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IM 11M12A01-04E

<Introduction>

Introduction

The EXAxt ZR Integrated type Zirconia Oxygen Analyzer has been developed for combustion control 

in various industrial processes. There are several version of this analyzer so you can select one that 

matches your application.
Optional accessories are also available to improve measurement accuracy and automate calibration. 

An optimal control system can be realized by adding appropriate options.
This instruction manual describes almost all of the equipment related to the EXAxt ZR. You may skip 

any section(s) regarding equipment which is not included in your system.
Regarding the HART Communication Protocol, refer to IM 11M12A01-51E.
IM11M12A01-51E has been published as ''Model EXAxt ZR series HART protocol''.
Regarding Separate type Zirconia Oxygen Analyzer, refer to IM 11M12A01-02E.
< Before using the equipment, please read any descriptions in this manual related to the equipment 

and system that you have, on appropriate use and operation of the EXAxt ZR. >

Models and descriptions in this manual are listed below.

Model

Product Name

Description in this manual

Specification

Installation Operation Maintenance CMPL

ZR202G  Integrated type Oxygen Analyzer

ZO21R  Probe Protector

ZA8F

Flow Setting Unit (for manual 

calibration use)

ZR20H  Automatic Calibration Unit

—

Case Assembly for calibration 

gas cylinder (Part No. E7044KF)

—

Check valve (Part No. K9292DN, 

K9292DS)

—

Dust Filter for the detector (Part 

No. K9471UA)

—

Dust Guard Protector (Part No. 

K9471UC)

ZO21S

Standard Gas Unit

CMPL: Customer Maintenance Parts List

Media No.IM 11M12A01-04E (CD) 

7th Edition :March 2012 (YK)

All Rights Reserved Copyright © 2000, Yokogawa Electric Corporation

Summary of Contents for ZR202G

Page 1: ...User s Manual R Model ZR202G Integrated type Zirconia Oxygen Analyzer IM 11M12A01 04E IM 11M12A01 04E 7th Edition ...

Page 2: ...R series HART protocol Regarding Separate type Zirconia Oxygen Analyzer refer to IM 11M12A01 02E Before using the equipment please read any descriptions in this manual related to the equipment and system that you have on appropriate use and operation of the EXAxt ZR Models and descriptions in this manual are listed below Model Product Name Description in this manual Specification Installation Oper...

Page 3: ...6 Components Major parts and functions are described 7 Startup Basic procedure to start operation of EXAxt ZR Chapter 7enables you to operate the equipment immediately 8 Detailed Data Setting Details of key operations and displays 9 Calibration Describes the calibration procedure required in the course of operation 10 Other Functions Other functions described 11 Inspection and Maintenance How to c...

Page 4: ...heck 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 probe especially at the tip becomes very hot Be sure to handle it with gloves 1 About This Manual The contents of this manual shall not be reproduced or copied in part or in whole wit...

Page 5: ...on describes these icons WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices IMPORTANT Indicates that operating the hardware or software in this manner may damage it or lead...

Page 6: ...on keys displays on the panel Enclosed in Ex MODE key Ex message display BASE Ex data display 102 lit 102 flashing Drawing for flashing Indicated by gray characters Flashing lit Displays on the LCD display panel 9 8 7 6 5 4 3 2 1 0 W V U T S R Q P O N M L K J I H G F E D C B A Alphanumerics Alphanumerics Alphanumerics LED Display LED Display LED Display Z Y ...

Page 7: ...suitable for the operation conditions before conducting analysis Where necessary set the instrument parameters for appropriate operation For details on setting data refer to Chapters 7 to 10 When user changes the operation parameter it is recommended to note down the changed setting data How to dispose the batteries This is an explanation about the new EU Battery Directive DIRECTIVE 2006 66 EC Thi...

Page 8: ...ty period Failure of components which are out of scope of warranty stated in instruction manual Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Elec tric did not supply Failure due to improper or insufficient maintenance by user Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize Failure due to power supply ...

Page 9: ...viii IM 11M12A01 04E Introduction ...

Page 10: ...ZR202G Integrated type Zirconia Oxygen Analyzer 2 2 2 1 3 ZO21R Probe Protector 2 9 2 2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit 2 10 2 2 1 ZA8F Flow Setting Unit 2 10 2 2 2 ZR20H Automatic Calibration Unit 2 12 2 3 ZO21S Standard Gas Unit 2 14 2 4 Other Equipment 2 15 2 4 1 Dust Filter for Oxygen Analyzer part no K9471UA 2 15 2 4 2 Dust Guard Protector part no K9471UC 2 15 2 4 ...

Page 11: ...3 9 3 4 1 Installation Location 3 9 3 4 2 Mounting 3 9 3 5 Insulation Resistance Test 3 10 4 Piping 4 1 4 1 Piping for System 1 4 1 4 1 1 Piping Parts for System 1 4 2 4 1 2 Piping for the Calibration Gas 4 2 4 1 3 Piping for the Reference Gas 4 2 4 2 Piping for System 2 4 3 4 2 1 Piping Parts for System 2 4 3 4 2 2 Piping for the Calibration Gas 4 3 4 2 3 Piping for the Reference Gas 4 4 4 3 Pipi...

Page 12: ...d Wiring Connections 7 2 7 2 Valve Setup 7 2 7 3 Supplying Power to Converter 7 2 7 4 Operation of Infrared Switch 7 3 7 4 1 Display and Switches 7 3 7 4 2 Display Configuration 7 4 7 4 3 Entering Parameter Code Selection Display 7 5 7 4 4 Selecting Parameter Codes 7 6 7 4 5 Changing Set Values 7 6 7 5 Confirmation of Equipment Type Setting 7 8 7 6 Selection of Measurement Gas 7 9 7 7 Output Range...

Page 13: ... 8 6 8 4 3 Alarm Setting 8 7 8 4 4 Default Values 8 8 8 5 Output Contact Setup 8 8 8 5 1 Output Contact 8 8 8 5 2 Setting Output Contact 8 9 8 5 3 Default Values 8 10 8 6 Input Contact Settings 8 11 8 6 1 Setting Input Contact 8 11 8 6 2 Default Values 8 11 8 7 Other Settings 8 12 8 7 1 Setting the Date and Time 8 12 8 7 2 Setting Periods over which Average Values are Calculated and Periods over w...

Page 14: ... 10 1 19 Time 10 7 10 1 20 Software Revision 10 7 10 2 Operational Data Initialization 10 7 10 3 Initialization Procedure 10 8 10 4 Reset 10 9 10 5 Handling of the ZO21S Standard Gas Unit 10 16 10 5 1 Standard Gas Unit Component Identification 10 16 10 5 2 Installing Gas Cylinders 10 16 10 5 3 Calibration Gas Flow 10 17 10 6 Methods of Operating Valves in the ZA8F Flow Setting Unit 10 19 10 6 1 Pr...

Page 15: ...s to Take When an Error Occurs 12 2 12 2 Displays and Measures to Take When Alarms are Generated 12 4 12 2 1 What is an Alarm 12 4 12 3 Measures When Measured Value Shows an Error 12 9 12 3 1 Measured Value Higher Than True Value 12 9 12 3 2 Measured Value Lower Than True Value 12 10 12 3 3 Measurements Sometimes Show Abnormal Values 12 10 Customer Maintenance Parts List CMPL 11M12A01 04E Customer...

Page 16: ... user to operate the equipment without opening the cover on site Analyzer calibration can also be fully automated and the automatic calibration unit is provided Choose the equipment which best suits your needs so that an optimal combustion control system can be obtained Some examples of typical system configuration are illustrated below 1 1 EXAxt ZR System Configuration The system configuration sh...

Page 17: ...ument air clean and dry air of oxygen concentration 21 is used as the reference gas and the span gas for calibration Zero gas is fed from a cylinder during calibration The gas flow is controlled by the ZA8F flow setting unit for manual valve operation ZR202G Integrated type Zirconia Oxygen Analyzer F1 2E ai ZA8F flow setting unit Reference gas Calibration gas Needle valve Flowmeter Instrument air ...

Page 18: ...to the sensor 100 to 240 V AC Automatic calibration unit Reference gas Calibration gas Zero Contact input Analog output contact output Digital output HART Air Set Instrument air Calibration gas unit case Calibration gas pressure regulator Zero gas cylinder ZR202G Integrated type Zirconia Oxygen Analyzer with automatic calibration unit ZR202G A A F1 3E ai Span gas ZR20H 3 Note The installation temp...

Page 19: ...ted type System configuration Example 3 Example 1 Example 2 T1 1 ai Items required for the above system example To be selected depending on each application For details refer to corresponding chapter Select either ZR202A Heater Assembly Spare Parts for ZR202G K9471UC Dust Guard Protector 1 2 2 Oxygen Analyzer and Accessories F1 4E ai Detector ZR202G Detector ZR202G Detector ZR202G Probe Protector ...

Page 20: ... 0 to 100 vol O2 in 1 vol O2 or partial range Digital Communication HART 250 to 550Ω 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 reference gas is by natural convection 0 5 Maximum value of set ran...

Page 21: ...in the furnace exceeds 3 kPa it is recommended to compensate the pressure When the pressure in the furnace exceeds 5 kPa you must perform pressure compensation No pressure fluctuation in the furnace be allowed Note When the detector is used in conjunction with a check valve and the ZA8F Flow Setting Unit the maximum pressure of sample gas is 150 kPa When with a check valve and the ZR20H Automatic ...

Page 22: ...ent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version Gas Connection Rc 1 4 or 1 4 FNPT Wiring Connection G1 2 Pg13 5 M20 by 1 5mm 1 2 NPT select one type 4 pieces Installation Flange mounting Probe Mounting Angle Horizontal to vertically downward When the probe insertion length is 2 m or less installing at angle...

Page 23: ...rmocouple reference junction temperature C maximum minimum average oxygen concentration vol O2 cell e m f mV cell internal resistance Ω cell condition in four grades heater on time rate calibration record ten times time year month day hour minute Calibration Setting Items Span gas concentration vol O2 zero gas concentration vol O2 calibration mode auto semi auto manual calibration type and method ...

Page 24: ...Low low alarm 5 Low alarm 6 Maintenance 7 Calibration 8 Range switching answer back 9 Warm up 10 Calibration gas pressure decrease answer back of contact input 11 Flameout gas detection answer back of contact input Contact Input Two points voltage free contacts The following functions are programmable for contact inputs 1 Calibration gas pressure decrease alarm 2 Range switching switched range is ...

Page 25: ...2 Dust Filter Dust Guard Protector SCT PT Stainless steel tag plate 5 Printed tag plate 5 C2 C3 Failure alarm down scale Output status at CPU failure and hardware error is 3 6 mA or less 10 Failure alarm up scale Output status at CPU failure and hardware error is 21 0 mA or more 10 1 For the horizontally installed probe whose insertion length is 2 5 m or more use the Probe Protector Be sure to spe...

Page 26: ...FF SUS304 JIS 10K 65 FF SUS304 JIS 10K 80 FF SUS304 JIS 10K 100 FF SUS304 JPI Class 150 4 RF SUS304 JPI Class 150 3 RF SUS304 Westinghouse 152 4 190 5 228 6 165 200 220 155 175 185 210 229 190 155 120 6 152 4 190 5 125 160 180 130 140 150 175 190 5 152 4 127 4 Ø19 4 Ø19 8 Ø19 4 Ø18 8 Ø18 8 Ø18 4 Ø15 4 Ø19 8 Ø19 8 Ø19 8 Ø19 4 Ø19 4 Ø11 5 A B C 19 24 24 18 20 20 14 18 18 18 24 24 14 t Ø50 8 Rc1 4 or...

Page 27: ...ss 150 3 RF SUS304 Westinghouse 152 4 190 5 228 6 165 200 220 155 175 185 210 229 190 155 120 6 152 4 190 5 125 160 180 130 140 150 175 190 5 152 4 127 4 Ø19 4 Ø19 8 Ø19 4 Ø18 8 Ø18 8 Ø18 4 Ø15 4 Ø19 8 Ø19 8 Ø19 8 Ø19 4 Ø19 4 Ø11 5 A B C 19 24 24 18 20 20 14 18 18 18 24 24 14 t L L 0 4 0 7 1 0 1 5 2 0 2 5 3 0 m 4 G1 2 2 1 2NPT etc Cable connection port Ø50 8 Rc1 4 or 1 4NPT Reference gas inlet Rc1...

Page 28: ...05m Approx 6 10 kg JIS ANSI 1 55 m Approx 9 13 kg JIS ANSI 2 05 m Approx 12 16 kg JIS ANSI Installation Bolts nuts and washers are provided for detector probe adapter 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 Class...

Page 29: ...onstruction 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 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 maximum pressure rating is 300 kPa pressure at inlet of the automatic calibratio...

Page 30: ...N Instrument 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 2B 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 ZA8...

Page 31: ...lowmeter MA Methacrylate resin Bracket SUS304 JIS Finish Polyurethane corrosion resistance coating Case Mint green Munsell 5 6 BG3 3 2 9 Cover Mint green Munsell 5 6 BG3 3 2 9 Piping Connection Rc 1 4 or 1 4 NPT Power Supply 24V DC from ZR202G Power consumption Approx 1 3 W Reference Gas Pressure Sample gas pressure plus Approx 150 kPa 690 kPa max Pressure at inlet of automatic calibration unit Ai...

Page 32: ...E SUFFIX MODEL ZR20H 20 TO 558C AUTO CAL UNIT SPAN IN REF IN ZERO IN 84 166 5 Ø80 243 258 166 5 56 44 180 MAX 44 40 40 66 5 49 111 66 5 40 40 Ø84 Span gas inlet Zero gas inlet Reference gas inlet Zero gas inlet Reference gas inlet Span gas inlet MAX 2 Vertical Mounting B Unit mm Ø80 44 PIPNG INSIDE THE AUTOMATIC CALIBRATION UNIT SPAN IN REF IN ZERO IN F4 11E ai Calibration gas Reference gas ZR202G...

Page 33: ...00 110 115 200 220 240V AC 10 50 60 Hz Power Consumption Max 5 VA Case material SPCC Cold rolled steel sheet Paint Epoxy resin baked Paint Color Mainframe Munsell 2 0 GY3 1 0 5 equivalent Cover Munsell 2 8 GY6 4 0 9 equivalent Piping Ø6 x Ø4mm flexible tube connection Weight Approx 3 kg Span gas Internal pump draws in air from atmosphere and feeds to detector Non CE Mark Model and Codes Model Suff...

Page 34: ...erpendicular to the probe Mesh 30 microns Material Carborundum Filter SUS316 JIS Weight Approx 0 2 kg Part No Description K9471UA Filter K9471UX Tool Unit mm Ø51 32 10 Carborundum filter SiC Increasing of insertion length F31 EPS Screw Detector Attach the filter unit to the tip of the detector by screwing it clockwise 2 4 2 Dust Guard Protector part no K9471UC Recommended to be used when sample ga...

Page 35: ...ration gas line directly connected to the detector This is applied to a system based on the system configuration System 2 and 3 This valve prevents the sample gas from entering the calibration gas line Although it functions as the stop valve operation is easier as it does not require opening closing at each calibration Screw the check valve into the calibration gas inlet of the detector instead of...

Page 36: ...inc alloy with adapter SUS316 Part no G7004XF or 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 1kg Part No Description G7004XF Joint RC 1 4 Material Zinc alloy K9473XG Joint 1 4 FNPT Material Zinc alloy with adapter SUS316 Ø74 Primary Secondary 88 Max 210 max 55 Approx 122 Secondary pressure gauge Panel Horiz...

Page 37: ...F32 ai 485 325 ø140 2 4 7 Pressure Regulator G7013XF or G7014XF for Gas Cylinder This regulator 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 4FNPT Material Brass body H I H AC A K T O Regulator handle W22 Right handed screw Stop valve Approx 112 ...

Page 38: ...assembly 158 3 160 The oblique line is an opening portion 2 4 9 ZR202A Heater Assembly Model Suffix code Option code Description ZR202A Heater Assembly for ZR202G Length 1 040 070 100 150 200 250 300 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 A Always A 1 Suffix code of length should be selected as same as ZR202G installed 2 Jig part no is K9470BX to order as a parts af...

Page 39: ...Blank Page ...

Page 40: ...o the probe for checking and maintenance work 2 Ambient temperature of not more than 55 C and the terminal box should not be affected by radiant heat 3 A clean environment without any corrosive gases NOTE A natural convection type analyzer model ZR202G C which uses ambient air as reference gas requires that the ambient oxygen concentration be constant Automatic calibration cannot be used when natu...

Page 41: ...han a 5 tilt 3 The detector probe should be mounted at right angles to the sample gas flow or the probe tip should point downstream 100mm vertical Bounds of the probe insertion hole location Flange matches the detector size horizontal 100mm Four hole flange Eight hole flange F3101E ai 1 Note 1 Type Outside diameter of detector With dust filter 51 mm in diameter Note With probe protector 60 5 mm in...

Page 42: ...as flow of 1 m sec or faster at the front surface of the filter When you specify option code F1 the detector is shipped with the dust filter mounted Follow this procedure when replacing the filter in the detector It is recommended that you read Chapter 11 prior to filter mounting for it is necessary to be familiar with the detector s construction especially the sensor assembly 1 Mount the dust fil...

Page 43: ...ching it apply the Never Seez Nickel Special to it 4 Ø6 122 Ø50 8 100 Increasing of insertion length F11 1 ai Figure 3 2 2 Installation of the dust guard protector Detector with a probe protector Model ZO21R L 200 B for enhance forth The detector is used with a probe protector to support the probe ZR202G when the probe length is 2 5m or more and mounted horizontally 1 Put a gasket provided by the ...

Page 44: ...lly the calibration reference gas inlet should face downward Direction of the sample gas flow Mount the protector so that the notch is on the downstream side of gas flow F3104E ai 1050 1550 2050 Gasket t1 5 Unit mm Detector top Calibration gas inlet Reference gas inlet Figure 3 4 Mounting of detector with a probe protector Dust wear protect NOTE When the probe protector is used in the ZR202G with ...

Page 45: ... 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 F3401E ai Figure 3 12 Pipe Mounting Wall Mounting 1 Make a hole in the wall as illustrated in Figure 3 13 223 140 F3 13...

Page 46: ...ctor and the converter 3 No corrosive gas 4 An ambient temperature of not more than 55 C and little change of temperature 5 No vibration 6 Little exposure to rays of the sun or rain 3 3 2 Mounting of ZR20H Automatic Calibration Unit ZR202G A or B is shipped with automatic calibration unit attached The automatic calibration unit includes flowmeters and solenoid valves so as to ensure reliable and a...

Page 47: ...or 1 4NPT Female 166 5 258 243 214 MAX 44 66 5 40 40 Vertical mounting on the ZR202G B F3 15E ai Horizontal mounting on the ZR202G A Unit mm Display side Zero gas inlet Rc1 4 or 1 4NPT Female Span gas inlet Rc1 4 or 1 4NPT Female Reference gas inlet Rc1 4 or 1 4NPT Female 166 5 60 45 160 66 5 40 40 180 MAX 44 Figure 3 15 Automatic Calibration Unit Mounting ...

Page 48: ...he temperature of the case should not exceed 40 C due to rays of the sun or radiated heat 5 No vibration 3 4 2 Mounting Mount case assembly on a pipe nominal JIS 50 A 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 weighs approximately 4 2 kg 2 Mount the case assembl...

Page 49: ...over wiring and terminal to ground 4 Turn the insulation resistance tester ON and measure the insulation resistance 5 After testing remove the tester and connect a 100 kΩ resistance between the crossover wiring and ground to discharge 6 Testing between the heater terminal and ground contact output terminal and ground analog output input terminal and the ground can be conducted in the same manner 7...

Page 50: ... 20 C or lower removed any dust oil mist and the like for reference gas Stable analyzing can be conducted when using instrument air 4 1 Piping for System 1 The piping in System 1 is illustrated in Figure 4 1 ZR202G Integrated type Zirconia Oxygen Analyzer ZO21S Standard gas unit Stop valve Calibration gas F1 1E ai 100 to 240 V AC 100 110 115 200 220 240 V AC Contact input Analog output contact out...

Page 51: ...analyzer Mount the stop valve of a quality specified by YOKOGAWA through a nipple found on the local market as illustrated in Figure 4 2 and mount a joint also found on the local market at the stop valve tip The stop valve may be mounted on the equipment when the oxygen analyzer is shipped Note Mount the stop valve in the vicinity of the equipment F4 2E ai Stop valve Tube connection joint Nipple F...

Page 52: ...arts Zero gas cylinder User s scope Pressure Regulator G7013XF or G7014XF recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts Reference gas inlet Air set G7003XF K9473XK or G7004XF K9473XG recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts Note Parts with marking are used when required General parts can be found on the local market 4 2 2 P...

Page 53: ... of System 2 Refer to Section 4 2 Adjust secondary pressure of both the air set and the zero gas regulator so that these two pressures are approximately the same The flow rate of zero and span gases normally instrument air are set by a individual needle valve After installation and wiring check zero gas calibration contact output see Sec 7 9 2 and adjust zero gas regulator and calibration gas need...

Page 54: ...Horizontal mounting on the ZR202G A Unit mm Display side Zero gas inlet Rc1 4 or 1 4NPT Female Span gas inlet Rc1 4 or 1 4NPT Female Reference gas inlet Rc1 4 or 1 4NPT Female 166 5 60 45 160 66 5 40 40 180 MAX 44 Piping Diagram SPAN IN REF IN ZERO IN F4 11E ai Calibration gas Reference gas ZR202G body Span gas solenoid valve Span gas flowmeter Reference gas flowmeter To Air set To Zero gas cylind...

Page 55: ...n is illustrated in Figure 4 12 49 342 4 25 F4 12E ai ØB ØA C 1 1 1 1 1 1 Dimension may vary depending on the detector type Ensure that the flange gasket does not block off the reference gas outlet Where necessary make a notch on the flange Rc 1 4 or 1 4 NPT Reference gas inlet 4 G1 2 2 1 2 NPT or the like Wiring connection Rc1 4 or 1 4NPT Calibration gas inlet Stop valve Reference gas outlet Flan...

Page 56: ...ment If piping connections are made between the detector and the needle valve condensation will result inside the piping and cause the sensor to be damaged when the calibration gas is introduced Figure 4 13 illustrates an example of System 2 using the analyzer with pressure compensation Supplying the air pressure flow may vary depending on the furnace pressure It is recommended to use a flow gauge...

Page 57: ...NPT General parts Zero gas cylinder User s scope Pressure regulator G7013XF or G7014XF recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts Reference gas inlet Air set G7003XF K9473XK or G7004XF K9473XG recommended by YOKOGAWA Joint for tube connection Rc1 4 or 1 4 NPT General parts Note Use parts with marking as required General parts can be found on the local market 4...

Page 58: ...re 1 Be sure to connect the shield of the shielded line to FG terminal of the analyzer 2 The most outer sheath of the signal line and the power cable should be stripped off to the minimum necessary length 3 Signal will be affected by noise emission when the signal lines power cable and heater cable are located in the same conduit When using a conduit signal lines should be installed in the separat...

Page 59: ...tput signal 2 Power and ground 3 Contact output 4 Contact input 1 DI 1 2 DI 2 3 DI C 4 DO 1 5 DO 1 6 DO 2 7 DO 2 8 FG 9 AO 10 AO 11 L 12 N 13 G 14 FG F28 EPS Model ZR202G Integrated type Zirconia Oxygen Analyzer Contact input 1 Contact output 2 Contact output 1 Analog output 4 20 mA DC 100 to 240 V AC 50 or 60 Hz Digital output Contact input 2 The protective grounding for the analyzer shall be con...

Page 60: ...hielded cables Analyzer Receiver Figure 5 4 Wiring for Analog Output 5 2 1 Cable Specifications Use a 2 core shielded cable for wiring 5 2 2 Wiring Procedure 1 M4 screws are used for the terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections Ensure that the cable shield is connected to the FG terminal of the equipment 2 Be sure to connect and polarities correctly...

Page 61: ...or three core cable 2 M4 screws are used for the terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections 5 3 2 Wiring for Ground Terminals The ground wiring of the analyzer should be connected to either the ground terminal of the equipment case or the terminal inside of the equipment Proceed as follows 1 Keep the ground resistance of 100Ω or less JIS Class D groun...

Page 62: ...contacts used 5 4 2 Wiring Procedure 1 M4 screws are used for the terminals Use crimp on terminals appropriate for M4 terminal screws for cable connections 2 The contact output relays are rated 30 V DC 3A 250 V AC 3A Connect a load e g pilot lamp and annunciator within these limits 5 5 Wiring for Contact Input The converter can execute specified function when receiving contact signals To use these...

Page 63: ...Each cable should be equipped with the corresponding crimp contact 2 The ON OFF level of this contact input is identified by the resistance Connect a contact input that satisfies the descriptions in Table 5 2 Table 5 2 Identification of Contact Input ON OFF Closed Open Resistance 200 Ω or less 100 kΩ or more ...

Page 64: ...uivalent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version Probe this part is inserted in the furnace Selectable of length from 0 4 0 7 1 0 1 5 2 0 2 5 or 3 0m Flange used to mount the detector Selectable from JIS ANSI DIN or JPI standard models F6 1E ai Bolt Washer Pipe support U shaped pipe Metal O ring Dust fi...

Page 65: ...etting Unit ZERO IN REF IN SPAN IN ZERO IN REF IN SPAN IN F6 3E ai Flowmeter for Span gas Flowmeter for Span gas Flowmeter for Reference gas Flowmeter for Reference gas Flowmeter for Zero gas Flowmeter for Zero gas Horizontal mounting Vertical mounting Span gas flow setting valve Span gas flow setting valve Reference gas flow setting valve Reference gas flow setting valve Zero gas flow setting val...

Page 66: ...bration F7 0E ai Place in normal operation Check piping and wiring connections Set up valves Supply power Confirm converter type setting Select gas to be measured Set output ranges Check current loop Check contact action Calibrate analyzer Set detailed data Figure 7 1 Startup Procedure For system tuning by HART communication refer to the IM 11M12A01 51E HART Communication Protocol ...

Page 67: ...tup be sure to tighten the lock nut NOTE The calibration gas flow setting will be described later Fully close the needle valve in the flow setting unit 7 3 Supplying Power to Converter CAUTION To avoid temperature changes around the sensor it is recommended that the power be continuously supplied to the Oxygen Analyzer if it is used in an application where its operations and suspensions are period...

Page 68: ...on after reaching the rightmost position of the digit 2 Selects Yes or No 3 When you touch this key together with the ENT key the previous display then appears or the operation will be cancelled Used to change values If you continuously touch this key the value of the digit will increase continuously e g from 1 to 2 to 3 for numeric data or from A to B to C for alphabetic characters and finally re...

Page 69: ...4 2 Display Configuration The parameter codes provided for the equipment are used to control the equipment display panels see below By selecting appropriate parameter codes you can conduct calibration and set operation parameters Figure 7 4 shows the configuration of display items The parameter codes are listed in groups of seven which are briefly described in Table 7 2 To enter parameters you fir...

Page 70: ...ously touch the ENT key for at least three seconds to display PASSno ENT 0000 Touch the ENT key again This allows you to change the leftmost digit that is flashing ENT 1000 Set the password 1102 If you touch the key the digit that is flashing will be 1 ENT 1000 Touch the key to move the position of the digit that is flashing to the right one digit ENT 1100 Touch the key to change the numeric value...

Page 71: ...to A Numeric values will change from 0 to 1 to 2 to 3 to 8 to 9 and back to 0 However numbers that are not present in the parameter codes will be skipped Each digit is changed independently Even though a low order digit changes from 9 to 0 a high order digit will not be carried ENT Set Value After you select the desired character touch the ENT key The set data will be displayed The symbol indicate...

Page 72: ...l change in sequence from 0 to 1 to 2 to 3 to 8 to 9 and back to 0 ENT 09 0 Touch the key to move the position of the digit that is flashing to the right ENT 09 8 Touch the key to set the numeric value 8 ENT 09 8 Where the correct numeric value is displayed touch the ENT key ENT 09 8 If you touch the ENT key again the flashing stops and the current set value will be in effect ENT C11 Touch the ENT...

Page 73: ...rd has been entered ENT F01 Touch the key to switch to Group F If an unwanted alphabetic character after F has been entered continuously touch the key to return to the original ENT 0 Touch the ENT key for confirmation If 0 zero is entered the oxygen analyzer is already set If 1 one is entered the humidity analyzer has been set Change the setting following the steps below ENT 0 Continuously touch t...

Page 74: ...ntered the oxygen concentration in a wet gas is already set If the oxygen concentration in a dry gas is to be entered follow the steps below to set 1 one ENT 0 Continuously touch the key and the position of the digit will change from 1 to 0 to 1 to 0 Release the ENT key when 1 one is displayed ENT 0 Touch the ENT key The numeric value will flash ENT 0 Touch the ENT key again to stop the value from...

Page 75: ...h to the parameter code selection display ENT C11 Set the oxygen concentration at 20 mA Touch the key to move the position of the digit that is flashing to the right ENT C12 Touch the key to enter the numeric value 2 ENT 025 Touch the ENT key to display the current set value ENT 025 Touch the key to move the position of the digit that is flashing to the right ENT 020 Touch the key to change the nu...

Page 76: ...utput is then issued ENT G01 Touch the ENT key once again to switch to the parameter code selection display At that point the output current returns to the normal value ENT Basic panel display Touch the key together with the ENT key to return to the basic panel display The symbol indicates that the key is being touched Light characters indicates that the digits are flashing 7 9 Checking Contact I ...

Page 77: ... the ENT key once again to switch to the parameter code selection display The contact then returns to the original state ENT Basic panel display Touch the key together with the ENT key to return to the basic panel display This is not required if you proceed to make another setting The displayed numeric characters indicate the measurement gas concentration The symbol indicates that the key is being...

Page 78: ... enter 1 ENT G11 Touch the key to move the position of the digit that is flashing to the right one digit ENT G15 Touch the key to enter 5 ENT 0 Touch the ENT key to have 0 flash The solenoid valve remains closed ENT 1 Touch the key to enter 1 ENT 1 Touch the ENT key The flashing continues ENT 1 Touch the ENT key again to stop the flashing and the solenoid valve will be open to let the calibration ...

Page 79: ...it that is flashing to the right one digit ENT G21 Touch the key to enter 2 ENT 0 Touch the ENT key 0 is displayed with the contact open If the contact is closed the display will be 1 one This enables you to check whether or not the wiring connections have been properly made or not ENT G21 Touch the ENT key once again to switch to the parameter code selection display ENT Basic panel display Touch ...

Page 80: ... manual 7 10 1 Calibration Setup Set the following three items before carrying out a calibration Parameter codes for these set items are listed in Table 7 11 1 Mode setting There are three calibration modes manual semi automatic and automatic Select the desired mode This section uses manual mode for calibration 2 Oxygen concentration in zero gas Enter the zero gas oxygen concentration for calibrat...

Page 81: ...ey to have all the digits flash ENT 000 98 Touch the ENT key again to stop the flashing ENT b01 Touch the ENT key once again to switch to the parameter code selection display Set the span gas concentration by above procedure set 21 ENT b03 Next set the calibration mode Switch the parameter code to B03 ENT 0 Touch the ENT key to display the currently set value If it is 0 you can leave it as is If i...

Page 82: ...ouch the ENT key again CAL then flashes To cancel the above touch the key and ENT key together the display will return to the B10 display ENT SPAn Y If you touch the ENT key again SPAn Y appears Y is flashing If you omit the span calibration touch the key and change Y to N If you touch the ENT key the display then jumps to ZEro Y ENT 21 00 Touch the ENT key to display the calibration gas value in ...

Page 83: ...gas solenoid valve and then the measured value changes to the zero gas value When the display becomes stable proceed to the next step To cancel the above touch the key and ENT key together then the display returns to ZEro Y ENT 0 89 If you touch the ENT key all the digits flash At that point no calibration is conducted yet ENT CALEnd Touch the ENT key again to get the measured value to agree with ...

Page 84: ...he output damping has been set for the current output values involving the output damping are displayed CAUTION If you set 3 in the parameter code A00 or F08 be sure to select Oxygen Concentration in the following mA output setting see Section 8 2 Current Output Setting 8 2 Current Output Setting This section describes setting of the analog output range Table 8 2 shows parameter codes for the set ...

Page 85: ...d up CAUTION When you select logarithmic mode the minimum output remains constant at 0 1 O2 and the parameter C11 display remains unchanged 8 2 2 Entering Output Damping Constants If a measured value adversely affected by a rapid change in the sample gas oxygen concentration is used for the control means frequent on off actions of the output will result To avoid this the converter allows the setti...

Page 86: ... Equipment Status 1 During warm up During warm up is the time required after applying power until the sensor temperature stabilizes at 750 C and the equipment is in the measurement mode This status is that the sensor temperature is displayed on the basic panel 2 During maintenance During maintenance is the time from when a valid password is entered in the basic panel display to enable the paramete...

Page 87: ...bration is the time starting when a calibration instruction is executed with an infrared switch or a contact input to make a series of calibrations until the preset output stabilization time elapses In an automatic calibration during calibration is the time starting when automatic calibration is carried out at the calibration start time until the preset output stabilization time elapses 4 Error ap...

Page 88: ...Parameter Codes for Output Holding Set items Parameter code Set value During warm up C04 0 4 mA 1 20 mA 2 Holds Set value During maintenance C05 0 Without hold feature 1 Last measured value 2 Holds set values During calibration C06 0 Without hold feature 1 Last measured value 2 Holds set values During error occurrence C07 0 Without hold feature 1 Last measured value 2 Holds set values Note C07 is ...

Page 89: ... delay time and allow for hysteresis for alarm canceling under the alarm output conditions as Figure 8 2 shows When the delay time is set an alarm will not be issued so quickly even if the measured value differs from the steady state and enters the alarm setpoint range If the measured value remains within the alarm setpoint range for a certain period of time for the preset delay time an alarm will...

Page 90: ...resis set value and the preset delayed time during measurement has elapsed so the alarm is canceled 8 4 3 Alarm Setting Set the alarm setpoints following Table 8 7 listing parameter codes Table 8 7 Parameter Codes for Oxygen Concentration Alarms Set item Parameter code Set value Oxygen concentration high high alarm setpoint D01 0 100 O2 Oxygen concentration high alarm setpoint D02 0 100 O2 Oxygen ...

Page 91: ...contact outputs Be sure to observe relay contact ratings For details see Section 2 1 General Specifications The following sets forth the operation mode of each contact output Output contact 1 you can select open or closed contact when the contact is operated For output contact 2 contact is closed The relay for output contact 1 is energized when its contacts are closed and vice versa Accordingly wh...

Page 92: ...ing ranges 1 Operated when changing ranges Note 3 Warm up E28 0 Not operated during warming up 1 Operated during warming up Calibration gas pressure decrease E29 0 Not operated while a calibration gas pressure decrease contact is being closed 1 Operated while a calibration gas pressure decrease contact is being closed Note 4 Unburnt gas detection E32 0 Not operated while a unburnt gas detection co...

Page 93: ...1 Output Contact Default Settings Item Output contact 1 Output contact 2 High high alarm High alarm Low alarm Low low alarm Error O Warm up O Output range change Calibration Maintenance O High limit temperature alarm Calibration gas pressure decrease Unburnt gas detection Operating contact status Open Closed fixed O Present NOTE The above blank boxes indicate the items have been set off ...

Page 94: ...l single output signal is available as a contact signal If this operation starts the sensor temperature decreases and an error occurs To restore it to normal turn the power off and then back on or reset the analyzer CAUTION Measurement range switching function by an external contact input is available for analog output 1 only and the range is fixed to 0 25 O2 To conduct a semi automatic calibratio...

Page 95: ...ey to move the position of the digit that is flashing to the right one digit ENT 00 06 21 Touch the key to change to 2 ENT 00 06 21 Touch the key to move the position of the digit that is flashing to the right one digit ENT 07 18 Let the rightmost character flash and touch the key to display the time Continuously touch the key then the date and time are alternately displayed Displayed on the left ...

Page 96: ...average maximum and minimum oxygen concentration values Periods over which average is calculated and periods over which maximum and minimum values are monitored can be set ranging from 1 to 255 hours If the set ranges are beyond the limits specified an Err will be displayed Table 8 15 Parameter Codes for Average Maximum and Minimum Values Set item Parameter code Set range Units Periods over which ...

Page 97: ... dry exhaust gas per unit quantity of fuel m3 kg or m3 m3 m Air ratio X Fuel coefficient determined depending on low calorific power of fuel m3 kg or m3 m3 3 in Table 8 16 Z Absolute humidity of the atmosphere kg kg Figure 8 4 water vapor caused by combustion and water vapor contained in the exhaust gas actual exhaust gas including water vapor per fuel water vapor contained in air for combustion x...

Page 98: ...t 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 percentage h Hydrogen co...

Page 99: ... 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 4E ai Figure 8 4 Absolute Humidity of Air ...

Page 100: ... 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 1 89 7 57 13...

Page 101: ... 4 Setting Purging Purging is to remove condensed water in the calibration gas pipe by supplying a span calibration gas for a given length of time before warm up of the detector This prevents cell breakage during calibration due to condensed water in the pipe Open the solenoid valve for the automatic calibration span gas during purging and after the purge time has elapsed close the valve to start ...

Page 102: ...e 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 tem...

Page 103: ...e used for calibration 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 vol O2 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 9 1 3 Compensation The dev...

Page 104: ...y the cell electromotive force for a span gas with oxygen concentration p1 is measured The cell electromotive force for the zero gas is carried over from a previous measurement to obtain the calibration curve The principle of calibration using only a span gas also applies to the one point calibration method using a zero gas only 21 0 p1 0 51 81 92 ez e1 es 0 C A B Zero correction ratio B A x 100 C...

Page 105: ...f zero correction ratio Recorded the past ten zero correction ratios 3 Response time You can monitor the response time provided that a two point calibration has been done in semi automatic or automatic calibration 4 Cell s internal resistance The cell s internal resistance gradually increases as the cell sensor deteriorates You can monitor the values measured during the latest calibration However ...

Page 106: ...tomatic calibration which is carried out automatically following preset calibration periods Calibrations are limited by the following mode selection When Manual calibration is selected Manual calibration only can be conducted This mode does not allow semi automatic calibration with a contact input nor automatic calibration even when its start up time has reached When Semi automatic calibration is ...

Page 107: ... For more details consult Section 8 3 Setting Output Hold When the calibration mode is in semi automatic set the hold output stabilization time and calibration time The calibration time is the time required from starting the flow of the calibration gas to reading out the measured value The set calibration time is effective in conducting both zero and span calibrations The calibration time set rang...

Page 108: ...the calibration start day no calibration will be conducted Table 9 1 Parameter Codes for Calibration Setting Set Item Parameter code Set value Engineering unit Zero gas concentration B01 Set Zero gas concentration O2 Span gas concentration B02 Set Span gas concentration O2 Calibration mode B03 0 Manual calibration 1 Semi automatic and manual 2 Automatic semi automatic and manual Hold Output stabil...

Page 109: ... display then appears Output holding will be released When CAL Err appears a calibration coefficient alarm alarm 6 or 7 may have occurred Press ENT key to return to basic panel display Check the alarm number Refer to Subsection 12 2 2 2 Alarm 6 or Subsection 12 2 2 3 Alarm 7 remove the cause and then recalibrate the instrument The symbol indicates that the corresponding keys are being touched and ...

Page 110: ...10 Other Functions 10 1 Detailed Display Select the desired parameter code to display the detailed operation data see Table 10 1 Parameter Codes for Detailed Operation Data NOTE Refer to Section 8 1 Setting Display Item for parameter code A00 ...

Page 111: ...A65 Zero correction ratio 5 A15 Cold junction voltage mV A66 Zero correction ratio 6 A16 Output current mA A67 Zero correction ratio 7 A20 Cell response time Seconds A68 Zero correction ratio 8 A21 Cell internal resistance Ω A69 Zero correction ratio 9 A22 Cell robustness A70 Calibration history 0 YY MM DD HH MM A23 Heater on time ratio A71 Calibration history 1 YY MM DD HH MM A24 Oxygen concentra...

Page 112: ...s the internal where the electronics is installed temperature of equipment which compensates for the cold junction temperature for a thermocouple measuring the cell temperature If this temperature exceeds 85 C the electronics may fail When the ZR202G is used the maximum C J temperature will be 150 C If the internal temperature exceeds this take measures to reduce the temperature such as by not exp...

Page 113: ...s cell voltage Table 10 2 Oxygen Concentration Vs Cell Voltage cell temperature 750 C O2 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 mv 117 83 102 56 93 62 87 28 82 36 78 35 74 95 72 01 69 41 O2 1 2 3 4 5 6 7 8 9 mv 67 09 51 82 42 88 36 54 31 62 27 61 24 21 21 27 18 67 O2 10 21 0 30 40 50 60 70 80 90 mv 16 35 0 7 86 14 2 19 2 23 1 26 5 29 5 32 1 O2 100 mv 34 4 T10 2E ai 10 1 6 Thermocouple Voltage The cel...

Page 114: ...on of the cell cannot be found only by changes in cell s internal resistance however Those changes in the cell s internal resistance will be a hint to knowing the sensor is degrading The updated values obtained during the calibration are displayed 10 1 11 Robustness of a Cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed as one of four time per...

Page 115: ...n will be displayed If the setup period of time is changed the current minimum oxygen concentration will be displayed for more details see Section 8 7 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 displa...

Page 116: ...er of the software installed is displayed 10 2 Operational Data Initialization Individual set data initialization enables you to return to the default values set at the time of delivery There are two types of initializations an all set data initialization and a parameter code based initialization Table 10 4 lists the initialization items by a parameter code and default values Table 10 4 Parameter ...

Page 117: ...T 1000 Enter the password 1255 for initialization ENT 1000 ENT 1200 ENT 1200 ENT 1250 ENT 1250 ENT 1255 ENT 1255 After you enter the password and then touch the ENT key all the digits flash ENT USr Go Touch the ENT key again to display USr Go ENT USr Go Touch the ENT key once more All the digits then flash for two to three seconds and data initialization starts ENT F30 The initialization is comple...

Page 118: ... 4 if an EEPROM write error occurs For details on error occurrence consult Chapter 12 Troubleshooting later in this manual If any of the above problems occurs the equipment turns off the power to the detector heater To cancel the error reset the equipment following the steps below or turn the power off and then back on CAUTION Make sure that before resetting or restarting the power that there is n...

Page 119: ...econds ENT 0000 Touch the ENT key again to switch to the password entry display ENT 1000 Enter the password 1102 Intermediate switch operations omitted ENT 1102 ENT A01 ENT G01 Change the parameter code to G30 ENT G01 ENT G30 ENT All the digits light up Touch the ENT key to execute resetting The symbol indicates that the corresponding keys are being touched and the light characters indicate flashi...

Page 120: ... A65 Zero correction ratio 5 A15 Cold junction voltage mV A66 Zero correction ratio 6 A16 Output current mA A67 Zero correction ratio 7 A20 Cell response time Seconds A68 Zero correction ratio 8 A21 Cell internal resistance Ω A69 Zero correction ratio 9 A22 Cell robustness A70 Calibration history 0 YY MM DD HH MM A23 Heater on time ratio A71 Calibration history 1 YY MM DD HH MM A24 Oxygen concentr...

Page 121: ...n B04 Hold Output stabilization time 0 minutes 0 seconds to 60 minutes 59 seconds MM SS 10 minutes 0 seconds B05 Calibration time 0 minutes 0 seconds to 60 minutes 59 seconds MM SS 10 minutes 0 seconds B06 Calibration interval 0 days 0 hours to 255 days 23 hours DD HH 30 days 0 hours B07 Calibration start date and time YY MM DD HH MM 00 01 01 00 00 B08 Calibration procedure 0 Zero and span Zero an...

Page 122: ...onstant 0 to 255 Seconds 0 second C31 Set value during warm up 2 4 to 21 6 mA 4 mA C32 Set value during maintenance 2 4 to 21 6 mA 4 mA C33 Set value during calibration 2 4 to 21 6 mA 4 mA C34 Set value in abnormal state 2 4 to 21 6 mA 3 4 mA Note C07 and C34 is not displayed when option code C2 or C3 NAMUR NE 43 compliant is specified Alarm related Items in Group D Code Item Tuning Engineering un...

Page 123: ...g action of output contact 1 0 Action with closed contact normally energized Action with closed contact 1 Action with open contact normally de energized E20 Output contact 1 error 0 No action No action 1 Action E21 Output contact 1 high high alarm 0 No action No action 1 Action E22 Output contact 1 high alarm 0 No action No action 1 Action E23 Output contact 1 low alarm 0 No action No action 1 Act...

Page 124: ...4 hours F15 Purging time 0 to 60 minutes Minutes 0 minute F20 Amount of water vapor in exhaust gas 0 to 5 m3 kg m3 1 0 m3 kg m3 F21 Theoretical amount of air 0 to 20 m3 kg m3 1 0 m3 kg m3 F22 X value 0 to 19 99 1 F23 Absolute humidity of the atmosphere 0 to 1 kg kg 0 1 kg kg F30 Initializing all data F31 Initializing data in group A F32 Initializing data in group B F33 Initializing data in group C...

Page 125: ... 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 zero gas A gas of 7 Nl is charged to 700 kPa Clamp Clamps the gas cylinder Zero gas valve Attaches to the gas cylinder for use Power cord F10 14E ai Figure 10 4 Standard Gas Unit Component Identification 10 5 2 Installi...

Page 126: ...leted However gases in the cylinders cannot immediately flow out after these procedures To discharge the gases it is necessary for the needle in the zero gas valves to puncture a hole in the gas cylinder see Section 10 5 3 10 5 3 Calibration Gas Flow Preparation before calibration 1 To operate the standard gas unit place it on a nearly horizontal surface in order to allow the flow check to indicat...

Page 127: ... zero gas valve back slowly counterclockwise At that time the flow rate also decreases as the inner pressure of the gas cylinder decreases Monitor the flow check and when the ball s position changes greatly readjust the valve 3 Touch the ENT key after the measured oxygen concentration becomes stable Then all the digits flash Touch the ENT key again so that the CALEnd flashes NOTE Be sure not to te...

Page 128: ...ar alternately during the span calibration open the span gas flow setting valve of the flow setting unit and adjust the flow rate to 600 60 ml min Loosen the lock nut if the valve shaft has a lock nut and turn the valve regulator slowly counterclockwise To check the flow rate use the calibration flowmeter If the sample gas pressure is extremely high adjust the sample gas pressure to obtain pressur...

Page 129: ...e the zero gas flow setting valve to stop the zero gas flow Be sure to tighten the lock nut if the valve shaft has a lock nut to prevent any leakage of zero gas into the sensor during measurement When the stabilization time elapses the zero calibration will be complete 10 6 4 Treatment After Calibration No special treatment of the instrument is needed after calibration However it is recommended th...

Page 130: ...erminal box first 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 gas inlet of the terminal box into the detector flows through the tube and comes out at the tip of the probe The tube might become clogged with dust from the sample gas If you become ...

Page 131: ...here is any corroded or discolored area 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 appropriate metal brush to eliminate any sharp protrusions on the groove The contact s resistance should be minimized Use cell assemblies manufactured in or after Sept 2...

Page 132: ...ting 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 its support then fully insert the U shaped pipe filter and its support into the probe 4 Coat the threads of the four bolts with antiseize grease and then screw them in along with the washers First tighten the f...

Page 133: ... the instructions given above 11 1 3 Replacement of the Heater Assembly This section describes the replacement procedure for the heater assembly The sensor or ceramic heater furnace core internal structure is subject to fracturing so do NOT subject it to strong vibrations or shock Additionally the heater assembly reaches high temperatures and is subjected to high voltages So maintenance services s...

Page 134: ... 11 Inspection and Maintenance 11 5 IM 11M12A01 04E A A View A A 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 14 13 17 18 19 20 21 22 23 24 24 24 F11 4E ai Figure 11 4 Exploded View of Detector ...

Page 135: ... plate and two caps If the O ring remains in the hole pull them out from the back Pass the heater and thermocouple leadwire through the connector Also pass the calibration gas and reference gas pipes through the opening of the connector If the O ring fails replace it with a new one Push the two caps into the associated opening of the connector Insert the plate aligning it with the groove of the ca...

Page 136: ...y lower If a large amount of water is condensed the sensor can be broken and never be used 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 unavoidably impossible to supply the power and removing the detector keep ...

Page 137: ...uch the grounded metal part to discharge any static electricity 1 Remove the display cover Figure 11 5 2 Remove the three screws that are located toward you among the four screws shown in Figure 11 6 Loosen the remaining one 3 Move the electronics up to remove it F11 5E ai Cover of Display F11 6E ai SCREW Figure 11 5 Cover of Display Figure 11 6 Location of Screw 4 Disconnect the three connectors ...

Page 138: ...e fuse is installed properly these are directly connected with connectors 9 Tighten the four screws in their positions 10 Replace and tighten the display cover properly If the cover is not tightened sufficiently the infrared switches will not operate correctly Fuse rating Check the rating of the fuse and that it satisfies the following Maximum rated voltage 250 V Maximum rated current 3 15 A Type ...

Page 139: ...o see is attached The end of the pin holding down the back plate must be on the bracket side 3 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 liquid leakage test Vertical mounting Horizontal mounting C C B B C B A A A Zr20h_g0 ai Connect piping pairs A A9 B B9 C C9 D ...

Page 140: ...r Output contact setup for that contact refer to Section 8 5 Output Contact Setup 4 Changes the analog output status to the one set in Output hold setting refer to Section 8 3 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 The content of errors that are displayed include those shown in Table 12 1 Disp...

Page 141: ...ss to the two connectors four connectors for the optional automatic calibration unit as indicated in Figure 12 2 Check these connectors are properly connected 6 If Error 1 still occurs the electronics may be defective Contact your local Yokogawa service or sales representative 12 1 2 2 Error 2 Heater Temperature Failure This error occurs if the detector heater temperature does not rise during warm...

Page 142: ...he electronics may be defective Consult your local Yokogawa service or sales representative 12 1 2 3 Error 3 A D Converter Failure Error 4 Writing to memory Failure A D Converter Failure It is suspected that a failure has occurred in the A D converter mounted in the converter electronics Writing to memory Failure It is suspected that a failure has occurred in an operation writing to the memory EEP...

Page 143: ...ge exceeds 42 1 mV about 1020 C or falls below 5 mV about 170 C Alarm 13 Battery low alarm Internal battery needs replacement If an alarm is generated such measures as turning off the heater power are not carried out The alarm is released when the cause for the alarm is eliminated However Alarm 10 and or Alarm 11 may be generated at the same time as Error 2 heater temperature error In such a case ...

Page 144: ...e approximately 10 mV Table 12 3 Oxygen Concentration and Cell Voltage Oxygen concentration Oxygen concentration O2 Cell voltage mV 1 67 1 21 0 4 Confirm whether deterioration of or damage to the sensor assembly that caused the alarm has occurred abruptly during the current calibration in the following procedure Check the history of the span gas correction ratio with the parameter codes A50 throug...

Page 145: ...ion of or damage to the cell sensor is suspected as the cause of the alarm Replacement of the cell with a new one is necessary However before replacement carry out the procedure described in step 3 and later of Search for cause of failure and taking measure in Section 12 2 2 2 Alarm 6 Zero Calibration Coefficient Alarm 12 2 2 4 Alarm 8 EMF Stabilization Time Over This alarm is generated if the sen...

Page 146: ... is generated when the emf voltage of thermocouple falls below 5 mV about 170 C or exceeds 42 1 mV about 1020 C 1 A failure of the thermocouple at the detector occurred 2 A failure of the electrical circuits occurred Search for cause of failure and Take measures 1 Turn off the power to the analyzer 2 Remove the probe from the analyzer Also remove all the connectors between the converter and probe ...

Page 147: ...ct stored parameters The internal clock is used for calibration and purge scheduling if you use this then after a battery alarm occurs until the battery is replaced be sure to check correct the date and time every time you turn on the power Corrective action When the battery low alarm occurs remember that the battery cannot be replaced by the user Contact your Yokogawa service representative NOTE ...

Page 148: ... reference gas changes increases greatly If air at the detector installation site is used for the reference gas large change of moisture 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 dry condition as a reference gas In addition change of moisture content in ...

Page 149: ...gas they burn in the sensor and thus oxygen concentration decreases Check that there are no combustible components 5 Temperature of the sensor cell reaches 750 C or more If the sensor temperature is 750 C or higher this may indicate that sample gas has leaks into the reference gas side corrosion Also check that the thermocouple resistance is no greater than 15Ω 12 3 3 Measurements Sometimes Show A...

Page 150: ...13 K9471UA E7042BR K9470BM K9473AN E7042DW G7109YC K9470BK E7042UD E7042BS K9470BJ E7042AY K9470ZF K9470ZG K9470ZK K9470ZL ZR202A A 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 1 Dust Filter Option Sensor Assembly Plate Pipe Pipe for Option code C Washer SUS316 stainless steel Bolt M5x12 SUS316 stainless steel Bolt M5x12 inconel for Option code C Cell Assembly Contact Metal O ring Filter Bolts and Washers G710...

Page 151: ...CMPL 11M12A01 04E 7th Edition Apr 2011 YK Hood for ZR202G ZR202G_F ai 1 Item Part No Qty Description 1 K9471UA 1 Hood ...

Page 152: ...o change without notice Model ZR20H Integrated type Zirconia Oxygen Analyzer High Temperature Humidity Analyzer Automatic Calibration Unit CMPL 11M12A01 12E 1st Edition Feb 2001 YK 3rd Edition Apr 2011 YK SPAN IN REF IN ZERO IN 10PSI SS 2C2 10 NUPRO 4 5 7 8 Item Part No Qty Description 8 K9473XC 1 Flowmeter ...

Page 153: ......

Page 154: ...l 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 Table 1 2 E7050BA 1 Zero Gas Cylinder x6 pcs 3 E7050BJ 1 Needle Valve Table 1 Power Pump AC 100 V 110 115 E7050AU AC 200 V 220 240 E7050AV ...

Page 155: ......

Page 156: ...of the ZR202G Detector 12 2 1 Corrected explanation of Alarm 10 Added Filter to CMPL11M12A01 04E and added ZR20H Automatic Calibration Unit to CMPL 11M12A01 12E 3rd Sept 2001 Revised section 1 2 Model ZR202A Heater Assembly added 2 2 1 ZA8F Flow Setting Unit error corrected 2 7 8 Model ZR202A Heater Assembly added 8 6 Table 8 12 Input Contact Functions changed 11 1 3 Reference document added to Re...

Page 157: ...t Output Changed description in table 7 10 8 3 2 Preference Order of Output Hold Value Deleted or blow back 8 3 3 Output Hold Setting Table 8 5 Parameter code C06 maintenance should read calibration 8 3 4 Default Values Table 8 6 Deleted or blow back 8 5 1 Output Contact Made some corrections 8 5 2 Setting Output Contact Table 8 10 Changed descriptions WARNING Deleted second warning 9 2 2 2 Semi a...

Page 158: ...ia Oxygen Analyzer User s Manual IM 11M12A01 04E 7th Edition supplied with the product some revisions additions have been made Please replace the corresponding pages in your copy with the attached revised pages Revisions CMPL Customer Maintenance Parts List CMPL 11M12A01 04E is updated to 8th edition IM 11M12A01 04E 7th Edition Model ZR202G Integrated type Zirconia Oxygen Analyzer ...

Page 159: ...71UA E7042BR K9470BM K9473AN E7042DW G7109YC K9470BK E7042UD E7042BS K9470BJ E7042AY K9470ZF K9470ZG K9470ZK K9470ZL ZR202A A 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 1 Dust Filter Option Detector Assembly Plate Pipe Pipe for Option code C Washer SUS316 stainless steel Bolt M5x12 SUS316 stainless steel Bolt M5x12 inconel for Option code C Cell Assembly Contact Metal O ring Filter Assembly Bolts and Washere...

Page 160: ...CMPL 11M12A01 04E 8th Edition Apr 2012 YK Hood for ZR202G ZR202G_F ai 1 Item Part No Qty Description 1 K9472UF 1 Hood ...

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