Tertiary value Figure 7 13 Basic Panel Display 1 Press the Setup key in the Basic panel display to display the Execution Setup display Then select M...

Page 104: ...quantity H2O in the exhaust gas Output 1 item Oxygen concentration with the equipment set for oxygen analyzer See 1 below Output 2 item Oxygen concentration with the equipment set for oxygen analyzer...

Page 105: ...ollowing the steps below Additionally if the humidity has been selected in the Detector Type Setting in Section 7 6 earlier in this manual the primary value is set to the humidity and the secondary an...

Page 106: ...ay Oxygen concentration Oxygen concentration during measurement Humidity Humidity H2O in the exhaust gas Mixing ratio Mixing ratio during measurement Relative humidity Relative humidity calculated fro...

Page 107: ...5 1E ai Figure 7 23 mA output loop check Panel Display 7 11 Checking Contact I O Conduct the contact input and output checking as well as operational checking of the solenoid valves for automatic cali...

Page 108: ...to display the panel display as Figure 7 25 shows 3 Open the Zero gas contact and the Span gas contact This will help check the automatic calibration unit and wiring connections Zero gas contact Open...

Page 109: ...he touchpanel or a contact input signal and conducts calibration operations based on a preset calibration time and stable time 3 Automatic calibration conducted at preset intervals Manual calibration...

Page 110: ...a 21 vol O2 value When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a portable oxygen analyzer to measure the actual oxygen concentration and then enter it NOTE...

Page 111: ...the span gas at 600 60 ml min Use the calibration gas flowmeter to check the flow Enter Open span gas valve Set flow span gas to 600ml min Valve opened Cancel calibration Manual calibration F7 19E ai...

Page 112: ...ibration gas flowmeter to check the flow Enter Open zero gas valve Set flow zero gas to 600ml min Valve opened Cancel calibration Manual calibration F7 23E ai Enter 21 00 0 5min div 1 00 21 0 O2 CAL T...

Page 113: ...flashes This time is referred to as the output stabilization time If the HOLD TIME has been set with the output hold setting the analog output remains held refer to Section 8 2 Output Hold Setting lat...

Page 114: ...mA and Maximum Current 20 mA To set the minimum humidity to 50 H2O and the maximum humidity to 100 H2O follow these steps 1 Select Setup in the Execution Setup display 2 Select the mA output setup in...

Page 115: ...20 mA output must be at least 75x1 3 98 vol O2 rounding decimal part up 5 15 25 35 45 55 65 75 85 95 5 15 25 35 45 55 65 75 Minimum oxygen concentration vol O2 for a minimum current of 4 mA Minimum Ma...

Page 116: ...kg kg and must be greater than 1 3 times plus 0 187 the mixing ratio set for the minimum Setting example 1 If the setting for a 4 mA current is 0 kg kg you must set the maximum 20 mA point at more th...

Page 117: ...xed 8 1 6 Default Values When the analyzer is delivered or reset to defaults the output current default settings by as shown in Table 8 1 Table 8 1 Output Current Default Values Item Default setting M...

Page 118: ...ses For automatic calibration Under calibration is the time required after performing an appropriate calibration until the hold output stabilization time elapses 4 During Blow back see Section 10 4 Bl...

Page 119: ...ired output status 3 If a preset value is selected set the corresponding output current If you select a preset value just below Maintenance on the screen the numeric data entry display will appear Ent...

Page 120: ...ay time and hysteresis are set an alarm will be issued if the measured value is in the alarm setpoint range and the delay time has elapsed For the alarm to be reset canceled the measured value must be...

Page 121: ...ee seconds enter 003 The delay time setting can be in the range of 0 to 255 seconds To set the alarm point proceed to the following steps 6 Select the Setpoints in the Alarms setup display The Oxygen...

Page 122: ...1 kg kg Low limit alarm OFF OFF OFF Low limit alarm setpoint 0 to 100 vol O2 0 vol O2 0 to 100 H2O 0 0 H2O 0 to 1 kg kg 0 kg kg Low low limit alarm OFF OFF OFF Low low limit alarm setpoint 0 to 100 vo...

Page 123: ...in Figure 8 8 then appears Select Calibration in the Contact1 Others display 7 The ON or OFF selection display then appears Select ON herein 8 Press the Reject key to go back to the previous display 9...

Page 124: ...Other settings Warm up If Warm up ON is selected contact output occurs during warm up For the definition of Warm up see Section 8 2 1 Output range change If Range change ON is selected contact output...

Page 125: ...atic or Automatic Calibration Measuring range change While contact input is On range of Analog Output 1 is switched as follows When analog output 1 range is set to Oxygen then range is switched to 0 t...

Page 126: ...2 Setting Procedure This setting example shows how to set When contact input 1 Opens Start Semi_Auto Calibration 1 From the Basic panel display touch Setup key and the Execution Setup display appears...

Page 127: ...ch enter Touch the Enter key The clock starts from 00 seconds Clock Averaging Fuel setup Purging Unit setup Passwords Defaults Enter Others F8 12E ai Enter Set date 1 3 0 7 0 0 Set time 1 4 3 9 1 3 J...

Page 128: ...uel m3 kg or m3 m3 2 in Table 8 8 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 hyd...

Page 129: ...n 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...

Page 130: ...026 0 024 0 022 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...

Page 131: ...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...

Page 132: ...m3 kg Theoretical air quantity required 1 0 0 m3 kg more Enter Fuel setup F8 17E ai Value of the X coefficient 1 0 0 Absolute humidity of the atmosphere 0 1 0 0 0 kg kg finished Enter Fuel setup F8 1...

Page 133: ...d the other is to enter the preset value manually Set the measurement gas temperature as follows 1 Press the Setup key in the basic panel display to display the Execution Setup display 2 Select Setup...

Page 134: ...ges and their default settings are as shown in Table 8 11 Table 8 11 Measurement Gas Temperature and Pressure Set Ranges and Default Settings Set Item Set range Default setting Temperature input selec...

Page 135: ...ing time 0 min Purging F8 21E ai Figure 8 22 Other Settings Figure 8 23 Purging Display 8 6 6 Setting Passwords Unauthorized access to lower level menu displays from the Execution Setup display can be...

Page 136: ...ot set as shipped from factory If you reset initialize the parameters and password settings are deleted If you forget a password select Commissioning in the Execution Setup display and enter MOON By d...

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Page 138: ...ventually arrive at the positive 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...

Page 139: ...inciple of Zirconia Humidity Analyzer A solid electrolyte such as zirconia allows the conduction of oxygen ions at high temperatures Therefore when a zirconia plated element with platinum electrodes o...

Page 140: ...Zirconia element F9 1E ai Figure 9 2 Schematic Diagram of Measurement Principle B For the mixing ratio measurement Assuming that the mixing ratio is rkg kg then r can be calculated from the value of...

Page 141: ...erature below 20 C and free of oily mist or dust as in instrument air For best accuracy as the span gas use oxygen whose concentration is near the top of the measurement range in a nitrogen mixture 9...

Page 142: ...nt calibration method using a zero gas only 21 0 p1 0 51 81 92 ez e1 es 0 C A B Zero point correction ratio B A x 100 Correctable range 100 30 Span correction ratio C A x 100 Correctable range 0 18 Ce...

Page 143: ...cise calibration conduct both zero and span calibrations The following sets forth the required calibration settings 9 2 1 Mode There are three calibration modes available 1 Manual calibration which al...

Page 144: ...setup display The numeric data entry display then appears Enter the desired oxygen concentration for the zero point calibration The zero gas set ranges from 0 3 to 100 vol O2 Enter 00098 for an oxyge...

Page 145: ...ation time and hold output stabilization time Analog output remains held when output remains held Calibration start contact or switch input Span calibration span gas valve open Zero calibration zero g...

Page 146: ...ond or later calibration will not be conducted 5 If a past date is set to the calibration start day no calibration will be conducted Default Values When the analyzer is delivered or if data are initia...

Page 147: ...ay 2 1 0 0 0 5min div 1 0 0 2 1 0 O2 CAL TIME Semi auto calibration F9 10E ai Figure 9 13 Semi auto Calibration Display To start calibration using an input contact follow these steps 1 Make sure that...

Page 148: ...temperature 750 C C J temperature 47 C Tag Hold F10 1E ai Figure 10 1 Detailed data Display 10 1 1 Span gas and Zero gas Correction Ratios These are used to check for degradation of the sensor cell I...

Page 149: ...he 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 no...

Page 150: ...1 26 5 29 5 32 1 O2 100 mv 34 4 T10 1E ai 10 1 7 Thermocouple Voltage The cell temperature is measured with a Type K chromel alumel thermocouple The thermocouple cold junction is located in the detec...

Page 151: ...oxygen concentration humidity and mixing ratio during the periods over which average values are calculated is displayed If the setup period elapses the average oxygen concentration that has been disp...

Page 152: ...dity graph under measurement Mixing ratio Mixing ratio graph under measurement Output 1 Output 1 selected item graph If this equipment is for the oxygen analyzer the trend graph will be an oxygen conc...

Page 153: ...The allowable settings for both upper limit and lower limit values range from 0 to 100 vol O2 0 to 100 H2O for humidity 0 to 1 kg kg for mixing ratio 10 2 4 Default Setting When the analyzer is delive...

Page 154: ...the Setup key from the Basic panel display to display the Execution Setup display Then select Maintenance from the Execution Setup display 2 Select the Display setup from the Maintenance display 3 Se...

Page 155: ...mi_Auto mode Setting Procedure 1 From the Basic panel display touch Setup key on the Execution Setup display which appears select Maintenance 2 On the Maintenance display select Blow back setup and th...

Page 156: ...Display the numeric data entry panel display to set the desired interval from 000 days 00 hours to 255 days 59 hours For the Start date and Start time set the date when the blow back is first executed...

Page 157: ...shown in Table 10 4 Table 10 4 Blow back Default Setting Item Default setting Mode No function invalid Hold time 10 minutes 00 seconds Blow back time 10 minutes 00 seconds Interval 30 days 00 hours S...

Page 158: ...em Current output 2 Tag name Deleted Trend graph Parameter Oxygen concentration Sampling interval 30 seconds Upper limit graph 25 vol O2 Lower limit graph 0 vol O2 Automatic return time 0 min Language...

Page 159: ...intenance Previous value held Set value of Maintenance 4 mA Calibration blow back Previous value held Set value of Calibration blow back 4 mA Error Preset value held Set value of Error 3 4 mA Alarm da...

Page 160: ...n gas press drop OFF Gas leak detection OFF Contact output action Closed Output contact 3 Alarm High high alarm OFF High limit alarm ON Low limit alarm ON Low low alarm OFF Calibration Coefficient Ala...

Page 161: ...ure Span zero Zero gas concentration 1 00 vol O2 Span gas concentration 21 00 vol O2 Output hold time 10 min 00 sec Semi_Auto Calibration time 10 min 00 sec Semi_Auto Interval 30 days 00 hr Auto Start...

Page 162: ...low alarm 0 vol O2 Humidity alarm setting Hysteresis 0 1 H2O Contact delay 3 seconds Humidity alarm set value High high alarm OFF Alarm value of High high alarm 100 H2O High limit alarm OFF Alarm val...

Page 163: ...it temp alarm OFF Calibration gas press drop OFF Gas leak detection OFF Contact output action Closed Output contact 3 Alarm High high alarm OFF High limit alarm ON Low limit alarm ON Low low alarm OFF...

Page 164: ...rn the power off and then back on NOTE Make sure that before resetting or restarting the power that there is no problem with the detector or converter If a problem arises again after the resetting tur...

Page 165: ...ker Span gas valve Checks the zero and span gas flow Controls the span gas air flow Zero gas valve regulator Tube connection Cover screws six pcs Pump Supplies span gas air Gas cylinder Contains the z...

Page 166: ...gas following instructions on the converter display Also check that no piping is disconnected Thus the work of installing a gas cylinder is completed However gases in the cylinders cannot immediately...

Page 167: ...rom the Manual calibration display shown in Figure 10 15 Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Fig...

Page 168: ...al Calibration Display NOTE Be sure not to terminate a calibration in progress because of a shortage of gas in the cylinder Each gas cylinder is operable for nine minutes or more provided the gas is d...

Page 169: ...w rate ml min 500 430 380 350 320 2 Adjust the flow rate and select Valve opened from the Manual calibration display Check the Trend graph display to see that the measured value is stabilized Then pre...

Page 170: ...ow setting valve to stop the zero gas flow If the valve has a lock nut be sure to tighten the lock nut to prevent the any leakage of the zero gas into the sensor because the valve may become loose dur...

Page 171: ...Blank Page...

Page 172: ...remove dust sand or the like from the terminal box cover 11 1 Inspection and Maintenance of the Detector 11 1 1 Cleaning the Calibration Gas Tube The calibration gas supplied through the calibration g...

Page 173: ...a in the metal O ring groove in which the contact is embedded sand the groove with sandpaper or use a metal brush and then sand further with a higher grade of sandpaper no 1500 or so or use an appropr...

Page 174: ...er inserting it until the metal O ring comes in contact with the probe s O ring contact surface properly align the U shaped pipe insertion holes with the bolt openings 3 Attach the U shaped pipe to it...

Page 175: ...s following the instructions given above 11 1 3 Replacement of the Heater Unit This section describes the replacement procedure for the heater unit The sensor or ceramic heater furnace core internal s...

Page 176: ...18 19 20 21 22 24 24 26 34 28 30 29 33 32 CELL TC TC F11 4 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 4 Exploded View of Detector When pressure c...

Page 177: ...t 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 2...

Page 178: ...parts from the high temperature probe adapter and then clean them To remove dust blow air on them or rinse them with water 11 1 7 Stopping and Re starting Operation Stopping Operation When operation...

Page 179: ...immediately there may be a problem in the circuit Go over the circuit completely to find out why the fuse has blown This fuse is for protecting the main power supply circuit and does not provide over...

Page 180: ...oft dry cloth to clean any part of the converter during inspection and maintenance 11 2 3 Adjust LCD screen contrast An LCD is built in the ZR402G converter The contrast of this LCD is affected by its...

Page 181: ...he bracket side 5 Replace piping and fix M6 bolts between brackets 1 1 When disassembling and reassembling mark original positions and tighten an extra 5 10 when reassembling After tightening do a liq...

Page 182: ...one set in Output hold setting refer to Section 8 2 Output Hold Setting When the display shown in Figure 12 1 appears pressing the error indication brings up a description of the error Figure 12 2 Th...

Page 183: ...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 ch...

Page 184: ...als 7 and 8 of the detector and measure the resistance value between these terminals The heater unit is normal if the resistance is lower than about 90 If the resistance value is higher failure of the...

Page 185: ...e to a temporary drop in the voltage falling below 85 V the least amount of voltage required to operate the converter or a malfunction of the electrical circuits affected by noise Check whether or not...

Page 186: ...or falls below 5 mV about 170 C Alarm 12 Input current alarm When mA input is selected in the Exhaust gas setup display this alarm occurs if the input current from the temperature transmitter is outsi...

Page 187: ...See Table 12 3 for the theoretical cell voltages Although the tolerance to the theoretical value cannot be generally specified a reasonable one may be approximately 10 mV Table 12 3 Oxygen Concentrati...

Page 188: ...the span gas set in 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 fa...

Page 189: ...the detector probe for example by changing the mounting position of the detector Alarm 9 Exhaust Gas Temperature Alarm When mA input is selected in the Exhaust gas setup display this alarm occurs if...

Page 190: ...to 1 6 k the cold junction temperature sensor is considered to be faulty Replace that temperature sensor with a new one 3 If the resistance value is within the above range the cold junction temperatu...

Page 191: ...is broken or shorted out and also whether the wiring cable is securely connected to the terminals Also check that the wiring resistance between the converter and the detector is 10 or less 4 If there...

Page 192: ...alue 2 The measured value is lower than the true value 3 The measured value sometimes shows abnormal values 12 3 1 Measured Value Higher Lower for Humidity Analyzer Than True Value Causes and Counterm...

Page 193: ...ne If the sensor is cracked the symptoms will be the same low humidity measured value Perform a visual inspection and if a crack is found replace the sensor assembly as described in 11 1 3 NOTE Data s...

Page 194: ...ion or other factors Check whether or not there are loose points in the wiring connections or loose crimping caulking at the crimp on terminal lugs 4 Combustible components in the sample gas may be ge...

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Page 196: ...7 8 9 10 11 K9471UA G7109YC K9470BK E7042DW K9470ZF K9470ZG E7042BR K9470BM K9473AN E7042UD ZR01A01 E7042BS K9470BJ E7042AY K9470ZK K9470ZL 1 4 4 1 1 1 1 1 1 1 1 1 Dust Filter Option Bolt M5x12 SUS316...

Page 197: ......

Page 198: ...rporation Subject to change without notice Model ZR402G Zirconia Oxygen Analyzer High Temperature Humidity Analyzer Converter CMPL 11M12C01 01E 1st Edition Jan 2000 YK 3rd Edition Feb 2011 YK 1 Hood f...

Page 199: ......

Page 200: ...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 E7046...

Page 201: ......

Page 202: ...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 P...

Page 203: ......

Page 204: ...for Separate type Zirconia Oxygen Humidity Analyzer ZR22G ZR402G CMPL 11M12A01 11E 1st Edition Dec 2000 YK 4th Edition Mar 2013 YK L ZERO LOCK OCK SPAN IN ZERO IN AUTO CALIBRATION UNIT 20 TO 558C Made...

Page 205: ......

Page 206: ...ZO21S Zirconia Oxygen Analyzer High Temperature Humidity Analyzer Standard Gas Unit CMPL 11M3D1 01E 1st Edition Jan 2000 YK 4th Edition Mar 2011 YK 1 2 3 Item Part No Qty Description 1 1 Pump see Tab...

Page 207: ......

Page 208: ...n of erroneous description 0 5 to 5 kpa 0 5 to 5 kPa 2 2 2 ZO21R Probe Protector Deleted the flange of the DIN standard and changed the dimension of the insertion length 2 3 2 ZO21P High Temperature P...

Page 209: ...dded Note 8 2 3 Output Hold Setting To set the output hold follow these setps The following Note description should be added Revised and Corrected over all Apr 2005 6th Edition Revised section Introdu...

Page 210: ...External Dimensions figure changed MS Code table 2 5 1 Changed reference gas pressure where check valves is used style changed of ZA8F 2 5 2 Added detail about ZR40H Automatic Calibration Unit 2 7 3 A...

Page 211: ...Blank Page...

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YOKOGAWA EXAxt ZR22G, User Manual, Page: 14 / 211

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